GEK–91675B

PLANNED MAINTENANCE
GE240AC ELECTRIC DRIVE SYSTEM

1. SCOPE
This publication is prepared to assist mine personnel using GE240AC Drive Systems in establishing effective
preventive maintenance programs. With proper planned maintenance inspections, maintenance personnel should be
able to observe developing problems and take the necessary corrective action. This will facilitate prevention of pos-
sible failures and as a result, minimize equipment downtime.

An effective preventive maintenance program enables the user to obtain:

– maximum component life,
– optimum performance,
– maximum availability through reduced, unscheduled downtime.
2. GENERAL INFORMATION
The intervals suggested in this publication are for the use of the mine maintenance personnel in preparing their
Preventive Maintenance Work Sheets.

The following systems are covered within this publication:

 17KG531 Control Group
 5GEB25 Motorized Wheel
 5GTA41 Alternator
 17EM139 Dynamic Retarding Assembly
Since geographical operating environments vary from one service assignment to another, these intervals are rec-
ommended only as a guide. Actual needs should be determined through experience.

Failure to implement a Preventive Maintenance Program may result in accelerated wear and premature failure of
drive system components.

The following preventive maintenance inspection recommendations are based on extensive experience under var-
ious operating conditions. This information is offered as a general guide which calls attention to the drive system com-
ponents that should be periodically inspected and the characteristics of those components that should be observed
and measured.

Whenever there is uncertainty regarding the corrective action required as a result of periodic maintenance and
inspection activities, contact your local General Electric service representative for assistance.

Revisions are indicated by margin bars.

Copyright 2003 General Electric Company. All rights reserved. This copyrighted document may be reproduced free of charge by General
Electric Company customers (OEM’s) and their customers, if such reproduction is used exclusively in connection with equipment used in those
customers’ internal operations.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or mainte-
nance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user’s purposes, the matter should be referred to the General
Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this material. GE has no
obligation to keep the material up to date after the original publication.
THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.
Verify numbers for parts, tools, or material by using the Renewal Parts or Tool Catalogs, or contact your General Electric
representative for assistance.
Do not order from this publication.
GEK–91675B, Planned Maintenance

WARNING: All checks and inspections should be made with wheels chocked and engine and battery pow-
er off except where indicated.

CAUTION: When performing any of the inspections, always protect the gearcase and its contents from
contaminants.

CAUTION: When welding on the truck:

1. Connect the welding ground as close as possible to the are being welded, i.e. directly to the part
being welded.
2. Never connect the welding ground so that current will pass through bearing of any rotating equip-
ment.
3. DO NOT pull any control cards or remove panel connectors. This practice puts unnecessary
cycles on connector pins, and may cause loose or dirty pins which could cause a control system
failure.

For successful truck operation, the mine must provide:

1. Knowledgeable workers and supervision.

2. Adequate maintenance facilities, tools, shop supplies and renewal parts.

3. Lubricating oil/grease equal to or better than that specified. Refer to GEK–30375, Lubrication Specifications
for GE Equipment.

4. Inspection and maintenance according to a planned schedule, and maintain adequate records of these activi-
ties.

When Servicing:

1. Never mix lubricants of different brands or grades.

2. NEVER OVERFILL lubricants –– too much lubrication can be as harmful as too little.

3. Clean equipment covers before they are removed to perform maintenance.

4. Use only clean containers when handling lubricants.

5. After servicing, operate the truck for at least 30 minutes, unloaded and at low speed (10 mph or less).

The following equipment have sealed bearings that do not require additional lubrication until the device
is overhauled:

1. Traction Motors,

2. Alternator,

3. Retarding Grid Blower Motors,

3. PLANNED MAINTENANCE SCHEDULE

Table 1 lists the recommended task, the publication number reference for details concerning the maintenance
procedure, and the recommended interval for the task.

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 Planned Maintenance, GEK–91675B

TABLE 1. PLANNED MAINTENANCE SCHEDULE

Publication
Recommended Task Interval
No.
MOTORIZED WHEEL

WARNING: Lethal Voltages may be present. Always turn off and Safety Tag the KEY SWITCH in the Oper-
ator Cab. Place the generator field cut–out switch located on the Operator Interface Panel on the Main
Control Cabinet in the CUT–OUT position and Lock and Safety Tag the Operator Interface Panel Cover.
Then, verify that ALL lights on either Capacitor Charge Indicating Light Panel (CCL1 or CCL2) are extin-
guished before entering the Traction Motor or Axle Box.
1. Visually check planetary gear box for oil leakage. GEK–91713 Daily
2. Check gearcase oil level. GEK–91713 Daily
3. Visually check wet disk brake seal. GEK–91713 Daily
4. Visually check for oil leakage elsewhere on wheel. GEK–91713 Daily
5. Visually inspect for mud and stone buildup. GEK–91713 Daily
6. Take and analyze oil sample. GEK–91713 500 Hours
7. Remove, check and clean gearcase oil–fill magnetic plugs. GEK–91713 500 Hours
CAUTION: Do not remove the center cover plate when cleaning the mag-
netic plugs. There is danger of the thrust washers falling off the cover
and entering the planetary gear train. Their recovery would require the
removal of the wheel from the truck and disassembly of the planetary
gear box.
8. Check cable connections for discoloration. GEK–91713 500 Hours
9. Change gearcase oil. GEK–91713 3000 Hours
NOTE: Change the oil after the first 500 hours; thereafter, at the indicated
3000–hour interval. 3000 hours is maximum. More frequent oil change in-
tervals may be required, depending on individual mine conditions.
10. Inspect sun pinion gear. GEK–91713 5000 Hours
11. Check tightness of exposed bolts. GEK–91713 At Tire
Change
ALTERNATOR

WARNING: Lethal Voltages may be present. Always turn off and Safety Tag the KEY SWITCH in the Oper-
ator Cab. Place the generator field cut–out switch located on the Operator Interface Panel on the Main
Control Cabinet in the CUT–OUT position and Lock and Safety Tag the Operator Interface Panel Cover.
Then, verify that ALL lights on either Capacitor Charge Indicating Light Panel (CCL1 or CCL2) are extin-
guished before entering the Alternator compartment.
1. Visually inspect covers, gaskets and ductwork. GEK–91719 Daily
2. Check brush length, condition, freedom of movement. GEK–91719 250 Hours
3. Check brush holder condition, spacing, and brush spring tension. GEK–91719 250 Hours
4. Blow out slip ring area with clean dry air (70 psi max.). GEK–91719 250 Hours
5. Clean air inlet screen. Ensure it is free from obstructions and foreign ob- GEK–91719 1000 Hours
jects.

3
GEK–91675B, Planned Maintenance

TABLE 1. PLANNED MAINTENANCE SCHEDULE (Cont’d.)

Publication
Recommended Task Interval
No.
DYNAMIC RETARDING ASSEMBLY
WARNING: Lethal Voltages may be present in this equipment. Ensure that the Control Power Switch
(CPS) is in the OFF position and that the Generator Field Contactor (GFCO) is in the CUTOUT position.
Open, Safety Tag and lock the battery isolation switch according to OEM’s instructions. Check that the
capacitor charge lights are not on. Use a volt–ohm–meter (VOM) to VERIFY that no voltage is present
before touching any terminal. Failure to comply with these procedures could result in electrocution
and death.
1. Check brush holders in both blower motors for condition, spacing, and GEK–87940 500 Hours
spring tension.
2. Check commutator and grounding brushes in both blower motors for GEK–87940 500 Hours
proper length, condition, and freedom of movement.
3. Check dynamic retarding assembly for tight electrical connections, GEK–91720 500 Hours
shorted elements, overheated or buckled resistors, broken or cracked
insulators, overheated terminals, missing hardware, etc.
4. Blow out dirt in dynamic retarding assembly with clean, dry, compressed GEK–91720 500 Hours
air (70 psi max.).
5. Mechanically remove caked on dirt and debris within dynamic retarding GEK–91720 500 Hours
assembly.
MAIN CONTROL GROUP
WARNING: Lethal Voltages may be present. Always turn off and Safety Tag the KEY SWITCH in the Oper-
ator Cab. Place the generator field cut–out switch located on the Operator Interface Panel on the Main
Control Cabinet in the CUT–OUT position and Lock and Safety Tag the Operator Interface Panel Cover.
Then, verify that ALL lights on either Capacitor Charge Indicating Light Panel (CCL1 or CCL2) are extin-
guished before entering the Main Control Group Cabinet.
1. Vacuum clean the control cabinet. GEK–91721 250 Hours
2. Check all air exhaust ducts for blockage. GEK–91721 250 Hours
3. Check all electrical connections for damage due to arcing and/or loose GEK–91721 250 Hours
connections.
4. Check contactors, interlocks and relays for tip wear, burning, and frayed, GEK–91721 250 Hours
broken or discolored shunts.
5. Check condition of contactor arc chutes. GEK–91721 250 Hours
6. Check cabinet door seals and latches. GEK–91721 250 Hours
7. Check cabinet covers for loose or missing mounting hardware. GEK–91721 250 Hours
VEHICLE OPERATION TESTS
Check battery voltage. Adjust as required. GET–6864 1000 Hours

GE Transportation
Systems
2901 East Lake Road
NEW 03–00, FSB Erie, Pennsylvania 16531
REV 10–02, PRG
PRINTED
REV 02–03, MET IN
U.S.A.
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