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3902 MA
MAINTENANCE INSTRUCTION
Installing wheel-axle-gear assemblies and gear cases ment can be used to confirm the surface finish
in D77 or D87 traction motors requires prior requirements.
preparation of components and on-going checks
during assembly before releasing a complete traction 2. The dimension between the axle gear hub face and
motor and wheel assembly for use under a locomotive. opposite wheel hub face for all D77/D87 series
This article will outline the recommended procedure traction motors must be 43.875 f .OlO”. In order to
for building up a traction motor mounting assembly. It accurately qualify this dimension, an accurate
will be assumed that the traction motor assembly has measuring device, preferably with a dial indicator,
already been properly assembled and/or maintained as should be used along with a permanent master
outlined in Maintenance Instruction 3900, M.I. 3950-l calibration stand to allow for frequent rechecks.
through -7 (D77 Series) or Maintenance Instruction
M.I. 3953-l through -7 (D87 Series). 3. The wheel and gear hub faces and adjacent outside
hub diameters must be smooth and finished to 16
To conserve gear case lubricant, it is recommended to micro-inches (0.41 microns) maximum. This en-
apply new plastic pinion seal part number 40007174 sures a good thrust surface for the support bearing
prior to applying pinion. flanges and a good rubbing surface for seals.
DE-L692
M.I. 3902
2. When reapplying used support bearings, renew the rotate, use a block of wood against one edge of the
“I” shaped felt thrust lubricators in the solid and bearing and tap to set against the key.
window half bearings (four pieces of 9557831 or
9534143 as applicable per bearing). Saturate these 5. After the solid-half bearing shells are installed
flange lubricators with suspension bearing oil. some sealant may squeeze out over the edges. This
Reused bearings must be qualified, especially with excess sealant should be wiped clean to avoid
regard to the condition of the babbitt lining material interference with the seating of the mating bearing.
and adequate flange thickness. Requalified bear- The bearing should also be pressed tight against the
ings should be used on the lighter loaded C.E. side motor frame to insure less than the maximum
of the traction motor whenever possible and use a allowable gap of 0.005” between the bearing flange
new support bearing on the P.E. side. and frame as shown in Fig. 1. This gap will be
checked later.
3. Prior to installing the support bearings, apply a
bead of RTV sealant behind the support bearing WHEEL-AXLE-GEAR ASSEMBLY
flanges, Fig. 1. Generally a l/4” to 3/8” bead of INSTALLATION
sealant is sufficient, but in any case the diameter of ’
the bead must be large enough to span the gap Prior to installing the wheel-axle-gear assembly in the
between the motor frame chamfer and the radius at traction motor frame, brush suspension bearing oil on
the base of the bearing flange. Note that oil residue the inside diameter of the bearing shells and on the
must be removed from all sealing surfaces by axle in the support bearing surface areas.
wiping with a solvent before applying sealant. The
sealant is added in order to reduce the possibility of Install the wheel-axle-gear assembly in the traction
water and dirt entry, thereby contributing to motor frame.
increased lubricating wick and support bearing life.
Once water migrates under the bearing shell, SEAL RING INSTALLATION
capillary action draws water to the split line and
results in water entry into the oil reservoir. Current support bearings are equipped with four
grooves and dual seals (seals at inboard and outboard
ends) to minimize support bearing oil leakage. Sealing
is accomplished by nylon rings that clip onto the axle
and rotate with the axle in circumferential grooves in
the bearings.
Motor Oil that would normally flow out of the bearing ends is
Frame retained by the seal rings and returns to the reservoir
through a drilled passage from the seal groove to the
.005”
b *Max. Gap
/
l/4” to 3/8” bead of RTV sealant must complete a 180’
arc on the radius at the base of the bearing flange. Do
not apply to the flat of the flange, since this may
prevent seating the bearing flange against the motor
frame (.005” maximum gap allowed).
29625
-2
M.I. 3902
.014” Minimum
.046” Maximum
NOTES
1. Total end play should be within .040” to .089”.
-3-
M.I. 3902
A l/4” to 318” bead of RTV sealant is also added The support bearing caps are machined and line
behind the window-half support bearing flange as bored to size when mounted on the traction motor
previously described for the solid-half bearing. How- with a 0.018” thick shim inserted between the cap
ever, to avoid excess sealant from working out at the and motor frame. When the motor assembly is built
parting lines when installed, stop the sealant bead up, a 0.010” thick shim is used between the axle cap
behind the flange approximately 3/8” from each edge and frame thus giving a 0.008” clamp fit or crush to
of the shell. the axle bearing shells. Line boring of the caps to
the motor frame is necessary to secure the accuracy
Install window-half of the support bearings. Ensure of bearing fit required. The caps are not inter-
that bearing flanges line up with upper bearing and changeable with caps of other motors. To ensure
both halves contact the mating surface on the motor that they are matched to the proper motor and
frame to maintain the gap between the flange and location, they are stamped with a serial number
frame of 0.005” maximum. If the existing gap is matching the motor frame number.
greater than 0.005”, an additional bumping of the
assembly may be necessary to better seat the bearing 2 . Apply caps straight, as rocking will distort
flange against the frame. splines and pinch the bearings.
4-
M.I. 3902
ensure the bearing flanges are aligned with each Obtain access through wick cover opening,
other and tight against the motor frame and axle and insert feeler gauge through wickwindow
cap. AT TOP OF AXLE.
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M.I. 3902
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M.I. 3902
Care must be taken to insure a good contact between GEAR CASE LUBRICATION
the dust guard and the hub of-the wheel. Mate the
rubber alignment pin on the dust guard with the mating After the gear case has been assembled on the
hole in the support bearing flange and with the split motor-wheel-axle assembly, approximately 14 to 18
opening of the dust guard located toward the bottom of lbs. of gear lubricant should be added as an initial
the traction motor (toward the rail). While tightening charge. Depending upon gear ratio, use the following
the dust guard clamp make sure that it seats properly in amounts of lubricant:
the slot provided, Fig. 8.
INITIAL CHARGE OF LUBRICANT
56 tooth gears . . . . ............. 18 lbs.
Wheel Hub 57 thru 60 tooth gears ............. 16 lbs.
/Dust Guard 61 and 62 tooth gears ............. 14 lbs.
I
66 and 67 tooth gears ............. 16 Ibs.
69 and 70 tooth gears ............. 14 lbs.
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M.I. 3902
Copyright 1992
Electra-Motive Division, General Motors Corporation. All rights
reserved. Neither this document, nor any part thereof, may be reprinted
without the expressed written consent of the General Motors Locomotive
Group. Contact EMD Customer Publications Office.