Page

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . 2 DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS AND EQUIPMENT . . . . . . . . . . . 8 GROUNDING INSTRUCTIONS . . . . . . . . . . . . . . . . 8

GROUNDING PROCEDURES . . . . . . . . . . . . . . . 9

OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

GREASE TUBES AND PIPE PLUGS . . . . . . . . . 9

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

MONTHLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SEMI??ANNUALLY . . . . . . . . . . . . . . . . . . . . . . . . . 13

BASIC REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

BRUSH REPLACEMENT . . . . . . . . . . . . . . . . . . . 13 BRUSHHOLDER REPLACEMENT . . . . . . . . . . 13

BRUSHHOLDER CLEARANCE

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 14 COMMUTATOR RESURFACING . . . . . . . . . . . . 14

BASIC OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . 19

TESTING BEFORE DISASSEMBLY . . . . . . . . . 19 TABLE 2. DRAWING REFERENCE . . . . . . . . . . 20 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

INSPECTION AND TEST OF

DISASSEMBLED MOTOR . . . . . . . . . . . . . . . . . . . 31

BEARING INSPECTION . . . . . . . . . . . . . . . . . . . 31 ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 COMMUTATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 ARMATURE SHAFT INSPECTION . . . . . . . . . . 32 MOTOR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . 32 BRUSHHOLDERS . . . . . . . . . . . . . . . . . . . . . . . . . 35

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

LUBRICATION OF BOLTS . . . . . . . . . . . . . . . . . 35

Revisions are indicated by margin bars.

Page

BRUSHHOLDER SLEEVE REPLACEMENT . . 36 ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

TABLE 3. STANDARD BOLT TORQUE

VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 TEST AFTER REPAIR (Armature) . . . . . . . . . . . 44

MOTOR FRAME FIELD COIL

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 45

TEST AFTER REPAIR

(Coiled Frame Without Armature) . . . . . . . . . . 55

TABLE 4. VARNISH VISCOSITY CHART

FOR DIPPING COILED FRAME . . . . . . . . . . . . . 55 VARNISH TREATMENT (ARMATURE) . . . . . . . 56 BALANCING ARMATURE . . . . . . . . . . . . . . . . . . 56 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

BRUSHHOLDER CLEARANCE

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 65 BRUSH INSTALLATION . . . . . . . . . . . . . . . . . . . . 65 HUB MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . 66

TESTING AFTER OVERHAUL . . . . . . . . . . . . . . . 67

TESTING SERIES MACHINES

(Models 5GE752AUP, AUT) . . . . . . . . . . . . . . . 67

TESTING SHUNT MACHINES

(Models 5GE752UP and US) . . . . . . . . . . . . . . 68

REMOVING ARMATURE

LOCKING ARRANGEMENT . . . . . . . . . . . . . . . . . . 69

LOCKING THE ARMATURE FOR SHIPMENT . . 69 SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 CLEANING AND SLUSHING . . . . . . . . . . . . . . . 69 SKIDDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 ARMATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 PREPARATION OF BOX . . . . . . . . . . . . . . . . . . . 70 BOXING THE ARMATURE . . . . . . . . . . . . . . . . . 71

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

PLACING INTO STORAGE . . . . . . . . . . . . . . . . . 71 REMOVING FROM STORAGE . . . . . . . . . . . . . 72

FIG. 1. GE752 VERTICAL DRILLING MOTOR.

E??39088.

INTRODUCTION

GE752 drilling motors designed for vertical opera- tion, Fig. 1, are available in GE's UP, AUP, US and AUT series. This instruction provides inspection, mainte- nance and basic overhaul procedures for all of these motors. See Table I (page 3) for the models covered.

These motors have a ball bearing and a reinforced framehead at the commutator end to support the arma- ture shaft vertically. They also have a shaft extension at the commutator end for installation of a brake. Mounting feet are precision machined to align with the rotational ovals of the motor.

Refer to GEK??64271C for coverage of GE752 mod- els designed for horizontal operation.

GE752 motors are used by the oil and gas industry to power offshore and land??based drill rigs. Designed for vertical operation, they are d??c machines which require a nominal 750 volt d??c power source.

With suitable switching, they will operate equally well in either rotational direction. The following provides a listing of basic features.

The GE752UP and US models are of the ??Shunt?? class of motors which means they are separately ex- cited with shunt wound fields.

The GE752AUP and AUT models are of the ??Series?? class of motors which means they are self excited with series wound fields.

GE752UP and AUP motors are original design mo- tors introduced in 1983. GE752US and AUT motors are Hi??Torque motors with:

1.A new shallow slot design and split conductor ar- rangement reduce heat generating eddy cur- rents. Kapton??? insulation and new slot design allow more copper cross??section and allow the field windings and armature to operate at in- creased power levels.

2.The spiral groove commutator provides better commutator and brush cooling, better commuta- tion ability, and increased brush life.

3.An additional six exhaust openings in the motor drive end framehead and revised air flow pas- sage increases air flow and the motor's ability to transfer generated heat.

*Kapton is a registered trademark of E.I. duPont de Nemours & Co.

SPECIAL TOOLS

AND EQUIPMENT

CAUTION: This machine is of open splash??proof construction. It is force??ventilated and requires an ample supply of cooling air. The cooling air should not contain combustible gases. If it is applied in an environment which may contain combustible gases, an adequate supply of non?? contaminated cooling air must be provided.

The following items are required to maintain, repair and overhaul the motors:

Part

Megohmmeter (or ??Megger??*)

600 volts . . . . . . . . . . . . . . . . 111X910 or equivalent

Voltmeter . . . . . . . . . . Simpson Multimeter, Model 260

or equivalent

Puller Tools . . . . . . . . . . . . . . . . . . . . . . . 41E903423G1

Commutator Grinder . . . . . . . . . . . . . . . . . 427C592G1

Resurfacing Stones:

Medium Grade . . . . . . . . . . . . . . . . . . . 8828492P11

Finish Grade . . . . . . . . . . . . . . . . . . . . . . 8828492P8

Brush??Seater Stone (White) . . . . . . . . . . . 106X98

Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . P9945894P8

Crows??Foot Pressing Tool . . . . . . . . . . 41C685430G1

Ball and Socket Tool . . . . . . . . . . . . . . . 41C685080G1

Guide Pins, Three (3) Recommended

for Armature Asm. In Frame . . . . . . . . 6717114P1

Spanner Wrench . . . . . . . . . . . . . . . . . . . . . 8843522G1

Spring Scale (for brush??spring

pressure check) . . . . . . . . . . . . . . 0??20 lb. capacity

Hub Assembly Gauge . . . . . . . . . . . . . . 41D790941G1

Hub Puller (Less Pump) . . . . . . . . . . . . 41B535703G1

Pump (For Above) . . . . . . . . . . . . . . . . . . . . 8843947G1

GROUNDING INSTRUCTIONS

Grounding motor frames is required to safeguard personnel from electric shock in event of an insulation failure in the machine.

WARNING: Failure to properly ground electrical equipment may expose personnel to a potentially hazardous condition in which serious or fatal in- jury from electrical shock is possible.

Grounding conductors must be provided between the machine frame and the supporting structure to avoid hazardous potential difference between the machine frame and the adjacent surface on which a person may be standing while touching the machine.

NOTE: This type of ground connection is re- ferred to in electrical standards as ??equipment grounding?? or ??enclosure grounding?? which is not to be confused with ??system?? or ??circuit?? grounding. Drilling drive systems normally do not have intentional circuit ground connec- tions, except through high impedance detec- tors.

Grounding conductors must be provided on drilling units on which the construction of the unit and/or the in- stallation of the machines do not inherently insure posi- tive grounding of the equipment. Examples are those portable (modular) platform rigs and land rigs which do not already have ground cables to all machinery struc- tures. Offshore rigs with equipment fastened to the

decks by bolting or welding should not require additional grounding. (References: ABS Rules for Building and Classing Steel Vessels, Section 35.9.6, and IEEE Stan- dard 45??1977, Recommended Practice for Electrical In- stallations on Shipboard, Section 21.4.)

GROUNDING PROCEDURES (Fig. 2)

Most GE drilling machines have extra tap blocks on the frame for mounting of the connection boxes. One of these may be used for attaching the grounding cable. If one is not available, use the lower chain case mounting boss on the end opposite the drive end in accordance with Step 2.

1.To attach the ground cable to a tap block, obtain a 0.75??10 bolt with length of 1.0 to 1.5 in. and a lockwasher. Also obtain a cable lug to fit the ground cable and large enough for the 0.75 di- ameter bolt.

2.To attach the cable to the chain case boss, obtain a 1.25??7 bolt with length of 1.0 to 1.75 in. and a lockwasher. Prepare a copper plate at least 1/8 in. thick with a 1.25 in. diameter hole for bolting to the chain case boss, and with enough extra area for holes to attach a cable lug. Drill hole(s) in plate for cable lug. Clean all paint, rust and oil from the chain case boss and bolt the copper plate to the chain case boss.

3.Prepare a ground conductor* long enough to run from the motor frame to an existing ground con- ductor system or to a suitable equipment ground point as defined by the National Electrical Code Article 250 or other applicable regulation. Check that the system ground detector is also con- nected to the Common ground point for the rig and make connection if necessary.

4.Install terminal lugs on cable. Remove paint, rust and oil from the surfaces to which the cables are to be attached and bolt the lugs securely to these surfaces.

*Use 4/0 size or larger copper cable for GE752 ma- chines. (Reference: National Electrical Code, 1978 Edition, Table 250??95.)

5.Use a digital ohmmeter to check that the bolted connections are solid, low resistance connec- tions from the cable conductor to the ground point and to the motor frame. The meter reading should be 0.2 ohms or less.

OVERHAUL

Overhaul intervals will depend on the severity of ser??? vice seen by the machine. However, General Electric Co. recommends that an overhaul be performed every 18,000 hours (approximately every two years) on all machines subjected to normal operation.

The motor should be removed, disassembled, cleaned, inspected and reconditioned as necessary (in- cluding varnish treatment of armature and fields). Motor bearings should be repacked with grease. See the DATA section for grease type and quantity.

LUBRICATION

Periodic lubrication is required on all GE752 drilling machines designed for vertical operation between scheduled overhaul periods. Every six months or 2500 hours, whichever comes first, apply approximately 2 oz. of grease at each end.

GREASE TUBES AND PIPE PLUGS

The following lists grease tube and pipe plug configu- rations for all models covered in this publication:

1.UP1 and AUP1 ?? Four grease tubes with pipe plugs, two at each end.

2.UP2 and AUP2 ?? Two grease tubes with pipe plugs, one at each end.

3.UP3, UP3A, UP4, UP5, UP6, AUP3, AUP4, AUP5 ?? One grease tube with a pipe plug at the drive end, one pipe plug only at the commutator end.

4.US1, US2, AUT1, AUT2 ?? One pipe plug only at each end.

Pipe plugs are provided on bearing caps and on the ends of all grease tubes to prevent the ingress of dirt or other contamination.

Remove the pipe plugs and install grease fittings to facilitate lubrication. Replace the pipe plugs after adding lubricant. See the DATA section for recommended grease type.

INSPECTION

MONTHLY

Inspect the exterior of the machine, including cables, for damage.

Covers, Seals, Latches

Clean the outside of the machine and remove the in- spection covers. Use clean, dry compressed air and blow the dirt and carbon dust from the interior of the ma- chine.

WARNING: When using compressed air for clean- ing purposes, flying debris and particles may present a hazard to personnel in the immediate area. Personnel should be provided with, and trained in the use of, personal protective equip- ment as specified by applicable federal or state safety regulations.

Check exterior covers to be sure felt seals are intact. If seals are missing or covers are damaged, replace seals or covers as necessary. Make sure covers fit prop- erly and cover latches work properly.

Brushholders (Fig. 5)

Satisfactory operation of the drilling motor requires the brushholders to be in good condition. Of particular importance is the inside dimension of the carbonways. Operation may also be impaired by brushholders which have been mechanically damaged or sustained dam- age as the result of motor flashovers.

Inspect the brushholders for damage. If they require replacement, refer to BASIC REPAIRS, Brushholder Replacement section for instructions.

When new, brushholder carbonways should mea- sure 0.753 +/??0.002 in x 2.2575 +/??0.0025 in. If or when the 0.753 in. dimension exceeds 0.765 in., the brushhol- der should be scrapped. If it falls between 0.758 and 0.765 in., the carbonway can be restored to its proper dimension according to the following instructions:

1.Remove the brushholder. Position it as shown in Fig. 3 and tap the metal ridge with a hammer.

FIG. 3. RESIZING BRUSHHOLDER

CARBONWAYS. E??11281.

Start at one end and work along the ridge to the other end.

2.Check progress frequently by means of a ??Go/ No??Go?? gage made to the dimensions shown in Fig. 4.

FIG. 4. BRUSHHOLDER CARBONWAY

GAGE. E??11283A.

3.Continue tapping as described in Step 1 until the 0.753 dimension falls between 0.751 and 0.755.

4.If, due to excessive pounding, the inside dimen- sion becomes less than 0.751 in., file back to size with a fine mill file.

Additional repairs can be made to restore damaged brushholder bodies. Brushholder damage is fairly typi- cal when flashovers have occured, resulting in some burning or melting of metal at the corners of the brush- holder. Metal thus removed can be restored according to the following instruction, unless more than 1/4 in. buildup of metal is required in the affected area, in which case the brushholder should be scrapped. Proceed as follows:

1.Thoroughly clean the affected area by wire brushing, and grind off any metal flow resulting from a flashover.

2.Apply a suitable brazing flux such as GE??A10B15 to the area to be built up.

3.Insert a carbon brush into the brushholder to pre- vent the brazing material from flowing into the carbonway.

4.Using a brazing torch and a 1/16 in. diameter brass brazing rod, puddle in sufficient metal to restore the metal that had been removed.

5.Check the carbonway for size with the ??Go/No?? Go?? gage after the brushholder has cooled to room temperature.

6.Resize as required using the preceding method.

Brushholder Sleeves

spots caused by flashovers. Replace any damaged brushholder or one having a damaged sleeve.

WARNING: MEK is a volatile solvent. The fumes should not be inhaled. Use only in a well??venti- lated area and take adequate precautions to pro- tect eyes, skin and hands.

NOTE: Never paint these sleeves. Periodically wipe them clean with a dry cloth or a cloth dipped in an approved non??oily cleaning sol- vent.

Inspect the brushholder cables and make sure all terminal bolts and all brushholder clamp bolts are tight.

Brush Spring Pressure

Lift the brush pressure fingers to the ??toggled??up?? position, Fig. 5, and check for free movement of the spring assembly.

Inspect the brush springs for obvious failure or dam- age. Check brush??spring pressure by comparing spring pressure with a spring known to be good. Refer to the DATA section for brush spring??pressure value.

BRUSH PRESSURE FINGER

(IN TOGGLED??UP POSITION)

BRUSH??SHUNT

TERMINAL

SCREWS

Use a clean, lintless cloth and wipe dirt and grease from the Teflon* brushholder sleeves, Fig. 5. If neces- sary, use a cleaner such as MEK (methyl ethyl ketone) to clean the sleeves. Inspect sleeves for cracks and thin

FIG. 5. BRUSH SPRING ARRANGEMENT.

E??18963.

*Product of E.I. duPont de Nemours Company.

Brush wear is determined by measuring actual brush length from the top of the carbon. Lift the brush spring, remove the brush and measure brush length on the longest side.

NOTE: If brush replacement is not required, be sure that brushes are of sufficient length to last until the next inspection.

If one or more brushes are worn to or near the mini- mum length listed in the DATA section it is generally rec- ommended that all twelve brushes be replaced at the same time.

WARNING: To avoid possible electrical shock or injury from rotating equipment, do not remove or replace brushes while equipment is energized or rotating.

If brushes are to be replaced, see the BASIC RE- PAIRS, Brush Replacement section for brush installa- tion instructions.

If brushes are not to be replaced, the following brush inspection should be made:

CAUTION: When replacing brushes, use only the GE recommended grade. Mixing of brush grades in the same motor or changing brushes to anoth- er grade may seriously affect commutation, sur- face film, commutator and brush life. See the DATA section for brush grade.

1.Inspect all brushes to be sure they are not chipped or broken. Make sure brush shunts are not frayed or broken. Replace any brush which shows damage of any kind.

NOTE: Chipped, burned or rough??faced brushes may indicate the commutator needs resurfacing.

2.Move the brushes up and down in their carbon- ways to be sure brushes slide freely.

3.Check brush shunts to be sure they are not twisted or out of position, Fig. 6. Make sure all

Commutator

Inspect the commutator for possible flashover dam- age. The commutator should be clean, smooth, glossy and free of high mica, high bars, flat spots or rough sur- faces.

If there are indications that the commutator is out?? of??round (as evidenced by variations in width of the ridge between brush paths), check the concentricity of the commutator with a dial indicator. Condemning limits for concentricity are listed in the DATA section.

If the commutator requires grinding, refer to Com- mutator Resurfacing in the BASIC REPAIRS section of this manual for instructions.

Creepage Band

Clean the creepage band (located on the commuta- tor cap) with a clean cloth dipped in an approved sol- vent. Inspect the band for possible flashover damage.

Make sure the creepage band is tight on the commu- tator cap.

Flash Ring

Examine the flash ring for possible flashover dam- age. Wipe the flash ring clean. Keep ring free of dirt and varnish.

FIG. 6. CORRECT POSITION OF BRUSH

SHUNTS. E??22568.

Measure the insulation resistance with a meg?? ohm- meter (Megger) to determine the condition of the insula- tion. If reading is low, make a further inspection to deter- mine if insulation failure or excessive moisture is caus- ing the low megohmmeter reading. Correct the cause of low readings before returning the motor to service.

Inspect all accessible parts of the field coil insulation for cracking and evidence of overheating.

Power Cables

Inspect the power cables for signs of excessive heat- ing, poor insulation or mechanical damage. Assure all terminals are tight. Replace any cables which show low insulation resistance or will not stand 75% above rated voltage.

Mounting Bolts

Check all mounting bolts to assure tightness.

SEMI??ANNUALLY

1.Perform inspection operations listed under Monthly section.

2.Refer to the DATA section for the Brushholder Clearance dimension, and check the clearance between the brushholders and the commutator surface.

If clearance adjustment is required, refer to the BA- SIC REPAIRS, Brushholder Clearance Adjustment sec- tion for instructions.

BASIC REPAIRS

BRUSH REPLACEMENT

NOTE: Brush spring pressure is pre??set and non??adjustable for the brushholders used on these machines. Any brushholder that is dam- aged or has a low spring pressure should be re- placed before installing new brushes. Spring pressure can be measured with a 20??lb. spring scale pulling radially on the brush pressure fin-

1.Remove the commutator inspection covers.

2.Disconnect the brush shunt from the terminal screw, Fig. 5, located on the brushholder body.

3.Lift the pressure finger away from the brush to the toggled??up position. Remove the brush.

4.Use dry, compressed air and blow the carbon dust from the carbonway.

WARNING: When using compressed air for clean- ing purposes, flying debris and particles may present a hazard to personnel in the immediate area. Personnel should be provided with, and trained in the use of, personal protective equip- ment as specified by applicable federal or state safety regulations.

5.Insert a new brush and make sure it slides freely in the carbonway.

6.Carefully lower the pressure finger on the brush. Do not allow the finger to snap down on the brush; this could damage the brush.

7.Bolt the brush shunt terminals to the brushhol- der(s). Arrange the brush shunt strands so they clear the pressure fingers, Fig. 6, and tighten the terminal screw(s). Make sure brush shunts are not positioned under the pressure fingers. Check and tighten all brushholder cable connections.

8.Seat the new brushes with a white seater stone.

CAUTION: When replacing brushes, use the GE recommended grade. Mixing of brush grades in the same motor or changing brushes to another grade will seriously affect commutation, surface film, commutator and brush life. See the DATA section for brush grade.

BRUSHHOLDER REPLACEMENT

Removal

1.Remove brushes from the brushholders and cover the commutator with heavy paper.

2.Disconnect the cable from the brushholder(s) in- volved.

1.Position the brushholder in the frame with the brushholder studs resting in the clamp surfaces of the brushholder support.

2.Install bolt and washer. Tighten bolt but do not torque until the brushholder??to??commutator clearance has been established. Refer to Brush- holder Clearance Adjustment section for instruc- tions to adjust brushholder clearance.

3.After brushholder clearance has been set, con- nect the brushholder cable and remove protec- tive paper from commutator surface.

4.Check brushes to insure they exceed the mini- mum brush length dimension and are free of any damage. If they are long enough and are not damaged, they can be re??used. If not, replace with new brushes.

BRUSHHOLDER CLEARANCE

ADJUSTMENT

Refer to the DATA section for the brushholder??to?? commutator clearance dimension and adjust brushhol- der as follows:

1.The brush surface diameter of the commutator must not be less than the minimum permissible diameter, listed in the DATA section, after resur- facing operations are completed.

2.The commutator can be resurfaced by sanding, stoning or grinding. Choose the method to be used based on the condition of the commutator.

NOTE: Outside power will be required to oper- ate the motor for the following commutator??re- surfacing procedure.

WARNING: For the safety of personnel during resurfacing operations, the following safety precautions must be adhered to:

1.A second person must be at the auxiliary power (welder) control station, ready to shut off power in case of an emergency during the grinding operation.

2.The grinding operator should wear goggles and a dust mask when resurfac- ing or blowing out the commutator.

3.To avoid electrical shock, do not touch any part of the machine interior during grinding operations.

1.Remove the brushes.

CAUTION: Do not allow the brushholder to touch, bump or rest on the commutator.

2.Insert a fiber gauge (equal in thickness to the clearance dimension) between the commutator and the brushholder. (Loosen brushholder first if below minimum allowable clearance.)

Do NOT use a metallic gauge.

3.Loosen the brushholder support bolt and move the brushholder against the fiber gauge so clea- rance??to??commutator is the same as the gauge thickness.

4.Torque bolt to 225??250 ft.??lb. and recheck the brushholder clearance gap.

Preparation For Operating Series Model

Machines For Commutator Resurfacing

1.Break the coupling (if applicable) so the machine can be operated from a d??c welding set or other outside d??c power source.

2.Lift all the brushes except two of opposite polarity (adjacent brushholders) which are necessary to operate the motor.

3.Connect the machine to an outside source of controlled d??c power; such as a 3??5 kw, 100 vdc welding set which is capable of driving it at a speed of 900??1000 rpm.

4.Refer to Fig. 7 for diagram of connections to run a series machine from a welding set. Connect

FIG. 7. DIAGRAM OF CONNECTIONS TO RUN

A SERIES MACHINE FROM A WELDING SET.

E??28718.

leads so machine will operate as a series motor, and the armature will rotate counterclockwise (viewed from the commutator end).

Preparation For Operating Shunt Model

Machines For Commutator Resurfacing

1.Break the coupling (if applicable) so the machine can be run from a d??c power source.

2.Lift all brushes except two of opposite polarity (adjacent brushholders) which are necessary to operate the motor.

3.Connect the machine to an outside source of controlled d??c power, Fig. 8.

4.Apply power as follows:

a.Increase the field supply (0??50 v) to 32.0 volts at 25 amps.

b.Increase the armature supply (0??150 v) to 150 volts.

c.Slowly decrease the field supply to bring the speed up to 1000 rpm.

FIG. 8. CONNECTIONS TO RUN A SHUNT

MACHINE FROM A D??C POWER SOURCE.

E??23930A.

NOTE: When shutting down, increase the field supply to maximum, and then turn off the arma- ture supply. After the armature supply has been shut off, shut down the field supply.

Sanding Procedure

If the commutator is dirty, blackened or slightly rough, resurface it by sanding with 00 sandpaper, or fin- er, as follows:

1.Attach the fine sandpaper to a wooden block shaped to fit the commutator, Fig. 9.

2.Run the machine at approximately 1000 rpm and hold the block against the commutator with a light, even pressure. Move the block back and forth longitudinally to clean the commutator.

3.Use clean, dry compressed air, to remove dust and sand.

Hand Stoning Procedure

If the commutator surface is mildly grooved, threaded or burned, and only a small amount of copper has to be removed to correct the trouble, use a hand stone. Hand stoning will not correct an out??of??round commutator. See ??Fixture Grinding?? section.

1.Use a fine??grade stone ground to fit the commu- tator curvature, Fig. 10. It should also be of suffi- cient width to bridge any flat spots; otherwise, the stone will ride in and out of the flat and will not correct it.

2.Remove one brushholder for access to the com- mutator.

FIG. 9. METHOD OF SANDING COMMUTATOR.

E??18149.

CAUTION: Never use an emery cloth on this or any commutator. The abrasive particles on emery cloth scratch the commutator surface and lodge in the groves between commutator segments. The condition creates the possibil- ity of an eventual flashover which could seri- ously damage the machine.

WARNING: Do not come into close proximity of an energized motor during the cleaning pro- cess. The armature commutator and brush rig- ging have a high electrical charge which could cause serious injury or death. Always use a hose tip that is an electrical non??conductor when cleaning with air.

WARNING: When using compressed air for cleaning purposes, flying debris and particles may present a hazard to personnel in the im- mediate area. Personnel should be provided with, and trained in the use of, personal pro- tective equipment as specified by applicable federal or state safety regulations.

3.Run the motor at approximately 1000 rpm.

4.Hold the stone firmly against the commutator surface, and with even pressure, move the stone back and forth longitudinally across the commu- tator surface.

5.Blow away dust and sand with clean, dry, com- pressed air.

FIG. 10. PROPER SHAPE OF

HANDSTONE. E??8779A.

WARNING: Do not come into close proximity of an energized motor during the cleaning pro- cess. The armature commutator and brush rig- ging have a high electrical charge which could cause serious injury or death. Always use a hose tip that is an electrical non??conductor when cleaning with air.

WARNING: When using compressed air for cleaning purposes, flying debris and particles may present a hazard to personnel in the im- mediate area. Personnel should be provided with, and trained in the use of, personal pro- tective equipment as specified by applicable federal or state safety regulations.

Fixture Grinding

Perform fixture??grinding operations to correct a commutator that is grooved, threaded or out??of??round.

CAUTION: Be sure there is enough material on the commutator so grinding will not decrease the commutator diameter below the minimum permissible diameter listed in the DATA sec- tion.

Refer to SPECIAL TOOLS AND EQUIPMENT sec- tion for commutator grinder part number. See Fig. 11 for grinder nomenclature.

Grinder Installation

NOTE: Inspect the grinder before installing it to be sure it is reasonably clean. Make sure the tra- verse slides are free of accumulated dirt and copper chips; otherwise, the carriage may bind during the grinding operation.

1.Remove the inspection covers from the ma- chine.

2.Remove the most accessible brushholder, and clamp the grinder mounting bracket to the frame.

3.Remove the brushes from one brushholder adja- cent to grinder in a CCW direction.

4.Install old brushes in remaining brushholders.

5.Bolt the grinder to the mounting bracket.

NOTE: For most applications, finish??grade resurfacing stones are recommended. Medium grade stones can be used for rough grinding a deeply grooved or threaded commutator, or a commutator with deep flat spots, followed by fi- nish??grade stones for the final grinding. If new stones will be used, they should be contoured on a Carborundum wheel to approximate the curvature of the commutator.

Install the stones in the grinder so the entire surface of the commutator will be resurfaced when the carriage is traversed from side??to??side. Proceed with alignment of the grinder as follows:

Install the resurfacing stones in the grinder and pro- ceed as follows:

1.Traverse the carriage to one end of the commu- tator and check the clearance between the com- mutator surface and one stone with a feeler gauge or a fiber strip (approximately 0.030 in. thick). Traverse the carriage to the other end of the commutator and check the clearance under the same stone. The clearance should be the same at both ends. If clearance is not equal at both ends, adjust the mounting bracket by means of the set screws to obtain equal clear- ance at both ends.

2.Turn the feed control to back the stones away from the commutator before starting the ma- chine.

NOTE: If possible, use some method of collect- ing the copper chips and abrasive dust pro- duced by the grinding operation. For example, use a vacuum cleaning device with the suction wand set just behind the trailing edge of the stones.

Grinding

1.Apply power to the machine and gradually in- crease speed to 900??1000 rpm.

NOTE: Do not grind the commutator to a depth where no mica undercut remains, or to a diame- ter which is smaller than the minimum permis- sible diameter listed in the DATA section.

2.Begin grinding by radially feeding the stones lightly against the commutator. Then, slowly move the carriage back and forth longitudinally across the surface. When the cutting action of the stone ceases, again feed the stone lightly against the commutator and continue grinding. Use care to make a light cut and to avoid chatter. Cutting action should take place at the trailing edge of the stones. Heavy cuts will cause exces- sive copper drag.

3.Grind the commutator to obtain a uniformly smooth surface, but do not remove any more copper than necessary.

4.Lighten the cutting pressure on the stones near the end of the grinding operation. If medium?? grade stones were used, stop the motor, change to finish??grade stones and repeat Steps 1, 2, 3 and 4. After the final cut, traverse the stones back and forth without changing the feed until cutting action ceases.

5.Remove power from the machine.

6.Check commutator runout with a dial indicator. Refer to the DATA section for concentricity limits.

FIG. 12. COMMUTATOR SLOT RAKING TOOL.

E??19771A.

7.If necessary, continue grinding to meet concen- tricity values listed in the DATA section.

8.Remove the grinder.

9.See Fig. 12 for slot raking tool. Rake the commu- tator slots to remove projecting mica fins or cop- per whiskers.

10.Run the machine again at 1000 rpm and polish the commutator with 00 sandpaper, crocus cloth or 400A Triemite* paper. The abrasive sheet should be mounted on a wooden block curved to fit the surface of the commutator.

CAUTION: Never use an emery cloth on this or any commutator. The abrasive particles on emery cloth scratch the commutator surface and lodge in the grooves between commuta- tor segments. This condition creates the pos- sibility of an eventual flashover which could seriously damage the machine.

11.Blow the dust from the commutator and the inte- rior of the motor with dry, compressed air. Hold the air nozzle one to two inches from the surface of the commutator and sweep nozzle longitudi- nally to dislodge copper chips and mica dust.

12.Air cure the commutator. See the following sec- tion for air curing instructions.

*Product of Minnesota Mining and Manufacturing

Co.

After the commutator has been sanded, stoned or ground and blown clean, it should be air cured as fol- lows:

1.Rotate the armature slowly with the same source of power used for sanding, stoning or grinding.

2.Use a rubber air??hose with the nozzle removed and sweep the commutator surface with 70 psi air pressure.

WARNING: Observe all the following safety precautions to avoid injury.

1.Remove all metal fittings from the air hose or, if impossible to remove, insulate the fitting.

2.Be certain an operator is stationed at the power??supply control to quickly remove power from the machine should an emer- gency arise.

3.Wear rubber??insulated gloves and goggles while air curing. Stand on an in- sulated platform.

4.Avoid contact with the cable terminals.

WARNING: Do not come into close proximity of an energized motor during the cleaning pro- cess. The armature commutator and brush rig- ging have a high electrical charge which could cause serious injury or death. Always use a hose tip that is an electrical non??conductor when cleaning with air.

7.Use a clean cloth and wipe off the brushholders, creepage band and accessible surfaces in the commutator chamber.

8.Brushholder Clearance ?? Install the brushholder previously removed and check and adjust as re- quired the brushholder??to??commutator clear- ance on all brushholders. See previous Brush- holder Replacement and Brushholder Clearance Adjustment sections for instructions to install the brushholder, and to adjust brushholder clear- ance.

9.Installing Brushes ?? Refer to BASIC REPAIRS, Brush Replacement section, and install serviceable or new brushes per instructions listed.

10.Vacuum interior of commutator chamber.

BASIC OVERHAUL

NOTE: Be sure to use the correct drawings for the machine being overhauled. Refer to Table 2 on page 20 to determine the correct drawing.

It is recommended that a basic overhaul be per- formed every two years, or 18,000 hours. The time inter- val between overhauls may vary, depending on the con- dition of the machine and the severity of service.

The following basic overhaul procedures include in- structions to disassemble, clean, inspect, repair, reas- semble and test the machine.

TESTING BEFORE DISASSEMBLY

Perform the following tests prior to disassembly of the machine:

Megohmmeter Test

Lift the brushes and perform a megohmmeter test on the armature windings and field coils to determine the condition of the insulation. A reading of less than 2 megohms indicates poor insulation, dirt accumulation or excessive moisture.

Bar??To??Bar Resistance Test

Test for open or short??circuited armature coils.

1.Pass a regulated d??c current through the arma- ture coils.

2.Read the voltage drop between the commutator bars with a millivoltmeter. if the reading varies more than +/?? 5% from the average value, a de- fective or short??circuited coil is indicated.

DISASSEMBLY

Armature Removal From Frame

Models UP, AUP

Before turning the machine from horizontal to verti- cal (or vice??versa), attach the armature locking ar- rangement to prevent the armature from moving axially. Remove the armature locking arrangement before op- erating the machine.

See Table 2 to determine the correct armature lock- ing arrangement drawing.

Refer to the longitudinal drawing, Fig. 15, and puller tool drawings, Figs. 16 and 17.

1.Clean the outside of the frame.

2.Remove the hubs from the shaft if not already re- moved.

3.Remove the commutator covers. Disconnect and remove all brushes and brushholders. Wrap

VIEW OF COMMUTATOR END FOR

ALL MODELS EXCEPT UP1, UP2, AUP1 AND AUP2

THIS GREASE TUBE CONFIGURATION

IS APPLICABLE TO MODELS UP1, UP2

AUP1 AND AUP2 ONLY. SEE VIEW ABOVE FOR

ALL OTHER MODELS

56

57

52

42

VIEW OF PINION END FOR ALL

MODELS EXCEPT UP1, UP2, AUP1

AND AUP2

8.Reach into the drive??end of the motor and dis- connect grease tubes.

a.On UP1 and AUP1 models, disconnect two grease tubes (21 and 22) from the inner bear- ing cap (51). Pull these tubes out through their hole in the frame. The sealing RTV in the hole will separate with sufficient force.

b.On UP2 and AUP2 models, disconnect one grease tube (21) from the inner bearing cap (51). Pull this tube out through its hole in the frame. The sealing RTV in the hole will sepa- rate with sufficient force.

c.On all other models, only one grease tube is used, connected between the inner bearing cap and the framehead. Remove this tube.

9.Place three 0.125 in. spacers (wedge shaped) around the armature in the air gap between the armature and the fields to maintain a vertical atti- tude of the armature and to prevent the armature from contacting the fields.

10.Remove bolts (10) and lockwashers (12) from the framehead (55). Insert bolts into the jackout holes in the framehead.

11.Install a lifting bail, Fig. 14, onto the end of the shaft.

12.Line up the hoist cable with the centerline of the armature before engaging the hook in the lifting bail on the end of the shaft. Engage the hook and lift slightly. With sufficient strain on the hoist cable to take the weight of the armature off the

framehead, jack the drive??end framehead loose, and lift the complete armature assembly out of the frame. DO NOT DAMAGE THE COMMUTA- TOR.

13.Move the armature to a suitable fixture for further bearing disassembly or repair.

14.Install puller (Part 6751547G4) and pull sleeve

(47)from the shaft at the drive end. Heat may be applied.

15.Remove bolts and lockwashers (53) from bear- ing cap (5). Remove the bearing cap and gasket

16.Remove the framehead. It will come with the bearing outer race and bearing rollers.

17.Pull the inner bearing race off the drive end of the shaft with puller (Part 6751547G5).

18.Remove flinger (49) and inner bearing cap (51) with puller (Part 6751547G6) by inserting the four puller bolts into tapped holes in the inner bearing cap.

19.If necessary, remove inner sleeve (50) with puller (Part 6751547G7).

20.Press the outer bearing race and rollers from the framehead with an arbor press.

NOTE: Before pressing the drive??end outer bearing race out of the framehead, observe and record the number on the face of the race which is opposite the arrow on framehead. After re- moval, mark the date (with electric pencil) un- der this number to indicate that this position has been used. Reassemble the bearing with another number opposite the arrow. If the bear- ing has not been previously marked, etch Nos. 1, 2, 3 and 4 (spaced 90 degrees apart) on the face of race with an electric pencil. Locate No. 1 opposite the arrow on the framehead and mark it with the date.

21.Install puller (Part 6751547G10) and pull spacer

(43)from the commutator end of shaft.

22.Install puller (Part 6751547G6) and pull bearing housing (46) with bearing (44) from the shaft.

23.Press ball bearing (44) from bearing housing

(46)using an arbor press.

24.If applied, remove the nilos ring (4), Fig. 39, from the bearing and discard.

25.If applied, remove the seal ring (5), Fig. 39, from the sleeve and discard.

26.Install puller (Part 6751547G11) and pull sleeve

(45)from the shaft.

27.If it is necessary to remove the commutator end framehead (56), place the frame commutator

end up and remove bolts (11) and lockwashers (12). Use bolts in the framehead jackout holes to break the fit and remove the framehead.

Armature Removal From Frame

CAUTION: When lifting the armature out of the frame, proceed slowly so that no damage will occur to the armature end??windings, bear- ings, bearing fits or the commutator.

Models US1, AUT

Before turning the machine from horizontal to verti- cal (or vice??versa), attach the armature locking ar- rangement to prevent the armature from moving axially. Remove the armature locking arrangement before op- erating the machine.

See Table 2 to determine the correct armature lock- ing arrangement drawing.

Refer to the longitudinal drawing, Fig. 18, and puller tool drawings, Figs. 16 and 17.

1.Clean the outside of the frame, using com- pressed air, a steam??jenny or cleaning solvents, to remove accumulated dirt.

2.Remove the coupling hub from the shaft, if not al- ready removed.

3.Remove the commutator covers. Disconnect and remove all brushes, and wrap heavy paper around the commutator for protection during handling.

4.Install puller tool (Part 6751547G4) and pull the sleeve (6) from the commutator end of the shaft.

5.Remove bolts (10) which hold the bearing cap and the bearing housing to the commutator??end framehead. Remove the bearing cap (8) and gasket (11).

6.Turn the machine on end on a stand, commuta- tor end down, and level it so that the armature can be lifted vertically out of the frame without damaging the bearings, commutator or brush- holders.

7.Screw three guide pins into the commutator??end bearing housing (3) to help guide the armature out of the frame.

8.Screw a lifting bail, Fig. 14, on the drive end of the shaft.

9.Remove drive??end framehead bolts (30) and in- sert three jack screws in the threaded holes pro- vided in the framehead.

10.Line up the hoist cable with the centerline of the armature before engaging the hook in the lifting bail on the end of the shaft. Engage the hook and lift slightly. With sufficient strain on the hoist cable to take the weight of the armature off the framehead, jack the drive??end framehead loose, and lift the complete armature assembly out of the frame. DO NOT DAMAGE THE COMMUTA- TOR.

CAUTION: Special precautions should be taken to avoid damage to the armature end??windings, bearings or bearing fits, and the commutator when lifting the armature in the vertical position or turning the armature to a horizontal position.

11.Place the armature horizontally in an armature saddle for bearing disassembly.

12.At the drive end, remove the lubricating tube as- sembly (9, 33, 32 and 28) from the framehead.

13.Using puller tool (Part 6751547G4), pull the out- er sleeve (37) from the drive end of the shaft. The sleeve has tapped holes for applying the puller. Heat may be applied.

14.Remove bolts (34), and then remove outer bear- ing cap (36) and gasket (35).

15.Slide framehead (29) off the shaft together with the outer race and rollers of bearing (38). The in- ner race will remain on the shaft.

16.Pull the inner bearing race off the shaft with puller (Part 6751547G5).

17.Remove flinger (39) and inner bearing cap (40) with puller (Part 6751547G6) by inserting the four puller bolts into the tapped holes in inner bearing cap (40).

18.Press the outer bearing race and rollers from the framehead with an arbor press.

NOTE: Before pressing the drive??end outer bearing race out of the framehead, observe and record the number on the face of the race which is opposite the arrow on the framehead. After removal, mark the date (with electric pencil) un- der this number to indicate that this position has been used. Reassemble the bearing with another number opposite the arrow. If the bear- ing has not been previously marked, etch Nos. 1, 2, 3 and 4 (spaced 90 degrees apart) on the face of race with an electric pencil. Locate No. 1 opposite the arrow on the framehead and mark it with the date.

19.Install puller tool (Part 6751547G10) and pull spacer (5) from the commutator end of the shaft.

20.Install puller tool (Part 6751547G6) and pull bearing (4) and bearing housing (3) from the commutator end of the shaft.

21.Press the bearing from the framehead with an arbor press.

22.If applied, remove the nilos ring (4), Fig. 39, from the bearing and discard.

23.If applied, remove the seal ring (5) Fig. 39, from the sleeve and discard.

24.Install puller tool (Part 6751547G11) and pull sleeve (2) from the commutator end of the shaft.

25.If necessary to remove the commutator framehead (14), turn the frame commutator end up and remove bolts and lockwashers (13). Use bolts in the framehead jack??out holes to break the fit and remove.

CLEANING

The two recommended methods for cleaning are steam cleaning and vapor degreasing.

CAUTION: Do not use caustic soda solution on the armature or coiled frame.

Steam Cleaning

(Recommended for both insulated and metal parts)

1.Use steam in combination with a commercial non??caustic cleaner.

2.Suspend the part in a position accessible from all directions to a direct flow of steam from the hose.

3.Rinse all residue from parts with a mixture of clean steam and water.

4.Bake insulated parts for at least 8 hours at 150??? C (302??? F) to remove all moisture.

Vapor Degreasing

(Recommended for metal parts)

1.Bring the cleaning solution to a boil, and allow the vapor line in the tank to rise to the condenser coils at the top of the tank.

2.Keep the vaporized cleaning solution at about 120??? C (248??? F).

3.Lower the part to be cleaned into the vapor??la- den atmosphere, so the vapor will condense on the part.

4.To speed the removal of heavy dirt accumula- tions, spray hot solution directly from the tank onto the part being cleaned. The temperature of the solution must be kept below its boiling point.

5.Remove the cleaned part from the degreaser. Drain and cool the part.

Anti??Friction Bearings/Shaft

Tapers/Bearing Fits

Use a cleaning solution that leaves an oil film to pro- tect finished surfaces from rust. Kerosene, petroleum spirits or other petroleum??base cleaners provide limited protection for these surfaces.

INSPECTION AND TEST OF

DISASSEMBLED MOTOR

BEARING INSPECTION

1.Clean the bearings. See Cleaning section.

2.Inspect for broken or cracked races, broken or cracked rollers and balls, broken, cracked or dis- torted retainers, scored, pitted, scratched or chipped races, and for indication of excessive

wear on rollers and balls. Replace the bearing if any of these conditions is found.

3.Look for evidence of smearing caused by inade- quate lubrication, and corrosion pitting (usually at roller spacing) caused by moisture or other corrosive agent. Replace the bearing if any of these conditions are found.

4.Inspect bearing outer races for indentations caused by dirt or foreign material having gone through the bearing. If the indentations are small and few in quantity, the bearing can be used. If the indentations are large and numerous, this may be an indication the rollers or cone are start- ing to spall out. Examine the rollers and cone carefully for spalled areas. Replace the bearings if spalled areas are found.

5.Dip good bearing parts in a light mineral oil (SAE??10) heated to 90??? C (194??? F) to avoid cor- rosion before reassembly.

6.If a bearing will not be mounted immediately, wrap it in an oil??proof paper.

CAUTION: Do not interchange bearing parts of different manufacture or mix new and used bearing parts.

Perform the following inspection and tests to deter- mine the condition of the armature, coiled motor frame and brushholders.

After the inspection and test procedures have been completed and all defects or damage noted, refer to the REPAIR section for the correct repair procedure.

ARMATURE

Handle the armature carefully during overhaul oper- ations to avoid damage to the core, banding, end turns, shaft fits and commutator. Support the armature in a saddle to protect the commutator and to coil the ends. Keep the commutator covered with heavy paper.

Armature Test

1.With the armature at room temperature, 25??? C (77??? F), use a 500 or 1000 vdc megohmmeter and make a dielectric test of the armature insula-

tion. A reading of one megohm or higher should be obtained. If necessary, perform additional cleaning and baking operations to obtain this val- ue before proceeding.

NOTE: If additional cleaning and baking opera- tions do not increase the resistance value of the insulation, it may be necessary to replace the creepage band and rewind the armature.

2.Measure and record armature resistance. See the DATA section for values.

3.If there are no armature coils grounded, perform

abar??to??bar comparison test to check for open or short??circuited armature coils.

a.Pass a regulated d??c current through the ar- mature coils.

b.Read the voltage drop between the commu- tator segments with a millivoltmeter. If the reading varies more than plus or minus 5%, a defective or short??circuited coil is indicated. If the armature fails the bar??to??bar test, the ar- mature must be rewound.

If the armature will not be rewound, proceed to inspect the following items.

Insulation

Inspect the insulation of armature coils for cracks, physical damage, burns and deterioration. If minor re- pairs are required, refer to Fig. 19 for insulation details.

Glass Band, Commutator End

Inspect the glass bands for split, frayed or loose con- dition.

Wire Band, Drive End

check for movement of the band to determine if loose. If the band is loose or has deep burns, replace it. See RE- PAIR section for instructions.

COMMUTATOR

Check the commutator for threading, pitting, groov- ing, burns, flat spots, high bars and copper drag.

Check the commutator to make sure that it is not out??of??round. See the DATA section for concentricity limits.

Resurfacing

For the resurfacing procedure for a commutator, see REPAIR, Armature section.

Refer to the DATA section for the minimum permissi- ble commutator diameter dimension and check the di- ameter of the commutator.

NOTE: If the brush surface diameter will be less than the minimum permissible diameter after resurfacing operations are performed, the com- mutator must be replaced.

Tightening

If the commutator is loose (has high bars), see the ??REPAIR, Commutator Tightening?? section for instruc- tions to tighten the commutator.

ARMATURE SHAFT INSPECTION

Armature shaft bearing fit dimensions can be checked and compared to armature shaft drawings pro- vided in Fig. 20. If the bearing fit dimensions are not within stated tolerances the shaft must be replaced or repaired. Refer to Table 2 to determine the correct shaft drawing for the machine being repaired.

MOTOR FRAME

Inspect the wire band for physical damage, loose tie clips or broken wire.

Creepage Band

Inspect the surface of the Teflon creepage band for possible flashover damage. Tap the band lightly and

1.Check the connection strap insulation for dam- age, signs or burning, cracks or discoloration.

2.Check the insulation on the coils for damage, signs of burning, cracks or discoloration.

3.Check the lead cables for damage, overheating and signs of deterioration.

NUMBERED SEGMENTS ARE FOR

PURPOSE OF INDICATING SPAN OF

EQUALIZER CONNECTIONS AND DO

NOT NECESSARILY CORRESPOND

TO NUMBERED SEGMENTS IN

MAIN CONNECTION DIAGRAM.

30

NOTE FOR P62:

APPLY TO SIDES OF CORE SLOT

ON PINION END ONLY.

INSTALL P11.

NOTE FOR P47:

ENCLOSE ONE IDENTIFICATION C??SIZE

PRINT OF 41D730423 IN EACH

CARTON OF SUPPLY INSUL.

NOTE FOR P32:

TAPE OVER RISERS WITH 3/4 WIDE A2L14B GLASS TAPE

LEAVING 1/4 IN. OF RISERS EXPOSED ON THE CORE END. FILL

BETWEEN ARMATURE LEADS BEHIND RISERS AND OVER BACK 1/4 IN. OF RISER. WRAP OVER PUTTY WITH A16B39B

MYLAR TAPE AND BAKE AS PART OF THE PREHEAT PERIOD

FOR INSTALLING P37.

SLOT #16

TOP COILS

SLOT #1

ORPHAN

COILMAIN WINDING

CONNECTIONS

ON MICA

L

BOTTOM COILS

NOTE FOR P37 (C.E. BINDING):

APPLY THE P37 PERMANET CE BINDING (COLD TAPE TO HOT 125??135 C ARMATURE)

APPLY 77 ACTIVE TURNS OF P37 AT 500

NOTE FOR TEMPORARY BINDING:

APPLY TEMPORARY BINDING. 6 TOTAL PASSES WITH 0.102 DIAM. B4Y19B AT 800 LB. TENSION. BAKE IN A 150 C OVEN FOR 4 HOURS.

FIRST TURN

2ND DECK

26PT26 TO BE APPLIED

OVER COILS TO LEVEL

THE SURFACE

12 SATURATE P2 THOROUGHLY WITH P56

SECTION B??B

272ND AND 3RD DECK

CONTINUOUS WIRE

NOTE FOR P38 (P.E. BINDING):

4.Conduct a 500 volt megohmmeter test on the coils. A reading of 20 megohms or more is ac- ceptable.

5.See Figs. 21 thru 24 and measure and record commutating and exciting??coil resistance. Re- fer to Table 2 to determine the correct connection diagram for the machine being repaired.

6.High??potential test the field coils to ground.

WARNING: Electric shock can cause serious injury or death. Strict safety precautions must be taken and observed by personnel conduct- ing a high??potential test.

Apply a high??potential test of 2000 volts, 60 Hz for one minute.

BRUSHHOLDERS

1.Inspect the brushholder for flashover damage, cracks and burned or pitted areas.

2.Check the brush springs to be sure they move freely and do not bind.

3.Insert a new brush in the carbonway and move it up and down in the carbonway to be sure it moves freely.

REPAIR

LUBRICATION OF BOLTS

The threads and washer faces of bolts and nuts should be lubricated to obtain maximum clamping force (at the nominal or at a recommended torque value) when bolts and nuts are installed at reassembly. Lubri- cate all bolts.

Use a High Pressure Lubricant such as; graphite in oil (1 part graphite to 5 parts machine oil by volume), Lu-

147X1640) to lubricate bolts.

NOTE: Threads and washer??contact surfaces must be clean before lubricant is applied.

Where specific torque values are not listed in these instructions, refer to Table 3 for standard bolt torque val- ues of lubricated bolts.

*Product of Fisk Bros. Refining Co., Newark, N.J. **Registered trademark of Dow Corning Corp.

***Acheson Colloids Co., Port Huron, Mich.

1.Remove the damaged Teflon sleeve from the brushholder stud. To remove sleeve, heat the brushholder in an oven to 150??? C (302??? F) then peel or cut sleeve from the stud.

2.Thoroughly clean the surface of the stud and re- move any carbon or dirt build??up.

3.Heat a new Teflon sleeve in a 150??? C (302??? F) oven for 15 minutes.

4.Using adequate hand protection, immediately assemble the hot sleeve on the stud.

ARMATURE

Creepage Band Replacement

TABLE 3

STANDARD BOLT TORQUE VALUES

(For Lubricated Bolts)

Because of its superior adhesion qualities, the Teflon creepage band on the outer end of the commutator should be applied using the ??hot bond?? process. A copy of this process is included in each Teflon Band Kit, Part No. 76518, which can be ordered from the following ad- dress:

General Electric Company

Insulating Materials Product Section

One Campbell Road

Schenectady, NY 12345

Attn: Customer Service

NOTE: The Teflon band is not included in the kit, but can be ordered through normal Renewal Parts channels.

Inspect the Band

1.There should be no gaps at the joint or between the edge of the Teflon band and the copper bars.

2.The band surface must be smooth, free of var- nish and bonded to the underlay material. There must not be any bubbles under the Teflon or buckling of the band.

3.The surface must be free of damage including scratches and cuts.

Rewinding Armature

The armature must be rewound if any coils are shorted or grounded.

Riser Width

During the rewinding procedure, the TIG welds on the commutator risers are machined to break the arma- ture coil connections. Machining reduces the width of the risers 1/32 to 1/16 in. each time, which in turn de- creases the current??carrying capacity of the risers.

If the calculated width of the risers (after machining) will be less than the Minimum Permissible Riser Width listed in the DATA section, a new commutator must be installed before new armature coils are assembled.

USE THE TORQUE VALUES IN THIS TABLE AS A GUIDE TO IN-

SURE SATISFACTORY TIGHTENING OF BOLTS AND NUTS

WHERE A SPECIFIC VALUE IS NOT GIVEN IN THE INSTRUC-

TIONS.

*INCLUDES SOCKET HEAD SCREWS.

Diameter

Refer to the DATA section for the Minimum Permissi- ble Commutator Diameter dimension. If the commutator brush??surface diameter will be less than the minimum permissible diameter after resurfacing operations are performed, replace the commutator before the new ar- mature coils are assembled.

If necessary, tighten the appropriate cap bolts to obtain this parallel relationship between the face of the cap and the segments.

2.Remove ONE bolt. Clean and lubricate the bolt threads under the bolt head. Reassemble bolt, and torque to 97 lb.??ft.

3.Repeat Step 2 for remaining bolts, following the crisscross tightening sequence shown on Fig. 27.

4.Repeat the tightening sequence increasing the torque by 10% each time until a FINAL value of 145 lb.??ft. torque for all bolts is obtained.

5.Check the dimension between face of cap and segments to assure these surfaces are parallel within 0.020 in.

NOTE: Do not tack??weld the bolts to the com- mutator cap before spin seasoning or resurfac- ing operations are performed.

Refer to following sections for instructions to spin season and resurface the commutator.

Spin Seasoning

(Commutator Assembled On Armature)

A commutator seasoning cycle is required after com- mutator tightening operations have been performed.

Prior to spin??seasoning, dynamically balance the ar- mature to within 12 grams on the commutator end and 10 grams on the drive end. Refer to longitudinal section for balance weight locations (see Table 2 to determine the correct drawing).

To spin season the commutator, place the armature in a spin??seasoning stand and proceed as follows:

1.Heat the commutator to 155??165??? C (312??330??? F) in 60 minutes at 2940 rpm. Spin at 155??165??? C (312??330??? F) for 60 minutes at 2940 rpm. Cool to 50??? C (122??? F) maximum in 30 minutes at 2940 rpm.

2.Allow the commutator to cool, and grind cold. See ??Commutator Resurfacing?? section.

3.Heat the commutator to 155??165??? C (312??330???

F)in 60 minutes at 2940 rpm. Spin at 155??165??? C (312??330??? F) for 30 minutes at 2940 rpm. Cool to 50??? C (112??? F) maximum in 30 minutes at 2940 rpm. Repeat for a total of 2 cycles.

4.Heat the commutator to 140??150??? C (284??302???

F)in 60 minutes at 2940 rpm, and check commu- tator smoothness at 2940 rpm.

5.Allow the commutator to cool, and grind cold. See the ??Commutator Resurfacing?? section. Check commutator runout per the information in the DATA section. If the commutator is rough or has high bars, repeat the pressing, tightening, spin??seasoning and resurfacing procedures un- til the runout is within the limits specified in the DATA section.

6.Tack??weld the bolts to the commutator cap with bronze welding rod, GE??B50E37.

7.Refer to the ??Test After Repair (Armature)?? sec- tion for the test voltage, and perform a High??Po- tential test on the armature windings.

Commutator Resurfacing

Prior to turning or grinding the commutator, be cer- tain there is sufficient stock so the commutator will not be turned or ground below the minimum permissible di- ameter.

Refer to the DATA section for the minimum permissi- ble commutator diameter dimension.

If the brush surface diameter will be less than the minimum permissible diameter after the resurfacing op- erations are performed, the commutator must be re- placed.

Grinding

1.Prior to grinding, true the shaft centers with re- spect to the bearing fits by scraping.

2.Place the armature in a lathe equipped with a grinding attachment or in a grinding machine.

Check the concentricity of the bearing fits. The TIR should not exceed 0.001 in.

3.Cover the armature windings to prevent entry of grinding dust and chips.

4.Grind the commutator and check commutator runout with a dial indicator. The maximum com- mutator runout is 0.001 in.

5.Perform the undercutting, raking and polishing operations.

Turning

If the surface of the commutator is badly worn, burned or scarred, turn the commutator in a lathe as fol- lows:

1.True the shaft centers with respect to the bearing fits by scraping. Place the armature in a lathe and check the concentricity of the bearing fits. The TIR should not exceed 0.001 in.

2.Cover the windings to keep out chips.

3.Set the cutting tool for turning copper, and set lathe speed to give a commutator surface speed of 300 feet per minute. Refer to the DATA section for dust groove dimensions.

4.Make clean, smooth cuts to remove just enough copper to renew the commutator surface. Do not allow the cutting tool to chatter.

5.After turning operations have been completed, check commutator runout with a dial indicator. The maximum runout is 0.001 in.

6.Perform the undercutting, raking and polishing operations.

MODELS

SEE TABLE 2

TO CHANGE MOTOR DIRECTION:

TO RUN CCW VIEWED FROM COMMUTATOR END,

I

??

O

??

I

??

N

??

I

??

#92

??

I N ??

O

N

??

I

??

A1

#93 #94

S

??

I

??

OS

A2

??

I

??

F2

F1

O

O

VIEW AT COMMUTATOR END

TO CHANGE MOTOR DIRECTION:

TO RUN CCW VIEWED FROM COMMUTATOR END,

MODEL

SEE TABLE 2

FIG. 25. COMMUTATOR TIGHTENING.

E??4270B.

WARNING: During resurfacing operations, eye protection and a respirator should be worn to protect personnel from dust and fly- ing particles.

use slot guides and depth gauges for accurate, uniform cuts. Make a few practice passes over a scrap commu- tator to get the ??feel?? of the tool. Care must be taken to prevent the power undercutter from jumping out of the slot and across the commutator surface. The high?? speed operation of the blade will quickly gouge the com- mutator.

1.After a commutator has been resurfaced, the mica between the bars should be undercut to a depth of 0.047 in. Undercutting should be done with a sharp??edged tool with a cutting width of 0.063 in.

2.Blow loose material off the commutator with dry, compressed air.

FIG. 26. COMMUTATOR PRESSING

DIAMETER. E??18140

WARNING: When using compressed air for cleaning purposes, flying debris and particles may present a hazard to personnel in the im- mediate area. Personnel should be provided with, and trained in the use of, personal pro- tective equipment as specified by applicable federal or state safety regulations.

Raking

Resurfacing usually leaves particles and slivers of copper hanging on the bar edges or lodged in the under- cut slots. These must be removed before the motor is placed in service, or the particles may bridge the side mica and cause a flashover.

1.Brush out dirt and copper whiskers attached to the trailing edge of the bars with a stiff??bristle brush; preferably one with nylon bristles. A new paint brush or stencil brush with the bristles cut short for added stiffness may also be satisfacto- ry. If stoning and undercutting have produced considerable dragging of copper from the edges of the bars, use a raking tool to remove the cop- per fins and ragged edges. Use the tool to rake the bar edges with the point inserted in the slot so that sides of the V rake the trailing edge of the bar. If the tool is ground with flat sides and used with moderate pressure as a raking tool, it will re- move ragged copper fins and break the sharp

FIG. 27. COMMUTATOR BOLT TIGHTENING

SEQUENCE. E??4502.

edges of the bars. See Fig. 12 for an illustration of the tool. Another method of removing copper fins is to rake the slots with a piece of fiberboard approximately 0.045 in. thick.

2.After slots have been raked with fiberboard or a raking tool, sand the commutator with fine sand- paper to remove small pieces of copper sticking from edges of slots.

3.Thoroughly clean the armature core and com- mutator with dry, compressed air to remove cop- per and dust.

1.If the commutator is discolored or smudged, pol- ishing with canvas, crocus cloth, fine (4/0) sand- paper or 400A Triemite paper is usually suffi- cient.

Abrasive paper should be mounted on a wooden block curved to fit the surface of the commutator.

Used Armature

Apply a high??potential test voltage of 2000 volts, 60 Hz for one minute.

Rewound Armature

Apply a high??potential test voltage of 3500 volts, 60 Hz for one minute.

NOTE: Measure leakage current to ground dur- ing test 3??85.0 milliamps.

WARNING: Electric shock can cause serious or fatal injury. To avoid such injury, personnel should take and observe proper precautions during the high??potential testing.

Resistance Measurement

Refer to the DATA section for armature the resis-

2.Blow loose material off the commutator with dry, compressed air.

3.Check commutator concentricity with a dial indi- cator. Refer to the DATA section for runout limits.

4.Cover the commutator with heavy paper or felt to protect it from damage.

WARNING: Personal injury may result if prop- er eye protection is not worn when cleaning with compressed air.

CAUTION: Never use an emery cloth on this or any commutator. The abrasive particles on emery cloth scratch the commutator surface and lodge in the grooves between commuta- tor segments. This condition creates the pos- sibility of an eventual flashover which could seriously damage the machine.

TEST AFTER REPAIR (Armature)

High Potential Test

Apply test voltage between the commutator (with all segments shorted) and the shaft.

tance value and measure armature resistance.

NOTE: Insulation Processing (Armature VPI)

After the armature has been cleaned and re- paired or rewound, it must be vacuum pressure impregnated. See the Varnish Treatment, ??Vac- uum Pressure Impregnation?? section for fur- ther required processing of the armature.

A.MICA PROPERLY UNDERCUT.

B.UNDERCUTTING TOOL TOO NARROW, LEAVING FIN

AT ONE SIDE OF SLOT.

C.UNDERCUTTING TOOL VERY NARROW, LEAVING

FINS AT BOTH SIDES OF SLOT.

D.SLOT IMPROPERLY INDEXED, PART OF BAR CUT

AWAY AND FIN OF MICA LEFT.

E.TOOL TOO WIDE, PART OF BAR CUT AWAY.

F.UNDERCUTTING TOO SHALLOW, SERVICE LIFE

SHORTENS BEFORE NEXT UNDERCUTTING.

G.UNDERCUTTING TOO DEEP, POCKET COLLECTS

CARBON AND COPPER DUST, SHORT CIRCUITING

BARS.

FIG. 28. COMMON MISTAKES IN

UNDERCUTTING COMMUTATOR SLOTS.

E??5024A.

1.Remove terminal insulation and disconnect coil leads. Use a gas torch or brazing tongs to sepa- rate brazed connections. When using brazing tongs use low voltage and high a??c current to heat coil connections.

WARNING: Safety glasses and leather gloves must be worn at all times during brazing oper- ations to protect personnel from physical harm.

NOTE: If a gas torch is used, coil insulation must be protected from heat by a non??flam- mable heat absorbent.

1.Pack absorbent around the insulation near the connection and over adjacent coils.

2.Make sure all exposed insulation is covered with a thick layer of absorbent, then heat and separate the coil connections.

2.Heat the coiled frame in an oven at 150??? C (302???

F)for four hours to soften the varnish so pole bolts can be removed.

NOTE: Install any exciting coils and braze their connections before installing commutating coils.

1.Before installing any coil and pole, clean the pole contact surface on the frame and the pole piece mounting surface.

2.Install the new pole and coil in the frame with any shims that were on the damaged coil. Use new washers under bolt heads. Lubricate the bolt heads, threads and washers and draw the pole bolts moderately tight.

3.Refer to Table 2, Page 20, to determine the cor- rect coiled frame assembly drawings. All coil connections must be brazed with silver solder, GE??B20A6. Use two pieces of solder (0.010 x 1 in. x 1 in.) between terminal surfaces and braze terminals as follows:

BEFORE ASSEMBLING

CONNECTIONS INSULATE

9 O'CLOCK CABLE SUPPORT

AS SHOWN WITH P20 TAPED WITH P21 (COMM. END)

INSULATE EXCITING & COMMUTATING FIELD COIL

TERMINALS BY FILLING ALL CAVATIES & COVERING

ALL BOLT HEADS WITH P24 THEN INSULATE ENTIRE

TERMINALASSEMBLY WITH P18 & P19 AND THOROUGHLY

BRUSH WITH P23.

PLUG IS EXPANDED & TIGHT IN HOLE

CARBON

BRUSH

37

VIEW SHOWING

BRUSH HOLDER ASSEMBLY

MODELS

SEE TABLE 2, PAGE 20

LUBRICATE BOLTS

TORQUE TABLE

NOTE FOR P61: ATTACH MARKING BAND (P61) TO

EACH END OF CABLE PTS. 11,12,13,45,46,47,48, 50,56,57,58,64,65,67 & STAMP WITH APPROPRIATE

MARKINGS AT ASSEMBLY.

8,60

18

33

11,

13

8 A1,

60

21,64

49

46

35

VIEW OF COMM. END

75 ASSEMBLE FLUSH TO TOP OF INSIDE WALL WITHIN .25 +

AND TIGHTEN UNTIL PLUG IS??

EXPANDED AND TIGHT IN HOLE

30

75

ENLARGED VIEW AT B

VIEW OF PINION END

ASSEMBLE FLUSH TO TOP OF INSIDE WALL WITHIN .25 +

AND TIGHTEN UNTIL PLUG IS??

EXPANDED AND TIGHT IN HOLE

.19 +?? .06

29

75

30

32

.12

31

VIEW OF PINION END

NOTE FOR P74:

ATTACH MARKING BAND (P74) TO EACH END OF CABLE PTS. 8,9,60,61,62,63,68,69,76,77,78, 81,82,83. STAMP WITH APPROPRIATE MARKING

AT ASSEMBLY.

SIDE VIEW OF COMM. CHAMBER

SHOWING PLUGS OPPOSITE SIDE

OF CONNECTION BOX.

CARBON

BRUSH

33

VIEW SHOWING BRUSH HOLDER ASSEMBLY

NOTE FOR P10 AND P15:

INSTALL P10 AND P45 WITH LARGER

TERMINAL ON EXC. COIL CONNECTION.

NOTE FOR P52 AND P53:

INSTALL P52 AND P53 ON CONNECTION

BOX END OF P10 AND P45.

MODELS

SEE TABLE 2, PAGE 20

127,10,45

VIEW SHOWING METHOD

OF CONNECTING SHUNT

CABLES.

MAG. FRAME

WALL

STAPLE

6

SECTION F??F

ATTACH BRUSH HOLDER

CABLES AGAINST INSIDE

WALL OF MAG. FRAME.

FILL C'BORES WITH P31 (12??PLACES)

13,

14

17

16 1,39

11

38

36,38

38

12

CARBON

BRUSH

VIEW SHOWING BRUSH

HOLDER ASSEMBLY

(COMMUTATOR END)

A1

32

24

A2 19

28

2,

4,

5

2,

4,

5

28

24

1,

39

PINION END

22,

23FOR FILLETS 8??PLACES

TYPICAL

28

.09 MIN. TYP.

24

29

32

F2

29 F1

32

1,39

25

26

SIDE VIEW OF COMMUTATOR

CHAMBER SHOWING PIPE PLUG

LOCATIONS (BOTH SIDES)

Flood Dipping Coiled Frame

After field coils have been repaired or replaced and electrical tests completed, insulate the coiled frame by flood dipping in GE??8001 varnish. See Table 4, Page 55, for varnish viscosity limits.

Varnish may be thinned, as necessary, with Solves- so* No. 100 thinner. Agitate varnish for 15 minutes be- fore dipping frame.

1.Be sure all coil connections are made and insu- lated, and all cables and ties for cables and con- nection straps are in place. Tie cable ends above the varnish level.

2.Coat all machine??fit surfaces with GE??271 black varnish or stripping compound and plug bolt holes with dummy bolts.

3.Heat the coiled frame to 40??80??? C (104??176??? F) and dip the frame drive end down (with all coil connections covered) for at least 15 seconds. Drain and remove the frame from the varnish. Al- low the frame to drain for at least 5 minutes in a vertical position, drive end down.

4.Bake the frame in a pre??heated oven at 150??? C (302??? F) for 30 minutes, minimum.

5.Clean the varnish from machined surfaces and unplug the tapped holes.

TEST AFTER REPAIR

(Coiled Frame Without Armature)

1.Pass 24.0 amperes(60 Hz current) through the exciting (series) field and read the voltage drop.

2.Pass 24.0 amperes (60 Hz current) through the commutating (CP) field and read the voltage drop.

For Non??Magnetic retainers:

*Standard Oil Co. of Pa.

TABLE 4

VARNISH VISCOSITY CHART FOR

DIPPING COILED FRAME

NOTE: When necessary, use Solvesso No. 100 to thin var- nish.

GE NO. 8001 VARNISH

NO. 3 ZAHN CUP

TEMP. DEGREES C

FIG. 33. FIELD COIL POLARITY CHECK. E??888A.

Apply a high??potential test voltage of 3500 volts, 60 Hz for one minute.

Measure leakage current to ground during this test. 5.0 milliamps is maximum.

WARNING: Electric shock can cause serious or fatal injury. To avoid such injury, personnel should take and observe proper precautions during the high??potential testing.

Resistance Measurement

Refer to the DATA section for values and measure the resistance of the exciting and commutating fields.

3.Lift the armature out of the varnish and spin until the excess varnish is removed. Clean the shaft with Xylene (GE Spec. No. D5B9).

4.Bake at 140??? C in an oven for at least eight hours.

BALANCING ARMATURE

Refer to the appropriate longitudinal section (see Table 2, Page 20, to determine the correct drawing) for balance weight locations. Dynamically balance the ar- mature within 10 grams (0.35 oz.) on the drive end and 12 grams (0.42 oz.) on the commutator end by adding weights on the commutator cap and the armature head.

VARNISH TREATMENT (ARMATURE)

Vacuum Pressure Impregnation (VPI)

After all repairs have been completed, the armature must be vacuum pressure impregnated in GE??702C polyester varnish.

Refer to GEK??101183 for VPI procedure.

Following the VPI processing, the armature must be given a varnish immersion treatment.

NOTE: Do NOT clean previously protected ma- chined surfaces, threads and tapped holes be- fore varnish treating the armature.

REASSEMBLY

Brushholders

1.Using a bolt and washer, attach the brushholder clamp to the frame mount. Position the studs of the brushholder in the clamp, and move the brushholder radially outward as far as possible.

2.Tighten the brushholder clamp bolt but do not torque. Install all brushholders.

3.Connect the brushholder cables. Refer to Table 2, Page 20, to determine the correct connection diagram.

NOTE: Parts that will be shrink??fitted should be heated in an oven and assembled hot. Make sure shrink??fitted parts are tight against adja- cent parts after they have cooled.

Drive??End Bearing (Figs. 34, 35, 36 and 37)

1.Place the armature in a saddle.

2.If the inner sleeve was removed, heat it to 110??? C (230??? F) and shrink it tight on the shaft against the shoulder.

3.Spread 0.5 oz. of grease onto the seals on the inner and outer bearing caps and the inner sleeve.

4.Pack 4.8 oz. of grease in the outer circumference of the inner bearing cap as shown by the shaded area in the bearing cap.

5.Install the inner bearing cap on the sleeve.

6.Heat and install the flinger tight against the sleeve.

7.Heat and install the inner race of the roller bear- ing tight against the flinger.

8.Install the outer race of the bearing in the framehead.

9.Fill the roller bearing completely with 29.0 oz. of grease.

10.Install the gasket onto the inner bearing cap.

11.Install guide pins into the inner bearing cap to guide the framehead into position.

12.Assemble the framehead/bearing assembly onto the shaft, over the guide pins until seated against the bearing cap. Remove the guide pins.

NOTE: Orient the inner bearing cap on UP, AUP, US and AUT models to facilitate grease tube as- sembly.

a.On UP1 and AUP1 models, there are two grease tubes, assembled to the inner bearing cap and protrude through a hole in the frame.

b.On UP2 and AUP2 models, there is one grease tube, assembled to the inner bearing cap and protrudes through a hole in the frame.

c.On all other models, there is one grease tube assembled to the inner bearing cap and pro- trudes through a hole in the framehead.

14.Pack 4.8 oz. of grease in the outer circumference of the outer bearing cap and install the bearing cap to the framehead. Secure the assembly with bolts and lockwashers. Torque to the appropriate value in Table 3, Page 37.

Commutator??End Bearing

(All Models Except US2, UP6, AUT2 and AUP5)

Refer to Fig. 38.

1.Clean and inspect the bearing and the shaft bearing fit. Remove nicks and burrs.

2.If sleeve (16) was removed, heat it to 110??? C (230??? F) and shrink it tight onto the shaft against the shoulder.

3.Pack 5.25 oz. grease into the outer circumfer- ence of the cavity of bearing housing (8).

4.Heat bearing housing (8) in an oven to 100??? C (212??? F). While hot, assemble ball bearing (3) into the housing firmly against the shoulder at the bottom of the bearing fit.

5.Fill all voids in the ball bearing completely with approximately 20.8 oz. of grease, Fig. 38. Smear 0.5 oz. of grease on the bearing housing and the bearing cap seals.

6.Heat the bearing and housing assembly in an oven to 100??? C (212??? F). While hot, assemble it onto the shaft, with the inner race tight against sleeve (16).

NOTE: Do not heat the bearing and housing as- sembly above 100??? C (212??? F). Higher tempera- tures may cause the oil to ??bleed?? from the grease.

7.Heat spacer (9) to 110??? C (230??? F) and shrink it onto the shaft tight against the inner race of ball bearing (3).

The bearing assembly will be completed when the armature is assembled into the frame.

Commutator??End Bearing

(Models US2, UP6, AUT2 and AUP5)

Refer to Fig. 39.

1.Clean and inspect the bearing and the shaft bearing fit. Remove nicks and burrs.

2.If sleeve (13) was removed, heat it to 110??? C (230??? F) and shrink it tight onto the shaft against the shoulder.

3.When sleeve (13) has cooled, assemble a new seal ring (5) onto the sleeve, oriented as shown in Fig. 40.

4.Pack 5.20 oz. grease into the outer circumfer- ence of the cavity of bearing housing (8).

16,21

19

18

2

NOT INCLUDED ON

14 ASSEMBLED TO EITHER P13

OR P17, DEPENDING ON MODEL.

13 NOT INCLUDED ON ALL MODELS

12 NOT INCLUDED ON ALL MODELS

APPLY P15 TO THREADS

AT BOTH ENDS OF P12

17

2

20USE IF NECESSARY TO

ADJUST FOR PROPER

ALL MODELS

24

USE 4.8 OZ. OF

P7 IN EACH CAVITY

23

SMEAR .5 OZ. OF

P7 ON SEALS

3TORQUE TO

110??120 FT. LBS.

22FILL BEARING COMPLETELY

WITH 29 OZ. OF P7

6

MODELS

SEE TABLE 2, PAGE 20

5.Heat bearing housing (2) in an oven to 100??? C (212??? F). While hot, assemble nilos ring (4) (ori- ented as shown in Fig. 40), and the ball bearing

(3) into the housing firmly against the shoulder at the bottom of the bearing fit.

6.Fill all voids in the ball bearing completely with approximately 20.8 oz. of grease. Smear 0.5 oz. of grease on the bearing housing and bearing cap seals, and on the seal ring wear surface on the nilos ring (4).

7.Heat the bearing and housing assembly in an oven to 100??? C (212??? F). While hot, assemble it onto the shaft, with the inner race tight against sleeve (13).

CAUTION: Be sure that the nilos ring is assembled over sleeve (13), not pinched between the sleeve and the bearing.

NOTE: Do not heat the bearing and housing as- sembly above 100??? C (212??? F). Higher tempera- tures may cause the oil to ??bleed?? from the grease.

SUPPORT FOR

INDICATOR ON

ARMATURE SHAFT

FIG. 37. CHECK ALIGNMENT OF BEARING

AFTER ASSEMBLY. A??120402.

8.Heat spacer (6) to 110??? C (230??? F) and shrink it onto the shaft tight against the inner race of ball bearing (3).

The bearing assembly will be completed when the armature is assembled into the frame.

Armature Assembly Into Frame

Models UP and AUP

Refer to Fig. 15.

1.Assemble the brushholders into the frame. Move them well back from commutator to avoid inter- ference when installing the armature. Fasten and insulate the connections and install outgoing cables.

2.Block and level the frame in a vertical position, commutator??end down, on a heavy duty stand. Be sure there is clearance for the commutator?? end shaft extension when the armature is low- ered into the frame.

3.Install three guide studs in the commutator??end bearing housing bolt circle to guide the housing into the framehead fit.

4.Pack 5.25 oz. of grease in the outer circumfer- ence of bearing cap (4).

5.Lift the armature with the hoist and lifting bail at the drive end. Line up the hoist directly over the center of the cavity in the frame.

6.Lower the armature slowly into the frame, being careful not to damage the commutator. When the armature is almost fully inserted, use the guide studs to align bearing housing (46) and framehead bolt holes (56). (Position the bearing cap to accommodate the grease tubes in UP1 and AUP1 models.)

7.When the armature has reached its limit of travel, remove the guide studs and install bearing cap

(4) with a new gasket (57) using bolts and wash- ers (52). Draw the bearing housing into framehead (56). Torque bolts to 105??115 ft.lbs.

8.Install framehead bolts (10) and lockwashers (12). Torque to 440??495 lb.??ft.

CAUTION: Alternate tightening of commu- tator??end bearing housing and drive??end framehead bolts. Uneven tightening of bolts could damage bearings or related fitted sur- faces.

NOTE: Be sure framehead bolt holes are aligned with bolt holes in inner bearing cap be- fore assembling bolts (10) and lockwashers (12).

9.Install grease tubes at the drive end:

ing cap so that they protrude through a hole in the frame. Seal around the grease tubes at their hole in the frame with RTV.

b.On UP2 and AUP2 models, one grease tube is required. The procedure is the same as in- dicated in Step 9a.

c.On all other models, one grease tube is re- quired. This tube connects the inner bearing cap with the framehead, and should have been assembled with the drive??end bearing assembly.

NOTE: Insure that all grease tubes are packed full of grease.

a.On UP1 and AUP1 models, two grease tubes are required. Clean all residual sealing RTV from the grease tube clearance hole in the frame. Then, reach into the cavity of the ma- chine, around the drive??end inner bearing cap (51), and install these tubes to the bear-

10.Use a feeler gauge and check the radial clear- ance on the drive??end bearing between each bearing roller and the inner race, at the top of the bearing, Fig. 40. Place the feeler gauge between the top roller and the inner race.

REF. DESCRIPTION

1FRAME HEAD

2BEARING HOUSING

3BALL BEARING

4NILOS RING

5SEAL RING

6SPACER

7SLEEVE

8BEARING CAP

10LOCKWASHER, N405P47B13

11GREASE

12GASKET

13SLEEVE

2

4

5

13

MODELS

US2, UP6, AUT2 AND AUP5

APPLY NALCO RC TO BORE

OF P7 AND SHAFT

HEAT P7 TO 180 o C. (356 o F)

RISE AND ASSEMBLE AS SHOWN

1

12

REFER TO ASSEMBLY INSTRUCTIONS

FOR DETAILS

9,10

8

USE 5.2 OZ. OF P11

FILL BEARING COMPLETELY WITH 20.8 OZ. OF P11

2

3

USE 5.2 OZ. OF P11

IN THIS CAVITY

4

IN THIS CAVITY

7

6

13

5

OUTER BEARING

RACE WITH

ROLLERS

BEARING

CAGE

FEELERS

SHAFT

INNER BEARING

RACE

FRAMEHEAD

FIG. 40. CHECKING INTERNAL CLEARANCE OF

BEARING. A-120403.

17.At the commutator end, smear the seals on bear- ing cap (4) and sleeve (42) with grease.

NOTE: Prior to heating sleeve (42), apply NAL- CO RC* ??Rail Conditioner?? to the inside diame- ter of the sleeve and to the mating surface on the shaft. Apply the NALCO with a Scott??150 white paper towel only and allow it to dry to a thin white film on both surfaces before pro- ceeding with Step 18.

18.Heat sleeve (42) to 180??? C (356??? F) rise and shrink it onto the shaft tight against the spacer

19.Assemble the grease tubes to the bearing cap

(4)(UP1 and AUP1 models only). Install pipe plugs in tubes and tube fittings as indicated in Fig. 15.

NOTE: Insure that grease tubes are packed full of grease.

Armature Assembly Into Frame

Models US1, AUT

Refer to Fig. 18.

11.The clearance between the rollers and the inner race should measure between 0.0012 and 0.004 in. Try various gauge thicknesses until clearance can be determined by the feel of the gauge as the gauge is slowly pulled from between the roller and the inner race.

12.Pack 4.8 oz. of grease in the outer circumference of outer bearing cap (5).

13.Install a new gasket (54) and bearing cap (5) with bolts and lockwashers (53).

14.Smear seals on bearing cap (5) and sleeve (47) with grease.

15.Heat sleeve (47) to 110??? C (230??? F) rise and shrink it onto the shaft tight against the roller bearing inner race (48).

16.Seal the grease tubes which protrude through the hole in the frame with RTV??108.

1.Assemble the brushholders into the frame. Move them well back from the commutator to avoid in- terference when installing the armature. Fasten and insulate the connections and install outgoing cables.

2.Block and level the frame in a vertical position, commutator??end down, on a heavy duty stand. Be sure there is clearance for the commutator?? end shaft extension when the armature is low- ered into the frame.

3.Install three guide studs in the commutator??end bearing housing bolt circle to guide the housing into the framehead fit.

4.Pack 5.25 oz. of grease in the outer circumfer- ence of bearing cap (8).

5.Lift the armature with the hoist and lifting bail at the drive end. Line up the hoist directly over the center of the cavity in the frame.

*Product of NALCO Chemical Co.

6.Lower the armature slowly into the frame, being careful not to damage the commutator. When the armature is almost fully inserted, use the guide studs to align bearing housing (3) and framehead bolt holes (14).

7.When the armature has reached its limit of travel, remove the guide studs and install bearing cap

(8) with a new gasket (11) using bolts and wash- ers (10). Draw the bearing housing into framehead (14). Torque bolts to 110??120 ft.lbs.

8.Install framehead bolts and lockwashers(30). Torque to 440??495 lb.??ft.

CAUTION: Alternate tightening of commu- tator??end bearing housing and drive??end framehead bolts. Uneven tightening of bolts could damage bearings or related fitted sur- faces.

NOTE: Be sure drive??end framehead bolt holes are aligned with holes in inner bearing cap be- fore assembling bolts and lockwashers (30).

9.Use a feeler gauge and check the radial clear- ance on the drive??end bearing between each bearing roller and the inner race, at the top of the bearing, Fig. 40. Place the feeler gauge between the top roller and the inner race.

10.The clearance between the rollers and the inner race should measure between 0.0012 and 0.004 in. Try various gauge thicknesses until clearance can be determined by the feel of the gauge as the gauge is slowly pulled from between the roller and the inner race.

11.Pack 4.8 oz. of grease in the outer circumference of outer bearing cap (36).

12.Install a new gasket (35) and bearing cap (36) with bolts and lockwashers (34). Torque bolts to 110??120 ft.lbs.

13.Smear seals on bearing cap (36) and sleeve (37) with grease.

14.Heat sleeve (37) to 110??? C (230??? F) rise and shrink it onto the shaft tight against the roller bearing inner race (38).

15.Finish the assembly of grease tube fittings and washer (27) where it passes through the framehead. Tighten all fittings and hardware.

16.At the commutator end, smear the seals on bear- ing cap (8) and sleeve (6) with grease.

NOTE: Prior to heating sleeve (6), apply NALCO RC ??Rail Conditioner?? to the inside diameter of the sleeve and to the mating surface on the shaft. Apply the NALCO with a Scott??150 white paper towel only and allow it to dry to a thin white film on both surfaces before proceeding with Step 18.

17.Heat sleeve (6) to 180??? C (356??? F) rise and shrink it onto the shaft tight against the spacer

(5).

18.Install pipe plugs in grease tubes and tube fit- tings as indicated in Fig. 18.

NOTE: Insure that grease tubes are packed full of grease.

BRUSHHOLDER CLEARANCE

ADJUSTMENT

1.Remove the protective covering from the com- mutator. Place a 1/16 in. fiber spacer between the bottom of the brushholder and commutator. Loosen the brushholder clamp bolts and move the brushholders so they touch the fiber spacer. Tighten the clamp bolts to 225??250 lb.??ft. torque and remove the spacer.

2.Connect the cable leads to the brushholder ter- minals and tighten the terminal bolts.

BRUSH INSTALLATION

1.Install new brushes.

CAUTION: When replacing brushes, use only the GE recommended grade. Mixing of brush grades in the same motor or changing brushes to another grade will seriously affect commutation, surface film, commutator and brush life. See the DATA section for brush grade.

2.Carefully lower the spring??loaded brush lever on each brush. Do not allow the lever to snap against the brush, as the brush may chip.

3.Attach the brush??shunt terminals to the brush- holder body under the screws provided.

4.Inspect the interior of the machine for foreign ob- jects. Install the commutator covers on the motor and check for proper fit and latch operation.

5.Clean the terminals.

HUB MOUNTING

Hub Fitting

NOTE: GE does not supply the hub for vertical drill motors. This procedure is included for cus- tomer use as a reference when installing the hub.

To prevent a hub from slipping, it should have at least 75 percent fit on the shaft; i.e., at least 75 percent of the tapered bore of the hub should be in contact with the ta- pered fit on the shaft. Before mounting a hub, check and correct the fit as follows:

1.Lightly cover the bore of the hub with a blueing compound such as Prussian Blue.

2.Snap the cold hub forcefully onto the shaft.

3.Mark the relative angular position of hub with re- spect to the shaft.

4.Remove the hub from the shaft. A convenient method of removal is by the use of two finely ta- pered steel wedges (hardened and ground) which are carefully driven between the hub and the bearing outer sleeve on the shaft.

5.Inspect the taper fit of the shaft; blueing of the hub bore should now show on the shaft. If at least 75 percent of shaft surface shows traces of blue- ing, the fit is satisfactory. If, however, only a few spots of blueing show on the shaft, the fit is not satisfactory.

6.Dress down the blue spots on the shaft very light- ly with a fine emery cloth such as No. 400A Trie- mite.

7.Blue the hub bore again (see Step 1) and repeat Steps 2, 4, 5 and 6. Be sure to place the hub onto the shaft in the same position as marked.

Generally, the fit will be improved, but the forego- ing procedure may have to be repeated several times to obtain a 75 percent fit.

Under no circumstances use a lapping com- pound since lapping will produce a shoulder at the large end of the tapered fit. A shoulder will prevent a perfect fit when the hub is mounted hot; i.e., when it is mounted in the advanced posi- tion.

8.After a good fit has been obtained, thoroughly clean the shaft and the hub bore to remove all blueing, oil or grease. Then mount the hub.

Hub Mounting

1.Thoroughly clean the hub fit on the shaft and bore of the hub (see the procedure in the Clean- ing section). Remove any scoring on the shaft or hub bore.

2.Spot the cold hub on the shaft by hand and check for at least 75 percent fit. See the ??Hub Fitting?? section. If necessary, dress the shaft to obtain this fit.

3.Trial mount the cold hub onto the shaft. Measure and record the position of the hub with respect to the end of the shaft. Take measurements with a micrometer advance gauge similar to that shown in Fig. 41. Zero the gauge.

Mark points of measurement, and mark across the end of shaft and hub face so that the hub, when heated, can be mounted in exactly the same angular position, and so the advance mea- surement can be made from the same point.

4.Mount the hub hot onto the shaft so as to secure an advance from the cold position to the hot posi- tion along the axis of the shaft as indicated in this section. The ESTIMATED difference between shaft temperature and hub temperature (temper- ature rise) which will provide this advance is also given. The temperature difference is only an esti- mate and should be adjusted (if necessary) to provide the advance within prescribed limits.

Measure the temperature of the shaft and the hub with the same instrument.

5.Insure that the hub bore and the shaft taper are clean. Then, using adequate hand protection, quickly mount the hot hub on the shaft in the same angular position as when cold. When the

FIG. 41. METHOD OF USING ADVANCE

GAUGE. E??5975A.

After the motor has been reconditioned and reas- sembled, make the following tests to assure it will oper- ate satisfactorily.

Connect the motor to a d??c arc??welding generator, Fig. 7. Refer to connection diagrams, Figs. 22 and 24, for connections. Run the machine series??connected without load at 900 rpm and measure bearing tempera- tures.

1.Use Duxseal* putty to hold the thermometers on the drive end and commutator??end outer bear-

PLACE PYROMETER

POINTS IN BORE

OF HUB

FIG. 42. MEASURING TEMPERATURE OF COUPLING HUB WITH PYROMETER. E??5976.

ing caps. Thermometers should contact the bearing caps for best results.

2.Seat the brushes and run for ten minutes at 900 rpm.

Frame temperature should not exceed 25 C rise.

3.With machine running up to speed, measure vi- bration. Vibration should not exceed 0.002 on commutator end. If vibration exceeds this amount, rebalance the armature.

4.Check the commutator for roughness and make sure the brushes are riding properly.

5.Use a listening rod to check for noisy bearings.

6.Stop the machine and mount an indicator on the frame. While turning the armature by hand, mea- sure commutator runout. It should not exceed 0.001 in.

7.Measure field impedance. With 60 Hz a??c and 24 amperes through each field, measure the volt- age drop across total exciting and commutating fields. See the DATA section for voltage limits.

8.Apply a high??potential test to the windings of the assembled machine, as specified in the DATA section.

WARNING: Electric shock can cause serious or fatal injury. Proper precautions should be taken and observed by personnel performing testing to avoid such injury.

TESTING SHUNT MACHINES

(Models 5GE752UP and US)

After the motor has been reconditioned and reas- sembled for service, make the following tests to be sure it will operate satisfactorily.

Connect the motor to a d??c welding generator. Refer to connection diagrams (Figs. 21 and 23) for connec-

*Product of Johns Manville Co.

tions. Run the machine by separately exciting the shunt field from a 125 vdc source. From another source of power, apply voltage to the armature circuit until the de- sired speed is obtained.

Motor Operation

Ventilated (2300 cfm at 7.6 in. H2O at Commutator Chamber)

Hold separate field excitation at 50.5 amperes. Vary the armature voltage to obtain the required rpm. At ap- proximately 700 terminal volts (no load), the speed will be 900 rpm.

Unventilated

Hold the separate field excitation at 10 to 15 am- peres. Vary the armature voltage to obtain the required rpm. At approximately 338 terminal volts (no load), the speed will be 900 rpm.

1.Run the motor for five minutes at 450 rpm. In- crease the speed to 900 rpm and run for two hours. Bearing temperatures should not exceed 70??? C (158??? F). Run until the bearing tempera- ture remains constant for 30 minutes. Increase the speed to 1300 rpm and hold it while perform- ing Steps 2, 3 and 4. Then shut down the motor. Do not exceed 1300 rpm.

2.Measure vibration when running the motor up to speed. Vibration should not exceed 0.004 in. If excessive, rebalance the armature.

3.Check the commutator for roughness. Be sure brushes are riding properly.

4.Listen for noisy bearings with a listening rod.

5.Stop the motor and mount an indicator on the frame. Turn the armature by hand and measure commutator runout. Runout should not exceed 0.001 in.

6.Measure the insulation resistance of the wind- ings with a megohmmeter. If the resistance mea- sures not less than one megohm, apply an a??c high??potential test to ground for one minute as outlined in the DATA section.

WARNING: Electric shock can cause serious or fatal injury. To avoid such injury, personnel should take and observe proper precautions during the high??potential testing.

REMOVING ARMATURE

LOCKING ARRANGEMENT

(See Fig. 43)

1.Remove the two shipping bolts (1) from the bear- ing cap. These bolts are longer and can be identi- fied from the factory by their yellow heads.

2.Install the two regular bolts which are in a bag at- tached to one of the shipping bolts.

3.Torque the regular bolts to 115 lb.??ft.

NOTE: The shipping bolts and bag should be saved for future armature locking require- ments.

LOCKING THE ARMATURE

FOR SHIPMENT

(See Fig. 43)

1.Remove two diametrically opposite bolts in the commutator end bearing cap.

2.Install shipping bolts (1) (painted yellow) with jam nuts (2) applied. Torque bolts to 30 lb.??ft. and tighten the jam nuts.

CAUTION: Do not rotate the armature when the locking bolts are in place. Bearing and commutator damage may result.

3.Attach the two regular bolts and bag??tag (5) to one of the locking bolts (1).

SHIPPING

Whenever drilling motors are to be shipped, they must be properly skidded and secured to prevent any damage in transit. The photographs and drawings which follow illustrate a proven method of skidding these ma- chines for handing and shipment.

FIG. 43. ARMATURE LOCKING ARRANGEMENT

(41B535748 CHG. 0). E??28735A.

HANDLING

To avoid damage to the machine during handling, re- view the following cautionary statements:

1.Do not lift motors by the shaft extension of the ar- mature.

2.Do not allow the armature to bump another ob- ject.

3.Do not tighten coupling assembly bolts with an air wrench or by pounding.

4.Do not remove armature end??play by any other means than axial blocking.

5.Do not load the armature radially (strap down) for shipment.

CLEANING AND SLUSHING

Before skidding the machine for shipment, all ex- posed finished surfaces not already painted should be cleaned and slushed as follows:

1.Remove all corrosion.

2.Wipe off the surface with clean rags and wet with petroleum spirits GE??D5B8.

3.Follow with a clean rag wet with methanol, then wipe dry. DO NOT touch the cleaned surface with bare hands.

4.Slush immediately after cleaning with GE??D6C6A1 slushing compound.

SKIDDING

curely support and enclose the armature in a totally en- closed wooden box of sufficient strength to protect the it from damage.

1.Clean the armature by removing dirt, oil or grease from its surface.

2.Treat all unpainted, exposed finished surfaces as follows:

a.Remove any corrosion.

b.Wipe off the surface with a clean cloth dipped in petroleum spirits, GE??D5B8.

Use yellow pine timbers large enough to support the weight of the machine. The recommended size is illus- trated in Fig. 44.

PROTECTION

When any apparatus is shipped in the open, it should be fully protected from rain, snow, dirt, etc., by covering with some suitable weatherproof material.

ARMATURES

To prepare drilling motor armatures for shipment or storage, clean, slush and wrap the armature. Then, se-

FIG. 44. CONSTRUCTION DETAILS. E??7754.

c.Wipe off the surface with a clean rag, dipped in methanol, and wipe dry. DO NOT touch the cleaned surfaces with bare hands.

d.Immediately after cleaning, slush the cleaned surface with GE??D6C6A1 shushing com- pound.

3.Wrap heavy paper or cardboard around the com- mutator for protection.

4.Wrap and secure waterproof paper around ar- mature punchings. This will prevent saddle tim- ber moisture from condensing on the core punchings.

5.Wrap both ends of the shaft with Grade C, Type 1, wax treated cloth and tape it securely into place.

NOTE: Wherever metal parts come in contact with the wood, insert a good grade of water- proof paper between metal and wood. This will prevent rust formation from the condensation of moisture on the metal.

PREPARATION OF BOX

1.Make a suitable box from yellow??pine lumber us- ing timbers of proper size to support the weight of each armature. See Fig. 45.

2.Make 4 saddle blocks of 3 by 6 in. timber cut out to fit circumference of armature core. Nail two to the bottom of the box in the proper position to

FIG. 45. BOX FOR SHIPPING

ARMATURES. E??3782A.

support the armature on core punchings.

CAUTION: Locate the saddle blocks so they do not project beyond the punchings; other- wise, scuffing of coil insulation could occur.

3.Support the commutator??end of the shaft by two 1 X 6 in. boards nailed to the end of the box. Drill a hole in the two boards just large enough for the end of the shaft. See Fig. 45. The end of the shaft will fit in this hole against the end of the box to prevent movement.

4.After the armature has been placed in the box, insert a board of proper thickness between the end of the shaft and the end of the box. Securely nail it in place. This will prevent any lateral move- ment of the armature in the box.

BOXING THE ARMATURE

1.Prepare the armature as specified in the forego- ing.

2.Place it in the box. Support it on two saddle blocks under the punchings and secure it against lateral movement. See Fig. 46.

3 X 6

ADJUST THICKNESS

OF END BOARD TO

SUIT LENGTH OF

SHAFT

FIG. 46. ARMATURE PLACED IN

SHIPPING BOX. E??3783.

3.Place two saddle blocks over the core punch- ings, as shown in Fig. 46, and nail them to the side boards. If the box is the correct size, the top of the saddles will be flush with the top of the side boards. See Fig. 47.

4.Nail the top cover in place. Also nail through to the top saddle blocks to prevent them from mov- ing.

STORAGE

PLACING INTO STORAGE

When placing GE drilling motors into storage, the fol- lowing preparations should be performed to prevent damage to the equipment as a result of the storage.

1.Machines should be placed on a pallet and stored indoors if possible. A clean, dry ambient of

60 F is preferred. In a high humidity environ- ment, an ambient of 70 F is recommended. Ev- ery attempt should be made to avoid widely vary- ing temperatures and high humidity.

2.If it is necessary to store outdoors, a protective cover should be used to prevent entrance of rain, dust, etc.

3.All exposed machined steel parts and surfaces should be slushed. These areas are slushed prior to shipment from the factory, but should be

examined for rust. Any rust found should be re- moved using fine abrasive paper, after the old slushing compound has been removed with min- eral spirits (GE??D5B8). Methanol should be used to remove all residue.

WARNING: Cleaning solvents may be toxic and/ or inflammable. They can cause serious or fatal injury if used without proper precautions. For safety:

1.Do not inhale solvent fumes.

2.Use solvents only in adequately ventilated areas.

3.Avoid contact of solvent with the skin.

4.Do not expose solvent to flame or sparks.

5.Observe caution statements issued by the manufacturer of the solvent.

Extreme care should be exercised not to dam- age critical machined surfaces such as the ta- pered shaft surface while removing rust. The surfaces should be reslushed with GE??D6C6A1

FIG. 47. SHIPPING BOX WITH ARMATURE,

LESS COVER. E??3784.

slush compound, Kendell Grade 5, or the equiva- lent.

4.Brushes should be removed from their holders and clamped under the spring clips to prevent corrosion of the commutator surface as a result of moisture absorption by the carbon.

5.Do not completely seal the motor, but cover ma- jor vent areas with a waterproof shipping tape. Leave enough opening so the machine can breathe ?? i.e., moist air is not trapped. The inten- tion is to prevent entrance of water, dust, small animals, etc., but not to seal airtight. GE does not recommend the use of a silica gel or dehydrating agent.

6.Since the lubricant drains from the top half of bearings during storage, this area is subject to corrosion. The shaft should be rotated periodi- cally to redistribute a protective film. If stored in- side, rotate every three months. If outside, every month. Before placing the machine back into service after prolonged storage (1 year or more) bearings should be inspected and repacked with new grease meeting the recommended GE lubri- cation specification.

7.The machine should be meggered when placed into storage and periodically while in storage (3??month intervals). Keep a record of these megger readings as a rapid decrease in insula- tion resistance indicates the machine condition is deteriorating and the storage conditions inade- quate.

Before placing a stored motor back into service, refer to the applicable instruction ??Removing Motors From Storage??.

REMOVING FROM STORAGE

Before placing a stored motor in service, perform the following:

1.Blow dust and dirt accumulation out of the wind- ings with clean, dry air.

2.Visually inspect for spring corrosion, sticking brushes in brushholders and general defects.

3.Check winding insulation continuity to ground with a 500 volt megger. If the megger reading is less than 2 megohms, the winding should be baked or dried until the moisture content is suffi- ciently reduced to raise the megger reading to 2 megohms.

4.An electrical source of heat is best for drying as it can be easily regulated and is clean. Proceed as follows:

NOTE: Before drying windings, consideration must be given to bearings and lubricants. Not only can bearing lubricants be damaged by heat, but they can also deteriorate with age. For this reason, it us usually best to remove bear- ings before drying and repack with new grease before reassembly.

a.Remove the armature from the frame and re- move bearings from the armature shaft.

b.Heat the frame and armature until dried suffi- ciently to obtain the 2 megohm reading.

c.Pack bearings with new grease. Refer to the DATA table for the proper grease. Refer to the appropriate bearing illustration for the proper amount of grease.

d.Reassemble the motor.

e.If facilities are available, give the reas- sembled machine a running test to check the bearings.

Refer to Figs. 48 and 49 for outline drawings.

9.56

AIR OUT

C ARMATURE

L

ARMATURE LOCK 7.88 ARRANGEMENT

SEE NOTE

.50 NPT FOR

AIR PRESSURE

MEASUREMENT

+?? .005

11.375

DIA.

1.06

.562 DIA.

2 HOLES

GE??752??AUP SHOWN IN MAIN VIEWS

GE??752??UP SHOWN IN FIG. 1

APPROXIMATE WEIGHTS

10.50

GE??752??UP 6750 POUNDS

GE??752??AUP 6850 POUNDS

AIR FLOW REQUIREMENTS

2300 CFM OF STANDARD AIR

MINIMUM 900 HP

2800 CFM OF STANDARD AIR MINIMUM 1000 HP

IMPORTANT

THE ELECTRICAL EQUIPMENT SHOULD BE

LOCATED IN A SPACE WHICH

(1)PROVIDES SUFFICIENT ACCESSIBILTY

FOR BRUSH INSPECTION

(2)ALLOWS REMOVAL OF ALL THE BRUSHES

AND PIGTAIL FASTENERS

(3)ALLOWS MAINTENANCE PERSONNEL TO

COMPLY TO THE GE MAINTENANCE

INSTRUCTION SPECIAL REQUIREMENTS

E HOLE

+?? .005

11.375

DIA.

13.50

.20

VIEW AT G

1.50

SECTION H??H

ENLARGED

NOTE: ALL MODELS EXCEPT UP1, UP2, AUP1 AND AUP2)

GREASE TUBE

FITTING ??C??

SEE TABLE 1

FURNISHED ON MODELS

SHOWN IN TABLE 1

.562 DIA. THRU

2HOLES

1.25TAPER IN DIA.

PER FOOT IN LENGTH (BOTH ENDS)

3.125??8 NS??2ATHREADS

(BOTH ENDS)

AIR INLET

FURNISHED ON MODELS

SHOWN IN TABLE 1

.50??13 TAP X 1.00 DEEP

6 HOLES

GREASE VENT TUBE

FITTING ??D??

SEE TABLE 1

+ .000

?? .010 36.000

1.12

.50??13 TAP THRU (4 HOLES)

11.00

SHOWING FLANGE

WITH COVER

REMOVED

.375??24 THREAD

??D??

AIR OUT

HOLES

1.06

4.63

1.74

23.12

16.500

8.25

22.120

+?? .12 2.38

16.500

3.62

.75??10 TAP

THRU5.25 (2 HOLES)

58.50

7.88

6.37

+?? .005

11.375

DIA.

1.06

A1

5.69

A2

6.50NOTE FOR ARMATURE LOCKING

ARRANGEMENT LOCATED ON

COMMUTATOR END:

TO BE IN PLACE DURING MOUNTING

OF MOTOR BUT TO BE REMOVED

BEFORE OPERATION OF MOTOR.

1.56 DIA. THRU (4 HOLES)

+ .002

?? .000

1.005 DIA. THRU

(2 HOLES)

DD

+??.005 11.375

13.50

5.31

.390 DIA. DRILL THRU

.578 DIA. DRILL X 1.50 DEEPAIR INLET FLANGE

1.25 DIA. C'BORE X .20 DEEP

.4375??20 TAP THRU AND .375 NPT

.20

1.50

REF

1.25

SECTION D??D

(ENLARGED)

.562 DIA.

THRU

(2 HOLES)

1.25 TAPER IN DIA.

PER FT. IN LENGTH (BOTH ENDS)

3.125??8 NS??2A

THREADS (BOTH ENDS)

AIR INLET

.50??13 TAP 1.00 DEEP

(6 HOLES)

9.50

TOP INSPECTION COVER

??C??

.25 NPT (2 HOLES)

FOR REGREASING

.50 NPT (2 HOLES) REF.

1.00??8 UNC??2B THREAD 1.50 DEEP (8 HOLES EQ. SP. ON 25.00 DIA. B.C.

.812 DIA. 1.94 DEEP

(8 HOLES EQ. SP. ON

25.00 DIA. B.C.

??B??

NEW 5??90, WLF REVISED 10??90, WLF REVISED 8??92, WLF REVISED 11??93, WLF REVISED 02??05, NBS

GE Transportation Systems

2901 East Lake Road

Erie, Pennsylvania 16531

PRINTED

IN

U.S.A.

E