e M.I. 3903 Rev, C sous I NSTRUCTION GENERAL MAINTENANCE—INDUSTRIAL MOTORS AND GENERATORS D339, p49. DS59, D69, D79 INTRODUCTION . This Maintenance Instruction contaizs general or “running’' maintenance for industrial motors and generators. The data will apply to Models D39, 49, D59, D69, and all D79 motors and gener tors unless specifically identified, ‘The exivat of maintenance required is determined by the operation and scrvice to whicti the motor or generator is subjected, Refer to recommended maintenance imervals: specified in the applicable Scheduled Maintenance Program. DESCRIPTION Other than the! Model, D79 ‘shaft and bearing configuration differences, all of the models are sintilay in appearance and ar the same general size, Fig. |. The differences are internal improve- ments to later models which have progressed from the original Model D39 to improve sorviee fe end to increase mator or generator output. The later model motors oF generators are similer to Model D39 with the following éifferonces: D49_ Increased copper size in stator field. 159 Application of a ‘modified’ silicone’ varnish to armature coils to improve hont resist- ance, improved commutator seasoning, and the use of constant prossuze. brush holders. 169° New amiatuse coil construction to’ reduce temperature end moisture, New type brust holders with brushes for extended brush [ife. longer Fig.1 - Motor/Generator Asaambly NOTE The longer brushes can’ not be used on. Models D39, D49, er DS9 uniess brush holders are changed ‘or medified, D79 A thinner armature insulation, (nolyimide fitm) which allows -an approximate 20% inerease in armature coil copper. “HIG, (tingsten invit gas) welded joint be- tween armature coil and commutator. to ensure 2 more pasitive . electrical connection, *This bulletin revised and supersedes previous issues of M.J. 3903, M.I, 3905, and M.1, 3906. DER(MDRXOUY) May 1979ML. 3903 Nomex V-rings inl’ thy commutator to improve commutator stability and performance. Alt motors of the same type are interchangeable as an assembly, The gencrator power limit must be adjusted for the lower motor or gonerator rating. All generators of the same type are also interchangeable us an assembly, out due to differ ences in field resistance, the generator maximum no load voltage setting must be made. The power limit must elso be adjusted, taking into account equipment motors and generators, aa well as the motors of generators being replaced. On. most motors und generators cooling air is, supplicd by a 5.6 KW (7.5 HP) AC blower motor, mounted on top of tlie uiit. ty CLEANING Bath the exterior and interior of the motor or generator should be kept Clean and free of dust, dirt, oil, end water which aro likely to have a detrimental effect on insulation and performance. As often as conditions warrant, tho motor or generator showld be blown out with low pressure air, Avoid excessive air pressure which could cause damage to the insulation. Ciean, bound-edge, fintless wiping cloths should be used as necessary (0 remove oil, grease, and accumplations of ditt, In eases where air and dry wipiig cloths: prove Incapaole of removing caked grease and ditt, a stiff’ brush and soft wood or fibre scrapers may be used. In severe cages it may bo necessary to dampen a cloth in solvwat such as Stoddards Solvent to loos:n and remove imbedded deposits. very precautian should be taken to keep fhe solvent off the commutator ancl copper parts. Chlorinated ydzocarbon type cleaning solvents are not recommended for use on the equipment because of the possibility of insutation damage. This type solvent can deteriorate semicured sili- cone rubber and can swell ethylene-propylens Tuboer, natural rubber, neoprene, and hypalon during extended soaking periods. ‘The vapor state, at 70° C (160" F) attacks uncured silicone rubber within 20 minutes. The vapors of these solvents abo have an adverse effect on commutation. Special care is also necessary: to avoid subjecting the polyester glass Insulated brush holder studs to alkaline type cleaning solutions. CAUTION ‘Adequate ventilation and safety precautions arc necessaty when handling inflaramable fluids such 2s Stoddards Solvent which has a flash point of 46° C (115* F). COMMUTATOR BRUSH HOLDERS The DS9, D69, and D79 motors or generators are equipped with ‘censtant prossure spring cell brush holders. The D69 end D79 models ust a brush holder which will accept a longer brush. The longer brush extends the period between brush changvouts. If the longer brush is desired for te Model DS9, a new style brush holder must be installed, The D39 and D49 model brush holders can be modified fo use the constant pressure spring cell, but if the longer brush is desired, the new style brush holder must be installed. Al D3 and D49 models rebuilt at te lactory are equipped with the latest model brash holder. BRUSH HOLDER INSPECTION AND REPAIR CARBONWAYS (BRUSH SLOTS) Check carbonways for wear. with gauge. Refer to Service Data for gauge part numer, Each carbone way should be between 15.95 mm to 16.13 nit (628" to 635"). NOTE Coil spring type (adjustable) brush holicr 8330411 carbonways cannot bv repaired by pevning and filing beceuse of the dic cast material of she brush elder. Coil. spring type brush holders with wor brush slots must be replaced with new brush holders On constant pressure type brush holders, when catbonways ate worn or distorted beyond accept: able limits and the wear is nol too great, it is possible to rework the slots, Insert the gauge into the slot and gently poen the outer sarface of the slot ‘to clase it in. By pecning and filing, carbon. toslot clearance can be restored. CONSTANT PRESSURE SPRING TYPE BRUSH HOLDER Constant pressure spring type brush bolder, Fig. 2, spring: pressure Is pre-set and cannot be. adjusted however, if there. is reason to suspect loss of spring pressure from xome cause, such as heat from a commutator flashover, spring pres- "MLL 3903 Groove Pin Groowe Pin {peen cesting into upper end of hale only) 19.69 mm Max, (7767) Finger Bear Spring (Cocked Position) Spring Cell |._ 15.95 mm— 16.13 mm (628" - .636") ‘Tab Gitset 9.8 mm 3/8") bres 9.58 — 9.65 mm Diametor 377" ~ 380") Fig.2 - Constant Proasure Spring Type : Brush Holder Assembly sure should be checked. It is difficult to check brush holder spring pressure agcurately with the brush holder in place, and if is recommended that the brush holders be removed. Refer to Spring. Cell Removal procedure which follows. ‘The spring pressure of © now. epring with tho spring celt in the’ brush holdet should be within 1.8 to 2.3 kg (4 to 5 Ibs). at:cach of the three springs as measured with a spring tension scale at thé osition shown in Fig. 3. The apring pressure of a used spring’ should be ‘a minimum of 1.6 kg (3.5 Ibs} when checked at the position shown in Fig, 3 Hf the spring pressure of a new os used spring cell with the spring: cell'in the brush holder is not within tolerance, temove the spring cell from the brush holder and check as.shown in Fig. 4. If the apcing is not within tolerance, replace the spring cell with a new spring cell. “a.ML 3903 Finger Pressure At This Point: New Spring 1.8 9 (4 Ibs) Min. 2.3 kg {6 Ibe} Max. Used Spring 1.6 kg (3.5 Ibs} Min. 1 mm (2°) To Bottom Of | Brush Box © OF Brush Slot Fig.3 - Measuring Constent Pressure Spring Type Brush Holder Finger Pressure (Spring Call In Place} Finger Prossure At This Point: New Spring + 1,8"g (4 lbs} Min. 2.3 ka {6 Ibs) Mon. Used Spring 1.8.kg (3.5 Ibs} Min, Fig.d - Measuring Constant Pressure Spring Type Brush Holder Finger Pressure ‘(Spring Gall Removed) To ensure proper tightness of brustt holders and connections, the followIng day torque valves should be applied; 7/8"-9. brush bolder block belt - 203 to 217 Nom (150 to 160 fi'tbs}. 12-13. brush holder, cable to brush holder Dolt - 95 to 102 Nem (70 to 75 flo). 5/1618, brush holder shunt serew - 15 to 20 Nan (19 to 15 felbs). | When inspection indicates it is. neavssary to remove the spring ecll assembfics, from the brush holler, Fig. 2, perform tae folloiving. 1, Plice brush “eavked™ position. holder fingers in 2. Pry lower end of cach groove pin (visible in the holes dircetly below and at each end of the apindle) slightly upward wutil pin pro- trades from the top of the helder. Pull pir out of hole, 3. Drive spindle out of brush holder to free spring cell assemblics. SPRING GELL REPLACEMENT Bofore replacing spring cell assemblies, inspect brush Holder casting and insulator pins. Replace any defective parte with new paris, Repalr all defects. 1. lngert the spindle in the spindie hole with the spindle pushed up against the top of the hots. Check the distare: from the bottom of the spindle. to the inside surface of the Dottom 6 of the brush holder casting, as shown in Fig. 2, If this dimeasion is greater than 19.69 may 775") of if the hole is more than $1 mm (.026") oversize, the “hole must be plugged and relocated, 2, Chock rear spring tab to ensure that offset of fab is 9.5 mum (3/8"), Fig. 2, Bond rear spring fab as required, Place brush holder fingers “coeked" position. 3, Plage vell assembly in brush holler, spris pocket with fingets centered in slot“ shown in Fig, 5. ‘AN as Brush Holser Pockets c (Aah nbs ARNO AE tnt AAS HR ean tee y cena | Fig5 - Itstalling Spring Call in Brush Holder i cae4, Insert aligning: tool through spindle hole and spring cell, Add necessury washers at areas ‘B” and "Cas shown in Fig. - 5. Check atignnient of spring cell with finger dot "A" and, if cell i cut of line, remove alignment tool and reassemble. 5. Follow sume procedure with center and teft hand cells, Use as many washers in the lineup as possible. After eveh cell is assembled, re- check the allgmment with finger slot ‘A. 6. When all cells have beet installed, drive the aigning tool out of the assembly with the spindie, Continus to drive the spindle through until the spindle is centeréd “in the brush holder. 7. 1f old spindle is uged, the twe 3.2 min (1/8") diameter holes In\the ends, “D" of Fig. 5, should be aligned with the matching holes of the brush holder. (f new spindle is used, drill two 3.2 mm 1/8") diameter holes at area "D" of Fig. 5. Insert groove pins in cach hole at arca "D."" Pen casting lightly into each hole (0 lock pins. + 8. Ensure each” spring cell is’ tight in the brush holder. [f cells are properly installed, the cells will be held firmly at contact points "E" and of Fig. 6. If required, adjust rear spring tab so thal spring colt is anchored tightly in assembly at points "E” and "F" when spindle “G" is driven-in place. Polats "E" and "F" must have definite contact with holder. Spring Cell Assemnly Pressure ear Soring Tab ase Fig.6 - Position Of Spring Coll Assembly In Holder 9. After -assembly, release brush bolder fingers from “cocked” position to prevent handling damage and to prepare. assembly for installation. MLL 3903 COIL SPRING TYPE (ADJUSTABLE) BRUSH HOLDER New or replacement brush holder springs for coil spring type brush holders should be set for an initial pressure of 4 to 5 ke (9 to IL lbs} as aneasttred with a spring tension scale with pros sure spring lifted 10 mm (3/8") above the top inside edee of the brush box as shown in Fig. 7. It is difficult to cheek brush holder spring pre stire accurately with the brush holder in plice and it Is recommended that the brush holders be removed. Since new brush older springs lose pressure duw to aging in the first few weeks of operation, rset the spring pressure as necessary. After onc adjustarent, the springs should avtain their pressure. Spring Scale initial Pressure 4To 6 kg (9 70 11 ths} Low Praseure Limi Ep Sig (7 ibs} =| When Checked At Gondemning Limit Of Brush 1.6 mm (1/16) Dis. Steel Wire Loop Spring ct 10 mm Doerr > Brush 7 Brush Holder Ls Commutator 26 mm a iy 778") 10 mm | Hare mN. ane Fig.7 - Measuring Coil Spring Brush Holder Finger Pressure ‘The minimum allowable pressure on a completely worn brush is 3 kg (7 Ibs). Thus spring pressure should always be set high enough (4 to 5 ke (5 to 11 Ibs]). to compensate for loss of pressure that results as the brush wears, Spring tension ean be regulated by removing the cotter pin locking the thimble to spindle and turniag the: thimble ond the spindle. The adjast- ing collar on the thimble can be set every half notch using alternately two cotter pin holes in the spindle, Fig. 8. This will allow a variation of tension from 0.57 fa 0.68 ke (1-1/4 to 1-1/2 Ibs) for cach half notch,Ml. 3903 t b= 2) Cotter Pin (2-7/16") 131.75 mm 2 0.05. 18,98 mm = 16.13 mm 6.187" = 002") (628 - 635) Insulator stud Peen casting into upper . end of hoe en Insulator Sleeve Retaining Pin. 9.58 9.65 mm Soldar {Do not allow edlder to Spindle Hole Diameter 3.18-3.23 mm flow Into shunt mora than 2 mm (377° - 380") 4.128" -"127"} Groove (1/16"} heyond surface of casting] Pin Dinmoto ne Fig.8 - Coil Spring Type Brush Holder The brush holder should be checked and adjusted if necessary to maintain @ dimension of 3 mm to, 5S mm (1/8" to 3/16") between “the bottom of the carbonway and dhe commutator surface, To ensure proper tightness of brush holders and connections, ‘the following dry torque values should be applied; 7/8"-9 brush holder block bolt - 203 to 217 Nem (150 to 160 ftlbs). 172"-13_ brush holder _cable_to_tsrush holder bolt - 95 to 102 Nm (70 to 75 fl-tbs). 5/16"-18 bnish holder shunt screw - 15 to 20 Nm (10 to 15 ft-tts). ialoe i SPINDLE AND THIMBLE REMOVAL When inspection ‘indicates it is’ necessary to femove the spindle to splace the thimble or brush folder finger, Fis. 8, perform the following. 1.Pry lower end of each groove pin slightly upward until pia protrudes from the top of the holder. Pull pin out of hole. It may bo necessary 10 use a drift end Kammer to drive pin out, If u drift is used to drive out pin, use care not ta damage the reamed hole. Ensure drift is smaller than rwemed hole, 2. Remove cotter pins holding the thimbles. Hold thimble to prevent it from tueniig while cotter pin is removed, [nsort a smalt drift into one of the adjustiay holes in the, thimble. Hold the drift Gnmly as the finger spring is under tension, 3. Release the spring tension on the thimble by removing the drift pin after the cotter pin is removed, The spindle eatt thon be driven out of the brush halder body, 4. If the spring, shunt, and thimble assembly are to be removed, heat the soldered end of the shunt with a soldering iron, The spring, shunt, and thimble assembly ‘can then be removed. S.{nspect all component paris for weer and damaye. Replace any defective parts with new parts 4 6. Inspect spindle to spindle hote clearance Maximum clearance of 0.51°mm (020°) is aceepiable. If clearance is greater than 0.5! mm (.020"), inspect spindle. If spindle kas cracks or has wear in excess of 0.25 mm (,010"), replace spindte with a new part, New spindle measures 9.462 mm - 9.525 min (.3725" « 3750"). If spindle is acceptable, repair spindle hole as follows: a, Roam or drill wom spindle holes to 12,77 mun fo 12.88° mm (803” to 507") diameter. b. Clean. and flux the étilled holes.and plugs to be used, Refer to Service Data for plug part numbor. ¢. Insert plug in drilled hole and sitver braze m place. Use care not to overheat and warp brush holder during brazing. —, M.1. 3903 4. Clean in hot water. ¢. Redrill the holes to.9.35 mm (.368") maintaic- ing the 61.9 mm (2-7/16") dimensions. f. Ream the 9.35 mm (,368") drilled holes to. 9.57 mm - 9.65 mm (.377" - 389"), SPRING SHUNTS Inspect brush holder spring shunts for wear and for condition of soldered joint ut brush holder. When shunt and/or tip shows oxexss've wear, replace shunt and tip assembly. If only slight wear on tip is found, slant surface may be cleaned by filing, Resolder shunt connection at brush holder with 63-37 solder or with pure lin solder. After the shunts have been soldered in place, reassemble the thimble and spindle assembly to brush holder. Install two groove pins at both ends of the spindle to. anchor spindle to brush holder. Stake upper ends of the pin holes. NOTE When the groove pin holes are oversize so that the pin is loose in the hole, rework the hole by filling the hole with silfos brazing alley (do mot overheat brush holder) and tedrill to drawing sizc, Fig. 8. CONVERTING COIL SPRING BRUSH HOLDER TO. CONSTANT PRESSURE BRUSH HOLDER Convert adjustable type coil spring brush holder to constant pressure brush holder with a conver- sion kit as follows: 1, Dismantle brush holder spindie, thimbles, and springs and thoroughly clean and inspect brush holder casting and insulator pins. Ro- place any defective parts with new parts. Repair all defects, NOTE In Step 2, do not remove the cblong boss from, rear of brush holder casting 83/0010. Ensuze that this surfuee is reasonably parallel with the éasting surface. 2. From spring celt poekets, remove all raised numbers, letters, trade marks or bosses which will not allow the spring cell to seat fimly. : “7MLL. 3903, 3. Insert the spindle in the spindle hale aind push spindle up against top of hole. Check the distance from the bottom of the spindle to the inside surface of the hottom web of the brush holder casting. If this dimension is 0.51 mam (0.020") greater than dimension shown in Fig. 2, perform Step 6 of Spindle And Thimble Rerroval. NOTE Spind: 8081883 muy be reused if in good condition, but it is recommended that the new Lypo spindle 8296216 is used, 4. The rear tab of cach mew spring cell which is furnished with the conversion kit is camectly adjusted for a 9.53 mm (3/8"), offset as shown in Fig. 2. If spring cell i8 being 1 applied, make certsin that this dimension is correet before applying tie cefl to the brush hokler, 5. Place cell "fingers" in cocked ‘position as shown in Fig, 2 when assembling cell 10 holder. 6. Center a. spring coll in vighthand pocket and aiign with finger dot "A" ag’ shawn in Vig. 9 Brush Holder Pockets < 9305181, D. Aligning Too! sot Fig.Q - installing Constant Pressure Cell In Brush Holder 7. Insert aligning tool through spindle hole snd ddl necessary washers at areas as shown in Fig, 9% Check alignment of spring coll with finger slot "A" and if cell is out, of line, remove aligninent tool and teassemble. 8. Follow same procedure with center and lett hand cells, Use as many washers in the lincup as possible, After each evll is assembled. re- cheek the alignment with finger slor"A." 9. When all cells have been installed, drive the allgning tool out of the assembly with the spindic, Continue to drive the spindle through uit) the spindle is contered in the brs holder. 10. Drill two 3.2 mm (1/8") diameter holes at area "D,” Fig, 9, Insert groove pins furnished with the coaversion kit) Peen the holes to held the pins Ensure spring el] is tight in the bush holder. 11. Alter aseembiy, release spring cell fingers from cacked position to prevent banding damage and to prepare aswmbly for installation, BRUSH HOLDER INSULATOR STUD Brush holder insulator studs shoul! be kept clean and free of defvets. The polyester msulated type jingukutor studs, Fig. (0, are unusually resistant to flashover’ damage. If Hashover darege should oveor, the insulstor studs ustally can be restored to satisfactory condition by polishing them with fine sandpaper. ‘Polyester glass material should never be subjected to alkaline cleaning solutions. Fig. 16 - Polyester Brush Holder Insulator Stud NOTE arly model brush holler insulator studs were insulated with porcelain and should be replaced with the polyester inculited studs. Polyester is more durable and does “not become permanently carbon tracked, Brush holder insulator studs tae a silicone rubber insulated sleeve over the base of the studs, Fig. 11. Whoa replacing of rceonditioning brush holder assemblies, ensure insulated sleeves are in place. v mLMax. Clearance 0.79 min (0,03: MLL. 3903 Min. Clearance 0.13 mm (0.005") Retaining Pin Brush Holder De Net Bottom [R= Rubber Sleeve 4 Fig.11 - Brush Holder Insulator Stud Inatallation Replacement polyester glass insulated studs ere available in the following Standard size - 8159003 To be used in new brush holders or when stud holes are within’ 25.235 mm 4 0.013 mm 9935" + 0005"), @.05 mm (.002") Oversize - 8209068 6.20 mim (.068"} Oversize - 8219773 For stud holes which hive had 2 standard size pressed cut. The following, studs cap be.used for extensively scored stud hdles which have been reamed out. 0.79 muni 1.031") Oversize = 8209069 0-84 mm (,039") Oversize - 8222653 1,57 wm (,062") Oversize - 8222652 1,65 mm (.065") Oversize.- 8222654 The oversice studs may be “identified by the number 2, 8, 31, 33, 62,,o1 65 stamped on the bottom of the stud,'The number is In reference to the amount oversize in thovsandths of un inch. For oxample, the aumber 2 identifies the 0.05 mm (,002") oversize stud. Tae number 65 Kdenti- fies the 1,65 mm (.065") oversize stud. INSULATOR STUD REPLACEMENT A.sleeve-type tool made of half-hard brass, Fig, 12, should be uscd for pressing the studs into the brish holder. 1.8mm (1.262") 319mm (1.256") yy TT aa 41.28m0 1.895") 1.58iemen (1/6") x a8" charifor (Material: Hatt Hard Brass Fig,12 - Insulator Stud Installation Tool To replace the brush holder inigulater studs, per- form the following procedure: 1, Press out brush holder retaining pin. lator stud, shearing 2.Cloan up stud holes of brush helder, if required. 3.Select proper oversize stuid. Ensure that 0.05 mim + 0.025 mn (,002" £ .005") press It fs obtained, Press in stud using sleeve-type tool, Fig. 12. Clearance between the stud shoulder and brush Holder must be maintained to insure tho insulation docs not get damage against the brush holder. 4, Drill and pin brush holder and stud. Use a No. 23 drill, (1540"}, and refer 10 Service Data for pin pact number. Pecn over hole on both onds after installing pin, COMMUTATOR BRUSHES The D79 machines are equipped with a three: wafer resilient pad brush, Three of these three wafer brushes are used in each of the four brushM.1. 3903 st holder assemblies: The brushes must move freely in the bruth holder and not be, restricted ‘with Girt or carbon, This may‘ be checked by lilting, the brush pressure spring and raising and lowering the “brushes. The constant pressure brush holdey springs must be reised by Hand and placed im a *cacked" pesition, The coil spring brush holdor springs may be lifted with the use of a lifter as shown in Fi Fig.13 - Brush Inspection Carbonways must be smooth and brushes must fit closely so they will not chatter. Brush holders with carbonways worn enough to pormit’ brash chatter should be replaced with new brush holders, Carefully tower the brush pressure spring. ‘over the brush to avoid snapping which is Tikely to cause the brush te chip. Brushes should be carefully inspected and ploeed with now brushes i chipped, broken. oF worn to the condemning limit, The brusi wear limit is determined by measuring the buight of tho brush pressure spring above the beush holder If the spring is 3.2 mm (1/8") fcom contacting the brush holder as shown in Vig. 14, the brush should be replaced with a new brush. Maximum Brush Wear 3.2 mm (1/87) From Brush Holder Brush Holder Spring Coll au 3.2 mm 178") To Commutator 4.8 mm (3/16) ners Fig.14 - Measuring Brush Wear, Brushes may: be replaced individually’ as they wear to condemning limit, Replacement brushes should be of thy same type and grdv as the other brushes. Mixing brushes in the same motor gan be detrimental to successful operation. Brush shunts should not be twisted or braided. "The shunt conneetion to the brush holder should be secure, Brushes should be replaced if shunts are broken or where Gamped shunt conneotion te the brush is loose. COMMUTATOR The commutator is a vital area on the motor or genomtor. It should be kept in the best condition possible. Inspections should by mate at frequent Intervals te ensue detection of surfaco faults before loss of service ot before repairs become neoessary, Such conditions as film stripping, bumed bars, high or Tow burs, high mics, or flat spots become more serious with time, When a defect is found, detenmine the cause and correct as soon as possible CREEPAGE SURFACES ‘The orepage ara on units equipped with a covoting over tho’ string band, Fig. 15, and ‘(1G (tungsten inert gas) welded commutator termina tions should be thoroughly cleaned with alcohol to remove all traces of carbon. The ereepage areas on unite which have the string band area cnated with epoxy or red eramel and: soldered commutator terminations, Fig. 16, should be cleaned and vepainted with rod air drying enante! as follows: 1.Clean surfaces thoroughly with alcohol. Remove any trace of carbon. NOTE Red enamel can be applied over polyester surfaces if the surface has been damaged, 2, Using a clean brush, apply the red insuleting enamel odtefully: 10 the creepage surfaces. Make as thin a coat as’ possible applying’ the enamel evenly leaving no dabs or overlapping areas. 10+ te tea° e Croepage Area Creapage Ar Fig. 15 - Greapage Areas On Commutator With String Band Covering And TIG. Welded Terminations Cregpage Ara: Creepage ;, Do Not Paint Past Area, Fig. 16 - Croapage Areas On Commutator With String Band And Soldered Terminations Tae enamel will enerally be of the proper consistency if thy cover on the container has been’ kept tight. If thinning is necessary, use mineral spirits sparingly. 3. Take care to avoid getting enamel into com- mutator slots or the relief at the bottom of the commutator nock. 4, Wait until enamel is dry before manning motor. NOTE De not apply enamel over carbonized or charred insulation. If the insulation can not be cleancd up satisfectorily as outlined above, the motor should be removed for more permanent repairs. M.1. 3903 COMMUTATOR SURFACE CONDITIONS Frayed brush -shunts, higily polished brush to brush box contact surfaces, excessively worn brush-pressure arms, broken pressure springs, and rapid brush wear are indications of more than normal brush movenient within the brush box and the cause should be determined. With few exceptions, the cause willbe found to be com- mutator surface inegularities. The constant monitoring of the brush probleme mentioned above is the best and caslest method of deter mining when a commutator should be ground, Road seasoning (repected heating and cooling of the commutator), standstill bums, and overspeed can cause some slight bar movement to occur. This bar ovement, depending on the amount, the number, and ication with respect to each other, could trigger conditions detrimentel to both the commutator and brushes. A commutator having certain itregularities in pro‘ile could oper- ale satisfactorily “at lower locomotive speeds, hhowover, when operated at higher spreds, the problems of flashover, brush breakage, and frayed brush shunts may develop. A very rough commu- tator would have these same conditions oscurring at lower speeds A rough commutator may be apparent. If in doubt, the condition of the surface can be deter- mined’ with the use of a dial indicator attached to the motor so the plunger rides on the commu- tator surface. Be sure indicator is on one of the brush tracks. Rotate the armature slowly and carefully observe the readings. By merely noting the- minimus and maximum tcadings, a’ true Picture of the commutator surface will not be obtzined, The 0,08 mm (.003") runout tolerance (or new or rebuild motors) is not applicable as a measurement of ‘commutator irregularity at the problem of iegulatity is not one of machining tolerances but of bar to bar movoment. An example of this would be-fo have readings around the commutator that give a tolal variation of 0.05 mm (.002"), however, hidden within the 0.05 mm ¢.002") variation are six low areas, each spanning one or more bars, This commutator would ‘cause the brushes to boones with resultant damage. A commutator having a total variation ofMI. 3903 pete 6.10 mm (.004") with the minimum, and maxi= rum readings 180° apart is an acceptable comet totor whereas the first gxaraplo, 0.05 mm (,002") variation with several low atvas, is not acceptable even though: the total variation Is much fess, {1 is difficult to give a number velue which woutd determine when @ commutator should be ground. The values obtained by diul indicator must be evaluated with respect to the performance of the motor (brush problems, flashovers, ei.) and a certain amount of personal judgement must be used. A uscful rule of thumb is that any condi- tion worse than 0.05 mm (.002") in a six (6) bar span calls for grinding the commutator. Resurfacing the commutator by. turning in a lathe, oF use of a grinder and grinder adapter, is the only conection recoramonded for a rough commutator, Hand stoning is definitely not recommended. COMMUTATOR GRINDER MAINTENANCE In order to produce an xéceptahle commutator surface finish, it is imperative that the Jig stoning fixture be maintained in good condition. The use of 2 poorly maintained or it grinder will result in pespetuating the: surface itregularitics, Rofor to Fig. J7 and, check the arinder as follows . ‘There can be no abnormal movement, however slight between the grinder, cressstide and the grinder frame or between the doiwa-feed slide and the crossslide, The mavemeat can be detected by placing a fingertip on the parting of the ovo picoes-and attempting to move vither one of the pieces in all directions other than the normal direction of travel The uavel of the erosssiide should be smouih with no binding, jerking, or tightness during the full travel from’ ‘end to end. Any binding oF tightness in the crosssfide travel is usually the result of one or more of the four Allen serews being incorrectly adjusted. Jerky movement of the crosslide travel is usually the result of either grinding dust trapped botween. the two sliding surfaces of an incorrectly adjusted or Loose bushing on the pinion shaft, ‘The grinder must be periodically cleaned and adjusted. ‘The frequency of the cleaning is deter mined by the use af the grinder and should be performed before there is any binding or jerky movement of the crossslide. borrectly adjusted © Twio Of Four Cross Slide Adjustments Cross Slide Thrae Down Faec \ Slide Adjustments Grinding Stone Ctamps aus Fig.17 - Commutaior Grinder Adjustments Do nat sttempt to clean an assembled grinder by dipping in a solvent of by using air pressure to blow out dust. The grinder must be completeiy disassembled to clean, COMMUTATOR GRINDING ‘Commutator aurface irregularities such as etching, roughness, or sight burning can often be cor- ected by resurfa a grineling fixture and an adapter, NOTE Jn order to -prodice an acceptable com- mutator surface finish, it is imperative that the jig stone fixtuze-be maintained in good condition, The in-feed and crossfeed sib ways must bo elvan and free from burrs so the dovice feeds smocthly. ‘The gib keys must be adjusted so that no free play exists in the sliding’ assemblics, but not so tight to causy binding, Refor to Comniutator Grinder Maintenance Section prior to grinding the commutator. -1n- hdI GRINDER ADAPATER INSTALLATION |. Remove the bolt securing the brush holder cable to the top brush holder, Remove the bolt securing the top brush holder clamp Ulock and remove brush holder. 2. Tape the copper lug of the Jead which was disconneeted from the brush holder 30 it will "not short against motor frame. 3. Install the adapter in the top brush holder position and secure it with the brush hofder clamp block and bolt as shown in Fig. 18, Refer to Service Data for gtinder adapter part number. Fig. 48 - Grinder Inetallation GRINDER INSTALLATION 1. Install alignment bar on the grinder dover feed slide, Check the alignment bar contact, to the feed slide for zero clearance with a thick- nioss gauge. Reler to Fig. 19. Any clearance at ither side of the ‘alignment bar contact surface indicetes the bar is not parallel to the grinder, Refer to Service Data for alignment bar and gender pert. numbers. 2. Install the grinder with the alignment bar on the adapter as shown in Fig. 18. 3. Position the motor armature so that the align- ment bar will contact approximate center of the commutator bar. Parallel the alignment bar to the commutator surface using the small areas outcide of the brush. track ut both ends of the commutator bar, The alignment bar should be within 0.08 mm,(.C03") of pecallc! ing the commutator bar. MLL 3903 ——Crose-Travel Fead Zero Clearance, Both Sides Alignment Bar Fig.19 - Commutator Grinder Alignment Bar Installation 4. Remove the alignment bar from the grinder and tustall two grinding stones. Use Taish grade stonos. Mount the stones so that they ave seated squarcly on the commutator, Pull stones away from the commutator using the grinder cross-trave! food GRINDING The supply voltage to, the traction motor ean be a DC welding qachine (or other source of DC electrical energy). The desired motor RPM for the erinding operation is approximately 1500 RPM. A. satisfactory surface finish can be obtained at a seduced RPM, but the grinding time will ve lengthened, Do not use a speed below 1000 RPM. NOTE Comimutstor can be ground by utilizing the + unit's power, Contact EMD Service Department for details.ML. 3903 ded © pee 1, Disconnect “all four traction motor Ieéds of the motor to be worked on, and tag the leads so they can be. recopnected in their original position. Connect tht moter eds to rotate the armature in a clockwise diction as viewed from the commutator end, Ineorrect rotation (counterctockwise) could cause the grinding stones to chatter on the comnuitator. Connect the traction motor leads as follows: Connect the positive supply lead to the "AA" lead of the mator, Connect the "A" and the motor together. leads of the Connect the negative supply lead ‘19 the "FE" feud of the motor. : NOTE Brushes that awe used i) the motor for wrinding operation have particles of grinding stone, dust, and copper imbedded in the surface that tides’ on the commutator. These particles can cause rapid deteriomtion of the commutator surfsee if the contam- inated brushes are not removed: from, the motor, It is recommended that if” the brushes in 2 motor are of sufficient length to continue service aftér the commutator is ground, they should be removed from the motor defore grinding is begun and then seinslalled after completion. of the operation. Ensure brushes are marked so that they can be relvstalled in their original position. Brushes that arc near the condemining limit for length should be used in the motor for the grinding operation. 2. Start the motor and feed the grinding stones into the commutator slowly, using the down- feed handle until light contsct is made. Pro- ceed to grind the commutator by feeding the stones not moro than 1/8 turn of the down- feed handle (45°) and move the stonos across the commutator al a moderate speed for three complete posses. Ono pass being the movement across the commutator in either direction. Upon completion of the third pass, the stones can be fed down another 1/8 turn of the down-feed handle. Altemating the end of the commutater from whieh the stones arc fed down will minimize the possibility of tho development of a taper acrose the commu tator, Continue this procedure until all low areas have been completely eliminated, -14- NOTE Feeding the grinding stones down more than, 1/8 turn of the down-feed handle will result in very rapid wear of the grinding stones and also Cause copper rollover on the trailing edge of the commutator bar. ‘The copper rollover will have to be remaved with the use of a de-burring tool, The recommended light fecé will result in very small copper sliveis on the trailing edge of the commu tator bar whieh can exsily be removed with a wire brush, 3. Remove the stones from the grinder and place thom in thie original box so that they will not become contaminated with oil or dict. Remove the grinder and adap te 4. With the armature rotating, clea the outer end of the commutator bars with a small piece of grinding stone, $.Remove and discard the brushes used in grinding operation. 6. Thoroughly clean the motor to remove all copper and grinding dust by directing clean, dry compressed ai at moderate pressure on the face of the commutatar, Blow out brush holders, statdr windings, and ond housing. Rotate the armature by hand when blowing ‘cut commutator slots. ‘7, Remove the slivers of copper on the trailing edge of the commutator bar with a clean wire brush, Position the brush close to the commu: fator riser with: the wite bristles fowsrd the riser face and roll the wire bristles down toward the commutator slot until they enter the slot. Move the orush actoss the commu- tator until the wire bristles have cleared the end of the commatator slot. While moving the brush across the commutator, apply moderate pressure in towards the conimutater ag well as pressure towards the trailing edge ‘of the commutator bar, This procedure will romoye all copper slivers on thy bar and in the -slots without damaging the commutator surface, NOTE The scratch marks will disappear when the soft grade of chalk stone is used to finish the seating of the brushes. 8. When the depth of the mica undereut be- tween, copper bats is less than 1.2 mm (3/64"), vse commutator slot file, Fig. 20, toFig.20 - Cleaning Commutator Slots undercut the mica to proper depth, Do not excurd the undereut maximum dopth of 2 mm (5/64. ! 9. Use chalk stone for final olzen up of eommu- ator. Do not use emery cloth or sandpaper for this purpose. Lubrican: should never be used on commutators, as brushes have enough graphite to supply their own lubrication. 10. Rotato umature by hand dad blow clean dry sit into the commutator slote to remove any loos: picees of copper. Wipe: dirt and copper cust away with clean cloths, Carefully inspect cleaning job and particularly the slots be- tween commutatdr bars te see-that all traces of undesired copper have been removed. 11. Replace brush holder, assemblies and brushes. Install cither new or the used brushes, but de not use any‘ brush that had been left in the brush hokler during the grinding operation, Reconnect cables. , 12. Reconnect cables and install inspection cover: Cheek motor for proper rotation before retarning unit so service, NOTE If the commutator has been damaged Lo such an extent that the grinding process proves ineffetive, the motor will bave to be removed and tho commutator tamed in o lathe, ARMATURE BEARINGS SEALED GREASE LUBRICATED BEARINGS Other than vertical niounted types, motors and generators ae manufactured with sealed grease lubricated bearings. A specific, type of grease is used. ‘The amount and method by which the greasé Is applied js carefully controlled. Other MLL. 3903 than the vertical mounted type motors, effective with Model D69 motor or generator, and avall- able for older models, is a sectionslized nylon insert installed in the’ commutator end bearing cover, The insert prevents an excessive amount of aso from being moved into rollers by “slumping action caused by vibration. This reduces churning of the grease which in time catwes the grease fibers to become soft and susceptible to purging. For information. .on repacking these bearings, refer to Grease Applica- tion To Bearing Caps And Covers procedure of this Maintenance Instruction. Refer to Service Data for grease part number and! quantity. ADDITIVE GREASE LUBRICATED BEARINGS (VERTICALMOUNTED CONFIGURATION) On vertical mounted (ype motors or generators, the coupling end is equiaped with a roller bearing and the commutator end is equipped with a spherical roller thrust bearing. Both of those beerings ate grease lubricated through fittirigs at either end. Add one ounce of grease fo both ends every 60 days, For information on repacking these bearings, refer to Greas: Application To Bearing Caps And Covers procedure of this M tenance Instnuction. Refer to Service Data for grease part mumber ang quantity. NOISE TEST Each time a traction anotor is removed, it shoukt tbe operated so that 2 noise check cia be made for faulty armature bearings, Performing this test will sorve as a means of detecting faulty bearings thus preventing such @ motor from operating in service ‘where it would likely result im a. road failure, The power source and cable connections for this test ere the same as described previously for rotating the armature during commutator grind- ing, ‘The armature speed should be Drought up to about 1500 RPM and then the power shut off to allow the armature to coast to 2 standstill. Care- fully listen and try to determine the source of any noise that -might be considered unususl. Experience and comparison with atker motors will help distinguish a. faulty bearing from a normal ono. BEARING CHANGEOUT ‘There ate four basic armature shaft and bearing arrangements; the standard type which has the -15-MLE. 3903, armature shuft extend through ‘the coupling ond of the motor or generator only, Fig. 21; a through armature shaft which protrudes (rom both ends of the motor or generator, Fig. 22; a commutator end stubshaft provision with either a standard shaft or through shalt, Fig. 23; and a spherical roller thrust beating with eithor a standart shaft or tough shaft, intended for vertical mounting, Fig. 24, NOTE. On all types of motors and generators built prior to tate 1975, the commutator end and coupling end bearing arrangement included an ail thrower between the immer spacer and the bearing inner eee (as shown in commu tator end of vertical’ arrengement,’ Fig, 24). All bearing caps also contained’ labyrinth grooves, Anticchutn insert not ineluded on all-types. Moen Bearing changeout procedures wil apply to sil type motors or generators unless specifically identified, ARMATURE REMOVAL TO REPAIR OR REPLACE BEARING ASSEMBLY ‘This procedure Is to remove the annature from the stator, Icaving the bearing housing and beating outer race in the stator and tho bearing inner race on the armature shaft, If bearing is not to be disassembled or replaced, perform Acmature Removel With Complete Bearing Assembly Intact procedure. Refer 10 Figs, 21, 22, 23, or 24 as applicable during this procedure, NOTE Refer to Service Data for tools or fixtures. required to remove armature, ®) LS : e Q © R T o © 0 COUPLING ExD 4 8 16 . tt 18 Oninidver 1 33 Boag E Amicutninset 12 2) Bening Can f ip 8 bee Bearing components may vary between model types. Mustrations presented to snow disassembly and assambly sequence. Fi Bearing Cover 21 - Standard Type Bearing Arrangement 16+LI, 3903, A . © D 7 Q @ @ e COMMUTATOR " SOUFLING ” END END Note Bearing assembly compunants may vary between madel typas. Illustration presented 10 show disassembly and aszombly sequonce. Tree Sprear 14, Baring cover Roler Bearng 1B. Cover Gastar Ceosut 16. Steter Frome Cocevrasher 12, Bearing Ftovsing Goer 16. Gover Gastat Bo Fig.22 - Through Shaft Type Bearing Arrangement 1hMLL. 3903, . . : @) \ @ COUPLING Ga) END. COMMUTATOR END 1. Reming Housing 17, Quer Seat £ Cop Gato Bo 3 cote OP 20. eller Bearing 3 Inrar Spacer 2" Inner Seal & Hole Beanro ie 7 Sibshet 3. ts & 38, Stub onan FF Drive nub a 28, tang Co i using caning Cover 18: Cover Gegtet™ 30: Seat AE: Rearing Gover. Lok 18. Guard NOTE Bearing assembly components may vary between mocel tyes. Illustration presented to show cisassembly and assambly sequence. aaere Fig.23 - Stub Shaft Type Rearing Arrangoment - IRS : :COMMUTATOR END ® M.1. 3903, DOO © © @ Borriag Housing 16 Gap Sester is u 1% 3 Innor Si : Si Threwer ‘Sphetica’ Roter Thrust Bearing Howie Fete Bearing Cov ibronion Fide inne en aaa Baering Cover NOTE Fig.24 - Vertical Mounted Type Bearing Arrangement -9. 7 COUPLING END Outer Seas On Fieg Sirinrgnar fallor Bearing Inter Seal Bearing assembly components may vary between model types. Illustration presented to show disassembly and assembly coquonco.M.L, 3903 ( the bearing reqpa.andhGressitig xthew-bedsing housing off the bvariag Taco with a beating press Fig.29 - Removing Commutator End Béaring Cap, ‘Oil Thrower, And Inner Race NOTE If bearing parts atenot to be used immediately, they should be coated with Shell Cyprina RA Grade 3 to prevent corrosion. COUPLING END BEARING ASSEMBLY REMOVAL NOTE Rofer to Service Data for tools or fixtures required to remove coupling end bearing assembly, Refer to Figs, 21; 22, 23, or 24 as applica- ble during this procedure. 1. Clean bearing housing, bearing -cover, ouler geal, and ofl ring so that no dirt will enter bearing. 2. Remove six 3/811 bolts from outer seal end Temove seal CAUTION Remove outer seal and cil ring’ before attempting to remove beating assembly, Failure to remove seul and ring. could result in damage to bearing cap when pulling assembly. 3. Apply heat quickly and sparingly to oil ring slinger and cemoys oil ring. 4, Remove the eight 5/8"-1i bolts from bearing cover. 5. Apply puller plate and studs through bearing cover into the beating cap, Tig. 39. Fig.20 - Removing Coupling End Bearing Areangement 6. Line up puller plate ard remove: complete coupling end beating essembly. Frsux: pul plate is pulling equally on all studs to prevent damage to beating cap. 7.When bearing assembly is free of shaft, re- mave puller plate and all but one sid. One stud should be [eft in assembly to prevent parts from failing. &.Support bearing assembly with a crane and slide bearing assembly and housing off the ‘beating inner race. 9. Remove bearing outer race fram bearing housing by completely supporting the tace of the bearing racu, and pressing ‘the beating housing off the bearing mee with 2 beaning press. 10. Apply sufficient heat to bearing inner seal to remove inner scal by hand. NOTE If beating parts arc not to be used immedi ately, they should be coated with Shell Cyprina RA Grade 3 to prevent corrosion REARING ASSEMBLY TO ARMATURE 1, Place the armature in a horizontal position on a cradle, supporting the armatuze on the core section only. 2.Cleas shaft diameters and ensue pinion end threads acc not damaged, Remove any grit or dust from retaining plate bolts holes on the commutator end of the shart.‘ . MLL. 3903 3. Ensure bearing parts are clean, Refer to Figs, the current 69.85 mm (2,750") inner scal 31 through 35, for proper locition of bearing 8499803. assembly. > NOTE : The bearing seal arrangement has been 4. Heat the beating paris © be shrunk on the improved since late 1975. [f replacing com- shaft by suspending parts in SAE 50 oil (with mutctor end inner, spacer, use the eurrent 2 safe flash point) at a temperature of S105 mm (2.010"} wide spacer 8499802, 118-125" C (240"-260" #), The of! container The current spacer is wider than previous should have a false perforated bottom which spacer and eliminates the oil slinger. will prevent direct tcansmission of heat from the Heating unit (© the bearing parts, Wipe oil If replacing coupling end inner oil ring and off ell “bearing parls with clean bound-odee outer grease seal, replace the inner ring cloths before applying to shaft. 56.19 mm +013 _| (2.178" + 008) TI t Previous Spacer Current Spacer 68.04 mm +013 _| 2718" * 006) KN LENSSSNSIZZ4 NOTE Funout of outer face of inner spacer shall not exceed 0.013 mm (,0006") total indicator runout when checked from bearing surface, . ‘ INNER SPACER DIMENSION - Beering Hovsing Til Can Gasket 1 2 2 Deering Cap 4. Collar 6. inner Specer 8 z 8 Ani-churn Ingort Beating Re Anii-Churn tasert 12 Gover Gasket 42. Gtoter Frame Fig.31 - Commutetor End Standard Type Bearing Assembly 238.ML. 3903 242.62 mm + 0.13 a 223.67 mm = 0.t3. ne {9.848" + 006) (8.798" .006) E TAPERED SHAFT STRAIGHT SHAFT NOTE : ve Runaut of outar face of inner spacer ehall not exceed 0.013 rom (.0005"} total indicator runout when ‘hacked from bearing surface. INNER SPACER DIMENSION ‘ 14. Thevet Gellar a 16, Bearing Cover A o> 15, Gover Gantot 16. Stator Frome » © 5 an Fig.82 - Commutatar End Through Shaft Type Bearing AssemblyM.1. 3903 e bfpeateere 1p ges outs ougtomne ieee G ec iiss, i eee SESE, mm é Fig.33 - Comimutator End Stub Shaft Fig.34 - Commutator End Vertical Mounted ‘Typo Bearing Assembly Type Bearing Assombly -a-MLL 3903 226.4 mm Ref,_* B74 1 NOTE Bearing housing may vary between motor ar generator types. Illustration pragonted te show assembly sequence, 4, Bearing Housina 7 Govt Gata 3 Bearing Coca 2 Outor Boat 5 Bi Ring Fig.36 - Coupling End Bearing Arrangement CAUTION Do not use a torch, induction ~ heater, brazing tongs, or any’ unvontralied heat. Dirset heating of bedring parts will warp or motallurgically upset the parts. 5.]f commutator end inner spacet_or coupling end. inner seal’ were removed, shrink inner spacer andjer inner scal onto. the shaft. Ensure inner spacer is tight against the com- mutator end collar end the inner seal is debt against the armature sore quill. Use a brass tube Targe enough lo fit over the: shaft to hold beating parts in proper position. 6. If commutator end inner spacer was removed and reassembled or If a new inner spacet is being used, chock tho distance between the end of the shaft and the inner spacer, Refer to Fig. 31 of 32 ws applicable, Machine outer face of inner spacer if required to obtain pro dimension, Use care not to cut into shaft if spacer is machined, 7. Check inner spacer otiter Cucz nimout from the bearing surfuce. Inner spacer outer face runout shall not oxeced 0.013 mm (0005") total indicator reading. 8. If coupling end inner scal was removed and reassembled or if a new inner seal is used, check the distance between the end aftheshefl andthe inner seal, Refer to Fig, 35 9. Apply grease to commutator end and cou pilag end bearlag caps. Refer to Greas: Appli cation To Bearing Caps And Covers procedure of this Maintenance Instruction 10. Unstall gaskets to beating saps. NOTE If motor is oquipped with SKF through hardened commutator end hearing assembly 9428485 (inner race 457058, ouler race 9428559), it ia recommended. that bearing assembly’ be replaced with SKF carburized commutator cad bearing assembly 947296 {inmar race 9437318, outer race 9437297) at first motor overhaul. The corbutized races have greater impact strength than the through hardened races. The through hardened bearing assembly 9428485 is. no longer available from Electro-Motive as a replacement part, I, Shrink the commutator end and coupling end inner bearing races onto the shaft. Coupling edd inner race is positioned on the shaft with the indentification numbers facing outboard, Commutator end liner race 9437315 is positioned on the shaft with the identification nutnbers facing inboard. Commutator end inner race 7451318 is positioned on the shaft with the identification numbers facing outboard. Push each race against the previously applied part. Rotate inner race while applying pressure until picce seizes the shaft. Ensure bearinginnes races are not distorted, misaligned, or out of position. Remove all traces of oil ftom the races. 5 12, Using a suitable bearing press, completely support the face surface of the outer roller ‘bearing race and press bearing into the bearing housing. Keep bearing level and wot cocked in bore, If bésrings have been in service previously, install bearings so that the former top of the outer race (before beating was removed from the housing) is assembled in a position 90° to either side of the housing top. . 228. ft ‘The face of the commutator end outer race should project 5.08 men (.200°) from each side of the housing when properly seated, The face’ of the coupling end outer race should be 8,46 mm (.333") from the outer face of the housing, Coupting end outer race is positioned in the housing with the idenuification numbers facing outboard, Commutator end. outer race 9437297 is positioned in the housing with the identification numbers facing inboard. Commutatar end oater race 7451864 is poistioned in the housing with the identification numbers facing outboard, 13. Basure grease is applied to the bearings before assembling bearings and housings to the armature, 14. Apply a light coating of grease to the bearing inner races and install two locating studs to the coupling end and commutator end bearing caps, Fig, 36. Taese studs will keep the hearing cap in position when the housizgs are assembled to the amature, Refer to Service Data for locating stud.part numbers, Fig.36 - Commutator End And Coupling End ‘Line Up Studs 13. Assemble the bearing housing assemblies to the armature, being: careful not to cock or force roliers over inner face. MLL 3903 16. Assemble bearing covers te the bearing, assemblies, Remove locating studs. 17. Use four bolts on the coupling end and three bolts on the commutator end to hold covers In position, ‘The covers will have 10 be ree moved after atmature assembly is pltced in stator to inspect the bearings for alignment. ARMATURE INSTALLATION AND ALIGNMENT Ensure stator has been cleaned, inspected, and repaited if required. Ensure brush holders are installed in stator prior to assembly of armature. Refer to Service Data for tools or fixtures required to install and align armature NOTE Mators pictured are’ not necessarily the correct model, but aro used to show proper assembly positions 1. Place stator on a_frame stand. with commu tater end down, Ensure bolt holes of stator clear the blocks on stand to allow for locating pins at commutator end of armature ta clear as armature is lowered into stator, Ensure coupling end stator bore face is lovol in all directions, 2.Position brush holders all the way buck against brush holder blocks to allow clearance for the commutator. 3. Install four locating pins in bearing housing bolt holes of coupling end of stator. Install four dine up studs to the commutator end bearing housing, 4. Apply lifting cye bolt to the coupling end of the shaft. 5.On standard shaft armature, apply armature turning plate to the commutator end bearing housing and insert bar through eye in plate, Fig, 37. Use steel stand to lift armature into vertical position and remove tuning plate, On through shaft armature, apply commu tator-end lifting eye to the commutator end of the armature shaft and insert bar through eye, Fig, 38. Use stecl stand ¢o lift armature into vertical position and remove lifting eye,sweet Fig.37 - Reising Standard Shaft Armature For Insiallation into Stator ho rE 6 ws a S$e gy nen and Ra ti S OTe, . of the al - see es ~ Mor32t SFOS innet apo SES IS? dimension. OS SS € & ap of 7. Check inner spats” 1375 the bearing surfad ossible, runout shall not ex (or passes total indicator readin, 8. Center the armature over the coupling end stator bore and lower armature slowly into tho stator. Guide the armature from the top of the stator past the cails. Carefully position the line-up stads through the inspeetion opening at the commutatar end of the frame: WARNING Keep hands out of the way of the ermature housing and the brush hoklers. 5. Lower armature into stator watil line-up studs are about to contact the stater, Line up the commutator housing studs and coupling end housing cap sctew holes with the stator holes, 10, Remove the coupling end guide pins and install coupling ond housing bolts and lock- washers, Fig, 39. Equally space three 19 mm 3/4") ‘spacer blocks between the coupling end housing and the bore face. ‘Tighten the Fig.39 - Securing Coupling End Housing ‘To Stator Frame <30-eee N$R’YN’’N"'— ~——>rs 12. 13, 14, 15, . On standard shaft érmutuires, such as f coupling end housing bolts evenly until the housing contacts the ‘spacer blocks. Rotate the armature while housing bolts are boing tightened: to imake sure the bearings do not bind. Binding can cause damage to bearings. Remove the three spacer blocks. Remove the traction motor from the assembly stand, using the coupling end lifting eye, and place traction motor in a vertical position an Ge floor. Using the upper lifting eyes of the traction motor frame, lower the traction motor into a horizontal position. Lift the traction motor and set on a stand so that the coupling end of the traction motor is 75 mm to 109 cam G" to 4”) higher than the cammutator end. This is done to kecp armature clearance in one direction. Remove commutator end bearing guide pins and install commntitor ond bearing housing to frame bolts, Carefully tighten coupling end and commutator end bearing housing to frame bolts evenly. Ensurc.housings.are drawn in evenly and not cocked, Keoping the com- mutator end bearing hogsing slightly ahead of the coupling ond bearing housing so-thet the commutator: outer sace will at no time be forced out of position in the housing. Torque commutstor ond ‘bearing housing to frame bolts to 366 Nem (270 ‘fe-ibs) and’ torque coupling end bearing housiig to frame bolts to 800. Nim (890 fetbs), is. 31, assemble contmutator end thrust collar and boaring retainer plate, Use a new thrust collar whan a now commutator end beating is uscd. ‘Torque commutator end thrust collac and bearing retainer plate to 68 to 75 Nm (50 to $5 ft-lbs} to pull beating into proper position. Assemble commutator end hearing cover with gasket and tighten until Jockwashers er set, Torque commatator end and coupling ond besring cover to hearing housing bolts to (70 to 190 Nim (125 10 146 fs), On through shaft armatures, such as Fig. 32, commutator end bearing must be positioned by assembling thrust collar (where used), outer seal, and tightening lockaut. Us: a 5” spanner wrench and sledge hammer to tighten lecknut. On stendard shaft armatures, remove the com- mutator end bearing cover, bearing retainer plate, and thrust collar. Gn’ through sheft armatures, remove Tockaul, outer gexl, and MLL 3903 fnrust collar (where used), Use a $" spanner wrench and sledge hammer .to tocknut, 16. Clamp an indicator to the frame and cheek uncut of the bearing race inner face, Fig. 40. Meximum runout should not exceed 0.038 mm (.0015") of total indicator reading, If synout exceeds 0.038 mm (.0015"), the inner sace must be eligned. Usually this will require removing the bearing assembly from the arin ture, checking the runout of the inner spacer face and reinstalling the bearing assembly. Fig.40 - Checking Alignment Of Commutator End Inner Race 17. Check tho internal radial clearance between the. bearing inner race and scHers by passing 2 focler gauge blade uncer the untoacded rollers af one point, The minimom interaal radi clearance eft should be 0.064 mm (.0025") wh nonnal position, 18. Check the internal radiat clearance with the lead side of the motor or generator up, With the motor in this position, the absolute mini: mum clearance shall be 0.05 mm (.002"). If the clearances are lower, check for tight cage or misalignment. 19, On regular shaft aumature, scassemble commu tator end beating thrust’ collar and bearing retainer sg ‘six “9420945. 7/16'-20 bolts, Ensure these special bolts arc used. Torque bolts in a crisscross pattem to 68 - 75 Nem (50 - 55 fabs), -31-MA. 3903 mutator end thrast collar (where uscd), outer seal, and locknut, Use -a §" spanner wrench and sledge hammer to lighten locknut. 21.On standard shaft armature, remove one of the bearing retainer plate, dolts and mount indicator as shown in Fig. 41. On through shaft armature, a magnetic base indicator will have to be mounted to the shaft, Check runout ot bearing ‘outer face, Maximum run out should not exceed 0.064 mm (.0025") total indicator reading. If outer race is out. ofsquare beyond 0.064 mm (.0025"), check the runout of the commutator end housing face and align end housing if requited and recheck outer race. Do not force outer race against the inner bearing cap to align outer race sings e 31 or 32 asses inner apon SES, FF & dimension. «Oe SS to spacer is mang oe) ve atid 4. Check imer spit.® od until the bearing. surta a fend play runout shall not ex £0055" to total indicator readin, =32- Sy adsinstatentegt Do, not force the shaft for this measurement The commutator end outer mice can be shifted or the thrust Manges ean be sprang with sufficient force to obtain an. erratic indication, Af geeater thax 0.350 mm. (.0138"), check the commutator end bearing. retainer and thrust collar for tightness, anc check the thrust collar for wear. 24, Apply grease to the conmiutator end beari cover, Refer to Grease Application To Bearing Covers And Caps procedure of this Main- tenance Instruction, 25. Inspect boaring cover gasket install a new gasket HW damaged, 26, Install commutator end bearing cover. Ensure grease are is at lower portion of cover, Fig, 42. Torque bolts evenly in the sequence [-3-5-2-4-6, Fig. 43, to 170 to 190 Nm (125 to 140 ft-lbs). Fig.42 - Applying Commutator End Bearing Cover 27. Remove coupling end beating cover. Clamp a dial indicator to the frome and check runout of the bearing inner race Face. Maximum runout should not exczed 0.038 mm (,0015"). [f ranout is grvator than 0.038 sm (.0015"), the inner race must be aligned. Usually this will require removing the bearing assembly from the armatue and rcinstalling the bearing ussombly properly.Fig.43 - Commutator End Balt Numbering 2, Clamp a dial indicator on the atmature shaft fo cheek the cunout of the coupling end bearing outer race face, Fig, 44. Maximum Tunout should not exceed 6.08 ‘mm (.003") of total indicator wading, Fig.44 - Chacking Alignment Of Coupling ‘ End Outer Race 29, When motor is In-normal horizontal position, chock internal -redial clearance between the bearing inner race and tollers by passing a foeler gauge blade under the unloaded roliers at one point, The minimum, intemal radial M.L. 3903) clearance after assembly shall be 9.08 mm (.003", 30. Check the internal radial etoorance the Jead side of the motor or generator up. With the motor in this position, the absolute mini= ‘mum clearance shall be 0,05 cam (,002"), 1. Shrink the coupling end outer grease slinger (outer oil thrower on motors manufactured prior to late 1975) to the shaft and hold it against the beating inner race, rotating the grease slinger until it seizos to the shaft, 32. Apply greasc to the coupling end bearing cover. Refer to Grease Application To Bearing Covers And Caps procedure of this Main- tenance Instruction, 33. Inspect beating cover gasket. If damaged install a new gasket, 34. Install coupling end bearing cover, “Ensue grease arc is at lower portion of cower, Torque bolts evoaly in the scqueace 13.5-72-4.68, Fig. 45, to 170 to 190 Nm (125 to 140 tbs). Fig.45 - Coupling End Bolt Numbering 35.0n throaigh shaft type bvaring assembly, Fig. 32, perform the following: a. Remove locknut (7) from sheft. 1b. Apply a new lockwasher (8) to shaft, “BeMLL. 3903 36. i. Apply locknat (7)6t6 shat! aid tighten, using a 5" spsnnet wrench ahd sledge hammer. Pound cays, of lockwasher (8) down tightly on loeknut flats, 4, Heat drive hub (11) to 128° (230° F) over room temperature and apply to shaft, Do not exceed 191" C G75" BD Assemble retainer plate (10) and svtainer plate bolts while dtive shaft is still hot. Resighten bolts when drive hub is cold. ©. Assemble guard (9). On stub shaft type bearing assembly, Fig, 33, perform the following: Regular Shaft ‘ 4 Bolt stub shaft (7) to mature shaft, b. Assemble guard (8) to stator frame. Through Shaft a. Remove locknut (19) from shaft. 8. Apply u new lockwisher (16) to shatt. €. Apply Jocknut (19) to shaft and tighten using a 5!" spanner wrench and sledg hammer. Pound vars of lockwasher (16) down tightly om locknat flats. 4G. Meat drive bub (15) te i128" C (230° Fy ever room twmperalure znd “apply to shaft. De- not exceed 191° C (375%). Assemble stubs shaft (14) and tighten stub shaft bolts waile drive bub Is still hot. Retighten bolts when drive hub is cold. &. Assemble guard (13) to stator. On vertical mounted through shaft type bearing assembly, Fig. 34, perform the following: a. Remove locknut (13) from shaft. b. Shrink pearing outer seal (12) to shaft, Ensure seal is tight against bearing inner mee. c. Apply a new lockwasher (15} to shaft, d. Apply loéknut (13) to shait and tighten, using, a 5" spanner wrench and. sledge 38, Remove protective paper cover From comm 39, 41, Connect brash hammer. Pound the cars of Jockwasher (13) down tightly on iocknut flats. ©. Bolt shiold' (14) to lockriut (13). fator and adjust brush holders so that the bottom faces of the brush slots ete 3 to 5 mm (1/8'-3/16") abore the commutator surface. ‘Torque brush holder clamp bolts to 200 - 220 Nam (150 + 160. frlbs) after obtaining clearance, Install brushes to brush holders, If old brushes are to be used, they should be installed in the same position in brush holder from which they were removed. When new brushes are installed, they must be "sanded in” by wrapping 1-1/2 turns of meditim gauge sandpaper (with the abrasive side out) around tho commutator bofore the brushes are epplied. Install brushes and rotate armature until all the brushes are seated. If new brushes were sanded in, remove sand paper and blow out carbon dust with clean, dry compressed cir at reduced prossuire, Use a clem, dry, boumdedge cloth to remove carbon from string: band and commutator siser. while manually rotating the armature. Wipe carbon dust from brush holder insulators. shunts to brush holders. Torque bolts to 15 - 20 Nm (LO ~ 15 tbs}. GREASE APPLICATION TO BEARING CAPS AND COVERS NOTE For scaled grease type beatings use Shell Cyprina RA’ Grade 3 gtoase, For additive grease Iype bearings use Lubrivo M6. Refer to Service Data for grease typé and part number, 1. Fill all Iabyzinth grooves in the bearing caps and covers flush with grease, as shown in Fig. 46, This grease need not be micasured, NOTE Depending upoa the model, not all bearing. caps and covers have labyrinth grooves, 2. Bor additive grease type boasings, fill grease pipe and grease groove in the bearing and bearing housing with grease.Fig.46 - Grease Application To Labyrinth Grooves 3, Weigh the picce of paper that will be used in handling the grease to fill the bearing cep and cover, Weight of paper must he compensated for when weighing grease. 4. Carefully woigh grease’ for specific bearing end to be greased. Refer to Service Data for proper quaittity, NOTE When antichurn insert is’ used with the bearing cap, it is recomntended that about two thirds of the weighed greuse be applied to the cavity. Then push insert into grease and apply the Tour-lacating buttons on the insert into four locating holes’ in the cap. Binish off ‘grease contour using the balaneo Of sie weighed grease. ‘5, Pack grease solidly intothe tower portion of the cap. Keep the ungreated portion’at the top of the bearing cap as shownin Fig. 47. The bottom of bearing cap has two drain holes, 6. Using @ spatula or putty-knife, rougitly form the grease into tho approximate’ desired con- tour, Fig. 48, and apply correct grease mask as determined from Service Data, Tho grease are must be packed without air voids. 7, Rotate groest mask to’ form’ proper contour, Keeping mask seated as shown in Fig. 49. Soveral tums may be required to get proper contour. Use spatula or putty knife to fill in Jow spats with erease from the, mask blade. The smal) amount of grease retwined on the blade should be removed and applied to the -38- Fig.49 - Application Of Grazse Mask ends of the grease arc. The contour should be built up to the limits of Fig. 50.MLL. 3903 5 mm‘? 8mm*9 210 6718" a6) S104 cover Cap ‘COMMUTATOR END. ROLLER BEARING WITH ANTI-CHURN INSERT ‘0 smm’g na aa" Yq)-| Cop Cover PINION END, ‘ROLLER BEARING WITH ANTI-CHURN INSERT 1 13 mm = 2 mm {4 f a2" £1718) TR 10 mm + 2mm (8/8 "4 1/16) Ha operate 19 mm 12 0 6/16" 64 22 mm 42 6 25 man S (er 718) Zw “0 Cover COMMUTATOR END, ROLLER BEARING WITHOUT ANTI-CHURN INSERT 0 +0 6 mm ‘9 8mm*o Cap Cover PINION END, ROLLER BEARING WITHOUT AATI-CHURN INSERT 10 mm #2 mm (37e" 44716) COMMUTATOR END, SPHERICAL ROLLER THRUST BEARING Fig.50 - Groase Contour -36- Mm© 7 e NOTE Bearing caps or covers without labyrinth ‘grooves or inner lin use identical grease contour. ' : 8. Remove roller cage ussembly from bearing outer race, Work grease “into the outside diameter of the raller cage assembly with a putty knife or spatula, Fig. 51, coating the rollers and spreading greare into the cage packets, Use full: amount specified for bearing. Apply some grease between the roller ends and cage end rings. Apply a continuous light coat of grease on the inner cace coiler paths before assembly of Gutet rave and roller assembly, Fig.G1 - Coating Outside Dismetar Of Roller And Cage Assembly 9. Replace roller cage in outer race and work grease around the inside diameter of rollers and inta the cage pockets. CAUTION In removing and replzcing roller cage assem- bly from beering outer race, ensure caze and outer race are handled squarely to prevent gouging or deforming cage bars on outer ra ORIVE FLANGE OR COUPLING A drive flange or coupiing provides ‘a means of Coupling the motor.or yenerator 40 a deview that M.1.-3903 it is (6 drive or be driven by, depending on ita application. All references to he drive flange in the following removal and application proceduces can be interpreted as couptings in those applica tions that ate so oquipped. The drive Qange is teited and shrunk onto the armature shaft 10 provide the fit necessary to withstand the strain imposed in operation, The Unive flange is removed either by pulling off with 8 hydraulic puller or by "Moating off" by means of hycraulic pressure, Refer to Service Data for special equipment required for drive anus ro moval, The drive flange is removed as follows DRIVE FLANGE REMOVAL WITH HYDRAULIC PULLER 1, Remove the nut from end of armature shaft with an air impact wrench, Fig. $2, or with a retaining nut wrench and handle, Fig.52 - Removing Retaining Nut 2.Clean threads in drive flange and in pulling pilot, 3. Apply spacer between the end of the arma- ture ‘shaft and the ram of the puller to protect the sheft from possible damage, 4. Install threaded pilot and hydraulic puller assembly using a suitable hoist, Fig. $3, The Chreaded pilot should enter the threaded Portion of tac’ drive ange to Lis complete depth so threads will nat strip. . “4.M1, 3903 . Fig.63 - Hydraulic Drive Flange Pulier WARNING Remow hoist before attompting to pull drive flange. Drive flange releases suddenly and i€ left suspended on hols: can swing violently, Clear orca in tive with drive ange to avoid damage to equipment of injury to personnel when drive flinge releases, $.Pump hydrwutic drive flange puller to build up pressure and remove drive Clange. DRIVE FLANGE REMOVAL BY FLOAT-OFF METHOD ‘The floatoff methéd of drive flange removal can be used on armature shafts which are manufacture ed with © groove around the shaft tapor which is conngeted Ay drilled passages to 8 1/2"-20 tapped hole in the center of the shaft, as shown in Fig, 54. The drive flange is romoved by applying high pressure oil through the dritled passages. to. the inside of the drive Mange bore which results in the drive flange being roleased from the. shaft. 1, Loosen the nut on end of aemature shaft with an air impact wrench, Hig. $2,.0r with a Fig.54 - Drive Flange Float-Off Removal retaining nut wrench and handle approximate, ly one turt, but do not remove. Clean the center of the armature shaft and remove the 1/2"-20 gocket head_sstserow. Ensure that threads and pressure fitting seat are clean, 3. Screw adapter nipple into shut and tighten ro. 34.41.N-m (25-30 tbs), Do nol overlightes as this will Gamage the shaft seat 4.Connect adapter nipple to the hydhrautie pump with the high pressure hose assembly. Close serew on tte pump and operate lever te build up pressure. When ‘pressure becomes high enough, drive Mange will bo reloasod fiom armature shaft and will move off against the retaining aut, 5. Remove equipment and replace sctserew in vad of shaft. DRIVE FLANGE APPLICATION It is essential: that the drive flange is properly mounted on the armature shaft (9 ensure it is fit with the proper tightness, Apply the drive flange as follows: 38 - sy # |* NOTE ‘The following, procedure applies to EMD supplied coupling oF drive flange 1. Remove any burrs or scoring on armature shaft. or in drive ange bore by honing or cleaning away with Arkansas stone (novacu- ite) or Grade 240 abrasive dott. 2. Clean threads on armature shaft with a wite brush, or if threads are damaged, rua on a toread chasing die.” Apply retaining aut to sheft fo check for proper fit, 3. Thoroughly clean drive flange bore and tapered end of armature shaft where pinion will be mounted. The slightest bit of lint or dirt will hinder pinion apptication. 4.Check the contact between the drive flange and shaft taper 2s follows: a. Apply a thin, oven coat of Prassian (non drying) bluing compound to the drive Mange bore with the fingers. A cloth should not be used'sines heavy deposits of bluing will not-ailow a true indication of fit. ‘ b. Place the drive lange on theshafi carefully, avoiding undue rubbing. With the drive Sange held snug on'the shaft, rotate drive flange approximately one-cigith turn and back, Remavethe drive flange carefully and inspect the amount of bluing transferred to the shaft and the areas of contact. {1 is necessary that the drive flange is in fiem contact with the small eed of the armature shaft taper. A 50% contact is expecied, but “it the two tapers are at opposite extremes of folcrance, it is required that the drive flange is in fiem contact with at least 20% at the smail end of the armature shaft taper, The large ond Of the.bore should not contact unless a line-to-line contact is obtained throughout the hore. Tf comection is required, polish the shart with Arkansas stone (novaculite) or Grade 240 abrasive cloth, . Thoroughly clean and remove all tracks of! ‘bluing trom the shaft and grive flange with @ solvent and wipe dry with elean, disposable tiseues, MLL. 3903 S.With armatore shaft and drive flange at room temperature, lightly mount drive flange on shaft to ensure proper alignaient. Withdraw rive flange about 12.7 mm (1/2") and then using both hands, push firmly in place as far as it will go. Ensure drive flange is mounted squarely on shaft. 6. Measure and record drive flange position with respect to tho shaft with a micrometer depth gauge. 7. Mark the points of messurement on the drive flange, then mark the ead of the shett and drive flange to retain the same angular relationship when re-applying and for final installation. 8. Remove drive flange. I this proves difficult, smal stecl wedges may be asod between the drive flange and the frame, To prevent damage to the bearing housing, @ strip of copper should be placed between wedge and housing. 9, Repeat Step 5, using the mating marks provi- ously made fo ensure proper relationship of drive flange and shaft. 10. Apply micrometer depth gouge to markings and again measare and record ‘drive’ flange position on the shaft. Compare readings to those previously taken in Step 6. A ininimum of two. such readings shauld be made to determine yatiations, if any, in readings, ‘To be acceptable for final mounting, successive cold readings should not vary more than 0.05 mm to 0.08 man (,002" to .003"). Uf variation exceeds these limits, again care fully clean drive flange bore and armature shaft to eliminate all possibility of dirt or contamination. If the veriation is as auch ag 0.25 mm C010"), the: drive flange fit to anmature dhaft must be checked by bluing and corrections made by lapping. [t is neces sary that the drive flange Is In fism contact with at least 20% at the small end of the armature shaft taper. Tho large end of the bore should not contact unless a line-to-ine contact is-abtained throughout the bore, JL. When. cold mounting variations are within limits, the drive flange may be heated with an induction heater, Fig.’ 55, for fial mounting, Heat and moont the drive flange as follows: “M-goer ld nants Drive Flange Fig.66 - Induction Heater Heat drive flange to a temperature of 12)° C QS" F) ABOVE that of the ‘shaft. Cheek temperature at various poinis on the drive shaft with @ hand pyrometex. Take readings ONLY when curtont to tae induction heater is turned off. Drive flengs tompereture should NEVER exceed 190°C G74" Fy, NOTE Since a change of 1° C is equivalent to a change of 1.8°F, a 121° C tise inv tempere- ture is therefore equivalent to a rise-of 218° K Ag on example of proper heating, sssume the shafl temperature is 24° C (75° F). The pinion should then be heated to obtain 145° C Q9F F}, which is the desired 121° C (218° F) ris: in temperature cver that of the shaft. b, When drive flange is heated to the proper temperature, mount the hot drive flange on the shalt in the sanic position used for the cold mountings. Measure drive flange position with respect to the shaft with @ micrometer depth gauge. Deive flange should have advanood 1.27 mm to 1.52 mm (0.050" to 0.060" on the shaft over the previous cold reading, The ideal advance is 140 mm (O.C55") (see Service Data), however, iF the position is within the limits specified, the mounting will be satisfactory. sth agaba's Saget se redesinte nyatayte 8 piles a. Ssatessh Hf advance ig less than 1.27 mm ox more 1.92 an, drive flange will have to be roroved and all preceding steps repeated after parts fave “cooled to room temperature. Place the drive flange retaining nut into the cup fockwesher. NOTE In Step f reused drive flange retalning nut should te checked for flatness pricr to assembly, using a straightedge and fecler gauge. The dish, if any, should be noted so an additional JO mm (.004") dish can be determined m Step f, After final correct mounting of the heated drive flange, quickly tighten the drive flange retaining nut {with cup lockwasher) before the shaft and drive flange tempera tures equalize, Check for tightness of the nut 10 minutes after pplication, by measuring nut dish 6.4 mm (1/4") from inside the chemfer, using a straightedge and: fecler gauge. A minimum dish of 10” mm (.004") is necessary. Secure the drive flange tetaining nut by staking the cup lockwasher into the wo notches in the drive flange and stake the cup lockwasher into two notches of the retaining wut, STATOR FRAME ‘The stator frame is a fabricated structure contain- Ing main poles, interpoles, and the brush holder assemblies, Between overhaul periods, the stator should be kept clean by blowing out dust and dirt at regular intervals. Periodic cleaning will prevent undesivable accumulations from forming, CABLES AND CONNECTORS ‘The motor and generator Jeads are equipped with clasp type connectors consist ned gf two rae! bbrasa couplings as shown in Fig. 56. Considerable forer is necessary to make np or disconnect these fittings and a special tool, Fig. 57, is available for this purpose. Rofor to Servier Data for part aiumber. No lubrication is required on these connectors and no maintenance is required if the recom. mended tool is used, Do not strike connectors with a kammer. If proper tool is not available, a 40-. M.L. 3903 wood block should bé used to protect the con. nector from darnage. Fig.56 - Clasp Type Connectors . Fig.57 - Motor Lead Breaker afteMe M.t. 3903 SERVICE DATA spent SPECIFICATIONS 039, D49, D59 BRUSHES Two wafer, flat top 34mm x 51mm x (6 mm (2-1/8! x 2" x 5/8") Grade DE-S : See eee eee se. 8215999 ‘Two wafer, fal top G6 mm x Stan x 16 mn [2:3/16" x 2" x 5/8"1D Grade ACH24 ee tee 9322055 Two wafer, flat top (S6inm « SI'mm x 16mm (23/16 x 2" x 5/8") Grade DET... See ee eee ee. 9922056 D69, D79 BRUSHES ‘three wafer, “loating center wafer (62 mm x 51, mm x 16 mm (2-7/16" x 2" x se" . Grade DE-7 tae . 8481803 Grade DE-7 : 9322058 Grade AC-1OG 2, . 9322059 Grade AGG 9096381 Grade AC-I24 . : 9322057 ‘Two water, ‘lat top (56 mm x SI mm x 16 mn [23)/16" 2" x 5/8") Gmde AC124 bene e eee bee eee 9093639 Grade A . bee vee es 9322055 Grade DET tae : 9322056 BRUSH HOLDERS Number of brush holders a te 4 Clearance - bottom of brush holdsr to commutator PET sti 3.2 mm 078") : Max. 4.8 mm 3/16") Spring Pressure Adjustable type... ee eee ete eee . Min. 3.2 kg (7 Ibs) Max, 4-5 kg (9-11 Ibs) Constant pressuire type New cee heen e es Min, 1.8 kg (4 Ibs) Max. 2.3 kg {§ Ibs) ee eee eee ee Min, 1.6 ke (3.5 Ibs) Used, . M.1. 3903 Torque Values 7/8"'9 brash holder-block bolt 6.2... fee ee) 203217 Nem (150-160 Felbs) ¢T 1/2"-13 brash helder cable to beush holder bolt 9S-102 Nem (70:75 fttbs) S/1G"-18 brush shunt screw MOTOR OR GENERATOR WEIGHT (Approximate) 14-20 Nem (10-15 Pets) Complete oar . ae wea 2545 kg (5545 ibs) Armature «821 kg (1810 ths} AIR GAP (Nominal) Main pole ve + we wae 5.94 min (0.234") Interpole : ss oe 7.24 mm (0,288") @ © commutator Mica groove width 2... ee bene 1.27 ram (0.050") Max, Mica groove depth ov. ieee ee eee ee EQ umm 3/64") Min, 2 mmm (5/64") Max. ORIVE FLANGE APPLICATION Heating temperature (approximate increase) 121° € QUE) above § at temperature Drive Mange advange ee eee. . 140mm £ 6.13 mm (0.055" # 0.005") ¢ RESISTANCE (AT 75° c) NOTE , Take interpol: resistanee between end of ‘ "brush holder lead AA and right brush holder (acing commutator), Toke field resistence : . : between ends of F and FF brush holder icads, Measure cold temperature with thermovouple probe and potentiometer on the commutator. @ Armature... tae . ‘Ohms # 2%, DISF, D7IMC | : os, 6.01232 DIOXS 2... : + OOHRS Allothers |. 2”, : : 0.01446 Seties Field Circuit D39 motor : neces = 0.00951 D39 generator ld : +. 0301 49, D9, D69 motor | 1 | | * 0.00870 és. 39, 969, DID gensrator te ses 0.842 DIO motor 2... a +. + 0.00886 DISMC motor ©. + + €.00876 DI9XIA motor : + + 6.00816 . AgeM.L 3903 Interpele Circuit, J 539 motor and generttor beeen eee 0.00736 D49, DS9, G9, DI9 generator TD eooea7 B49, DS0, Dé motor : + 0.00045 179K motor 0.00785 D79MC motor 10,0065 DI9X2A motar 0.00695 HtGH POT TEST Motos... cones pv ee 2400 volts «10 sce. Generators bees Fees + + 2400 volts - 10 Separately excited generator Fivids ” : see + 900 volts 10 see, SEALED GREASE BEARING LUBRICANT QUANTITY + 7 g (1/4 az) : PINION END. COMMUTATOR END. Kilograms — Ounees Kilograms Ounces Cover 0.340 n 0.170 6 Cp 0397 14 0.198 1 Roller C: 0.087 2 0.028 1 Roller C 0.057 2 0.028 a 851 30 0.424 1s ADDITIVE GREASE BEARING LUBRICANT QUANTITY = 7. g (174 oz} : PINION END COMMUTATOR END. Kilograms — Ounees Kulograms Ounces 12 0.227 8 : 4 O27 8 4 6.198 a 30. o.052 23 EQUIPMENT LIST Pact Number Grease Masks Commutatcr End Cover, Without Ensert Pe eee 8298023 Commutaior End Cover, With nse ee eee 8252767 Commutaiot End Cap... Pete ++ Bz2e024 Coupling End Cap And Cover (built prior to January L191) 7 2 LD epzenes Coupling End Cap And Cover (built after January 1, 1971). . sees File NO. 777 Locating Studs - Coupling End Bearing Cap... se + 8155976 Locating Studs - Commutator End Bearing Cap pene 8155077 Lifting Fixture Coupling End Shas eee ee 8067122 Tusing Plate, Comumutator End eee eee) BO67HT Stand, Traction Motor Frame ee ROGAILT Rethreading Dic, Armature Shait : ee eee ee BOSOTEL DieHolder ee et Pelee cee ee ee 8057022 wd@ iy : , M2. 3903, Part Namber Brush Spring Lift ee beeen eee beeen es 8140869 we Nut Wrench sees 8127829 iding "I" Handle | |: : BI27S28 Depth Gauge, Driv Flange Advanes 8160273 Brush Slot Gauge. cee Seen see 8259133 Aligning Tool, Brush Holder Spring Cell 8305181 Adapter, Commutatoz Grinder (Brush Holder Mounted) sees + 8354239 Commututor Grinder eee ee) BESSROT Grinder Alignment Ber bobbie cee eee eee ee BNOMT Vacuum Cleaner Blower 8210140 Dust Collector . s 210142 Grinding Stones, Finish Grade - 2 reqd. 8201791 Grinding»Stones, Medium Grade = Ztead. 21101 “ SLL I ITD gase9a1 Brush Scating Stonie (Chalk Stone)... : 1AT3686 Sandpaper, 220 Grit - 216 mm x 46.m (8-1/2 x 50 Ody roll, 3 ia Cio fo per ai I9ABI2 Uydraulic Drive Flange Puller Kit ee 8309742, Hydraulic Pomp... : 8302969 Hydreulic Oil, 3.8 litres (1 ey 8246430 Hose Assembly : : 8327054 Nipple, 1/220. on see 309741 Adapter Nipple, 3/8"-24 | : 8302965 Retaining Nut. oa +5 8303020 Manval Drive Flange Puliee Kit "1 | | 8303330 Pulling Plate Assembly 8168577 Pulling Plate 8168604 Includes Studs: 5/8"-I1 NC (C.f. bearing cap) 8148606 3/8"-16 NC (PE. outer oil ring). 816861 | 5/811 UNC-2A {P.B, bearing cap) 8208436 Motor Lead Breaker. . Peer eesti 2D gaaaaar Lifting Eye, Standact. Shaft Amuatuiv, Commututor Endo 8174231 Lifting Eye, Through Shaft Armature, Commutator End 11) |) Pee a MENG, 906 *File numbers represent Facility drawings that are available (at no charge) from EMD Servies Puisication Department, These drawings include construction details of tooling that can be manufuctused by we customer. MATERIAL LIST Anmature Bearing Liibricant Scaled Bearing - Shull Cyprina RA Grace 3 15.9 kg (35 Ibi Pall... cee see eee. 8240819 54.4 kg (120 Ib) Drum). Fee BI49820 Adiitive Bearing - Lubrico M6 4 ke € 10 th) Pail 8102584 11 kg € 25 Ib) Pail : 8068104 54 ke (120 1b) Drum 8102808 Litho la U.S.A. . 48