GEK84745D

GE788 MOTORIZED WHEEL

SERVICE MANUAL

E33551.

E28194A.
 TABLE OF CONTENTS GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

TABLE OF CONTENTS
Title Section Page

SECTION 1. GENERAL INFORMATION

SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MODEL DIFFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 2. PREVENTIVE MAINTENANCE GUIDE

SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TWICE A WEEK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ONCE A WEEK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OVERHAUL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
AT TIRE CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SECTION 3. TOOLS AND HANDLING

TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

SECTION 4. REPAIR AND ADJUSTMENTS WHEEL MOUNTED ON TRUCK

SPEED SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
COMMUTATOR RESURFACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
MOTOR/ARMATURE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

SECTION 5. REMOVAL, CLEANING AND CHECKS BEFORE DISASSEMBLY

REMOVAL OF MOTORIZED WHEEL FROM VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ENDPLAY CHECK BEFORE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Revisions are indicated by marginal bars.

Copyright 1994 General Electric Company. All rights reserved. This copyrighted document may be reproduced free of charge by General
Electric Company customers (OEMs) and their customers, if such reproduction is used exclusively in connection with equipment used in those
customers internal operations.

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

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GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL TABLE OF CONTENTS

TABLE OF CONTENTS (Contd)

Title Section Page

SECTION 6. REMOVAL OF MAJOR COMPONENTS

SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SUN PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
MAGNET FRAME/ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SEAL RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
PLANET GEAR ENDPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
PLANET GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
SEAL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

SECTION 7. DISASSEMBLY OF MAJOR COMPONENTS

SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SUN PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
MAGNET FRAME/ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
TORQUE TUBE/FLINGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
SEAL RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
PLANET GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
FRAME STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

SECTION 8. OVERHAUL PROCEDURES

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

SECTION 9. ASSEMBLY OF MAJOR COMPONENTS

SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
FRAME STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
PLANET GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
SEAL RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
TORQUE TUBE/FLINGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
MAGNET FRAME/ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
SUN PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 929
SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 929
OUTBOARD BEARING SEAL RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 929
THRUST RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 929

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 TABLE OF CONTENTS GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

TABLE OF CONTENTS (Contd)

Title Section Page

SECTION 10. FINAL ASSEMBLY OF COMPONENTS TO FRAME STRUCTURE

SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SEAL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
PLANET GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SEAL RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1013
TORQUE TUBE/FLINGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1013
SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1014
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1015
MAGNET FRAME/ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1016
SUN PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1017
BRAKE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1017

SECTION 11. INPROCESS AND FINAL TESTS

FINAL WHEEL HUB ENDPLAY (Rotating Method) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
BRAKE LINE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
THERMAL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
TESTING DURING OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
TESTING AFTER OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

SECTION 12. AFTER OVERHAUL PROCEDURES

ARMATURE LOCKING ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
INSTALLATION OF MOTORIZED WHEEL TO TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
GEARCASE VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
SHIPPING REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

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GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL TABLE OF CONTENTS

NOTES

iv
 SECTION 1 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
SECTION 1. GENERAL INFORMATION
CONTENTS
Page
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MECHANICAL BRAKES . . . . . . . . . . . . . . . . . . . . 11
MODEL DIFFERENCES . . . . . . . . . . . . . . . . . . . . . 12
DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SCOPE
This publication describes inspection, maintenance,
removal, basic overhaul and installation of the GE788
Motorized Wheel. Also included are tool requirements,
lifting techniques and special fixtures and equipment
stands for the repair shop. Extensive repairs such as ar-
mature rewinding and machining of component parts
are not included.
These instructions apply to the models indicated in
the MODEL DIFFERENCES section. As new models
become available, Model Difference Sheets will be is-
sued to cover any differing instruction.
DESCRIPTION
GENERAL
The GE788B1 Motorized Wheel is a forceventi-
lated dc motor which converts electrical energy into me-
chanical energy. This mechanical energy is transmitted
to the wheel hub through a speed reducing transmission
consisting of a double reduction gear train. The Motor-
ized Wheel is mounted to the trucks axle box at the
flange end and serves as the trucks axle, transmission
and traction motor.
The GE788B1 model has the following general fea-
tures:
D 64.5 in. flange diameter with 61.75 bolt circle
D 26.075:1 gear ratio (32 mph max. truck speed)
D 36 X 51 tires.
The major components are the Frame Structure,
Sun Pinion, Planet Gears and Pinion Assemblies,
Torque Tube, Wheel Hub and the removable motor. The
removable motor is complete with armature, armature
bearings, armature framehead, exciting and commutat-
ing coils and pole pieces.
If necessary, the entire motor or just the armature
can be removed from the Motorized Wheel without re-
moving the tires or the Motorized Wheel from the truck
or disassembling any of its major components.
Motor torque is transmitted from the motor to the sun
pinion through a drive ring, which is press fitted to the
splined pinion end of the armature shaft. The sun pinion
is secured laterally by a retaining plate and a onepiece
snap ring assembly.
The three planet gears, driven by the sun pinion, ro-
tate in their own bearings mounted in the frame struc-
ture. The planet pinions engage the internal ring gear of
the torque tube.
The torque tube is bolted to the wheel hub to form an
assembly which rotates about the frame structure on
two large tapered roller bearings. The wheel hub pro-
vides the mounting surface for the tire rims.
FUNCTION
In motoring, electrical energy applied to the motor
portion of each wheel is converted to mechanical energy
with the rotation of the motor armature turning the
wheels through the planetary gear assembly. Motor
torque is amplified through the gear ratio of the plane-
tary gear/pinion assembly.
In Dynamic Retarding (the primary means of speed
reduction), mechanical energy of the moving truck is
converted to electrical energy by the motor, now acting
as a generator. This electrical energy is dissipated as
heat through braking resistor grids, located elsewhere
on the truck.
MECHANICAL BRAKES
Mechanical brakes for the Motorized Wheel are pro-
vided by the truck builders. For operating, maintenance
and repairs of the mechanical brakes, refer to the brake
manufacturers instructions.
The Motorized Wheel provides the necessary brake
hub and adapter ring for mounting various disc brakes
and drum brakes.
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GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
MODEL DIFFERENCES
5GE788BS1 Similar to B1 except the BS1 has a
universal brake adapter and Trolley Assist capabilities.
5GE788BS2 Similar to BS1 except the BS2 has
straight roller planet gear bearings.
5GE788BS3 Similar to BS2 except the BS3 has 15
turn commutating coils (instead of 30 turn on BS2), se-
ries connected (instead of seriesparallel connected on
BS2).
5GE788BS4 Similar to BS3 except the BS4 has
tighter fits on the wheel hub bearings, a lube groove for
the outboard wheel hub bearing, a new armature com-
mutatorend bearing seal, a nonregreasing dirt seal, a
new oring on the sleeve (paddle pump area), changes
in the brake line using a new brake line adapter and new
wheel hub bearing lubricating holes.
5GE788CS1 Similar to BS2 except the CS1 has a
21.73:1 gear ratio.
5GE788CS2 Similar to BS3 except the CS2 has a
21.73:1 gear ratio.
5GE788CS3 Similar to CS2 except the CS3 has
tighter fits on the wheel hub bearings, a lube groove for
the outboard wheel hub bearing, a new armature com-
mutatorend bearing seal, a nonregreasing dirt seal, a
new oring on the sleeve (paddle pump area), changes
in the brake line using a new brake line adapter and new
wheel hub bearing lubricating holes.
5GE788DS1 Similar to BS4 except the DS1 has a
higher torque armature, a new wheel hub which uses 37
X 57 tires, a new framehead, magnet frame and brake
adapter ring which make it possible to remove the arma-
ture without first removing the brake adapter.
5GE788DS2 Similar to DS1 except for new arma-
ture pinionend bearing assembly which utilizes a For-
sheda vring face seal.
5GE788ES1 Similar to BS4 except the ES1 has
the removable armature feature of the DS1, has wide
commutating pole tips and DS1 connections.
12
SECTION 1
5GE788ES2 Similar to DS1 except the ES2 has an
AFstyle armature and commutator and uses standard
duplex brushes.
5GE788FS1 Similar to DS1 except the FS1 has a
21.73:1 gear ratio, standard wheel hub for 37 X 57 tires
with tapped holes (no thru holes) and regreasible wheel
hub bearings.
5GE788FS2 Similar to FS1 except the FS2 has a
26.075:1 gear ratio.
5GE788FS3 Similar to FS1 except the FS3 has a
new armature pinionend bearing assembly which uti-
lizes a Forsheda vring face seal.
GE788FS3A Similar to FS3 except the FS3A does
not use the Forsheda vring face seal in the new arma-
ture pinionend bearing assembly.
5GE788FS4 Similar to FS2 except the FS4 has a
new armature pinionend bearing assembly which uti-
lizes a Forsheda vring face seal.
GE788FS4A Similar to FS4 except the FS4A does
not use the Forsheda vring face seal in the new arma-
ture pinionend bearing assembly.
5GE788FS5 Similar to FS4 except the FS5 has a
new coarse pitch ring gear and planet pinion which re-
sults in a new 26.825:1 gear ratio.
GE788FS5A Similar to FS5 except the FS5A does
not use the Forsheda vring face seal in the armature
pinionend bearing assembly.
5GE788FS6 Similar to FS3 except the FS6 has a
new coarse pitch ring gear and planet pinion which re-
sults in a new 22.354:1 gear ratio.
5GE788FS7 Similar to FS5 except the FS7 has
new brakeline fittings with orings and attachment
bracket at the inboard end of the wheel and new brake
hub.
GE788FS7A Similar to FS7 except the FS7A does
not use the Forsheda vring face seal in the armature
pinionend bearing assembly.
SECTION 1 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
5GE788FS8 Similar to FS6 except the FS8 has
new brakeline fittings with orings and attachment
bracket at the inboard end of the wheel and new brake
hub.
GE788FS8A Similar to FS8 except the FS8A does
not use the Forsheda vring face seal in the armature
pinionend bearing assembly.
5GE788FS9 Similar to FS7 except the FS9 has a dif-
ferent wheel hub, which has holes drilled through for tire
studs.
GE788FS9A Similar to FS9 except the FS9A does
not use the Forsheda vring face seal in the armature
pinionend bearing assembly.
5GE788HS1 Similar to FS1 except the HS1 has a
wheel hub for 36 X 51 tires.
5GE788HS2 Similar to FS2 except the HS2 has a
wheel hub for 36 X 51 tires.
5GE788HS3 Similar to HS1 except the HS3 has a
new armature pinionend bearing assembly which uti-
lizes a Forsheda vring face seal.
GE788HS3A Similar to HS3 except the HS3A does
not use the Forsheda vring face seal in the new arma-
ture pinionend bearing assembly.
5GE788HS4 Similar to HS2 except the HS4 has a
new armature pinionend bearing assembly which uti-
lizes a Forsheda vring face seal.
GE788HS4A Similar to HS4 except the HS4A does
not use the Forsheda vring face seal in the new arma-
ture pinionend bearing assembly.
5GE788HS5 Similar to HS3 except the HS5 has a
new coarse pitch ring gear and planet pinion which re-
sults in a new 22.354:1 gear ratio.
5GE788HS6 Similar to HS4 except the HS6 has a
new coarse pitch ring gear and planet pinion which re-
sults in a new 26.825:1 gear ratio.
GE788HS6A Similar to HS6 except the HS6A does
not use the Forsheda vring face seal in the armature
pinionend bearing assembly.
5GE788HS7 Similar to HS5 except the HS7 has
new brakeline fittings with orings and attachment
bracket at the inboard end of the wheel and new brake
hub.
GE788HS7A Similar to HS7 except the HS7A does
not use the Forsheda vring face seal in the armature
pinionend bearing assembly.
5GE788HS8 Similar to HS6 except the HS8 has
new brakeline fittings with orings and attachment
bracket at the inboard end of the wheel and new brake
hub.
GE788HS8A Similar to HS8 except the HS8A does
not use the Forsheda vring face seal in the armature
pinionend bearing assembly.
13
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 1

DATA

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5GE788B1, BS1, BS2, BS3, BS4, CS1, CS2, CS3, DS1, DS2, ES1, ES2,
FS1, FS2, FS3, FS3A, FS4, FS4A, FS5, FS5A, FS6, FS7, FS7A, FS8, FS8A, FS9, FS9A,
HS1, HS2, HS3, HS3A, HS4, HS4A, HS5, HS6, HS6A, HS7, HS7A, HS8, HS8A
Motor Speed (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2350 rpm
Classification:
Separately Excited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC, 4pole, separately excited motor
Impedance Test: Min. Max

Without armature, pass amperes through field and read AC voltage drop, 60 Hz
Exciting Field (4 coils in series) 12 amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.0 99.0
Commutating Field (4 coils in series) 24 amps . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 7.5
Pole Bore Diameters (in.): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Min. Max.
Exciting Poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.605 19. 641
Commutating Poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.635 9. 665
Resistance @ 25_C (77_F) (Ohms): Min. Max.
AF Armature, 47 bar span (B, BS, CS, ES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00855 0.00873
AG Armature, 46 bar span (DS, FS, HS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00773 0.00800
Brush Data:
Pressure (new brush) (oz.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 (min.), 192 (max.)
Size (in.):
All Models except DS (Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 thick x 21/4 wide x 21/4 long
Model DS (three wafer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 thick x 21/4 wide x 21/4 long
Minimum Length Allowable (in.) (long side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
Brushholder Clearance to Comm. Surface (in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/16 to 3/32
Carbon Brush (All Models):
Grade T900 (Recommended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41B537963P1
Grade T959 (Alternate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41B537963P2
Grade T508 (Alternate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41B537963P5
Commutator (spiral groove type):
Grooves per Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Groove Width Final Size (in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.094
0.002
Groove Depth Final Size (in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.046
Diameter (in.):
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.675
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.675
Side Mica (in.):
Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 (nominal)
Undercut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.047 min., 0.073 max.
Dust Groove (in.):
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.437
Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.125
Riser (minimum permissible width) (in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/16
Concentricity New Commutator (in.):
Maximum Total Runout (TIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.001
Maximum Runout within 20 bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0004
Maximum Runout within Adjacent Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0001

14
 SECTION 1 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

DATA (Contd)
Lubrication:
PinionEnd Armature Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6A2C10
CommutatorEnd Armature Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6A2C10
Gear Box Lubrication:
Capacity (qts.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Synthetic Oil:
Temperature Range, 55_C to +15_C (67_F to +59_F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D50E27A
Temperature Range, 37_C to +25_C (35_F to +77_F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D50E27B
Temperature Range, 34_C to +35_C (29_F to +95_F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D50E27C
Temperature Range, 29_C to +40_C (20_F to +104_F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D50E27D
Temperature Range, 23_C to +50_C (9_F to +122_F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D50E27E
Torque Tube Dirt Seal Ring:
Periodic Relubrication Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D50E16
Periodic Relubrication Not Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6A2C10
Wheel Hub Bearings (inboard and outboard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D50E26
Wheel Hub Bearings (inboard and outboard) (GE788DS1 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41A330204P19
Wear Bands and Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6B20H5
Sealant:
Silmate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497A806P60
Epoxy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497A806P9
Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497A806P33
Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497A806P12
EndPlay Settings (in.):
Armature (Max) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060
Wheel Hub Bearing Shim Adjustment (without tires mounted):
Models B1, BS, CS, ES1, FS1, FS3, FS3A, FS6, FS8, FS8A, HS1HS8A . . . . . . . . . . . . . . . . . . 0. 025 0.030
Models DS, ES2, FS2, FS4FS5A, FS7, FS7A, FS9, FS9A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 0.020
Max. Permitted in Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.055
Planet Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 0001 0.016
Max. Permitted in Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040
Backlash (Planet Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.100 max. difference
Approximate Weights (lbs.):
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,200
Complete Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,800
Complete Motorized Wheel (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,000
Gear Ratio:
Models B, BS, DS, ES, FS2, FS4, FS4A, HS2, HS4, HS4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.075:1
Models CS, FS1, FS3, FS3A, HS1, HS3, HS3A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.730:1
Models FS5, FS5A, FS7, FS7A, FS9, FS9A, HS6, HS6A, HS8, HS8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.825:1
Models FS6, FS8, FS8A, HS5, HS7, HS7A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.354:1
Tire Size:
Models B, BS, CS, ES, HS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 x 51
Models DS, FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 x 57
Megger* Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 megohm (min.)

* Tradename of James G. Biddle.

15
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 1

DATA (Contd)

HighPotential Testing (Volts, 60 Hz ac to ground for one minute):

Brushholders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000
Exciting Coils (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500
Exciting Coils (Series) (Cable FFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3500 (New)
2000 (Used)
Exciting Coils (Shunt) (Cable SSSX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 (New)
1750 (Used)
Armature Coils, Commutating Coils and Brushholders (Cable AAA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3500 (New)
2000 (Used)
Air Flow Requirements:
Air Flow (CFM) per Motorized Wheel (all models except DS) (1800 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2600
Air Flow (CFM) per Motorized Wheel (Model DS) (1800 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800
Bolt Torques (lb.ft.):
Air Baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5560
Armature Framehead (GE788B1, BS, CS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8090
Armature Framehead (GE788DS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160180
Brake Adapter Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530575
Brake Line Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124
Brushholder Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293326
Busbar Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124
Cable Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124
Commutating Coil Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215240
Commutator End Bearing Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5156
End Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440490
Exciting Coil Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293326
Flinger Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5560
Outboard Seal Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124
Pinion End Bearing Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5156
Pinion End Bearing Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8090
Planet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124
Planet Gear Bearing Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124
Planet Pinion Bearing Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5560
Planet Pinion Retaining Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8090
Seal Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5560
Seal Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5560
Shunt Mounting Insulator Bolts:
Small (0.375 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2224
Large (0.50 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4145
Sun Pinion Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2124
Sun Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5560
Thrust Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110120
Wheel Hub Bearing Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110120
Wheel Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777863

NOTE: Bolts and washers must be lubricated with a mixture of graphite and oil.

16
SECTION 2 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
SECTION 2. PREVENTIVE MAINTENANCE GUIDE
CONTENTS
Page
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TWICE A WEEK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ONCE A WEEK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OVERHAUL RECOMMENDATIONS . . . . . . . . . . 25
AT TIRE CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SCOPE
The following preventive maintenance guide de-
scribes inspection and maintenance procedures and
the recommended time intervals when those proce-
dures should be carried out.
TWICE A WEEK
NOTE: Motorized Wheels which have been
overhauled with new D6A2C10 grease applied
to the dirt seal area do not require periodic dirt
seal relubrication. Also, all GE788 Motorized
Wheels manufactured after January 1988 do not
require periodic dirt seal relubrication. For all
other Motorized Wheels, proceed as follows:
At least twice a week, grease the dirt seals by adding
2.0 oz. of D50E16 sealing grease to each dirt seal
grease fitting. Extremely dirty environmental conditions
may require more frequent greasing and/or doubling of
the grease quantity.
IMPORTANT NOTE: When a Motorized Wheel is
first mounted onto a truck, lubricate the dirt
seals with sealing grease using the following
procedure:
1. Before grease lines are connected to the
wheel, pump grease into each line until
grease purges from the line. After all
grease lines are full of grease, connect
them to the wheel.
2. Pump grease into each grease line again
until grease purges from the entire dirt
seal area.
3. Whenever the tires are removed for any
reason, clean the dirt and old grease from
the outside of the wheel at the dirt seal
area and repeat Step 2.
ONCE A WEEK
Once a week, perform the TWICE A WEEK proce-
dures plus check the Motorized Wheel gearcase oil lev-
el. To perform an accurate check, the truck should be
parked on a level surface and allowed to stand for 15
minutes before checking. This will allow the oil to drain
into the sump. If the oil is cold and the truck has been
recently run, allow the truck to stand for at least an hour.
To check the oil level, remove the oil filler cap (Fig.
21). If the oil is below the bottom of the filler neck, top it
off with new oil.
Before replacing the filler cap, check that the gasket
is in good condition. Replace it with a new one if neces-
sary.
250 HOURS
After each 250 hour period of operation, perform the
TWICE A WEEK and ONCE A WEEK procedures plus
the following:
1. Make a visual inspection. Check for:
a. Damaged cables or loose cable connections
CAUTION: To prevent insulator damage, shunt
mounting hardware should not be torqued more
than:
Small Insulators 2224 lb.ft.
Large Insulators 4145 lb.ft.
b. Loose mounting bolts or nuts
c. Clogged or restricted air inlets or outlets
(damaged hubcaps)
d. Excessive dirt buildup on equipment
e. Tightness of axlebox door seal
f. Loose cable connections and brush shunts.
21
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 2

c. With the axlebox closed and the engine run-

ning, blow the commutator and brush area
with compressed air.

3. Remove and clean the Motorized Wheel gear-

MAGNETIC case vent filters located on the axlebox. Check
PLUGS
that vent pipes or hoses do not droop or form a
U where oil can become trapped preventing
gearcase depressurization.

4. Remove and clean the two magnetic plugs lo-

MAGNETIC
PLUG cated on the sun pinion and gearcase covers
OIL FILLER
CAP (Fig. 21). Check for metal particles. If plugs
have an excessive accumulation of metal par-
DRAIN PLUGS
ticles, it may indicate gear or bearing distress or
the need to change oil more frequently. If so,
CHECK FOR GREASE AT
FLINGER AND SEAL RING drain the sump and put in new oil. Refer to the oil
CHECK FOR change procedures under 1500 HOURS.
GREASE AT
OUTBOARD 5. Take an oil sample. Use the procedure in the
SEAL RING
PLANNED MAINTENANCE MANUAL,
GEK75889.
BRUSH
LOCATIONS
GREASE 6. Check for oil or grease leakage. Some oil leak-
FITTINGS age may be normal; an excessive leak may be a
symptom of trouble. If there is an excessive oil
leak (five quarts of makeup oil in a week), cor-
rective action must be taken. Check for the fol-
lowing:

a. Grease squeezing out past the outboard seal

FIG. 21. MAINTENANCE LOCATION POINTS.
E28196A.
2. Clean the Motorized Wheel as follows:
CAUTION: If high pressure water is used for
cleaning the outside of the truck, it should not be
applied to the Motorized Wheel, especially in the
area of the wheel hub bearings. If bearing grease
becomes contaminated with water, bearing dam-
age and reduced bearing life may result.
a. Vacuum inside the axlebox to remove accu-
mulated dirt.
ring (Fig. 21). On a new or recently over-
hauled wheel, this may be a normal purging of
excess grease in the bearing and no cause
for alarm. If there is a large quantity of grease
and/or if the grease is thinned by oil, it may in-
dicate dilution of the bearing grease by gear-
case oil, usually due to overfilling or pressur-
ization of the gearcase. Check these condi-
tions before taking other corrective actions.
b. Grease accumulation on the tire rim of the in-
board tire. Accumulation of grease and dirt at
the seal ring and flinger area is not desirable
(Fig. 21).

b. Remove hubcaps and blow the motor with c. Oil draining from the bottom of the seal ring
dry, clean, compressed air from the axlebox (flange end of wheel). This may be due to
out. loose bolts or inadequate sealing.

22
SECTION 2 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
500 HOURS
After each 500 hour period of operation, perform the
TWICE A WEEK, ONCE A WEEK and 250 HOURS pro-
cedures plus the following:
1. After the first 500 hours of operation, change the
oil using the oil change procedures outlined un-
der 1500 HOURS. Thereafter, change the oil at
the 1500 hour interval.
2. Inspect brushes for wear, chipping and broken
and/or frayed shunts. If brushes are worn to or
near the minimum length of 1.0 in., replace them.
Chipped brushes may mean that the commuta-
tor needs resurfacing.
3. Check brush shunts to be sure they are not
twisted or out of position. Also, visually check for
signs of overheating.
4. Move brushes up and down in their brushholders
to ensure that they move freely and do not bind
(Fig. 21).
5. Wipe dirt, grease, etc., from the brushholder in-
sulators with a clean, lintless cloth. If necessary,
dip the cloth in a nonoily cleaner to remove the
foreign material. Inspect the insulators for flash-
over damage, cracks and burned or pitted sur-
faces.
6. Inspect the motor commutator for low spots or
flashover damage. Low spots can best be de-
tected by measuring brush path runout with an
indicator, but they can also be detected by feel-
ing for a difference in the height of the ridge be-
tween brush paths or by looking for a narrowing
in the width of the brush path. Low spots will be
found where the brush path narrows. For resur-
facing criteria, refer to SECTION 4, COMMUTA-
TOR RESURFACING. See SECTION 8 for con-
demning limits.
7. Clean the Teflon* creepage band on the commu-
tator end of the armature and inspect it for possi-
ble flashover damage. When cleaning, use a
* Product of E.I. duPont de Nemours Co., Inc.
suitable electric cleaner or a dry rag. DO NOT
USE A CLEANER WITH AN OIL BASE.
8. Check the brushholdertocommutator clear-
ance. This should measure from 1/16 in. (min) to
3/32 in. (max). If clearance is within tolerance,
check/tighten brushholder clamp bolts to the
proper torque value. Recheck the clearance if
any clamp bolts were loose. If an adjustment is
necessary, remove the brush. Loosen the clamp
bolt and place a 1/16 in. piece of fiber board on
the commutator surface under the brushholder.
Tighten the clamp bolt. Check for excessive
clearance with a 1/8 in. piece of fiber board. It
should not be able to pass under the brushhold-
er.
9. Check/tighten coil lead connections on the
brushholder.
10. If commutator is found to be in poor condition,
check brush spring tension. It should be 160 to
192 oz. with new 23/4 in. brushes. DO NOT
TRY TO MEASURE SPRING TENSION WITH
BRUSHES IN PLACE.
11. Visually inspect the accessible parts of the field
coil insulation for cracking or signs of overheat-
ing.
12. Check for damaged Motorized Wheel hubcaps.
Replace if air outlet passages are restricted or if
holes in the hubcap are found.
13. Inspect brakes and brake linings. See truck
builders instructions. Clean up any accumulated
brake fluid found in the frame. Locate and repair
the leak.
1500 HOURS
After each 1500 hour period of operation, perform
the TWICE A WEEK, ONCE A WEEK, 250 HOURS and
500 HOURS procedures plus the following:
Change the oil. Use the following procedures:
1. Drain the oil from the gearcase oil sump (Fig.
21).
2. Remove and clean the oil sump magnetic plugs.
Check for an unusual amount of metal accumu-
lation.
23
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 2

3. Clean out the sump with a rag (through the filler of distress; i.e., high readings of FE, CR, SI at oil
cap opening). Flush out the sump and gearcase analysis. Perform the following to make a planet
if necessary. gear endplay check:

4. Refill the oil sump with new oil. See the SEC- a. Remove the sun pinion cover and the sun pin-
TION 1, DATA for oil type and quantity. ion.

b. Mount a dial indicator as shown in Fig. 22.

2500 HOURS
After each 2500 hour period of operation, perform
the TWICE A WEEK, ONCE A WEEK, 250 HOURS,
500 HOURS and 1500 HOURS procedures plus the fol-
lowing:
1. Remove the sun pinion and check the condition
of the spline teeth. An easy check for spline tooth
wear is to measure the width of the flat at the top
of the spline tooth. A new sun pinion should have
spline teeth measuring 0.125 in.; the condemn-
ing limit is 0.046 (3/64) in. Also check the condi-
tion of the gear teeth on the sun pinion and the
planet gears.
c. Using a pinch bar, press the planet gear to be
checked in as far as it will go. Be careful not to
deform the gearcase cover.
d. Set the dial indicator to zero.
e. Pry the planet gear out as far as it will go (Fig.
23).
f. Read the dial indicator. If it reads more than
0.040 in., excessive planet pinionend bear-
ing wear is indicated. The wheel should be re-
moved from the truck and sent to an autho-
rized shop for repair.

2. Check the oil baffle and snap rings for damage. g. Repeat Steps b through f for each planet
gear.
3. Check to ensure that there is sufficient clearance
6. Check planet gear backlash as follows:
from the sun pinion to the gearcase cover.
NOTE: The magnetic base dial indicator must
4. Check the drive rings internal spline teeth for
be placed on a gear face and not the gearcase
wear. Use the Pie Gauge, 41A239826, and the
cover to avoid reading gearcase cover deflec-
following procedure:
tion as part of the gear endplay reading.
a. Insert the gauge into the bore of the coupling
at an angle (handle tilted down).
BAR GEAR IN
b. Raise the handle and position the tip of the AND SET INDI-
CATOR TO 0.
gauge between two spline teeth.

c. Continue raising the handle to tip the gauge

past center (handle tilted up). If the gauge can
be tipped past center, the coupling is worn be-
yond limits and must be replaced.

5. Check planet gear endplay. This check is used

to identify planet pinion bearing wear. It should
be performed at 2500 hour intervals or whenever
there is concern as to whether or not a Motorized
Wheel should remain in service. This may be
when a high hour wheel is running satisfactorily
but has reached the scheduled mine removal in-
terval or, when a low hour wheel is showing signs FIG. 22. CHECKING GEAR ENDPLAY. E24093.

24
SECTION 2 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
BAR GEAR OUT, RE-
LEASE PRESSURE,
AND READ END
PLAY. REPEAT FOR
ALL THREE GEARS.
FIG. 23. CHECKING GEAR ENDPLAY. E24094.
NOTE: This check is used to indicate the differ-
ence in backlash from gear to gear. When back-
lash becomes too large, the gear load distribu-
tion may be affected and may adversely affect
the spline end of the sun pinion and the arma-
ture drive ring coupling. Comparison of the
three readings may indicate worn or spalled
wheel hub bearings.
a. Remove the sun pinion.
b. Install a magnetic base dial indicator to the
gearcase cover with a 3 in. long piece of angle
iron. A hole drilled into one leg will allow it to
be bolted to the threaded hole at the 5 oclock
position of the sun pinion cover.
c. Locate the indicator pointer at the pitch line
(approximately center) of the tooth.
d. Rotate the gear tooth away from the pointer
as far as it will go by hand. Set the indicator to
zero.
e. Rotate the gear tooth toward the pointer as
far as it will go. Read the indicator and record
the finding.
f. Repeat Steps c, d and e for all three gears.
g. Compare the readings. If the difference be-
tween any two gears is 0.100 in. or greater, or
if the backlash of any one gear is less than
0.005 in., the wheel should be removed from
service.
OVERHAUL RECOMMENDATIONS
A basic overhaul is recommended at 15,000 hours
as a general guide for properly maintained and applied
Motorized Wheels. However, the severity of duty, main-
tenance practices and environmental conditions all ef-
fect Motorized Wheel service life, and will be contribut-
ing factors in the determination of overhaul intervals.
Three important criteria should be used in deciding
when a Motorized Wheel should be removed for over-
haul. They are:
1. Oil sampling and trend analysis.
2. Planet gear endplay check. See previous in-
structions under 2500 HOURS.
3. The results of other maintenance inspections
performed according to the maintenance sched-
ule; excessive metal on magnetic plugs, exces-
sive oil or grease leakage and unusual noises.
If no internal problems are indicated by the above
checks, then it is recommended that the Motorized
Wheel continue in service as determined by followon
inspections.
AT TIRE CHANGE
Whenever tires are removed, perform the following:
1. Clean dirt and grease buildup from the dirt seal
ring and flinger area.
2. Inspect dirt seal ring grease fittings and hoses for
breakage or other damage.
3. Inspect mounting flange bolts for tightness.
4. Lubricate the dirt seal until grease purging is vis-
ible around the seal ring area of the wheel. Use
the procedure under TWICE A WEEK.
5. Check for loose bolts.
25
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
CAUTION: When assembling tires and rims to the
Motorized Wheel, it is important that the correct
mounting nut and stud torque values be used.
Torque values must be sufficient to prevent rim
slippage and those values must not be unneces-
sarily exceeded. If the torque values are too high,
wheel hub bearing life may be limited. Consult
the truck builders instructions for the correct
torque values. Under no circumstances should
torque values exceed 900 lb.ft.
6. Retorque thrust ring bolts on models equipped
with disc brakes.
7. On GE788BS4, CS3 and DS1 Motorized Wheels
(which are equipped with wheel hub bearing lu-
NOTES
26
SECTION 2
bricating holes in the wheel hub), perform the fol-
lowing:
a. Replace all pipe plugs with 1/4 in. grease fit-
tings.
b. Pump 5 to 6 oz. of grease into each grease
fitting. See the SECTION 1, DATA for the
type of grease required.
c. Remove all grease fittings and replace the
pipe plugs. On the GE788DS1 models only,
insert the plugs until the threaded portion of
the plugs are flush with the top of the pipe
plug hole.
SECTION 3 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
SECTION 3. TOOLS AND HANDLING
TOOLS AND EQUIPMENT
1. Grease gun for SAE J513C grease fittings.
2. Commutator grinding fixture, Part
41C635995G1, for grinding the commutator with
armature installed.
3. Crocus cloth and/or fine sandpaper (00 or finer).
4. Saw for undercutting mica. Nominal width of side
mica is 0.060 in. The saw width should be 0.063
in.
5. Stiff brush or fiber board for removing burrs.
6. Two magneticbase dial indicators for checking
wheel hub bearing endplay, planet gear end
play and planet gear backlash.
7. Megohmmeter, 0 to 2000 megohms, 250, 500
and 1000 volts. Biddle, Model No. 21158 (field
portable) or equal.
8. Puller tools (Figs. 31, 32 and 33 ) to facilitate
disassembly of the complete Motorized Wheel.
9. Wheel hub outboard bearing assembly spacer,
Part 41A236415 (Fig. 34), used to assemble
outboard wheel hub bearings.
10. Pie gauge, Part 41A239826 (Fig. 35). Used to
check internal spline teeth wear on the drive ring.
11. Planet gear rotating tool, Part 41E908727G1
(Fig. 36). This tool is used in place of the sun
pinion for rotating the planet gears, torque tube
and wheel hub when checking wheel hub bear-
ing endplay when the Motorized Wheel assem-
bly is without a motor cartridge.
12. Wheel hub bearing inspection pin removal tool,
Part 41B537598 (Fig. 37). This tool facilitates
the removal of a bearing roller when performing
an inspection of the bearing races. It is applica-
ble only to Timken bearings.
13. Air flow measuring fixture, Part 41C636650 (Fig.
38). This tool is used for measuring air flow
across the Motorized Wheel, from the axle box to
the commutator chamber.
14. Swivel lifting bail (Fig. 39). Three rated at
10,000 lb. each for handling the magnet frame
while in a vertical position (pinion end down).
WARNING: Do not attempt to lift a magnet frame
complete with armature out of a Motorized Wheel
using the 1 x 8 tapped hole in the end of the arma-
ture shaft. This hole is designed for lifting the ar-
mature only. The added weight of the magnet
frame (3,665 lb.) could cause the threads to fail
and, as a result, the assembly could fall and may
cause serious injury.
15. Commutatorend lifting fixture, Part 41D794774
(Figs. 310 and 311). This fixture is bolted to the
outboard end of the frame structure using the in-
side pair of holes. It is used for handling the
frame from the commutator end. Two fixtures are
required.
This fixture also bolts to the outboard end of the
wheel hub, using the outside pair of holes. It is
used for the assembly of the wheel hub to the
frame, for checking wheel hub bearing endplay
and for horizontal movement of the assembled
frame. Two fixtures are required.
16. Flangeend lifting fixture, Part 41D793797
(Figs. 310 and 312). This fixture bolts to the in-
board end (flange end) of the frame structure and
is used for turning the Motorized Wheel end for
end, lowering into a cradle for planet gear as-
sembly, and for horizontal movement of the
frame. Two fixtures are required.
17. An acceptable means of lifting an assembled
Motorized Wheel is with the use of a 25,000 lb.
(minimum) capacity basket sling and two flange
end lifting fixtures referred to in Step 16. As
shown in Fig. 310, the basket sling is placed
around the wheel hub and a cable is hooked to it.
Additional cables are then connected to the
flangeend lifting fixtures. Lifting in a horizontal
position can now be performed.
18. Eyebolt (Fig. 313). These eyebolts are used for
lifting the torque tube. They screw into the jack
out holes. Three eyebolts are required.
31
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
NOTE: After using these eyebolts to assemble
the torque tube onto the frame, remove them
before assembling the inboard wheel hub bear-
ing. They cannot be removed with this bearing
in place.
19. Wooden support block, Part 41A285958 (Fig.
314) These blocks bolt to the inboard flange of
the Motorized Wheel. They are used to support
the frame in a vertical position (gearcase down).
Four blocks, equally spaced around the flange,
are needed. Used in conjunction with these
blocks are four metal blocks, Step 20.
20. Metal support block, Part 41B585572 (Fig.
315). These blocks are used in conjunction with
the wooden blocks, Step 19, to support the
frame in a vertical position. In addition, six of
NOTES
32
SECTION 3
these blocks can also be used to support the re-
movable magnet frame in a vertical position.
21. Cradle, Part 41E907675P1 (Fig. 316). This fix-
ture is used to support the Motorized Wheel in a
vertical position, flange end (gearcase) up, for
planet gear assembly.
22. Catwalk, Part 41D793799 (Fig. 317). This fix-
ture is used in conjunction with Step 21.
23. Motor/armature removal tool, Part 41D732935
(Fig. 318). This tool is used for removing and in-
stalling a complete motor or motor armature from
a Motorized Wheel while mounted on a truck.
24. Transmission puller tool, Part 41D794806. This
tool is used to remove the wheel hub, torque
tube, seal ring and wheel hub bearing parts.
SECTION 3 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 31. PULLER TOOLS (41C636386). E34849.

33
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 3

FIG. 32. PULLER TOOLS (41E903513). E28630A.

34
SECTION 3 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 32. PULLER TOOLS (41E903513). E28630A.

35
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 3

FIG. 33. PULLER TOOL FOR REMOVAL OF MOTOR CARTRIDGE (41C636546). E33589.

36
SECTION 3 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 34. WHEEL HUB OUTBOARD BEARING

ASSEMBLY SPACERS (41A236415). E18260.

FIG. 35. PIE GAUGE (41A239826). E28927.

NOTES

37
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 3

FIG. 36. SUN PINION ROTATING TOOL (41E908727). E28928.

38
SECTION 3 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 37. WHEEL HUB BEARING INSPECTION PIN FIG. 39. SWIVEL LIFTING BAIL. E28198.
REMOVAL TOOL (41B537598). E28929.

NOTE FOR P8:

FURNISH ONE PRINT OF
INSTRUCTIONS (P8) WITH
EACH COMM. CHAMBER
PRESSURE FIXTURE KIT.

ADAPTER RING BRAKE

MOUNTING PAD (LOWER)

FIG. 38. AIR FLOW MEASURING FIXTURE FIG. 310. WHEEL LIFTING FIXTURES
(41C636650). E28933. DIAGRAM. E28261A.

39
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 3

FIG. 311. COMMUTATOR END LIFTING FIXTURE (41D794774). E28195A.

310
SECTION 3 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 312. FLANGE END LIFTING FIXTURE (41D793797). E28262A.

311
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 3

FIG. 313. EYEBOLT. E17901A.

FIG. 314. WOODEN SUPPORT BLOCK.

E17903A.

NOTES

312
SECTION 3 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 315. METAL SUPPORT BLOCK. E17904.

NOTES

313
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 3

FIG. 316. CRADLE (41E907675P1). E28202.

314
SECTION 3 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

NOTES

315
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 3

FIG. 317. CATWALK FOR MOTOR ASSEMBLY CRADLE. E28203.

316
SECTION 3 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 317. CATWALK FOR MOTOR ASSEMBLY CRADLE. E28203.

317
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 3

FIG. 318. MOTOR/ARMATURE REMOVAL TOOL (41D732935). E28206.

318
SECTION 4 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
SECTION 4. REPAIR AND ADJUSTMENTS
WHEEL MOUNTED ON TRUCK
CONTENTS
Page
SPEED SENSOR ADJUSTMENT . . . . . . . . . . . . . 41
COMMUTATOR RESURFACING . . . . . . . . . . . . . . 41
INSPECTION STANDARDS . . . . . . . . . . . . . . . . . 41
PREPARATION FOR COMMUTATOR
GRINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
GRINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Grinding Procedure . . . . . . . . . . . . . . . . . . . . . . . 43
MOTOR/ARMATURE REPLACEMENT . . . . . . . . 43
TOOL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 44
MOTOR REMOVAL PROCEDURE . . . . . . . . . . . 44
ARMATURE REMOVAL PROCEDURE . . . . . . . 45
MOTOR REPLACEMENT PROCEDURE . . . . . 45
ARMATURE REPLACEMENT
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SPEED SENSOR ADJUSTMENT
The gap between the speed sensor and the gear
teeth can be reset with a dial indicator if the sensor is re-
placed in service. Reset as follows:
1. Remove cable.
2. Loosen the locknut. Bottom the sensor on top of
a gear tooth.
3. Mount a dial indicator on the motor with the stem
on the sensor body.
4. Back out the sensor 0.020 in. and tighten lock-
nut.
5. Reconnect cable.
CAUTION: If sensor is positioned between gear
teeth, the sensor will be ruined when the gear is
rotated.
COMMUTATOR RESURFACING
The following explains the procedure for resurfacing
the commutator without removing the armature from the
Motorized Wheel. Use commutator grinder, Part
41C635995 (Fig. 41).
INSPECTION STANDARDS
Outofround commutators present an undulating
surface to brushes. If surface changes are sudden (due
to high rotational speed or abrupt surface changes),
brushes cannot maintain contact with the commutator.
Sparking will occur and the commutator surface will be
electrically eroded. If the changes are severe, as occurs
when the commutator is considerably outofround or
has low spots, the electrical erosion will rapidly deepen
the low spots, leading to reduced brush life, breaking of
brushes and, possibly, damage from flashover.
The amount of outofroundness that can be toler-
ated depends on the speed and duty of the motor. A
commutator having a smooth eccentric profile (one
high, one low per revolution) might operate successfully
with 0.003 or 0.004 TIR (total indicator runout) at 1000
or 1500 rpm even with heavy current loading. The same
commutator would show distress from excessive spark-
ing at some higher speed.
A commutator having a profile with abrupt changes
(e.g., 0.001 runout in seven or eight bars) would prob-
ably operate successfully at 1500 rpm (approx. 15
mph), but would spark at 3000 rpm. This sparking would
erode the bars, deepening the hole in the commutator,
causing more violent sparking and further hole deepen-
ing.
Since operating speed and abrupt changes in com-
mutator profile both affect commutating ability of a mo-
tor, it is not sufficient to simply specify a maximum per-
missible TIR.
Commutators can be jigstoned in place to remove a
small amount of stock using the commutator grinder.
PREPARATION FOR
COMMUTATOR GRINDING
Prepare the vehicle and Motorized Wheel as follows:
1. Block a vehicle wheel to prevent vehicle move-
ment in either direction.
41
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
FIG. 41. COMMUTATOR GRINDER. E28204.
2. Remove the sun pinion from the Motorized
Wheel on which the grinder will be installed. Also,
remove the hubcap.
3. Disconnect the power cables to the Motorized
Wheel.
4. Disconnect the hydraulic brake hose to the park-
ing brake. Remove the parking brake assembly
from the framehead.
5. Remove the 10 oclock brushholder. Remove all
brushes from the remaining brushholders and in-
sert old worn brushes in any two adjacent brush-
holders 90 degrees apart.
6. Connect the armature and field of the Motorized
Wheel in series. A 400 amp, dc welding ma-
chine is recommended as a source of current to
rotate the armature at 9001000 rpm for the
grinding operation. Connect the welding ma-
42
SECTION 4
chine to the seriesconnected Motorized
Wheel as indicated in Fig. 111.
WARNING: To protect personnel from physical
harm, the following safety precautions must be
adhered to:
1. Block the vehicle wheels to prevent vehicle
movement during the grinding operation.
Make blocks positively secure.
2. A second person must be at the power source
ready to shut off power in case of an emer-
gency during the grinding operation.
3. The grinding operator should wear goggles
and a dust mask when grinding or blowing
out the commutator.
GRINDING
Installation
1. Before installing the grinder, inspect it for cleanli-
ness. A dirty grinder may tighten and bind during
the grinding operation. If the grinder is dirty, it
may be necessary to disassemble the grinder to
SECTION 4 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
remove the accumulated dirt and copper. After
the grinder is reassembled, lubricate the grinder
ways with the graphite lubricant furnished in the
grinder kit. Proper distribution of the lubricant will
minimize the tendency to collect dirt and copper
chips.
2. Install the grinder support on the framehead so
that the grinder stones will be in the 10 oclock
position as shown in Fig. 41.
3. Use coarse or mediumgrade stones if 0.010 or
0.005 in. of copper is to be removed, or finish
grade if 0.002 in. or less is to be removed.
Grinding Procedure
1. Turn the feed control to back the stones away
from the commutator before starting motor.
2. Apply power to the motor and gradually bring the
speed up between 900 and 1000 rpm.
3. Begin grinding by radially feeding the stones
lightly against the commutator and then moving
them back and forth longitudinally across the
surface. More pressure can be applied as the
stones are seated and this can be maintained at
about 1/20th of a revolution of a radial feed for
every four to six sweeps of traverse motion. Cut-
ting action should take place at the trailing edge
of the stones. Do not take too deep a cut. Deep
cuts will result in dragging an excessive amount
of copper over the edges of the commutator
bars. If possible, use some means of collecting
the copper and abrasive dust thrown off by the
grinding operation. For example, use a vacuum
cleaner with a cleaning nozzle set just behind the
trailing edge of the stones.
4. Grind the commutator until a uniformly smooth
surface is obtained and all flat spots have been
removed. Do not remove more copper than nec-
essary.
5. Reduce the pressure on the stones near the end
of the grinding operation. A very light finish cut
will minimize copper drag and thus reduce the
amount of time required to clean the commutator
slots after grinding.
6. Stop the motor. If mediumgrade stones were
used, change to finishgrade stones and repeat
Steps 2, 3, 4 and 5.
7. Check commutator concentricity with a dial indi-
cator for the following limits:
a. Total indicated runout 0.001 in.
b. Variation of indicator runout within any group
of 20 bars 0.0004 in.
c. Variation of indicator reading between any
two adjacent bars 0.0001 in.
Continue grinding until these values are met.
8. Remove grinder assembly.
9. Scrape the slots between the bars to remove
projecting mica fins or copper whiskers with a
slot raking tool.
WARNING: When using compressed air for
cleaning purposes, an environment potentially
hazardous to personnel in the immediate area is
created. To prevent physical injury by flying de-
bris, observe all safety regulations.
10. Run the motor again at 1000 rpm and polish the
commutator with 00, or finer, sandpaper. Blow
dust from the commutator and interior of the mo-
tor with dry, compressed air. Hold the end of the
hose about 1 or 2 in. from the commutator sur-
face and sweep longitudinally to blow away cop-
per chips and loose mica.
11. Remove power. Reassemble brush holder and
readjust the brushholder clearance to commuta-
tor for 1/16 to 3/32 in. Install new brushes in all
brushholders.
12. Make the necessary mechanical and electrical
changes to place the Motorized Wheel back in
service.
MOTOR/ARMATURE
REPLACEMENT
The complete motor or just the armature can be re-
moved and replaced without removing the Motorized
Wheel from the vehicle. A special tool (41D732935G2)
has been designed for GE788 Motorized Wheels.
43
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
NOTE: Whenever a motor is replaced, the oil
seal (16, Fig. 1023) between the magnet frame
and the seal housing should also be replaced.
See instructions on page 83.
TOOL DESCRIPTION
The special tool is designed as a welded assembly,
primarily consisting of a steel plate and a steel Ibeam.
Fig. 318 is a drawing of the tool, presenting fabrication
details to aid the user in tool construction.
The tool with the armature adapter assembled is
used for armature removal. Without the adapter, the tool
is used for motor removal.
The counterweight is provided by ten 330 lb. steel
plates which can be removed or repositioned to pro-
vide the correct counterweight for the application.
Two comealongs are also recommended to be
used as shown in Sketches A and B, Fig. 42. The
comealongs adjust tilt laterally and adjust the tool ax-
ially for proper positioning.
FIG. 42. LONGITUDINAL AND LATERAL
COMEALONG CONFIGURATIONS. E28597.
44
SECTION 4
Tool storage and transport is simplified by position-
ing the ten counterweights in the center position of the
tool. Stability is maintained when transporting or posi-
tioning the tool using both lifting bails.
When resting on the floor, tool stability is increased
by protruding bosses welded to the motor removal
flange.
WARNING: The weight of the tool and the com-
bined weight of the tool and an assembled motor
or armature are important considerations when
performing removal and assembly operations.
To help avoid accidents which may cause injury
or death, use lifting equipment of adequate ca-
pacity and follow all applicable safety regula-
tions.
Tool Weights (approximate) lb.
Tool with Motor and Counterweights . . . . . . . . 10,300
Tool with Armature, Adapter Plate
and Counterweights . . . . . . . . . . . . . . . . . . . . . . . 6,900
Tool with Adapter Plate
and Counterweights . . . . . . . . . . . . . . . . . . . . . . . 4,740
Tool with Counterweights . . . . . . . . . . . . . . . . . . . . 4,500
Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,200
Counterweights (ten) . . . . . . . . . . . . . . . . . . . . . . . 3,300
Adapter Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,150
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,800
NOTE: Do not attempt to replace a motor or ar-
mature from a Motorized Wheel on a loaded
truck. Either unload the truck or use jacks to re-
move the weight from the Motorized Wheel. De-
flections in the wheel frame may make reas-
sembly impossible.
CAUTION: Do not allow the tool to hang on the
motor or armature (brake hub) during removal
and replacement procedures. To do so may
cause distortion of motor, armature shaft or tool.
Always block hanging end of tool with a suffi-
ciently strong support before releasing hoist.
MOTOR REMOVAL
PROCEDURE
Perform the following to remove a motor from a Mo-
torized Wheel mounted on an empty truck:
1. With the truck parked safely on the level, block
the wheels and release the parking brake.
SECTION 4 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
2. Remove the service and parking brake appara-
tus.
3. Remove the brake adapter ring.
4. Disconnect the speed and thermal sensor
cables.
5. Remove the sun pinion.
6. Disconnect the motor leads.
7. Remove the motor mounting bolts. Break the
motor free using the hydraulic jacking device
which is part of the puller tools group. The motor
can also be jacked out using jacking bolts in
tapped holes.
8. Using a hoist, crane or other lifting device capa-
ble of 12,000 lb. minimum, position the removal
tool to permit attachment of the removal plate to
the motor. Attach plate using six 114 x 31/2 in.
bolts in the jacking holes of the motor. Tighten
bolts securely. Use a comealong (Fig. 42A) to
align bolt holes if necessary.
9. Block up the hanging end of the tool. The tool is
approximately 77 in. above the ground.
10. Lower the hoist and remove the cable attached
to the smaller lifting bail.
11. With the main hook of the hoist attached to the
large main lifting bail (Fig. 42), lift just enough to
support the weight of the motor and the tool.
Then attach a comealong from the main hook to
the small lifting bail. Tighten comealong (Fig.
42A).
12. Reposition the ten counterweights from the cen-
ter of the tool to the end. Insert pins. (Use Carr
Lane Part No. CL16DEP or equal.)
13. Pull the motor slowly horizontally to remove it
from the frame structure. Make the final tilt ad-
justment with the comealong (Fig. 42A).
ARMATURE REMOVAL
PROCEDURE
Perform the following to remove an armature from a
Motorized Wheel mounted on an empty truck.
1. Perform Steps 1 through 5 of MOTOR RE-
MOVAL PROCEDURE.
2. Disconnect brushholder cables. Remove brush-
holders and air deflectors.
NOTE: For Model DS, Step 3 may be omitted.
3. Remove six framehead mounting bolts. Jack fra-
mehead loose, if necessary, using the two
1/213 tapped jackout holes and two 1/213
bolts.
4. Assemble armature removal adapter plate to the
tool.
5. Using a hoist, crane or other lifting device capa-
ble of 8,000 lb. minimum, position the removal
tool to permit attachment of the adapter plate. At-
tach plate using eight bolts to the brake hub.
Tighten bolts securely. The counterweights
should be in the center position on the tool for ar-
mature removal.
6. Block up the hanging end of the tool.
7. Lower the hoist and remove the cable attached
to the smaller lifting bail.
8. With the main hook of the hoist attached to the
large main lifting bail (Fig. 42), lift just enough to
support the weight of the armature and the tool.
Then attach a comealong from the main hook to
the small lifting bail. Tighten comealong (Fig.
42A).
9. Pull the armature slowly horizontally to remove it
from the magnet frame. Adjust tilt with comea-
long (Fig. 42A).
MOTOR REPLACEMENT
PROCEDURE
Perform the following to install a motor into a Motor-
ized Wheel mounted on an empty truck.
NOTE: Coil speed and thermal sensor cables in
frame structure pockets to prevent damage dur-
ing motor assembly.
1. Using a hoist, position the motor with the tool for
insertion into the frame structure of the Motor-
45
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
ized Wheel. ensure that the motor/tool assembly
is at the correct tilt. Use comealong to make fi-
nal tilt adjustment (Fig. 42A).
2. Very slowly, approach the motor cavity of the
frame structure, noting the alignment of the key-
way in the motor with the key in the frame struc-
ture. If the keyway is rotationally misaligned, use
a comealong as shown in Fig. 42B to make ad-
justments.
3. Apply a film of rust preventive or oil to the outside
of the motor to ease motor assembly and future
disassembly.
4. Insert the motor into the motor cavity as far as
possible. Pull the motor home with mounting
bolts.
5. Block up the hanging end of the tool.
6. After the motor is securely tightened down,
slacken the lifting force.
7. Reposition the counterweights to the center of
the tool.
8 Remove the comealongs and reattach a lifting
cable from the main hook to the small lifting bail.
Take a light strain with the hoist.
9. Disassemble the tool from the motor.
10. Move the tool away from the motor and lift it
away.
11. Torque the motor assembly bolts to the pre-
scribed amount. Refer to the SECTION 1,
DATA.
12. Install the sun pinion. Torque bolt to the pre-
scribed amount.
13. Connect speed sensor and thermal sensing cir-
cuits and all motor leads. Insulate all motor leads
using the instructions in Figs. 1011 through
1018.
14. Install the brake adapter ring. Torque bolts to pre-
scribed amount.
15. Install the service and parking brake apparatus.
46
SECTION 4
ARMATURE REPLACEMENT
PROCEDURES
Perform the following to install an armature into a
Motorized Wheel mounted to an empty truck.
NOTE: If it is necessary to replace the pinion
end armature bearing, install a complete new
bearing. Do not mix old and new bearing parts
or mix new bearing parts which are of different
manufacture.
1. Using a hoist, position the armature with the tool
for insertion into the magnet frame of the Motor-
ized Wheel. ensure that the armature/tool as-
sembly is at the correct tilt. Use comealong to
make final tilt adjustment (Fig. 42A).
2. Very slowly, approach the armature cavity of the
magnet frame.
3. As the armature enters the cavity, adjust for any
rotational misalignment of the framehead
mounting bolt holes by rotating the framehead on
its own armature bearing.
CAUTION: Dont damage the pinion end bearing
with the end of the armature shaft (drive ring).
4. Insert the armature into the magnet frame as far
as possible. Insert bolts and pull the framehead
home. Tighten bolts in an alternating sequence
to prevent distortion of framehead.
5. Block up the hanging end of the tool.
6. After the framehead is securely tightened down,
slacken the lifting force.
7. Remove the comealong and reattach a lifting
cable from the hook to the smaller lifting bail.
Take a light strain with the hoist.
8. Disassemble the tool from the armature.
9. Move the tool away from the armature and lift it
away.
10. Torque the framehead bolts. Refer to the SEC-
TION 1, DATA.
11. Install the sun pinion. Torque bolt to the pre-
scribed amount.
SECTION 4 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

12. Connect all electrical connections including
speed sensor cable. Insulate all motor leads us-
ing the instructions in Figs. 1011 through
1018. Replace brushholders and reconnect
cables. Install air deflectors.
13. Install the brake adapter ring. Torque bolts to pre-
scribed amount.
14. Install the service and parking brake apparatus.

NOTES

47
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 4

NOTES

48
SECTION 5 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
SECTION 5. REMOVAL, CLEANING AND
CHECKS BEFORE DISASSEMBLY
CONTENTS
Page
REMOVAL OF MOTORIZED WHEEL
FROM VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
STEAM CLEANING . . . . . . . . . . . . . . . . . . . . . . . . 51
VAPOR DEGREASER . . . . . . . . . . . . . . . . . . . . . . 52
SOLVENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ENDPLAY CHECK BEFORE
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
REMOVAL OF MOTORIZED
WHEEL FROM VEHICLE
1. Raise the corner of the truck from which the Mo-
torized Wheel is to be removed and block up the
truck.
2. Remove the tires, wheel rim and brake rigging
from the Motorized Wheel.
3. Drain the lubricating oil from the gearcase.
4. Lock the armature: see SECTION 12, ARMA-
TURE LOCKING ARRANGEMENT.
5. Disconnect the motor cables and brake hoses.
Disconnect breather hoses, oil hoses, greasing
lines, speed sensor cable and thermal sensor
circuits.
6. Attach a crane, hoist or special dolly to the Mo-
torized Wheel to support it and take the weight off
the Motorized Wheel mounting bolts. The dolly
supports the Motorized Wheel only at the mount-
ing flange and the wheel hub. If the Motorized
Wheel is slung, refer to SECTION 3 for the cor-
rect method.
7. Remove the flange mounting bolts which hold
the Motorized Wheel to the truck frame.
8. Move the Motorized Wheel away from the truck.
This must be done carefully as there is very little
clearance between truck and gearcase.
9. Clean the outside of the Motorized Wheel with
compressed air, steam or other cleaner. The hub
cap remains in place when cleaning the outside
of the Motorized Wheel. Plug gearcase vent
threaded holes. DO NOT DIRECT CLEANING
FLUIDS INTO THE HUBCAP OPENINGS OR
ROTATING SEAL AREAS.
10. Refer to SECTION 3 for lifting tools used during
handling.
11. To disassemble disc or drum brakes, see Ve-
hicle Builders Publication.
CLEANING
WARNING: Cleaning agents may be toxic and/or
flammable. They can cause serious or fatal injury
if used without proper precautions. For safety:
1. Do not inhale fumes.
2. Use only in adequately ventilated areas.
3. Avoid contact of cleaning agent with the skin.
4. Do not expose cleaning agent to flame or
sparks.
5. Observe caution statements issued by the
manufacturer of the cleaning agent.
STEAM CLEANING
NOTE: Care must be taken in the selection of
detergents used in conjunction with steam
cleaning. Cleaning agents are usually alkaline
and not chemically neutral. Satisfactory results
have been obtained with the proper use of Na-
vee 42* and Superlode**.
1. Suspend the Motorized Wheel so that it is acces-
sible from all directions of flow from the hose.
2. Dilute detergent according to manufacturers in-
structions and heat to 65_C (150_F) to 80_C
(175_F).
NOTE: The detergents noted above have been
used at full strength without any apparent ef-
fects on insulation or varnish. However, it is
* Manufactured by the Penetone Co.
** Manufactured by West Chemical Prod. Co.
51
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 5

recommended that full strength be used only Acid Neutral Base (Alkaline)
when heavy accumulation of contaminants 56 7 8 9 10
must be removed. Orange Yellow Green Ivy Blue
Green Green
3. Spray on detergent and allow 5 to 20 minutes for 11
detergent to penetrate accumulated contami- Purple
nants. NOTE: Do not immerse commutator in water.

4. Thoroughly wash off detergents with steam and
hot water. Recommended pressure 120 psi;
temperature 160_C (320_F).
5. Air blow with clean, dry, compressed air (if nec-
essary) and remove motor.
NOTE: Prior to the disassembly of the Motor-
ized Wheel, bearing endplay checks should be
performed to indicate condition of bearings.
6 After disassembly, repeat Steps 3 and 4 for both
magnet frame and armature.
NOTE: When cleaning armatures, make sure air
holes in armature core are cleaned thoroughly.
Scrape out build up if necessary.
7. Armature and magnet frame must be thoroughly
flushed with clean water; move components to
fresh, hot water tank.
8. Immerse armature (commutatorend up) and
magnet frame in hot water for approximately 20
seconds; raise and immerse again for 20 sec-
onds.
9. Move armature and magnet frame to a ventilated
oven and bake for 8 to 12 hours at 160_C
(320_F).
10. Perform Megohmmeter and HighPotential
tests per SECTION 11.
11. If armature or field coils do not meet standards in
SECTION 11, armature and magnet frame
should be baked for an additional two to four
hours.
VAPOR DEGREASER
1. Bring the cleaning solution to a boil and allow the
vapor line to rise to the condenser coils at the top
of the tank.
2. Keep vaporized cleaning solution at approxi-
mately 120_C (248_F).

NOTE: Cleaning agent is alkaline (contains so-
dium phosphates, silicates or sodium carbon-
ate, sodium hydroxide and wetting agents). If
not thoroughly rinsed, the lack of chemical neu-
trality results in a residue (generally a dry pow-
der) that will absorb water in normal service and
cause leakage paths to ground.
3. Lower the part to be cleaned into the vaporla-
den atmosphere so the vapor will condense on
the apparatus.
4. To speed removal of heavy accumulations,
spray the hot solution directly from the tank onto
the apparatus. The temperature of the solution
must not be below its boiling point.

5. Remove the apparatus. Allow it to drain and cool.

NOTE: Water tank should have a filtration sys-
tem to remove solid particles and a pH control SOLVENTS
to monitor alkalinity of water. The water should
be kept below its boiling point and be agitated. 1. Select a suitable solvent as follows:
If water tank does not have pH control, pH level
a. For insulation, use a nonoily, quickdrying
can be controlled with pH paper, which can be
cleaner such as trichlorethylene.
obtained from a laboratory supply house. When
testing water, the color indicated by paper b. For metal surfaces, use a cleaner which will
should be yellowgreen (pH of 7 neutral). not leave an oily deposit on the finished sur-

52
SECTION 5 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
faces. An acceptable cleaner is Solvesso No.
100*, or equivalent.
c. For antifriction bearings, gears and bearing
fits, use a cleaner which will not completely
remove the oil from the finished surfaces. Ac-
ceptable cleaners are kerosene, petroleum
spirits or other petroleum solvents.
2. Dip a clean, lintless cloth or brush into the solvent
and wipe or brush the part clean. Do not dip insu-
lated parts into the solvent.
ENDPLAY CHECK BEFORE
DISASSEMBLY
Before the Motorized Wheel is disassembled, the
endplay of the wheel hub should be checked and the
results recorded. This will provide information on the
condition of the bearings. The endplay must also be
checked after the Motorized Wheel is reassembled, us-
ing the more accurate rotating method (SECTION 11).
* Product of Standard Oil Co.
NOTES
1. Assemble two lifters on both the outboard end of
the wheel hub and flange end of frame (Figs.
311 and 312).
2. Lift the Motorized Wheel and place it on suitable
blocking with the gearcase end down.
3. Place two magneticbase dial indicators diamet-
rically opposite on the braking adapter. Set the
dial indicator pointer to rest on the wheel hub.
4. Set indicators to zero. Allow for 0.060 in. of indi-
cator travel.
5. Attach cables of proper size to lifters (Step 1).
Using a swivel hook and crane of sufficient ca-
pacity (25,000 pounds), raise wheel clear of floor
(approximately 1/2 in.).
6. Record reading for use after overhaul.
NOTE: Maximum inservice endplay using the
nonrotating method is 0.050 in. Maximum in
service endplay using the rotating method is
0.055 in. See SECTION 11 for the rotating meth-
od.
7. Lower the wheel and remove indicators.
53
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 5

NOTES

54
SECTION 6 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
SECTION 6. REMOVAL OF MAJOR COMPONENTS
CONTENTS
Page
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SUN PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
MAGNET FRAME/ARMATURE . . . . . . . . . . . . . . . 61
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SEAL RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
PLANET GEAR ENDPLAY . . . . . . . . . . . . . . . . . . 64
PLANET GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
SEAL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
SCOPE
This section provides stepbystep instructions for
removing the major components which make up a com-
plete Motorized Wheel, less tires, rims and brake rig-
ging. The following components are discussed here and
appear in the text in SECTIONS 6 and 7 in the order
shown, and in the reverse order in SECTIONS 9 and 10.
1. Sun Pinion
2. Magnet Frame/Armature
3. Wheel Hub
4. Torque Tube/Flinger
5. Seal Ring
6. Planet Gears
7. Seal Housing.
NOTE: Disassemble the Motorized Wheel only
to the extent needed to complete repairs.
SUN PINION
NOTE: The sun pinion is easiest to remove
when the wheel is in a horizontal position.
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Remove bolts (74) and gearcase cover (80).
2. Remove bolt (68) and slide sun pinion (72, 103)
from fit in the drive ring (65).
MAGNET FRAME/ARMATURE
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Rotate the wheel to a vertical position with the
framehead up.
CAUTION: Do not let the wheel rest on the gear-
case. Use the recommended blocks in SECTION
3.
2. Remove sockethead capscrews and washers
(37) holding adapter ring (88) and magnet frame
(39) to the frame structure.
3. Separate the adapter ring from the magnet
frame using bolts in threaded jackout holes. Re-
move the adapter ring.
4. Disconnect the speed sensor cable from the
speed sensor and remove tied connections to
the motor magnet frame. Coil cable into the re-
cess in the frame structure.
5. Disconnect the thermal sensor cannon plug.
6. Strip the insulation from the bolted terminal con-
nections shown in Fig. 61. Remove the bolts
and lockwashers (21, 22, 23, 24, Fig. 61) from
these connections.
7. Loosen and remove bolts connecting the motor
to the frame structure.
8. Using jackout bolts in the holes provided, alter-
nately tighten to break the fit of the motor and the
frame structure. If necessary, use puller tool
(Fig. 33).
WARNING: Do not attempt to lift a magnet frame
complete with armature out of a Motorized Wheel
using the 1 x 8 tapped hole in the end of the arma-
ture shaft. This hole is designed for lifting the ar-
mature only. The added weight of the magnet
frame (3665 lb.) could cause the threads to fail
and, as a result, the assembly could fall, causing
serious injury.
61
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
FIG. 61. TYPICAL COMMUTATOR END CABLE CONNECTIONS. E28263B.
9. When the motor is free, use three swivel lifting
bails (Fig. 39) to remove the motor from the
frame structure. Place the motor on suitable
blocking in a vertical position for armature re-
moval.
WHEEL HUB
NOTE: Numbers in parentheses refer to Fig.
62, unless otherwise noted.
1. Remove bolts (33) holding the bearing cap (32)
to the wheel hub.
62
SECTION 6
2. Do not remove bolts and washers (36) holding
the seal ring (34) to bearing cap (32) at this time.
3. Insert bolts into threaded holes provided and
jack the bearing cap from its fit on the wheel hub.
Be careful not to damage the seal (100).
4. Now separate the seal ring (34) from the bearing
cap by removing bolts and washers (36).
5. Remove bolts (33) holding the thrust ring (38) to
the frame structure.
6. Insert bolts into threaded holes provided and
jack thrust ring from its fit on the frame structure.
SECTION 6 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 62. WHEEL HUB REMOVAL. E34850.

7. Remove shims (40). Tie each pack together and hole (Fig. 63). Apply low pressure hydraulic oil
mark them so they can be replaced in the same to lubricate the bearing fit. Then proceed to Step
location at reassembly. 9.

8. To avoid scoring the bearing fit when the out-
board wheel hub bearing is removed, inject lubri-
cating oil into the wheel hub bearing groove in the
frame. Install a hydraulic line with a 1/4 in. NPT
connector to the wheel hub bearing lubrication
9. Loosen all wheel hub bolts (19). Remove all but
six bolts, leaving them spaced evenly around the
assembly. They should be handtight to pull the
assembly from the frame, and will be removed
later.

FIG. 63. OIL APPLICATION HOLE FOR OUTBOARD WHEEL HUB BEARING REMOVAL. E34797.

63
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
NOTE: If wheel hub bolts must be broken loose
by hand using a breaker bar, lock the wheel hub
to the frame by inserting studs into the frame
and the wheel hub. Tie the frame and wheel hub
together with a cable or a piece of flat stock
drilled to pass over the studs. This will prevent
the rotation of components as the bolts are
loosened.
10. (Preferred Method) Install puller tool
41D794806 to flange of wheel. Connect three (3)
hydraulic pumps to the puller and jack the wheel
hub, torque tube and seal ring free. All wheel hub
bearing parts will also be removed.
(Alternate Method) Install puller tool
41E903513G8 (Fig. 32) and eight hydraulic
pumps; jack the wheel hub, sleeve and torque
tube free. All wheel hub bearing parts will also be
removed.
11. Remove remaining wheel hub bolts and use four
of them for jacking the wheel hub loose.
12. Using a wheel hub lifting fixture, remove the
wheel hub from the torque tube.
13. Place the wheel hub on suitable blocking. Cover
the wheel hub and bearings to prevent contami-
nation.
14. Lift the inboard hub bearing and sleeve from the
torque tube. Protect the bearing from contamina-
tion.
SEAL RING
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Remove the wheel hub and torque tube as pre-
viously described.
2. Remove bolts and washers (3) which secure the
seal ring (2) to the frame structure.
64
SECTION 6
3. Insert four bolts in the jackout holes provided.
Tighten and break the fit of the seal ring to the
frame.
4. Insert eyebolts into the seal ring and lift it from
the frame.
PLANET GEAR ENDPLAY
If the Motorized Wheel is not scheduled for overhaul
but is in the shop for other repair work, it is recom-
mended that the planet gear endplay be checked. This
will indicate planet pinion bearing wear which could be
corrected if found excessive.
Check the planet gear endplay as follows:
1. With the Motorized Wheel in a vertical (flange up)
position, locate an overhead crane directly over
one of the planet gears.
2. Thread two eyebolts into the two threaded holes
in the planet gear.
3. Place a dial indicator onto the frame such that it
will indicate vertical gear travel when the gear is
lifted. Set it to zero.
4. Using an overhead crane and two eyebolts, raise
the gear.
5. Observe the dial indicator to determine when the
upward travel stops. Hold the gear at the top of
its travel and read the indicator.
6. If the reading in Step 5 is less than 0.0001 in., the
bearing may be preloaded. Remove the gear
and measure the depth of the pinion end bearing
bore. The dimension should be 3.875
0.005 in.
7. If the dimension in Step 6 is correct, replace the
bearing. If the dimension is too small, machine to
correct.
8. If the reading in Step 5 is more than 0.018 in., the
bearing is too loose. Remove the gear and re-
place the bearing.
9. Repeat Steps 1 through 8 for each of the three
planet gears.
SECTION 6 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

PLANET GEARS 5. The pinionend bearing is a doubletaper bear-

ing and the inner race will come out on the planet
NOTE: Numbers in parentheses refer to items
gear shaft. Retrieve bearing cup and spacer
listed in Fig. 1023 (Longitudinal Section draw-
from bearing bore. Keep them together with their
ing for latest production models), unless other-
bearings. The gearend bearing is a single
wise noted. Figs. 1019 through 1022 provide
straightroller bearing and the inner race only will
similar views for older models but the item
come out on the shaft. The rollers and outer race
numbers may be different.
will remain in the frame.
1. Place the Motorized Wheel flange up in an ap-
propriate cradle. The flange surface must be lev- SEAL HOUSING
el.
NOTE: Numbers in parentheses refer to items
2. Remove planet pinionend bearing cap lockwire,
listed in Fig. 1023 (Longitudinal Section draw-
bolts and washers (96).
ing for latest production models), unless other-
3. Install two lifting eyes in the threaded holes in the wise noted. Figs. 1019 through 1022 provide
planet gear. Lift the planet gear straight out of the similar views for older models but the item
frame structure. numbers may be different.

4. Remove planet gearend bearing cap lockwire,

bolts and washers (50). Insert bolts into the jack
out holes and loosen the bearing cap (76) from
its fit.
NOTE: Repeat Steps 2, 3 and 4 for each of the
three planet gears.
1. Remove the seal housing (71) from the frame by
removing lockwire, bolts and washers (75). In-
stall bolts in the jackout holes to loosen the seal
housing from its fit.
2. Lift the seal housing from the frame.

NOTES

65
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 6

NOTES

66
SECTION 7 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

SECTION 7. DISASSEMBLY OF MAJOR COMPONENTS

CONTENTS
Page
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SUN PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
MAGNET FRAME/ARMATURE . . . . . . . . . . . . . . . 71
ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
PINIONEND BEARING AND DRIVE RING
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
BRAKE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
COMMUTATOREND BEARING . . . . . . . . . . . . 73
FIELD COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 FIG. 71. SUN PINION. E28934A.
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
TORQUE TUBE/FLINGER . . . . . . . . . . . . . . . . . . . 74 1. Ring (oil baffle) (81) can be removed by tapping
SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
with a pipe or bar thru the sun pinion hole.
SEAL RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
PLANET GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 2. A snap ring (64) holds the retaining plate (63) in
PINIONEND BEARINGS . . . . . . . . . . . . . . . . . . 75
the sun pinion. This ring can be removed with a
GEAREND BEARINGS . . . . . . . . . . . . . . . . . . . . 77
FRAME STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . 77 pair of TruArc pliers.
3. When snap ring (64) is removed, retaining plate
SCOPE (63) may also be removed.

This section describes disassembly procedures for MAGNET FRAME/ARMATURE

each major component removed in SECTION 6. Repair
persons should only disassemble to the extent needed
ARMATURE
to make repairs.
NOTE: To determine if a bearing is reusable,
generally an inspection can be made without
removing the bearing from its assembly. If the
bearing is reusable, removal is not necessary.
NOTE: If reusable bearings are removed, they
should be kept together in their original sets.
Also keep bearings together with the compo-
nent from which they were removed, so they
will be reassembled to their original location in
the Motorized Wheel assembly.
SUN PINION (Fig. 71)
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
(Figs. 93 through 96)
Remove the armature with the following procedure:
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Remove brushes from carbonways and lower
brush levers.
2. Disconnect the brushholder cables from all four
brushholders and remove bolts and washers
(42).
3. Remove brush clamp (41) and brushholders
(44). Remove air deflectors (30).
4. Remove bolts and washers (67) securing frame-
head (35) to the magnet frame (39).
5. Insert an eyebolt in the armature shaft. Center a
crane over the armature as close as possible.

71
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
6. Insert bolts into jackout holes to break frame-
head fit, then lift the armature assembly out of
the magnet frame. Be careful not to bump the ar-
mature against the pole pieces.
7. Place the armature assembly horizontally on a
padded cradle. Do not rest the armature on the
commutator, end windings or framehead.
PINIONEND BEARING AND
DRIVE RING ASSEMBLY
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Remove bearing housing (57) from magnet
frame (39) as follows:
a. Remove bolts and washers (56).
b. Insert bolts into threaded holes provided in
bearing housing.
c. Carefully jack bearing housing from its fit by
alternately tightening jackout bolts.
d. Remove bearing housing from motor frame.
2. Remove outer race of bearing (59) from bearing
housing (57) as follows:
a. Remove bolts and washers (56) from bearing
cap (62).
b. Insert bolts into threaded holes provided in
bearing cap.
c. Carefully tighten jackout bolts to break fit of
bearing cap. Remove bearing cap (62) and
packing (61).
3. Inspect bearing. If it is reusable, do not remove it
unnecessarily. If a reusable bearing must be re-
moved, carefully tap outer race loose with a mal-
let and a soft steel bar. Remove and wrap to
avoid contamination.
72
SECTION 7
4. Remove drive ring (65) from armature shaft as
follows:
a. Install puller tool, Part 41E903513G1 (Fig.
32).
b. Pull drive ring from shaft. A force in excess of
16 tons (32,000 lb.) is needed to remove drive
ring.
5. Inspect bearing outer race. If damaged, remove
bearing collar (60) from armature shaft as fol-
lows:
a. Install puller tool, Part 41E903513G2 (Fig.
32).
b. Pull collar from armature shaft.
6. Remove inner race of bearing (59) and collar (58)
from armature shaft as follows:
a. Install puller tool, Part 41E903513G3 (Fig.
32).
b. Pull inner race and collar from armature
shaft.
7. Inspect bearing inner race. If it is to be reused,
wrap it to avoid contamination. Store it with the
outer race to which it was originally mated.
NOTE: If either bearing inner or outer race is
deemed unfit for further service, a completely
new bearing assembly must be used.
BRAKE HUB
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Remove bolt and washer (92) and end plate (91)
from end of armature shaft.
2. Pull disc brake hub (90) from its spline fit on the
armature shaft. Use puller tool 41C636386G5
(Fig. 31). A force in excess of 16 tons (32,000
lb.) is needed to remove the hub.
SECTION 7 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
COMMUTATOREND
BEARING
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Remove bearing cap (46) from framehead (35)
as follows:
a. Remove bolts and washers (45) securing
bearing cap (46) to framehead (35).
b. Remove bearing cap.
2. Remove speed sensor gear (47) from armature
shaft as follows:
a. Install puller tool, Part 41E903513G6 (Fig.
32).
b. Pull gear from shaft.
3. Remove the speed sensor (49) by unscrewing
the sensor from the bearing cap (46).
4. Remove framehead (35), bearing (52) and
spacer (48) from armature shaft. Inspect bear-
ing. If damaged:
a. Install puller tool, Part 41E903513G5 (Fig.
32).
b. Pull framehead, bearing and spacer from
shaft.
c. Install puller tool, Part 41E903513G9 (Fig.
32).
d. Pull bearing and spacer from framehead.
NOTE: Bearing (52) should not be reused after
being disassembled.
5. Remove collar (54) from armature shaft as fol-
lows:
a. Install puller tool, Part 41E903513G4 (Fig.
32).
b. Pull collar from shaft.
FIELD COILS
1. Remove all fiberglass air deflectors.
2. Remove the insulation from the field coil termi-
nals and disconnect the leads. Heat the connec-
tions with brazing tongs or a gas torch to melt the
silver solder.
NOTE: When heat is applied to melt the solder,
cover the insulation on the coils with a wet non
flammable material (ceramic cloth) to prevent
the heat from damaging the insulation.
3. Field coils and pole pieces are best removed with
the magnet frame in a horizontal position,
mounted in a fixture which permits a rotational
movement. Field coils and pole pieces then, be-
cause of their weight (exciter coils with pole
piece 225 lb., commutator coils with pole
pieces 135 lb.), can more easily be removed af-
ter rotating each to the 6 oclock position.
4. Remove the pole piece bolts and lift the coil as-
sembly from the magnet frame. Remove each
coil individually, using an appropriate lifting de-
vice. Coils are too heavy to lift manually.
NOTE: The pole pieces are bonded to the field
coils to form an integral assembly.
WHEEL HUB
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
Inspect bearings before removal. Do not remove un-
necessarily.
1. Place wheel hub (29) on flat surface, outboard
end up.
2. Remove the outboard bearing inner race (cone)
and rollers (31) by simply lifting them out of the
wheel hub.
3. Inspect outboard bearing. If damaged, install
puller tool, Part 41E903513G11 (Fig. 32). Pull
outer race (cup) of bearing (31) from wheel hub.
73
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
NOTE: Inspect both races and rollers. If they are
to be reused, store and cover to avoid contami-
nation.
4. Turn wheel hub over.
5. Inspect inboard bearing outer race. If damaged,
install puller tool, Part 41E903513G11 (Fig. 32).
Pull outer race of bearing (22) from the wheel
hub.
NOTE: Inner race and rollers of outboard bear-
ing (22) have already been removed (see SEC-
TION 6, WHEEL HUB).
6. Inspect both races and rollers. If they are to be
reused, store and cover them to avoid contami-
nation.
TORQUE TUBE/FLINGER
(Figs. 72, 73)
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
FIG. 72. TORQUE TUBE, ALL MODELS. E28936A.
74
SECTION 7
similar views for older models but the item
numbers may be different.
1. Remove flinger (8) from torque tube (11) as fol-
lows:
a. Remove bolts and washers (9) and clamps
(10) from the flinger.
b. Lift the torque tube and flinger assembly just
off the floor and rotate slowly. Heat flinger
with a torch until flinger drops off. Use a mallet
if necessary.
2. Remove oil seals (18) and paddle pump (97)
(Fig. 74) from flanged end of torque tube. Use
puller tool 41C636386G4 (Fig. 31). Discard oil
seals.
3. Remove wear band (78) and packing (6) from
flinger.
SLEEVE
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
SECTION 7 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 73. FLINGER, ALL MODELS. E28937A.

similar views for older models but the item PLANET GEARS
numbers may be different.
Inspect bearings before removal. Do not remove un-
necessarily.
1. Remove sleeve (20).
Perform the following procedure on all three planet
2. Remove Oring (21) from sleeve.
gears.

3. If wear bands (17) on sleeve (20) are worn, re-
place them.
SEAL RING (Fig. 75)
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
PINIONEND BEARINGS
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
Remove the pinionend bearing (13) from the shaft
using either of the following methods:

1. Remove the oil seal (7). NOTE: After the bearing is removed, regardless
which of the following removal methods is
2. Remove the grease line connectors (4). used, it is not reusable and must be scrapped.

75
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 7

FIG. 74. PADDLE PUMP, ALL MODELS. E28938A.

Puller Tool Method: 2. Cut the lower bearing cage with a cutting torch,
first on one side then the other, to allow the lower
1. Remove bearing nut (15) and its lockwasher bearing rollers to fall off.
(14). 3. Cut the upper bearing cage with a cutting torch,
first on one side then the other, to allow the upper
2. Install puller tool, Part 41E903513G14 (Fig. bearing rollers and outer race to fall off. The inner
32). race should now be exposed.

3. Pull bearing from shaft. 4. Start the gear rotating slowly in one direction.
5. While the gear is rotating, use a torch to apply
4. Remove bearing cap (95). heat directly on the lower end of the bearing race,
well away from the pinion. Keep the flame small.
5. Remove sleeve (82). Do not play the flame on the shaft since the ob-
ject is to cause the bearing race to expand from
Torch Method: the heat while the shaft stays relatively cool.
6. Periodically reverse the rotation of spin while ap-
1. Suspend the planet gearpinion on a cable or
plying heat, but keep the gear rotating.
heavy wire with the pinion end down. The cable
should have a swivel hook to allow the gear to ro- 7. Continue applying the heat and rotating the gear
tate. until the bearing race drops off.

76
SECTION 7 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

.5013 TAP THRU AND X HOLE

.625 DIA. CBORE 1.25 DEEP A TOP VERICAL CL
(FAR SIDE) 4 HOLES EQ. SP.
(FOR JACKOUT)
1.25 N.P.T.
.3438 TAP DRILL 1.18 DEEP
16 HOLES EQ. SP.. AS SHOWN

.5625 DIA. THRU

16 HOLES EQ. SP.
EXCEPT HOLE A 250 4.07
LABELED X

53.25
DIA.

APPROX. WR. = 310 LBS.

BOTTOM VERT. CL

.50 DIA. HOLE THRU ENLARGED

SECTION AA

FIG. 75. SEAL RING, ALL MODELS. E28939F.

GEAREND BEARINGS
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Remove bearing inner race (77) and sleeve (87)
from the shaft as follows:
a. Install puller tool, Part 41C636386, Asm. 1
(Fig. 31).
2. Install puller tool, Part 41C636386, Asm. 4. Re-
move bearing rollers and outer race from bearing
bore in frame structure.
3. Inspect the bearing races and rollers. If they are
reusable, store and cover to avoid contamina-
tion.
FRAME STRUCTURE
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.

Remove speed sensor cable (51), thermal sensor

b. Pull race and sleeve from the shaft. cable (89) and brake lines from the frame structure.

77
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 7

NOTES

78
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

SECTION 8. OVERHAUL PROCEDURES

Repair The Hub . . . . . . . . . . . . . . . . . . . . . . . . . 848
CONTENTS BOLT HOLE REPAIR . . . . . . . . . . . . . . . . . . . . . . 848
WHEEL HUB TIRE RIM STUD REPAIR . . . . . 849
Page Replacing A New Stud . . . . . . . . . . . . . . . . . . . 851
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 CHECKING BEARING CAPS AND
BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 HOUSINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 851
TORQUE TUBE RING GEAR . . . . . . . . . . . . . . . 82 FINAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . 851
OIL SEALS AND WEAR BANDS . . . . . . . . . . . . . 83
FIELD COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 INSPECTION
Armature Insulation . . . . . . . . . . . . . . . . . . . . . . . 84
Commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 BEARINGS
Creepage Band Replacement . . . . . . . . . . . . . . 86
Armature Shaft Replacement . . . . . . . . . . . . . . 86 Refer to Table 81 when inspecting the bearings,
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 87 shafts and housings.
GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
GEARCASE AND GEARCASE COVER . . . . . . 87 1. Clean the bearings. See SECTION 5, CLEAN-
RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . 88 ING.
COILED FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
VARNISH TREATMENT (Armature) . . . . . . . . . . 88 2. Inspect for:
COMMUTATOR RESURFACING . . . . . . . . . . . . 88
MACHINING SPIRAL GROOVED a. Broken or cracked bearing races
COMMUTATORS . . . . . . . . . . . . . . . . . . . . . . . . . 88
MACHINING SPIRAL GROOVE b. Scored, pitted or chipped bearing races
(New Commutator) . . . . . . . . . . . . . . . . . . . . . . . . 89
BURR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 810 c. Broken or cracked rollers or balls
UNDERCUTTING . . . . . . . . . . . . . . . . . . . . . . . . . 810
POLISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810 d. Excessive wear on rollers or balls
MACHINING SPIRAL GROOVE
(Resurfaced Commutator) . . . . . . . . . . . . . . . . . 810 e. Broken, cracked or distorted bearing cages.
ARMATURE BALANCING . . . . . . . . . . . . . . . . . 811
Balance Weight Attachment . . . . . . . . . . . . . . 811 Replace any bearing which exhibits any of these
Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 811 discrepancies.
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812
COMMUTATOR SPIN SEASONING . . . . . . . . . 812 3. Look for evidence of smearing caused by inade-
COMMUTATOR PRESSING AND quate lubrication, corrosion pitting (usually at
TIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . 812 roller spacing) caused by moisture or other cor-
BRUSHHOLDER OVERHAUL . . . . . . . . . . . . . . 817
Teflon Sleeve Replacement . . . . . . . . . . . . . . . 817 rosive agent. Replace the bearing if any of these
Carbonway Resizing . . . . . . . . . . . . . . . . . . . . . 818 conditions are found.
Restoration of Brushholder Bodies . . . . . . . . . 818
Spring Replacement . . . . . . . . . . . . . . . . . . . . . 819 4. Inspect wheel hub bearing outer races for inden-
Disassembly and Reassembly . . . . . . . . . . . . 819 tations caused by dirt or foreign material having
FRAMEHEAD BEARING BORE . . . . . . . . . . . . 821 gone through the bearing. If the indentations are
WHEEL HUB RIM SEAT . . . . . . . . . . . . . . . . . . . 822 small or not numerous, the bearing can be used.
Equipment Required . . . . . . . . . . . . . . . . . . . . . 822 If the indentations are large and numerous, this
Wheel Hub Rim Seat Repair . . . . . . . . . . . . . . 822
may be an indication the rollers or cone are start-
WHEEL HUB BEARING FITS (Frame) . . . . . . . 824
Inboard Bearing Fit . . . . . . . . . . . . . . . . . . . . . . 835 ing to spall out.
Outboard Bearing Fit . . . . . . . . . . . . . . . . . . . . . 836
TIRE FIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . 844 5. Examine rollers for wear, etching or spalls. Par-
Prepare The Wheel Hub . . . . . . . . . . . . . . . . . . 844 ticular attention should be given the roller ends.
Assemble Plates And Rings . . . . . . . . . . . . . . 844 Check for excessive lapping or scoring.

81
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

TABLE 81.
Inner Race Housing Outer Race New
Shaft Diam.
Location Bearing Part No. Brg. Bore Diam. Brg. O.D. Assembled
(in.)
(Cone) (in.) (in.) (Cup) (in.) EndPlay (in.)
Armature KK8864950P206 5.1197 5.1181 9.0560 9.0551
Comm. End 5.1187 5.1171 9.0548 9.0539
Armature KK8864951P163 5.9071 5.9055 8.8592 8.8583
Drive End 5.9061 5.9045 8.8580 8.8571
Planet KK8864951P200 8.004 8.0012 12.2060 12.2047
Gear 8.003 8.0000 12.2046 12.2033
Planet KK8864961P12 3.3495 3.3465 5.9077 5.9055 0.0001
Pinion* 3.3486 3.3457 5.9061 5.9045 0.016**
Wheel Hub KK8864953P119 36.632 36.6142 41.723 41.7323 0.025
Inboard 36.628 36.6100 41.718 41.7270 0.030**
Wheel Hub KK8864953P120 36.553 36.5355 41.723 41.7323 0.025
Outboard 36.549 36.5315 41.718 41.7270 0.030**
*Consist of two (2) matched ground, single row, tapered roller bearings and spacer.
**Endplay dimensions taken without tires and rims.
NOTE: Inboard wheel hub bearing shaft diameter (frame) on new wheels manufactured after January,
1988, and on older wheels after bearing fit repair: 36.632 +0.000/0.004 in.
NOTE: Outboard wheel hub bearing shaft diameter (frame) on new wheels manufactured after Janu-
ary, 1988, and on older wheels after bearing fit repair: 36.553 +0.000/0.004 in.

6. If the bearing is a Timken bearing, use tool

41B537598 (Fig. 37) to remove roller pin and
remove bearing roller. Inspect cone for imperfec-
tions. Replace roller and pin.

7. Dip the good bearing parts in a light mineral oil

(SAE10) to prevent corrosion before assembly.

8. If the bearing is not to be mounted immediately,

wrap it in an oilproof paper.

NOTE: Do not interchange bearing parts of dif-

ferent manufacturers. Do not interchange bear-
ing parts of wheelhub bearings.

TORQUE TUBE RING GEAR

The condemning limits in Fig. 81 are published as a

guide for the reuse of a torque tube found to have minor FIG. 81. TORQUE TUBE TOOTH WEAR
spalling and cracks. CONDEMNING LIMITS. E28266A.

82
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
OIL SEALS AND WEAR
BANDS
There are various materials and components used in
the wheel motor to seal lubricants in and seal dirt out. All
except wear bands should be renewed at overhaul.
Wear bands can be used again unless they have wear
grooves.
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Oil Seals There are five oil seals used:
a. Ref. No. 7, for sealing between seal ring (2)
and flinger (8).
b. Ref. No. 18, two seals for sealing between
torque tube (11) and sleeve (20) (Fig. 82).
c. Ref. No. 94, for sealing between seal ring (34)
and thrust ring (38).
d. Ref. No. 16, for sealing between seal housing
(71) and magnet frame (pinion end) (39).
2. Felt Packing There are three felt packings
used:
a. Ref. No. 6 for sealing between seal ring (2)
and flinger (8).
FIG. 82. SLEEVE. E28941B.
b. Ref. No. 61 for sealing between pinionend
bearing cap (62) and collar (60) on armature
shaft.
c. Ref. No. 53 for sealing between framehead
(35) and collar (54) on armature shaft.
3. ORings There is one ORing used:
Ref. No. 21 for sealing between sleeve (20)
and frame structure.
4. Sealers There are five locations where a seal-
ing compound is used:
a. Ref. No. 12 for sealing between pinionend
armature bearing housing (57) and magnet
frame (39).
b. Ref. No. 5 for sealing between planet cover
(80) and frame structure (1).
c. Ref. No. 12 for sealing between seal hous-
ing (71) and frame structure (1).
d. Ref. No. 5 for sealing between seal ring (2)
and frame structure (1).
e. Ref. No. 5 for sealing between pinionend
bearing housing (57) and bearing cap (62) on
armature shaft.
5. Wear Bands there are four wear bands:
a. Ref. No. 78 on the flinger (8).
b. Ref. No. 17 two on the sleeve (20).
c. Ref. No. 17 on the thrust ring (38).
83
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
6. Gaskets there is one gasket:
Ref. No. 98 for sealing between the sun pinion
cover (73, 105) and the planet cover (80).
After removing Items 1 through 6 above, thoroughly
clean the grooves and mating surfaces into which they
fit. Then install new seals, packing, Oring and wear
bands (replace any grooved or worn wear bands).
Packing Installation:
NOTE: On all new models, the packing groove
in sleeve (20) has been eliminated. Older mod-
els, however, may still have a sleeve with the
packing groove. In such cases, the old packing
could be left in place or, if it is removed, new
packing need not be installed.
1. Coat the packing groove with 497A806P9 adhe-
sive.
NOTE: Install the packing on sleeve (20) so that
when the sleeve is assembled to the frame, the
sewn joint will be at 12:00.
2. Install new packing into groove.
3. Press packing into groove at four diametrically
opposite locations, one at a time. Firmly seat en-
tire packing with a roller.
4. After adhesive has cured, saturate packing with
D6B20H5 oil.
Wear Band Installation:
1. Apply a thin (0.06 in.) bead of 497A806P33 seal-
er to the wear band diameters of sleeve (20) and
flinger (8).
2. Install wear bands (78) and (17). Wear bands
may have to be heated to 200_C (392_F).
3. Wipe off all excess sealer.
4. Coat wear bands with a film of grease.
Oil Seal Installation:
It may be necessary to either cool the oil seal or heat
the component into which the oil seal is assembled.
84
SECTION 8
FIELD COILS
1. Inspect the coil insulation for burns, charring, arc
damage and foreign object damage.
2. Test coils per SECTION 11.
ARMATURE
Armature Insulation
Insulation that has been nicked or scuffed on the pin-
ion end loops can be repaired by wrapping with glass
tape and varnishing with a good grade of insulating var-
nish.
Conduct Megger, hipot, surge and resistance tests
per SECTION 11. Armatures that are grounded, shorted
between turns, roasted out from excessive temperature
or that show weak insulation in surge test (high voltage
pulse test, coiltocoil) should be rewound. If such re-
pair is necessary, the armature should be taken to a GE
service shop or other authorized heavy repair facility.
The following surge testing criteria is recommended:
1. For newly rewound armatures, surge testing
should be done at 750 volts maximum.
2. For armatures which have been in service and
have been repaired or are in need of repair (re-
banded, commutator pressed, etc.), surge test-
ing should be done at 500 volts maximum.
3. For armatures which have been in service but
have not been repaired nor are in need of repair,
no surge test is recommended.
Commutator (Fig. 83)
New commutators are thoroughly tightened and
seasoned at the factory and do not require additional
tightening unless the armature is rewound. Occasional-
ly, however, a commutator will show indications that it
has loosened. If a commutator is thought to be loose,
check it by making runout measurements of the surface
outside the brush paths. Smooth runout indicates that
the commutator is stable and does not need to be tight-
ened. Uneven runout variations showing different
heights from bar to bar may indicate that the commuta-
tor has loosened and the bars have shifted. Variations
as small as 0.0005 in. are significant.
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 83. COMMUTATOR ASSEMBLY. E27169.

When inspecting the commutator, the maximum lim-
its for runout are as follows:
1. Outofround 0.003 in. TIR (before regrinding)
2. Rate of change 0.001 in. within any group of 12
bars (before regrinding)
1. Measure diameter to determine if grinding or
turning will result in an undersized commutator.
The minimum diameter is 15.375 in.
2. Inspect bars for severe baredge burning which
will not clean up after turning.

3. Runout 0.001 TIR (after regrinding) 3. Inspect end of bars for severe flashover damage
which enters the brush path and will not clean up
4. Rate of change 0.0004 in. within any group of by turning.
20 bars (after regrinding)
4. Conduct armature insulation tests under ARMA-
5. Rate of change 0.0001 in. between adjacent
TURE INSULATION section.
bars (after regrinding).

If resurfacing is required, perform the following in- If the armature passes these tests and is deemed re-
spection to determine if commutator can be reworked usable, proceed with resurfacing procedures, found un-
and reused: der COMMUTATOR RESURFACING section.

85
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

Creepage Band Replacement Shaft Removal

After cleaning, inspect the creepage band for thin
spots, cracks or lifting of the band. If replacement is nec-
essary, a new Teflon creepage band should be installed
by means of the Hot Band method.
Items Required
1. Oven of sufficient size and capacity to hold arma-
ture and heat to 150_C (302_F).
2. Banding or winding lathe for installation of Teflon
band.
3. Kit 41A237905G1 which contains cement, cata-
lyst, tapes, patches and instructions in sufficient
quantities to install approximately fifty (50) Teflon
bands.
4. GE Part 41B537080P1 Teflon band.
5. GE Part 41C6877661 clamp band/pressure
plate.
Armature Shaft Replacement
Perform the following instructions to replace an ar-
mature shaft:
1. Remove the commutatorend collar.
2. Heat the armature in an oven to 150_C (302_F)
quickly to prevent shaft expansion.
3. Place the armature in a press. Support it on the
pinionend armature head with a steel pipe 6 in.
in diameter and 30 in. long. Protect the end of the
shaft with a piece of copper or brass so the spine
will not be damaged. See Fig. 84.
4. Press on the commutatorend of the shaft to
force the shaft out of the core assembly. 150 to
200 tons of force is required to press a shaft out
of a cold core assembly. Heating the armature
assembly will lower the required force to approxi-
mately 100 tons.
Shaft Installation
1. Heat the armature in an oven to 150_C (302_F).
2. Brush the core fit of the shaft with a mixture of
graphite and oil.
3. Support the armature on the commutator shell,
adjacent to the shaft. The support should be a
piece of extraheavy steel pipe, 4.5 in. ID by 7.5
in. long.
4. Cool the new shaft to 40_C (40_F).

APPLY 150 200 TONS

PRESSURE HERE TO
PRESS SHAFT OUT OF
CORE
TO PRESS SHAFT INTO CORE,
150 200 TONS PRESSURE SHOULD
BE APPLIED TO END OF SHAFT IN
SUCH A MANNER THAT THE SPINE OF
SHAFT IS NOT UPSET. USE BRASS
BLOCK OR EQUIVALENT ON
PRESSED SURFACE.

SUPPORT HERE TO PRESS

IN NEW SHAFT. SUPPORT ON SUPPORT HERE TO PRESS OUT SHAFT.
4 1/2 EXTRA HEAVY PIPE 7 1/2 LONG. SUPPORT ON 6 PIPE 30 LONG.

FIG. 84. METHOD OF REPLACING ARMATURE SHAFT. E3494B.

86
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

5. Press the cold shaft into the hot armature from GEARCASE AND GEARCASE
the pinion end. Protect the end of the shaft with a COVER
piece of copper or brass so the spline will not be
damages. It will require from 150 to 200 tons of 1. Remove all sludge and accumulated residue
force to press in the shaft. from the sump and gearcase. Clean thoroughly.

SPEED SENSOR 2. Clean oil passages on cover and check to see if

they are clear.
1. Clean the speed sensor thoroughly. Remove all
metal particles from the magnet end of the sen- 3. Check the gear box for damage. If the gear box is
sor. dented or bent out of shape, the planet gear may
2. Check the coil for continuity with an ohmmeter. be rubbing on the inside.

GEARS 4. Check the cover to see if the planet gears have

Table 82 provides condemning limits for Ring
Gears, Planet Pinions, Planet Gears, and Sun Pinions.
Refer to these values when inspecting this equipment to
establish replacement criteria.
been rubbing. This can be caused by failed bear-
ings, bearings that moved in their fits or a bent
cover.
5. Check for bent or missing oil troughs.

TABLE 82. GE788 GEARING WEAR LIMITS.

Diameter Diameter Condemning
Over/Between Over/Between Pin Diameter Limit Diameter
Description Drawing No.
Pins Max. Pins Min. (Inches) Over/Between
(Inches) (Inches) Pins (Inches)
Ring Gear 41D735718 36.7531 36.7424 0.7720 36.8328
(Torque Tube) 41D732487 36.4846 36.4687 0.7720 36.5475
Planet Pinion 41D735719P1 8.2938 8.2857 0.7720 8.2060
41D732493P8 8.0537 8.0483 0.5760 7.9854
Planet Gear 41D735097P1 26.6987 26.6929 0.8000 26.6241
41D735098P1 25.9044 25.8985 0.8000 25.8318
41D735811P1 26.6987 26.6929 0.8000 26.6241
41D735812P1 25.9044 25.8985 0.8000 25.8318
Sun Pinion 41D735091P1 6.0910 6.0870 0.5760 6.0268
41D735092P1 7.1713 7.1664 0.5760 7.1081

87
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

RECONDITIONING 4. Take clean, smooth cuts to remove just enough

COILED FRAME
Use red Glyptal* to touchup around any coils that
have been replaced and on new taped joints.
NOTE: Separately excited field coils have a bare
midriff (no taping on middle turns) which must
be kept clean of Glyptal; therefore, spray paint-
ing is not recommended.
VARNISH TREATMENT
(Armature)
Refer to VACUUM PRESSURE IMPREGNATION
(VPI) PROCESS, GEK101183 for the latest VPI pro-
cedure.
COMMUTATOR
RESURFACING
If a commutator surface is not in good condition, re-
surface the commutator by turning the armature in a
lathe. After commutator resurfacing, the diameter must
be at least 15.375 in.
1. Place the armature in a lathe.
a. If adapters for the armature bearings are
available, mount the armature in its bearings.
b. If adapters are not available, mount the arma-
ture on its shaft centers and measure the
bearing seat runout. If the measurement is
greater than 0.001 in. with respect to the shaft
bearing fit, repair the centers. See MACHIN-
ING SPIRAL GROOVED COMMUTATORS
section.
material to provide a smooth surface. Do not
drag the copper over the mica when taking cuts
and do not burn the tool.
5. Remachine the spiral groove per MACHINING
SPIRAL GROOVED COMMUTATORS section.
6. Polish the surface with 00 sandpaper (or finer).
DO NOT USE EMERY CLOTH.
7. After turning, clean up the front ends of the bars
by breaking the sharp edge with a file.
MACHINING SPIRAL
GROOVED COMMUTATORS
A spiral grooved armature is shown in Fig. 85.
Mount the armature in a lathe geared to cut three
threads to the inch. Position the armature so the com-
mutator end faces the tailstock and clamp the armature
securely (Fig. 86).
NOTE: Undercutting operations should be per-
formed after the spiral groove is machined.
If commutator resurfacing is necessary, use a round
nose cutting tool and take a light cut at the surface of the
commutator. The TIR should be within 0.001 in. with re-
spect to the armature shaft bearing fit. If this relationship
is more than 0.001 in., perform the following:
1. Closely inspect the shaft center for upset metal
or a protrusion in the shaft center that has misal-
igned the shaft.

2. Cover the windings to prevent entrance of chips

and dust.

3. Use a cutting tool ground for turning copper, and

set the speed of the machine so the commutator
surface speed is approximately 300 feetper
minute (80 rpm).

* Tradename of General Electric Co., GE1251 FIG. 85. SPIRAL GROOVED COMMUTATOR.
A15B17A. E18607.

88
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
FIG. 86. ARMATURE MOUNTED AND CLAMPED
IN LATHE. E18608.
2. Using a 60degree included angle reamer and a
metal scraper, clean the shaft center to remove
metal upsets and protrusions.
3. If shaft TIR is still out of tolerance, check the
shaft for straightness. If the shaft is bent, it must
be replaced.
4. If the shaft is straight and the TIR is still out of tol-
erance, dial indicate the bearing fit to within toler-
ance using an accurate steady rest. Then, re-
generate the shaft center using a 30degree
angle tool (60degree included angle).
5. Proceed to turn the commutator true to the bear-
ing fit.
NOTE: When cutting a spiral groove, cut the
spiral groove first, then undercut the mica to
the same depth.
MACHINING SPIRAL
GROOVE (New Commutator)
1. Setup the lathe to turn at 45 rpm and to cut three
threads per inch.
2. Install a cutoff tool in the lathe that will provide a
0.094
0.002 in. wide groove. Install tool on the
left side of the tool rest (Fig. 87). Keep over-
CUTOFF TOOL
(GROUND TO NOMINAL
GROOVE WIDTH)
FIG. 87. METHOD OF MOUNTING CUTOFF
TOOL. E18609.
hang of tool to a minimum to avoid sidespring
and possible breakage.
NOTE: The spiral groove will be cut starting at
the riser end of the commutator.
3. Position the tool on the edge (riser end) of the
commutator and adjust tool to just touch the sur-
face of the commutator.
4. Move the tool off the edge of the commutator.
Record the reading of the toolfeed micrometer
dial and adjust the feed for a light cut (0.003 in.).
5. Start the lathe. Engage the thread cutting lever
and cut the spiral groove (Fig. 88) until the tool
clears the edge of the commutator.
6. Stop the lathe, back the tool clear of the commu-
tator and move the carriage to position where cut
was started.
7. Based on the previously recorded tool feed mi-
crometerreading, adjust tool to same depth as
first cut and make a second pass over the groove
to check the thread cutting operation of the lathe.
The lathe operator should repeat Steps 6 and 7
until satisfied that the lathe setup is working
perfectly, before machining the groove deeper.
8. For each pass through the spiral groove, adjust
the tool to cut approximately 0.010 in. deeper.
Machine the groove to 0.046 in. deep.
89
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

UNDERCUTTING
1. The undercutting operation will raise burrs at the
intersections of the slots and the spiral groove.
Remove burrs with a file and rake the slots with a
short section of hacksaw blade to remove cop-
per chips and mica particles.

2. Use a wire brush and clean the spiral groove and

the slots.

3. Undercut mica to a depth of 0.047 in. min., 0.073

in. max. Use a 1 in. diameter saw with a width of
0.065 in.

4. Remove sharp edges from the bars with a stiff

brush or fiberboard. Do not bevel edges of com-
FIG. 88. CUTTING A SPIRAL GROOVE.
E18610. mutator segments.

5. Blow out the commutator mica slots to remove

BURR REMOVAL
fins, chips, dust and foreign material.
Machining the spiral groove raises small burrs along
POLISHING
the edges of the groove and at both ends of the commu-
tator. Remove burrs as follows: CAUTION: Never use emery cloth on a commuta-
tor. The abrasive particles will not only scratch
1. Start the lathe and follow both edges of the the surface, they are conductive and lodge be-
groove with a knife file to remove burrs. Also, re- tween the commutator segments. A flashover
move burrs from both ends of the commutator may result.
with a flat file (Fig. 89). Run the lathe at 1000 rpm and polish the commutator
with 00 sandpaper, crocus cloth or 400A Triemite* pa-
2. Hold a pad of sandpaper against the commutator
per. Abrasive sheet material should be mounted on a
for a few seconds to remove remaining burrs.
wooden block curved to fit the surface of the commuta-
tor.

Blow the dust from the commutator with dry, com-

pressed air. Hold the air nozzle 1 to 2 in. from the surface
of the commutator and sweep nozzle longitudinally to
dislodge copper chips and mica dust.

MACHINING SPIRAL
GROOVE (Resurfaced
Commutator)
Prior to machining the spiral groove, the commutator
will have to be turned. The TIR must be within 0.001 in.
with respect to the armature shaft bearing fit. If the TIR is
outside this tolerance, refer to MACHINING SPIRAL
GROOVE (New Commutator) section.
FIG. 89. REMOVING BURRS FROM END OF
COMMUTATOR. E18612. * Product of Minnesota Mining and Mfg. Co.

810
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
When recutting a spiral groove, cut the spiral groove
first, then undercut the mica to the same depth.
When the mica is observed to be even with the sur-
face of the commutator, the spiral groove should be re-
cut and the mica undercut. This is because the mica is
too close to the brush and may accelerate brush wear.
When recutting the spiral groove, the spiral groove
depth should be approximately 0.050 in. deeper than
the rough turned commutator surface. This will allow ap-
proximately 0.005 in. per side stock for finish.
When resurfacing a commutator, do not remove
more stock than absolutely necessary. If some portion
of the spiral groove remains after resurfacing, the
groove can be recut to the proper depth provided that
the brush surface diameter is not smaller than the mini-
mum permissible diameter of 15.375 in.
If no trace of the original spiral groove remains after
resurfacing, follow the instructions under MACHINING
SPIRAL GROOVE (New Commutator) section and ma-
chine a new spiral groove accordingly.
If a portion of the original spiral groove remains after
resurfacing, the groove can be recut to the proper depth
per the following instructions.
To recut a spiral groove on a commutator that has
been resurfaced, proceed as follows:
1. Setup the lathe to turn at 45 rpm and to cut three
threads per inch. Position armature in lathe with
the commutator end facing the tailstock and
clamp armature securely.
2. Install a cutoff tool which will cut the groove to
0.094
0.002 in. wide. Keep tool overhang to a
minimum to avoid sidespring and possible
breakage.
3. Move carriage to locate tool near the edge (riser
end) of the commutator and move tool close to,
but not touching, the surface of the commutator.
Align tool with the spiral groove.
4. Start the lathe and engage the thread cutting le-
ver. Check the alignment of the tool and the spiral
groove as the tool traverses the commutator.
Feed tool into groove in small increments (0.003
in.) for each succeeding pass until tool contacts
some part of the groove. If tool is not aligned per-
fectly with the groove; leave threadcutting lever
engaged, stop the lathe, loosen the clamp and
rotate armature (very slightly) to align tool with
groove. Tighten the clamp and make several trial
passes to see that tool tracks the groove. Try not
to widen the groove.
5. Adjust the tool to remove about 0.010 in. of stock
for each pass through the spiral groove. Machine
the groove to 0.046 in. deep.
6. Remove burrs from spiral groove and undercut
and polish the commutator per instructions given
above under MACHINING SPIRAL GROOVE
(New Commutator) section.
ARMATURE BALANCING
Dynamic balance of an armature assembly is re-
quired for smooth running and low vibration. Severe im-
balance will result in selfdestruction of the motor.
The following instructions will deal only with location
and method of attaching the balance weights. The set
up, fixtures to hold parts in the balance machine and
procedure to obtain a balance within the specified limits
is determined by the type of balance machine being
used. Follow the balance machine manufacturers op-
erational procedure. Refer to Figs. 1019 through
1023 for location and identification of parts.
Balance Weight Attachment
Attach balance weights by welding. Use welding rod,
BRONZE (AWS ECuSnC).
Limits
Armature must be balanced within 12.0 grams at the
commutator end and 10.0 grams at the pinion end.
These weights refer to the unbalance tolerance at the lo-
cations shown in Fig.810.
811
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

Procedure 4. Turn off heat and allow armature to cool to

4050_C (104122_F) while continuing to spin
CAUTION: Use only the specified weld rod. Use at 3000 rpm. Cooling will take approximately 30
of other types may result in inadequate welds
minutes.
and cause motor failure.
1. Remove old balance weights. 5. Repeat Steps 2, 3 and 4 for a total of two cycles.

2. Determine amount of weight required to bring the

6. Remove armature from spin stand.
armature within limits. Trim balance weight light-
er than that determined, to allow for weight add-
7. Remove bearings from armature.
ed by weld.

3. Position the balance weight and tack weld in 8. Press and tighten commutator cold, 50_C
place. Refer to Fig. 810. (122_F) max., using tightening procedure in the
COMMUTATOR PRESSING AND TIGHT-
4. Check balance and adjust as necessary. ENING section.

COMMUTATOR SPIN
9. Check dynamic balance and reassemble bear-
SEASONING (Fig. 811) ings on armature.

A commutator seasoning cycle is required if any of

10. Set the armature in a spin stand.
the following maintenance procedures have been per-
formed on the commutator:
11. Repeat Steps 2, 3 and 4 for two more cycles.
1.* When a new, unseasoned commutator is
mounted on the armature 12. Final grind or diamond turn.

2. When a shaft is replaced NOTE: When commutator is used or seasoned

3. When a commutator is tightened prior to assembly, seasoning prior to tighten-
ing can be deleted.
4.* After a commutator has been TIG welded after
rewinding the armature. COMMUTATOR PRESSING
Commutator seasoning is performed in the following AND TIGHTENING
manner:
CAUTION: This procedure is applicable only
1. Apply bearings to the armature and set it in a spin when the commutator and mica cones have NOT
stand. been replaced. Commutator and mica cone re-
placement should only be done by a factory au-
2. Spin armature at 3000 rpm and apply heat to the thorized Service Shop.
commutator. Heat to 160_C (320_F) in approxi-
mately 45 minutes. Operation of the motor over a long period of time and
at high operating temperatures, will tend to relax the
3. Hold temperature at 160_C and spin hot for 60 arch pressure built up between the commutator seg-
minutes. ments and maintained by the stability of the segment
plate mica. This combination will result in loose commu-
tator segments and will also result in prematurely rough
commutators unless periodically the arch pressure is
adequately restored to the commutator assembly. Prop-
* To be performed only by a factory authorized Ser- er pressure can be restored by pressing and tightening
vice Shop. the commutator.

812
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 810. BALANCE WEIGHT LOCATION. E28213.

813
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

5. Assemble spacer, 41C633390G1 (Fig. 815),

and swivel joint, 41C685080G1 (Fig. 812), to
OVEN the crows foot as shown in Fig. 816 and apply
HEAT COVER
DRIVE SENSOR 80 tons of force to the assembly.
COUPLING
CAUTION: The commutator cap bolt torque is
calculated with Molykote* GN Paste (or equiva-
lent) used as a bolt lubricant. Use of a nonap-
proved lubricate may cause an incorrect bolt
OVEN stretch, which could result in commutator dam-
IGNITION age. Also, do not dip the bolts in the Molykote
GN Paste or apply the lubricant further than 3/4
in. up on the threads.
6. Remove the commutator cap bolts one at a time
GAS
SUPPLY and lightly lubricate the first 3/4 in. of threads and
under the bolt head with Molykote* GN Paste,
41A219134P3.

FIG. 811. SPIN SEASONING STAND. E18266.
The swivel, 41C685080G1, as shown on Fig. 812,
contains a ball joint to assure as true an axial force to the
commutator as possible, even if the two reaction mem-
bers in the hydraulic press are not in the same place.
CAUTION: Do not attempt to tighten a commuta-
tor unless it can be spinseasoned after tighten-
ing.
1. The armature must be at room temperature.
Pressing and tightening a hot commutator will
not stabilize the mica. The mica flakes will slip
with respect to each other and cause greater in-
stability if pressed while hot.
2. Chip the tack welds from the commutator cap
bolts.
3. Assemble stand, P8895973, to the base plate of
the hydraulic press, then place the armature on
the stand.
7. Using a properly calibrated torque wrench, tight-
en the commutator cap bolts to 110 lb.ft. torque.
The bolts should be uniformly tightened in a
crisscross sequence as shown in Fig. 817. The
torque values have no significance if the bolts
are not properly lubricated as called for in Step 6,
since much of the torque will go into bolt friction
and not bolt stretch.
8. Remove the 80 tons force and move the arma-
ture from the press. Tack weld the bolt heads to
the commutator cap with bronze welding rod
(GEB50E37).
9. Spin season.
10. Resurface the commutator by turning, regroov-
ing, undercutting, polishing and engraving the
slots. If possible, the final polishing or grinding
should be done on its own bearings to minimize
eccentricity or runout.

4. Assemble crows foot, 41C685430G1 (Fig.

813), to the commutator cap as shown in Fig. * Registered Trademark of The Alpha Molykote
814. Corp., Division of Dow Corning Corp.

814
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 812. SWIVEL FOR COMMUTATOR PRESSING. E17897A.

815
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

FIG. 813. CROWS FOOT PRESSING FIXTURE (41C685430). E28942.

CROWS
FOOT

COMMUTATOR

FIG. 815. COMMUTATOR PRESSING SPACER

FIG. 814. CROWS FOOT. E14270. (41C633390). E28943.

816
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG.816. COMMUTATOR PRESSING ARRANGEMENT. E28214.

BRUSHHOLDER OVERHAUL Teflon Sleeve Replacement

The following instructions are for the overhaul of Inspect sleeves for cracks or thin spots. If replace-
toggleup brushholders. ment is necessary, proceed as follows:

These instructions cover four primary repairs: Teflon
sleeve replacement, carbonway resizing, restoration of
brushholder bodies and replacement of weak or broken
springs. Disassembly and reassembly instructions are
for replacement of worn parts.
1. Remove damaged sleeve. Removal may be
aided by heating the support in oven to 150_C
(302_F). Peel or cut the sleeve from the insu-
lated stud.
WARNING: When using compressed air for
cleaning purposes, an environment potentially
hazardous to personnel in the immediate area is
created. To prevent physical injury by flying de-
bris, observe all safety regulations.

1 2. Thoroughly clean surface of insulated stud. Re-

12 5 move any carbon deposits and irregular surface
conditions with sandpaper. Blow it off with dry,
compressed air.
8 9
3. Measure insulation resistance of the stud with a
megohmmeter. If it measures less than 40 meg-
ohms, do not apply the Teflon sleeve until the
4 3 stud is baked to obtain this value.

4. Heat a new Teflon sleeve in an oven with a maxi-

mum temperature of 150_C (302_F) for 15 min-
10 7 utes.

5. Using gloves, immediately assemble the hot

6 11 sleeve on the stud and press the sleeve down
2 tight against the brushholder body. This can be
done best with a fiber or metal plate with a hole
FIG. 817. SEQUENCE TIGHTENING drilled in the center to the dimensions of the stud
COMMUTATOR BOLTS. E4502. diameter.

817
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

Carbonway Resizing

In the manufacturing process, brushholder carbon-

ways are machined to an inside dimension of 0.755
+0.000/0.005 in. If, as the result of normal wear in ser-
vice, this dimension exceeds 0.765 in., the carbonway
should be restored to its proper dimension as follows:

1. Position the brushholder as shown in Fig. 818

and tap the metal ridge with a hammer. Start at
one end and work along the ridge to the other
end.

2. Check progress frequently with a Go NoGo

gauge, Part 2770817P20. A gauge may be made
to the dimensions shown in Fig. 819.

3. Continue tapping as described in Step 1 until the

carbonway dimension is within the range of the
Go portion of the gauge.
4. If, due to overpounding, the side dimension be-
comes less than the Go portion of the gauge,
file back to size with a fine mill file.
FIG. 819. BRUSHHOLDER CARBONWAY
GAUGE. E11283.
ners can be built up if less than 1/4 in. buildup is re-
quired in the affected area. If more than 1/4 in. buildup
is required, the brushholder should be replaced.

Restoration of Brushholder Repair as follows:

Bodies (Fig. 820)
Motor flashovers usually result in some burning or
melting of metal at the corners of brushholders. The cor-
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 Spec.
A10B15) to the area to be built up.

BRAZING
TORCH
BRASS
BRAZING
ROD

FIG. 818. RESIZING BRUSHHOLDER FIG. 820. BRAZING BURNED BRUSHHOLDERS.

CARBONWAYS. E11281. E11282.

818
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
3. Insert a carbon brush into the carbonway to pre-
vent the brazing material from flowing into the
way.
4. Use a brazing torch and a 1/16 in. diameter brass
brazing rod to puddle in sufficient metal to re-
store the metal that has been removed.
5. Check the carbonway for size with the Go No
Go gauge after the brushholder has cooled to
room temperature.
6. Resize as required.
Spring Replacement
WARNING: Wear approved face shield for protec-
tion against possible injury.
Replace weak or broken springs as follows:
1. Refer to Fig. 821 for parts identification.
2. Drive out spring dowel pins (5).
3. Open lever combination all the way and pry out
old springs with a screwdriver.
4. Use GE tool, Part 41D782238G1, to compress
the new spring. Pick up the spring with loading
device, GE tool, Part 41D782314G1 (Fig. 822).
5. Apply small amount of Molykote BR2* to the ra-
dius of spring seat (11, 12) and insert springs.
6. Insert spring in brushholder as shown in Fig.
823.
7. Replace spring dowel pins (5).
* Registered Trademark of The Alpha Molykote
Corp., Division of Dow Corning Corp.
Disassembly and
Reassembly
The brushholder may not have to be completely dis-
assembled for the replacement of worn parts; however,
complete reassembly instructions are given since they
will be needed if a brushholder is built up from a new
body.
The order of disassembly is not important with the
exception of removing spring dowel pins (5) before at-
tempting to pry out the springs.
Reassemble the brushholder as follows:
1. Refer to Fig. 821 for parts identification.
2. Assemble hinge pin (15) into the brushholder
body.
3. Apply Molykote BR2 to the bore and ends of le-
ver combinations (2). Assemble hinge pin (4),
three lever combinations (2), two bushings (9)
and four bushings (8) into the brushholder (Fig.
821).
4. Assemble springs in brushholder as previously
described in Spring Replacement section.
NOTE: If a used brushholder body and hinge
pin is used, the 3/32 in. dowel pin holes will
have to be lined up with each other.
5. Drive both dowel pins (5) into position (Fig.
824).
6. Assemble screw and washer assembly (7).
NOTE: It will not be necessary to drill a used
brushholder body and hinge pin.
7. Drill two 3/32 in. holes through boss and hinge
pin where it is shown in Fig. 821 and drive in
dowel pin (6).
819
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

FIG. 821. BRUSHHOLDER ASSEMBLY. E28215A.

820
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

AIROPERATED
SPRING COM-
PRESSOR PART
41D782238G1





SPRING LOAD-
ING TOOL, PART
41D782314G1
FIG. 824. ASSEMBLING LEVER
COMBINATIONS. E14228A.
FIG. 822. SPRING COMPRESSOR AND
LOADING DEVICE. E14226. 2. Indicate the register fit to within 0.002 in. TIR
(parallelism and concentricity).
FRAMEHEAD BEARING
3. Machine 0.250 in. from the bearing bore (do not
BORE break into threaded holes). Care must be taken
to maintain the 2.060 +0.005/0.000 in. depth of
Repair framehead bearing bore damaged due to
this bore.
bearing failure:
4. Measure the bore.
1. Mount framehead (Figs. 825, 826) on vertical
boring mill. 5. Machine a standard 1020 steel seamless pipe as
a bearing bore liner. Machine the O.D. to 0.0075
to 0.009 in. larger than bore diameter and 2.060
to 2.065 in. long.

6. Thoroughly clean the machined surfaces of the

framehead and bearing bore liner.

7. Cool liner to a temperature of 40_C (40_F).

Dry ice can be used as cooling agent.

8. Assemble cold liner in the framehead bearing

bore. Liner must be properly seated on bearing
shoulder. Allow the liner to reach ambient room
temperature before releasing holding pressure.

9. Grind four (4) weld preparations on the outer

face of the liner at the joint line of the framehead.
Weld preparations are to be Utype, 1 in. long,
0.186 in. deep and 0.186 in. wide. Weld prepara-
tions are to be equally spaced at 45 degrees from
tapped holes.

10. Set welding machine at 180210 amps. Using

5/32 in. E6027 electrode, weld four (4) 1in. fil-
FIG. 823. ASSEMBLING SPRINGS. E14227. lets at the weld preparation.

821
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
FIG. 825. GE788DS FRAMEHEAD. E35201.
11. Repeat Steps 1 and 2.
12. Face the protruding section of the bearing liner
flush with the framehead bearing cap mating sur-
face. Bore the bearing liner to 9.0548
+0.0012/0.000 in. (Fig. 827).
WHEEL HUB RIM SEAT
Repair rim seat damaged due to tire spinning.
Equipment Required
1. Welding machine, 400 amperes capacity or
equivalent.
a. MIG welder Using solid wire with a shielding
gas of 75 percent Argon and 20 percent CO2.
822
SECTION 8
b. Flux core welder Using flux core wire with
CO2 shielding gas.
2. Vertical boring mill 60 in. table.
3. Outboard end cover (Sketch 2, Fig. 828).
4. Inboard end cover (Sketch 1, Fig. 828).
5. Rotating stand, if available.
Wheel Hub Rim Seat Repair
NOTE: To protect bearing fits from distortion
due to heat caused by welding, the entire cavity
of the hub must be submerged or filled with wa-
ter.
1. Remove both inboard and outboard wheel hub
bearing outer races (cups).
2. Place the outboard cover in position, with the
cover Oring mating with bearing fit. Use eight
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 26. GE788BS, CS FRAMEHEAD. E35261.

823
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
FIG. 827. FRAMEHEAD INSERT. E28216B.
0.62511 bolts to retain the cover in place, utiliz-
ing the same holes normally used for the bearing
cap (Sketch 2, Fig. 828).
3. Turn the hub (Figs. 829 through 830) outboard
end down, and fill with water.
4. Place inboard end cover in position, with 3/8 in.
Oring, mating at face of wheel hub, and 1/8 in.
FIG. 828. WHEEL HUB AND COVERS.
E28267A.
824
SECTION 8
Oring under the heads of the 1 in.14 bolts
used to secure cover to wheel hub (Sketch 1,
Fig. 828).
5. Turn the hub so that the areas to be welded are in
a horizontal plane, to provide the best possible
welding condition.
6. With welding machine set at 320 to 370 am-
peres, use 1/4 in. E7018 electrode, weld each
fillet continuously around the circumference of
the hub until the desired weld thickness is
achieved. Remove covers.
7. Mount wheel hub on vertical boring mill. Using
dial indicators, indicate at bearing bores for par-
allelism and concentricity (0.002 in. TIR).
8. Machine per hub drawings (Figs. 829 through
830).
WHEEL HUB BEARING FITS
(Frame)
Inspect both inboard and outboard bearing fits. If the
average of three readings is below the minimum dimen-
sions of 36.622 in. (inboard) and 36.542 in. (outboard),
then restore both bearing fits as outlined below and ma-
chine them to new dimensions as indicated. This will in-
crease the bearing cone fit to 0.0140.022 in. tight.
Fig. 831 provides a frame structure machining
drawing.
NOTE: If only one bearing fit requires repair, it is
recommended that both bearing fits be re-
stored to the new dimensions.
NOTE: It must be remembered that the wheel
hub bearing seats are used as the reference for
machining all other bearing bores (planet gear
and pinion bores, etc.). Therefore, extreme care
is required in repairing the wheel hub bearing
fit.
NOTE: All welding must be performed using
1/8in. diameter electrodes E7018.
 SECTION 8

.015
25.896

825
GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 829. GE788B1, BS, CS, ES1, HS WHEEL HUB. E28631C.

GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

FIG. 830. GE788DS, ES2, FS WHEEL HUB. E35202B.

.015
24.194

826
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

SEE SHEET 2 FOR A CL FRAME STRUCTURE

BEARING BORE
MACHINING
DIMENSIONS .37516 TAP THRU
49 HOLES
.018 R
1.375 DIA. THRU
48 HOLES TOTAL
21 SPACES AT 7.5
1.257 TAP THRU (BOTH SIDES)
2 HOLES FOR H .030R.
JACKOUT
H .060R.

157.5 157.5

67.75 DIA.
B.C.

11

28.50
30.00 .25
23.98

1.50 DIA. THRU

2 HOLES
.06 R. 5.00 5.00
A
FIG.1 MAKE FROM 41E903515 G1 .37516 TAP .75 DEEP
USE .25 HIGH LETTERS TAP DRILL 1.12 DEEP
FOR STAMPING. 7.88 3 HOLES EQ. SP. ON
26.50 DIA. B.C.
.018 R
15.76 (RELATIVE TO 49 HOLES
(5 HOLES ON 3.94 CENTERS IN GEAR CASE FLANGE)
3.00 DIA. S.F. TO DIM.)

FIG. 831. FRAME MACHINING DRAWING (SHEET 1),

FLANGE AND GEAR CASE HOLE DATA. E38320A.

827
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

.37516 TAP 1.38 DEEP CL FRAME STRUCTURE

.5
TAP DRILL 1.84 DEEP
13
& .41 CBORE .70 DP.
6 HOLES ON G1 ALL WELDS PER P8GEP21 OR 41A204889.
12.88 DIA. B.C. 3.44 OIL PIPE TO BE CLEAR BEFORE WELDING OF P3.
LEAK TEST BY FILLING GEAR CASE WITH
23 REF.
A .018R DETERGENT & WATER & EXAMINING FOR
G2 LEAKS WITH AIR PRESSURE APPLIED TO
BACK OF GEAR CASE.

39 90 A
STAMP A 39
A POSITION
90

.37516 TAP 1.38 DEEP

7 TAP DRILL 1.84 DEEP
7
& .41 CBORE .70 DP.
.5013 TAP 1.00 DEEP 6 HOLES ON
TAP DRILL 1.50 DEEP 12.88 DIA. B.C.
6 HOLES ON B .018R
6.88 DIA. B.C.
D E .001
A .018R 36
A S .005R S
36

120
K 32 23_
2 15.301 R.
30
30
120 60

23
36 90
D E .001
C S .005R S

7
39
35
36
36
7
39
120
36
D E .001
7 7
B S .005R S 90
90
39
32 32
C
STAMP B
39

C POSITION

90
STAMP C
.5013 TAP 1.00 DEEP
32 32 B POSITION TAP DRILL 1.50 DEEP
6 HOLES ON
6.88 DIA. B.C.
.37516 TAP 1.38 DEEP
B .018R
TAP DRILL 1.84 DEEP .5013 TAP THRU
.5013 TAP 1.00 DEEP 6 HOLES ON
& .41 CBORE .70 DP.
TAP DRILL 1.50 DEEP 14.25 DIA. B.C.
6 HOLES ON 6 HOLES ON NOTE: FOR A LISTING OF SURFACE LOCATIONS
12.88 DIA. B.C. 6.88 DIA. B.C. K .018R SEE SHEET 8.
C .018R
C .018R

FIG. 831. FRAME MACHINING DRAWING (SHEET 2),

BEARING CAP AND SEAL HOUSING HOLE DATA. E38320A.

828
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

.010
1.240 .010
4.870 LAYOUT AND MACHINE FROM
250 SURFACE MARKED THUS
2.75 SURFACES MARKED THUS
250 TO BE FLAT WITHIN .005.
H
4.50 .12 R.
250
.06 X 45 CHAM.
.44
64.500 .000 59.00 .0008 MAX. TAPER
.005 .010 .06 X 45 DIA. IN BORE LENGTH
DIA. .560 CHAM. 3 BORES
D E .010
58.50 250
DIA. 125 F
.06 X 45 22.63
CHAM. +.015 .005
4.028 .000 LOCATION OF PLANET
3.875
.06R 50.740 .000 STAMPING ON FRAME
+.00 .005
DIA.
59.00 .13
DIA. 250
C
MACHINE IF D
NECESSARY 125
+.0014
.0000
13.74 12.2046 11.38
DIA. .50 .0016
DIA. DIA. .0000 5.25 .06 R
BRG.FIT 5.9061 DIA.
D E .0019 DIA.
125 BRG. FIT
DS ES .005 R S .25 R.
8.90 .005 4.00 125
DIA. 37.160 R. MAX.
.0009 MAX. TAPER
IN BORE LENGTH DIA.
3 BORES 17.592 .010
125
NEED NOT
CLEAN UP
.62 DIA.
HOLE
3.00

125
9.00
.002
.000
13.310
DIA.

INBOARD END

15.44
DIA.

.06 X 45
CHAM.

250 36.25
DIA.
.810 .005

26.80
8.28

.09

MACHINE THIS SURFACE NOTE: FOR A LISTING OF SURFACE LOCATIONS

FLUSH WITH SURFACE
MARKED THUS SEE SHEET 8.
WITHIN .005 2.75

SECTION AA 250

FIG. 831. FRAME MACHINING DRAWING (SHEET 3),

PLANETARY BORE MACHINING DATA. E38320A.

829
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

NOTE: FOR A LISTING OF SURFACE LOCATIONS

SEE SHEET 8.

29.38

2.20
BEGIN 1 .06 X 45
M E TAPER HERE CHAM.
2.65 250 125 125

250
E 1 TAPER
ON DIA.

+.000 +.000
32.893 .003 DIA. .004 .004
D 36.553 36.520
DIA DIA
BRG
+.000 FIT
36.632 .004
.50 DIA. HOLE REF. .75
DIA. (SEE SH. 5)
BRG FIT

+.000
.004 .004
+ .000
36.650 36.600 .000
DIA .010 33.365
DIA DIA.
D E .010
OUTBOARD END

20
36.00
125
D E .010

J 125 125
.84

6.07
7.44

27.07
250

38.232 .005

37.38
SECTION AA (contd)
250
63.538 .010

FIG. 831. FRAME MACHINING DRAWING (SHEET 4),

WHEEL HUB BEARING SEAT DATA. E38320A.

830
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

HOLE X .5013 TAP 1.00 DEEP

TAP DRILL 1.50 DEEP
16 HOLES EQ. SP. EXCEPT HOLE
LABELED X ON 52.00 DIA. B.C.
F .018R

1.0014 TAP 2.75 DEEP

TAP DRILL 3.25 DEEP
36 HOLES TOTAL ON
35.00 DIA. B.C.
E .018R

.5
13

L 4.5

4.5

4.5 L
27 EQ. SP. AT
9 = 243
5.12
REF.

17.32
4.5
4.5

17.32 F
5.12
17.75 REF. F
5

.5
3.62 13
G REF.
G
4.5

31

4.5

7 EQ. SP. AT H
9 = 63
4.5
4.5
N 1.875

H .503.00
4.5
125 .12
3.751
125 .004
.000
+.001
.500 DIA
.000
.75 DEEP 1 HOLE
(FOR TOOLING)
E .005R

.62511 TAP 1.75 DEEP

TAP DRILL 2.32 DEEP
10 HOLES ON
35.00 DIA. B.C.
E .O18R
OUTBOARD END VIEW

FIG. 831. FRAME MACHINING DRAWING (SHEET 5),

OUTBOARD END HOLE DATA. E38320A.

831
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

.104 (#37) DRILL .50 DEEP

2 HOLES FOR NAMEPLATE
.030 R

2.80 .02

1.40 .02 2.18

1.09

REF.

HORIZONTAL CL
1.38 OF FRAME

2.75 .12
REF.

ENLARGED VIEW IN
DIRECTION OF ARROW B

SEAL WELD P4 & 5

.09

4.25 R.
37.160 MIN.
DIA. REF.
18.18 R.
MAX. CL
(P4 & 5)
PLANET
BORE B 2.83
18.30 R.
MAX. (P3)
4.25 R.
MIN. (P4 & 5)
2 PLACES
.09
CL PLANET
BORE C

REDUCED SECTION CC

3.00
1.00

5.02 7.31

6.00 R.

BLEND MACHINED CONTOUR TO VIEW AT D

CAST SURFACE WITH 3.00 R MIN.
SHOWING CONTOUR REQUIRED
TO CLEAR TORQUE TUBE.
MACHINE IF REQUIRED 500

FIG. 831. FRAME MACHINING DRAWING (SHEET 6),

MISCELLANEOUS REFERENCES. E38320A.

832
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

4SLOTS
1.00 AS SHOWN
.04 R

.30
3.45

38.232
REF.
2.12 .37516 TAP THRU &
4.25 .50 DIA. CBORE.
1.00 DEEP.
13 4 HOLES
.018 R
23

23
32
32

2.12

4.25

13

SECTION EE

.375 16 TAP THRU

2 HOLES
4.25
.018 R
5.56 2.12

R.

.06 x 45

.12 X 45 4.75 1.31 2.56 RADIUS OF

CHAM. CUTTER
5.12

ENLARGED
SECTION FF

.37516 TAP THRU &

.50 DIA. CBORE 1.00 DEEP
4 HOLES
.018 R .625 DIA. THRU
4 HOLES
.018 R
RADIUS OF
CUTTER
27.00 7.00 4.5 4.5

R.
.06 x 45
4.75 1.12 .62
1.25

17.18 .62
TO C L 1.25
ENLARGED 1.81
SECTION GG
3.62

FIG. 831. FRAME MACHINING DRAWING (SHEET 7),

MISCELLANEOUS REFERENCES. E38320A.

833
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

.38 R

33.365
13
DIA. REF. .49 REF.

.00
.49 .02

1.80 .75
REF.

250
1.62 .06

ENLARGED
SECTION HH

CL VERTICAL

SECTION JJ
.375 16 TAP THRU
2 HOLES
.018 R 4.25

7.06 2.12 .333

REF.
.045R
R. .020
.06 x 45

.12 X 45 6.25 1.31 2.56

CHAM. RADIUS OF
5.12 CUTTER

4
ENLARGED
SECTION LL

ENLARGED VIEW
AT M

.250 DRILL
1.00 DEEP
1 HOLE
35.00 DIA. B.C.
.03 R
SURFACE LOCATIONS

SYMBOL DESCRIPTION/LOCATION REFERENCE DIMENSION

SHEET SHEET
A PLANETARY GEAR BORE @ A 2 3
.625R .250 N.P.T., .437 TAP
B PLANETARY GEAR BORE @ B 2 3 .03 DRILL, 1.25 DEEP,
REF.
C PLANETARY GEAR BORE @ C 2 3 .382 .250 DRILL 2.50 DEEP
D INBOARD HUB BEARING FIT 4 4 1 HOLE
2.48 .03 R
E OUTBOARD HUB BEARING FIT 4 4
F SEAL RING FIT 3 3
G OMITTED
ENLARGED
H FLANGE O.D. 3 3 SECTION NN
I OMITTED
J OMITTED
K SEAL HOUSING FIT 2 3

FIG. 831. FRAME MACHINING DRAWING (SHEET 8),

MISCELLANEOUS REFERENCES. E38320A.

834
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

Inboard Bearing Fit

Equipment Required:
Rollforming machine capable of rolling1 in. plate.
Welding machine 600 amperes ac.
Vertical boring mill 72 in. table.
Five ton crane.
1. Cut a piece of 0.75 in. thick mill stock (recom-
mend AISI 1020 for weldability) into a strip 6 in.
wide and 113.85 in. long. Bevel both ends for
weld preparation. FIG. 833. RING DIMENSIONS AFTER
MACHINING. E35737.
2. Lay out, drill and countersink nine 0.625 in. holes
along the centerline of the strip. The first hole is d. Remove the ring and turn it over on the boring
to be 6.0 in. from the end of the strip. Thereafter, mill placing the machined surface down. Ma-
each hole must be evenly spaced (Fig. 832). chine the other end until the ring measures
5.70
0.010 in. in width.
3. Form the strip into a ring having a 35.500
e. Machine a 0.06 x 45_ chamfer on the internal

0.062 in. internal diameter.
diameter.
4. Weld the ring closed. With the welding machine 6. After machining the ring, weld two 1 in. nuts, 3 in.
set at 180210 amperes, apply the first two apart as shown in Fig. 834. Then cut the ring be-
passes. Increase welding amperes to 290320 tween the nuts.
and weld the bevel groove flush with the exterior
surface of the ring. 7. Deburr the ends of the ring to remove all high
metal on the inside diameter.
5. Place the ring in a vertical boring mill and ma-
8. Place the frame structure on a vertical boring mill
chine as follows (Fig. 833):
with the gearcase down, taking proper precau-
tions to block the flange so that the gearcase is
a. Machine one end of the ring, removing ap-
not damaged.
proximately 0.120 in., or until the rough sur-
face is completely machined. 9. Position the frame to minimize the runout as
measured at the outboard hub bearing fit.
b. Machine the internal diameter of the ring to
36.0995
0.0025 in. 10. Machine the outside diameter of the frame struc-
ture at the inboard bearing fit to 36.126
0.0025
c. Machine a 0.06 x 45_ chamfer on the internal in. diameter (Fig. 835). Leave the frame set up
diameter. in the boring mill.

FIG. 832. STRIP WITH PLUG WELD HOLES. E35736.

835
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
FIG. 834. WELD TWO NUTS ONTO RING.
E34808.
11. Machine two 0.250 x 45_ chamfers on each of
the new shoulders (Fig. 835).
CAUTION: Do not torque up the nut and bolt as
excessive weld stresses could occur.
12. Heat the ring to between 500 and 600_F and po-
Outboard Bearing Fit
sition it onto the bearing fit. Install a 3/4 in. diame-
ter bolt through the 1 in. nuts and assemble a nut
to the bolt. Tighten until the ring is snugly seated.
13. While the ring is hot, weld the ring gap closed ty-
ing it to the barrel of the frame. Then, burn off the
nuts.
FIG. 835. INBOARD WHEEL HUB BEARING
FRAME MACHINING DETAILS. E34809.
836
SECTION 8
14. Weld the ring to the frame using the following se-
quence:
a. Weld the nine plug holes full.
b. Weld four 4.5 in. fillets in the inboard chamfer
of the frame, 90_ apart around the frame (Fig.
836).
c. Weld four additional 4.5 in. fillets directly op-
posite the inboard weld fillets in the outboard
chamfer of the frame (Fig. 836).
15. Hand peen all welds.
16. Machine the inboard bearing fit dimension to
36.632 +0.000/0.004 in.
17. Whenever the inside wheel hub bearing fit has
been resleeved or welded to restore the bearing
fit then the 1 degree taper on diameter should be
checked as it may also require machining to size.
Measure 32.893
0.003 in. diameter at 29.38
in. from the end of the barrel (Fig. 837).
Equipment Required:
Rollforming machine capable of rolling 1 in. plate.
Welding machine 600 amperes ac. Vertical bor-
ing mill 72 in. table. Five ton crane.
1. Cut a piece of 0.75 in. thick mill stock (recom-
mend AISI 1020 for weldability) into a strip 7 in.
wide and 113.85 in. long. Bevel both ends for
weld preparation.
2. Lay out, drill and countersink nine 0.625 in. holes
along the centerline of the strip. The first hole is
to be 6.0 in. from the end of the strip. Thereafter,
each hole must be spaced per the indicated di-
mensions (Fig. 838).
FIG. 836. WELDING RING. E35738.
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

NOTES

837
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

29.38
2.20 .06 X 45 o
BEGIN 1 o CHAM.
TAPER HERE

1 o TAPER
ON DIA.

+ .003

32.893 DIA.

+ .004
.000
33.365 DIA.

OUTBOARD END

FIG. 837. FRAME MACHINING DRAWING. E38054.

838
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

2
H

OUTBOARD END VIEW

REF. DESCRIPTION
1 FRAME STRUCTURE
2 KEY

2
1 .49 + .00 / .02

1.80
REF.

1.62 2 1
ENLARGED
SECTION HH

FIG. 837. FRAME MACHINING DRAWING. E38054.

839
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
FIG. 838. STRIP WITH PLUG WELD HOLES. E35320.
3. Form the strip into a ring having a 35.500

0.062 in. internal diameter.
4. Weld the ring closed. With the welding machine
set at 180210 amperes, apply the first two
passes. Increase welding amperes to 290320
and weld the bevel groove flush with the exterior
surface of the ring.
5. Place the ring in a vertical boring mill and ma-
chine as follows (Fig. 839):
a. Machine one end of the ring, removing ap-
proximately 0.120 in., or until the rough sur-
face is completely machined.
b. Machine the internal diameter of the ring to
36.3295
0.0025 in.
c. Machine a 0.06 x 45_ chamfer on the internal
diameter.
d. Remove the ring and turn it over on the boring
mill placing the machined surface down. Ma-
chine the other end until the ring measures
6.50
0.010 in. in width.
FIG. 839. RING DIMENSIONS AFTER
MACHINING. E35321.
840
SECTION 8
e. Machine a 0.250 x 45_ chamfer on the inter-
nal diameter.
6. Place the frame structure on a vertical boring mill
with the gearcase down, taking proper precau-
tions to block the flange so that the gearcase is
not damaged.
7. Position the frame to minimize the runout as
measured at the outboard hub bearing fit.
8. Machine the frame structure as follows (Fig.
840):
a. Machine the outboard wheel hub bearing fit to
36.3615
0.0025 in. This dimension should
extend 6.50
0.03 in. from the outboard end
of the barrel.
b. Also machine a 0.250 x 45_ chamfer on the
newly machined shoulder on the frame as
shown in Fig.840.
9. Before adding the sleeve to the frame, remove
key (2, Fig. 837), at the end of the barrel. Grind
away most of the weld holding the key to the
frame. Then cut through the remaining joint with
a hack saw. Remove the key from the frame.
10. Remove the adapters from the ends of the brake
lines at the end of the barrel.
FIG. 840. FRAME MACHINING DIMENSIONS.
E35322.
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

11. Disassemble the clamps holding the brake lines one of the plug weld holes is properly located at
to the inside of the frame. Remove the brake the bottom of the frame (Fig. 841). Hold the ring
lines from the frame and set them aside. in position and allow it to cool.

12. Thoroughly clean the prepared surfaces. The

machine surface must be completely free of 15. Weld the ring to the frame using the following se-
grease or oil film. quence (Fig. 841):

13. Using an oven, heat the ring to 120_C above am- a. Tack the ring at the inner and outer faces to
bient. hold the ring in place.
14. Assemble the hot ring onto the frame structure
with the 0.250 x 45_ chamfer up, making sure b. Weld the nine plug holes full.

FIG. 841. RING/FRAME WELDING DETAILS. E35323.

841
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

of 2.20 in. (Fig. 837). Also machine a 0.06 x 45_

chamfer, as shown.

18. Cut out the slot in the sleeve for the key (2) at the
end of the barrel as shown in Fig. 837. Then, as-
semble the key into the frame and weld it in
place.

19. Reassemble the brake lines and clamp them into

position in the frame. Reinstall the adapters to
FIG. 842. WELDING RING INBOARD FACE. the ends of the brake lines. Secure them in posi-
E35324. tion with the locking plate.

20. With the new bearing interference fit, future

c. Weld four 4.5 in. fillets in the inboard chamfer
of the frame, 90_ apart around the frame (Fig.
842).
d. Place the frame in a horizontal position and
weld four additional 4.5 in. fillets directly op-
posite the inboard weld fillets in the outboard
chamfer of the ring. Each of these fillet welds
must consist of three 1.5 in. fillet welds
located between frame bolt holes as shown in
Fig. 841.
16. Hand peen all welds.
17. After all bearing fit repair work has been com-
pleted, machine the inside diameter at the end of
the barrel to 33.365 +0.004/0.000 in. to a depth
bearing removal may be difficult and may dam-
age the bearing fit as it comes off without lubrica-
tion. On new frames, lube holes for applying lu-
bricant are provided at the factory when the
frame is machined. If the frame being repaired
does not presently have lube holes, they must be
added. If the frame being repaired does have a
lube hole, only a lube hole in the ring is needed.
Proceed as follows:
a. Place the frame in a drill press, gearcase
down. Take care to protect the gearcase.
b. Drill a 0.250 in. lube hole laterally to the speci-
fications indicated in Fig. 843.
c. Drill and tap a 0.250 in. lube hole axially to the
specifications indicated in Fig. 843.

FIG. 843. OIL APPLICATION HOLES FOR OUTBOARD WHEEL HUB BEARING REMOVAL. E35325.

842
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
FIG. 844. OUTBOARD BEARING FIT DIAMETER.
E23928.
d. On frames which already have a lube hole,
drill a 0.250 in. lube hole laterally through the
ring as indicated in Fig. 843.
e. Remove all burrs left from the drilling pro-
cess.
21. Place the frame structure on a vertical boring mill
with the gearcase down, taking proper precau-
tions to block the flange so that the gearcase is
not damaged.
22. Using dial indicators, indicate the outboard bear-
ing fit at two places (Fig. 844):
a. Just inboard of the outboard bearing fit.
b. Just outboard of the inboard bearing fit.
23. Adjust the frame until the readings on both indi-
cators are within 0.001 in. TIR. When the preced-
ing set up is obtained, indicate the inboard bear-
ing diameter. Maximum total runout must be
within 0.003 in. TIR.
FIG.847. RING MACHINING FOR OIL GROOVE. E35328.
FIG. 845. RING MACHINING FOR BEARING.
E35326.
24. Machine the outboard bearing fit dimension to
36.553 +0.000/0.004 in. The outboard bearing
bore must remain concentric to the inboard bear-
ing bore within 0.003 TIR. This dimension should
extend 6.07 in. from the outboard face of the bar-
rel (Fig. 845).
25. Machine the thrust ring fit dimension to 36.520
+0.000/0.004 in. This dimension should extend
0.740 in. from the outboard face of the barrel
(Fig. 846).
26. Add a 0.030
0.010 in. deep circumferential oil
lubrication groove as shown in Fig. 847. This
groove is necessary to the application of oil
which aids in outboard bearing removal at the
next overhaul.
FIG. 846. RING MACHINING FOR THRUST
RING. E35327.
843
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

TIRE FIT REPAIR TABLE 83. PLATES.

Bolt
This procedure describes the recommended proce- O.D. No. Of
Plate I.D. Circle
dure for repairing damaged tire rim mounting surfaces (in.) Holes
(in.)
(tire fit) on wheel hubs. Such damage can occur if tire Inner 46.800 9 44.750
clamps or wedge blocks become loosened, allowing the (P1) (11/16)
rim to slip on the hub. Hub material is thus worn away, Outer 44.500 6 43.125
reducing critical mounting surface dimensions, and (P2) (13/16)
causing a loose wheel hub/tire rim fit. Restoration of the Outer 45.140 10 43.250
hub is accomplished by building up the affected areas by (P3) (11/16)
welding new material, then machining to original dimen- NOTE:
sions. P1 is for All Models.
P2 is for Models DS, ES2, FS.
P3 is for Models B, BS, CS, ES2, HS.
Prepare The Wheel Hub
TABLE 84. RINGS.
Unless certain precautions are taken, the wheel hub
Bolt
can become distorted (warped) when heat builds up O.D. No. Of
Ring I.D. Circle
during the welding process. Therefore, to minimize any (in.) Holes
(in.)
such heat buildup, the wheel hub is filled with water
Inner 41.750 46.800 9 44.750
during the welding process. (R1) (11/16)
Outer 41.750 44.500 6 43.125
To retain water in the hub, make up two plates and (R2) (13/16)
two support rings, one each for the inboard side of the Outer 41.750 45.140 10 43.250
hub and one each for the outboard side. Support rings (R3) (11/16)
are necessary to provide additional support for the NOTE:
plates to prevent them from warping when bolted to the R1 is for All Models.
hub. R2 is for Models DS, ES2, FS.
R3 is for Models B, BS, CS, ES2, HS.
It is also suggested that a 3/4 in. or 1 in. pipe fitting be
welded to each plate to facilitate filling and draining the 4. Remove wheel hub bearings to prevent bearing
hub. damage.

Assemble Plates And Rings

Perform the following:
1. Cut out plates and rings per the Tables 83 and
84. Use 1/4 in. plate steel. Refer also to Figs.
848 and 849.
2. Tack weld the rings to their respective mating
plates. Ensure that mounting bolt holes are
aligned. Use only short welds in order to mini-
mize disruption or warping of the plates.
To prevent water leakage, it will be necessary to use
Orings between the plates and the wheel hub and un-
der bolt heads. See Figs. 848 and 849. Should the
large Orings required for the plates not be available, a
3/8 in. bead of Silicon (black, white, or clear Silmate as
used on gearcase covers) may be used. Silicon requires
at least four hours to cure and will have to be completely
removed prior to reassembly of the wheel.

Perform the following:

NOTE: In order to conserve material when
building rings, the rings may be cut into seg- 1. Place the hub inboardside up.
ments before welding to the plates.
2. Assemble 1.0 x 3/8 in. Orings to nine 1.0 14 x
3. Remove the wheel hub from the Motorized 1.0 in. mounting bolts. Loosely assemble bolts
Wheel. and inner plate to the hub.

844
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

Z .006 DIA

+ .015
24.194

28_

Z .006 DIA
A B

+.00
+.00 51.14.03 DIA.
52.75.03 DIA.

+.003
41.750
.000
DIA. +.005
+.005 41.718 .000 41.750 +.003
41.718 .000 44.50 .000
46.80 DIA. DIA.
DIA. DIA.
DIA. BRG. FIT
BRG. FIT

13/16 IN.
11/16 IN.
6 HOLES IN PLATE AND RING
9 HOLES IN PLATE AND RING

44.750 DIA. B.C. 43.125 DIA. B.C.

VIEW AT A VIEW AT B
3/8 IN. ORING
OR SILMATE

1/8 IN. ORING

1/4 IN.
PLATE

LOCATION OF O RINGS

FIG. 848. GE788DS, ES2, FS WHEEL HUB DIMENSIONS AND ORING PLACEMENT. E40851.

845
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

Z .006 DIA

.015
25.896
DO NOT PAINT

28_
250 Z .006 DIA
A
46.750 B
+.000
.030 45.140
DIA. +.000
.030
DIA.
41.750 41.718
+.003 41.718
+.005 41.750
.000 +.005 +.003
DIA. .000 .000
DIA. .000
DIA. DIA.
BRG. FIT BRG. FIT

11/16 IN. 9 HOLES EQUALLY

SPACED IN PLATE AND RING
SEE VIEW C
11/16 IN. 10 HOLES IN
PLATE AND RING AS SHOWN
IN VIEW D

43.25
DIA. B.C.
44.75 REF
DIA. B.C.
REF. VIEW AT A VIEW AT B

FIG. 849. GE788B1, BS, CS, ES1, HS WHEEL HUB DIMENSIONS AND ORING PLACEMENT. E40853.

846
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

3 HOLES EQUALLY
SPACED AT 37.5 o
15 o
7.5 o
9 HOLES EQUALLY
SPACED AT 40 o 7 HOLES EQUALLY
SPACED AT 37.5 o

344 o
C SLOT 75 o
255 o

44.75 C
L SLOT
DIA. B.C.
43.25
DIA. B.C.

15 o

10 HOLES SPACED
AS SHOWN

VIEW C
VIEW SHOWING LOCATION OF VIEW D
HOLES IN RELATION TO DRIVER
SLOT INBOARD END VIEW SHOWING LOCATION OF
HOLES IN RELATION TO DRIVE
SLOT OUTBOARD END

3/8 IN. ORING

OR SILMATE

1/8 IN. ORING

1/4 IN.
PLATE

LOCATION OF O RINGS

FIG. 849. GE788B1, BS, CS, ES1, HS WHEEL HUB DIMENSIONS AND ORING PLACEMENT. E40853.

847
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
3. Stretch a 3/8 x 44.000 in. Oring over the outside
circumference of the bolts, or apply the Silicon as
described above. Tighten bolts snugly.
4. Turn the hub over and fill it with water.
5. Assemble outboard plate (P2) in a similar man-
ner using 3/4 x 1/8 in. Orings and 3/410 x 1 in.
bolts or assemble outboard plate (P3) in a similar
manner using 1.0 x 1/8 in. O rings and 1.014 x
1 in. bolts.
6. Stretch a 3/8 x 43.000 in. Oring over the outside
circumference of the bolts, or apply the Silicon as
described above. Tighten bolts snugly.
Repair The Hub
1. Weld the rim mounting surface to make neces-
sary repairs. The available welding equipment
will determine the procedure. Use the standard
technique for the method used:
a. Hand weld using 1/4 in. E7018 electrode, or
b. MIG weld using solid wire with shielding gas
75% Argon, 25% CO2.
c. Flux core. Use flux core wire with CO2 shield-
ing gas.
2. Remove all slag and clean welds.
WARNING: When using compressed air for
cleaning purposes, an environment potentially
hazardous to personnel in the immediate area is
created. To prevent physical injury by flying de-
bris, observe all safety regulations.
3. Drain the water from the hub and remove both
plates and Orings. Blow the hub dry with com-
pressed air.
4. Set up the wheel hub in a boring mill or large lathe
and machine the rim mounting surfaces. All ma-
chining dimensions are referenced to the hub
bearing fits. Maximum allowable runout on all
surfaces is 0.003 in. Refer to Figs. 848 and
849.
5. Remove all machining burrs and round over all
edges.
848
SECTION 8
6. If Silicon was used to seal the plates, remove all
traces completely.
7. Remove the hub from the machine.
8. Paint the hub as necessary.
NOTE: Do not paint tire rim mounting surfaces;
instead, cover them with rust inhibitor.
BOLT HOLE REPAIR
NOTE: This procedure is recommended for ap-
proved service shops only.
If one or more 1 in.14 bolt holes in the end of the
frame are found to have damaged threads, the following
repair procedure is to be used:
1. With the wheel completely disassembled, set up
the frame in a vertical press or horizontal boring
mill.
2. Align the hole(s) to be repaired and tap drill
1.1719 in. diameter to a depth of 3.25 in. maxi-
mum.
3. Follow Step 2 with a 1.25 in. 12 tap to a depth
of 3.0 in. minimum. Bottom tap if necessary.
4. Insert a 1.25 in. 12 X 3.0 in. long low carbon
steel plug in the hole(s) to be repaired. To do this,
tack weld a hex stock rod to the plug and turn the
plug into place. Make sure the plug is firmly
seated against the end threads.
NOTE: A special plug with a breadoff head
may be used, as shown in Fig. 850. If this is
used, tighten plug until the head breaks off.
5. Break off the hex stock rod (or plug head) and
prickpunch the threads in four places to lock the
plug in place.
FIG. 850. PLUG FOR BOLT HOLE REPAIR.
E35329.
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
6. MIG weld the top of the plug to the inside of the
hole and fill the hole flush with the end of the
frame with weld metal.
7. Grind the welded surface smooth and even with
the end of the frame.
8. Machine a 1.0 in. 14 hole to replace the re-
paired hole area as follows:
a. Tap drill 3.25 in. deep, maximum.
b. Tap to a depth of 2.75 in. minimum.
NOTE: This process describes the only accept-
able method of repairing these holes. Any
method not employing a solid plug is not per-
missible.
WHEEL HUB TIRE RIM STUD
REPAIR
This procedure applies only to those GE788 Motor-
ized Wheels having the following stiff wheel hubs:
1. 41D735080 (36 X 51 Tire Size)
2. 41D735373 (37 X 57 Tire Size)
When studs used to tighten tirerim wedges become
damaged, the only approved repair method is to drill a
clearance hole through the stud hole in the wheel hub. A
new stud is then inserted into the clearance hole and
welded in place.
The only other option is to replace the wheel hub.
NOTE: It is not recommended that this repair be
made on adjacent tirerim stud holes. If adja-
cent tirerim stud holes are in need of repair, all
24 holes should be done.
1. After locating a stud hole with damaged threads,
attempt to repair the threads by retapping.
2. If the retapping procedure is unsuccessful, re-
move the wheel hub from the frame and com-
pletely remove all bearing races, etc.
3. Set the hub in a vertical drill press to machine out
the damaged hole.
4. Using a 1.000 in. drill, drill out the damaged hole.
Drill completely through the wheel hub flange.
5. Using a 1.010 in. reamer, finish the holes to size.
6. Remove all sharp edges from the finished holes.
7. Insert a new stud (Fig. 851). This may require
pressing in place due to the straightness of the
hole and the stud. Insert the stud far enough to
allow 1.5 in. of thread to extend from the inboard
side of the flange.
8. Assemble a nut to the stud and run it up to the
inboard face of the wheel hub flange.
9. Press the stud/nut assembly tight against the in-
board face of the wheel hub flange.
10. TIG weld the interface between the nut and the
stud in one location. Refer to Fig. 852.
11. MIG weld the nut to the frame in three locations.
12. Repeat Steps 1 through 11 for all damaged stud
holes.
1.50
8.90 A
+ .002
1.000 DIA.
2.0 2.0
1.014 THREADS
BOTH ENDS
MATERIAL:
AISI 4140 OR 4340; HEAT TREAT TO 300350 BHN
NOTE:
1.50 DIMENSION IS THE INBOARD EXTENSION
8.90 IS THE SECTION IN THE WIDTH OF THE HUB
A IS A DIMENSION TO BE DETERMINED BY THE
MODIFICATION SHOP TO SATISFY THE DESIGN
OF THE WEDGE BLOCKS TO BE USED ON THAT
PARTICULAR WHEEL.
FIG. 851. STUD SPECIFICATIONS. E38397.
849
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

8.90 A DIM.

DRILL AND REAM HUB

TO 1.010 DIAMETER

WELD

NOTE:
WELD NUT TO HUB IN THREE PLACES.
WELD NUT TO STUD ONE PLACE AS SHOWN.

FIG. 852. ASSEMBLED STUDNUT MODIFICATION. E38398.

850
SECTION 8 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
Replacing A New Stud
If a new stud eventually becomes damaged and
must be replaced, use the following procedure:
1. Remove the wheel rim and all hardware.
2. Grind off the welds between the nut and the in-
board face of the wheel hub flange.
3. Lightly tap the stud toward the inboard section of
the hub (approximately 0.25 in.)
4. Cut off the nut, then remove any rough edges.
CAUTION: Do not attempt to press a damaged
stud through the wheel hub flange toward the in-
terior of the wheel hub. This can cause irrepara-
ble damage to the hole in the hub and distortion
of the bearing fit.
5. Press the stud out of the hub from the inboard
end of the hub. This will require a smooth drift
tool to prevent damage to the drilled hole.
6. Proceed to install a new stud using the proce-
dure outlined above.
NOTES
CHECKING BEARING CAPS
AND HOUSINGS
GE788DS2, FS3, FS4 and HS4 Motorized Wheels
built before April 1992 do not have the latest armature
pinionend bearing caps and housings. These wheels
built after April 1992 will have the new bearing caps and
housings installed at the factory.
Inspect the bearing caps and housings when these
wheels are in the shop for overhaul. The work involves
inspecting for a groove and four drain holes in the bear-
ing cap, and checking a dimension on the bearing hous-
ing. Refer to Fig. 853 for dimensional details. If the
groove and drain holes are present, and the bearing
housing checks OK, no action is needed. If not, contact
your local OEM or GE representative to obtain the ap-
propriate modification instructions.
FINAL INSPECTION
All of the major components should be inspected
prior to reassembly to determine if excessive wear has
occurred in service.
851
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 8

BEARING HOUSING
250
6.880 .000
+.010
NEW DIA. 6.880
OLD DIA. 6.780
.25 + .01 DIA.
THRU
4 HOLES EQ. SP.

.28

250

.125 250

6.910 +.010 250

.000
DIA. .31

BEARING CAP

FIG. 853. NEW BEARING CAP AND HOUSING DIMENSIONAL DETAILS. E40850.

852
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
SECTION 9. ASSEMBLY OF MAJOR COMPONENTS
CONTENTS
Page
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
FRAME STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . 91
PLANET GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
GEAREND BEARINGS . . . . . . . . . . . . . . . . . . . . 91
PINIONEND BEARINGS . . . . . . . . . . . . . . . . . . 96
SEAL RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
TORQUE TUBE/FLINGER . . . . . . . . . . . . . . . . . . . 96
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
MAGNET FRAME/ARMATURE . . . . . . . . . . . . . . . 97
MAGNET FRAME . . . . . . . . . . . . . . . . . . . . . . . . . 97
COMMUTATOREND ARMATURE
BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 926
PINIONEND ARMATURE BEARING . . . . . . . 927
ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 928
SUN PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 929
SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 929
OUTBOARD BEARING SEAL RING . . . . . . . . . 929
THRUST RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 929
SCOPE
This section deals with the assembly of major com-
ponents of the GE788 Motorized Wheel. These steps
must be accomplished prior to the buildup of the wheel.
In cases where a long period of time may elapse be-
tween the assembly of components and their installa-
tion onto the frame structure, precautions must be taken
to prevent rusting and contamination of bearings,
grease and exposed machine surfaces.
Keep bearing sets together. To mix bearing compo-
nents invites future problems. When inner and outer
bearing races are assembled at different operations, the
bearing manufacturer should be identified on the as-
sembly.
Do not use copper bars for seating bearings. Copper
chips get into the bearing which may cause bearing fail-
ures.
FRAME STRUCTURE
1. Assemble brake lines and fittings to the inside of
the frame structure. Refer to Fig. 91. Tape
brake lines together with 0.010 glass tape and
coat with Glyptal. Tape at location shown.
2. Assemble speed sensor cable to the inside of the
frame structure.
3. Assemble cables (17,18) to inside of the frame
structure.
4. Test both brake lines and speed sensor cable per
instructions in SECTION 11.
5. Clamp cables securely using insulation pads to
obtain a tight fit.
6. Assemble thermal sensor cable to the inside of
the frame structure.
PLANET GEARS
GEAREND BEARINGS
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
NOTE: Ensure that the oil baffle (70) in the bore
of each planet gear is in place and in good con-
dition.
1. Place the planet gear (79 or 104) on a flat surface
with the pinion end up. Check all teeth for upsets,
use a honing stone if necessary. Clean all bear-
ing surfaces with a noncaustic cleaner.
2. Place gearend bearing cap (76) over the shaft
with the flange down.
3. Heat the inner race of bearing (77) to 100_C
(212_F). Install onto the shaft bearing fit, tight
against the bearing shoulder. (Oven or hot oil
bath must be used.) When cool, seat the inner
race with a soft steel bar and a mallet.
4. Heat sleeve (87) to 250_C (480_F). Install the
hot sleeve onto its fit on the shaft, tight against
the bearing. When cool, seat sleeve with a soft
steel bar and a mallet.
5. After all components have cooled, check shoul-
der fits with a 0.001 in. feeler gauge to assure
tightness.
91
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

STAMP TERMINALS WITH

PROPER IDENTIFICATION
(S,SS,SX,SSX) TO CORRESPOND 26
WITH STAMPING ON OPPOSITE
END OF CABLE ASSEMBLIES 24

E 27,28

SSX 32
17 18
SX B
48
45 E 1,47
SS

19 S
D
C B
15
27,28 C
15
25
46 46
D

38

1,47

36,
49

2,
3,
4,
5

SECTION BB
(TYPICAL4 BRAKE LINES)

FIG. 91. SPEED SENSOR CABLE, THERMAL SENSOR CABLE AND BRAKE LINE ASSEMBLY. E28522C.

92
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

1,47

STAMP CONNECTING STRAP

ON THIS SIDE. .12 HIGH
SX NEARSIDE
SSX FARSIDE
J 34 K
24 21

22 34
J 32 K 23 .75
STAMP CONNECTING STRAP
ON THIS SIDE. .12 HIGH
S NEARSIDE
SS FARSIDE
TIE 4 BRAKE LINES TOGETHER
WITH P20 IN THIS AREA. PAINT 2
P20 WITH 2 COATS OF P29. 3 36,49
A
8,9

16 7
14 16 7 8, 4
9 5 END OF P45

19
2.00

38
6.00
46 15.00
45
ASSEMBLE HOSE WITH
SLACK AS SHOWN LAY CABLES AND TUBING
THRU SLOT IN KEY. CHECK
FOR CORRECT LENGTHS OF
CABLES BEFORE ASM. MOTOR.
LENGTH OF CABLE
NECESSARY TO REACH
THERMAL SENSOR CABLE
LENGTH OF CABLE
NECESSARY TO REACH
SPEED SENSOR CABLE

25
27,28 1,
47
L 34 F
34
21

23 .75
L 22 17 F
17 34
45
19,38

SECTION CC

FIG. 91. SPEED SENSOR CABLE, THERMAL SENSOR CABLE AND BRAKE LINE ASSEMBLY. E28522C.

93
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

9, 23, 21
35 34

1,47
9,35
2
3
4 17 21 1,47
16
5
23,34
G 15
G

16
45

17
21 SECTION DD
TYPICAL 2 PLACES

VIEW AT A
39 24 9,35

23 34 CENTER P34
ENLARGED UNDER BRACKET
SECTION FF
BRAKE ADAPTER
32 RING
1, .50 1 55
47

27,28

18 26
ENLARGED 7 2,
SECTION EE 36,
8, 3, 49 55 8, 4 3
2
9 4, 7 9 5 .12 .25
40,54 5 ENLARGED .12 .25
41,42 SECTION GG 34
17
42,43

40,54
ASSEMBLE P48 SO THAT THREADED 8, 34
48 PORTION FACES OUTWARD AS SHOWN 22
9 CENTER P34
FILL WITH P44 UNDER BRACKET
24 22 24 ENLARGED
41,42 40,54 SECTION LL
21
24 23 24

2,3,4,5
1,47 9,
8, 35 34
9 34 32 CENTER P34
32
ENLARGED ENLARGED ENLARGED UNDER BRACKET
VIEW AT H SECTION JJ SECTION KK

FIG. 91. SPEED SENSOR CABLE, THERMAL SENSOR CABLE AND BRAKE LINE ASSEMBLY. E28522C.

94
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

REF. DESCRIPTION
1 FRAME STRUCTURE
2 BRAKE LINE
3 BRAKE LINE
4 BRAKE LINE
5 BRAKE LINE
7 CLAMP
8 BOLT 3/816 X 3/4
9 LOCKWASHER 3/8
14 HOSE
15 HOSE
16 HOSE CLAMP
17 CABLE/STRAP
18 CLAMP
20 TIE
21 CLEAT
22 CLAMP
23 BRACKET
24 CABLE/CONNECTOR
25 CLAMP
26 SLEEVE
27 BOLT 1/213 X 1 1/4
28 WASHER 1/2 NARROW
29 VARNISH
32 CABLE/CONNECTOR
34 INSULATION
35 BOLT 3/816 X 1 IN.
36 ADAPTER
38 CABLE
39 PAD
40 CLAMP
41 BOLT
42 WASHER 1/4 REGULAR
43 STOP NUT
44 SEALER NO. 1473 SILMATE 497A806P60
45 TUBING
46 TIE WRAP
47 FRAME STRUCTURE
48 SWIVEL ELBOW
49 ADAPTER
55 LOCKING PLATE

FIG. 91. SPEED SENSOR CABLE, THERMAL SENSOR CABLE AND BRAKE LINE ASSEMBLY. E28522C.

95
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
PINIONEND BEARINGS
CAUTION: Be careful not to mix parts of each
fivepiece bearing set.
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Place the bearing cap (95) onto the shaft with the
flange end down.
2. Install sleeve (82) chamfered end down.
3. Place bearing outer race onto gear shaft with the
thick end down. Do not assemble other outer
race and spacer.
4. Heat the pinion bearing (two inner races) (13) to
100_C (212_F). Ensure bearing orientation is as
shown in Fig. 1023. Assemble hot bearing
races onto their fit on the shaft, tight against the
bearing shoulder and each other. When cool,
seat the bearing with a soft steel bar and a mallet.
5. Check shoulder fits with a 0.001 in. feeler gauge
when components have cooled.
6. Assemble bearing nut (15) and lockwasher (14)
to the end of the shaft. Tighten nut. Bend tab of
lockwasher into slot in nut (15).
7. Coat rollers and races with gearcase oil.
8. Install bearing cup and spacer into the frame
structure bearing fit. Tap cup into place with a
soft steel bar and a mallet.
SEAL RING
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Fill 16 grease holes with grease (see SECTION
1, DATA for grease type).
96
SECTION 9
2. Install and tighten 16 pipe plugs (4) into holes.
3. To install a new oil seal (7), heat seal ring to
100_C (212_F). Inspect seal, metal case and
spring to ensure it is held by all retaining fingers.
TORQUE TUBE/FLINGER
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Position torque tube with ring gear up.
2. Apply a bead of sealer (497A806P33) to the bot-
tom of the torque tube groove.
NOTE: If flinger packing (6) is not installed, re-
fer to page 84 for packing installation proce-
dure.
3. Assemble flinger (8) to the torque tube (11) as
follows:
a. Heat flinger to 200_C (392_F).
b. Assemble hot flinger to the torque tube; en-
sure that flinger is tight against its shoulder fit.
4. Assemble clamps (10) to the flinger with 36 bolts
(9) and 144 cup washers. Use four washers per
bolt and install per Fig. 92. Torque bolts to
5560 lb.ft.
5. Turn the torque tube over, placing the ring gear
down.
6. Install two seals (18) and the paddle pump (97)
as follows:
NOTE: Seals and pump can be tapped into
place or cooled to approximately 2_C (35_F)
and then installed. Check that each seal is tight
against its shoulder and lips are correctly ori-
ented after installation.
a. Apply a 0.06 in. bead of 497A806P33 sealer
at the first seal seat on the ID of the torque
tube.
b. Install the first seal (18).
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
FIG. 92. FLINGER CLAMP ASSEMBLY DETAILS.
E28944.
c. Install the paddle pump (97).
d. Apply a 0.06 in. bead of 497A806P33 sealer
at the second seal seat on the ID of the torque
tube.
e. Install the second seal (18).
WHEEL HUB
NOTE: Refer to Fig. 1023, Longitudinal Sec-
tion drawing for latest production models, un-
less otherwise noted. Figs. 1019 through
1022 provide similar views for older models.
1. Place the wheel hub flat on blocking with the in-
board end up. Clean the bearing bore with a non-
caustic cleaner. Check to see that the locating
pin is in place and oriented correctly.
2. Insert the inboard bearing cup. It may have to be
slightly cooled (approximately 2_C (35_F)) using
dry ice or a cooler or the wheel hub heated in an
oven to approximately 100_C. Ensure that the
cup is solidly seated against its bearing shoulder.
Check with a 0.001 in. feeler gauge.
3. Pack grease in the inboard bearing cavity of the
wheel hub (approximately 102 oz.). See SEC-
TION 1, DATA for the grease type.
NOTE: If hub is not to be assembled immediate-
ly, defer applying grease to prevent contamina-
tion during storage.
4. Turn the wheel hub over and set it on a clean sur-
face. Clean the outboard bearing bore with a
noncaustic cleaner. Check the bearing bore and
shoulder for imperfections. Correct as neces-
sary with light filing.
5. Insert the outboard bearing cup. It will either
have to be driven or slightly cooled (approxi-
mately 2_C (35_F)) using dry ice or a cooler. En-
sure that the cup is solidly seated against its
bearing shoulder. Check with a 0.001 in. feeler
gauge.
6. Pack grease in the outboard bearing cavity of the
wheel hub (approximately 102 oz.).
MAGNET FRAME/ARMATURE
(Figs. 93 through 96)
MAGNET FRAME
1. Place the magnet frame in a horizontal position
for installing exciting and commutating coil and
pole assemblies.
2. Install each coil in its proper location within the
magnet frame, one at a time, keeping in mind
that a lifting device is required because of the
weight involved.
3. Coat bolt threads, bolt heads and washers with
graphite and oil. Assemble and torque bolts and
washers to torque values listed in SECTION 1,
DATA.
NOTE: Each coil assembly is installed in the
bottom or 6 oclock position of the magnet
frame. This requires that the frame be turned af-
ter each coil assembly is installed.
97
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

CAUTION: Do not allow connection straps to 6. Attach S, SS, A and AA cables and the two
contact the frame or any other connection straps. brushholder connection cables to the proper coil
Such contact points are grounds or shorts. Main- terminals by brazing.
tain at least a 0.25 in. minimum clearance.
CAUTION: Do not exceed torque recommenda-
tions of bolts.
4. Braze connection straps in place per the appro- 7. Check that poles are seated against the frame by
priate drawing (Figs. 97 through 99) and insu- measuring pole bore diameters. Refer to SEC-
late the connections per the appropriate drawing TION 1, DATA for dimensions. If measurements
(Figs. 910 through 913). are too low, reheat coils to 125135_C
(257275_F) and retorque bolts.

8. Install all fiberglass air deflectors.

5. Hot draw the field coils and retorque. See the
note on the appropriate drawing (Figs. 910 9. Perform highpotential and impedance tests.
through 913). Refer to SECTION 11.

NOTES

98
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FIG. 93. GE788B, BS, CS MAGNET FRAME ASSEMBLY. E28250D.

99
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

REF. DESCRIPTION
1 ARMATURE ASSEMBLY
2 COILED FRAME
3 BOLT, 1/213 X 1 1/2
4 HARDENED WASHER 1/2
6 CARBON BRUSH
10 BOLT GRADE 8, 5/811 X 1 1/2
11 HARDENED WASHER, 5/8
12 AIR BAFFLE
13 AIR BAFFLE WITH CUTOUT
14 BOLT, 3/816 X 3/4
15 LOCKWASHER, 3/8
16 BRUSHHOLDER ASSEMBLY
13 19 BAFFLE ASSEMBLY
20 ARMATURE ASSEMBLY
21 BEARING ASSEMBLY CE
22 BEARING ASSEMBLY DE
12 23 BEARING ASSEMBLY DE
24 BEARING ASSEMBLY DE

TAPER ON DIA.

REDUCED 18.33
VIEW AT A

3
4
AIR
TORQUE P3 TO .197 GAP
58 2 LB.FT. (EXC)

SPLINE 8/16 D.P. ARMATURE C

L
35 TEETH 19.25 DIA.
22
1

7.75

5.50 6.50 6.031

DIA. DIA. DIA.
C ARMATURE SHAFT
L
8.8583DIA.

5.9055 DIA.

4.500
225 MM

DIA.
150 MM

1.378 14.905
35MM
38.140
58.71

FIG. 94. GE788DS1, ES2, FS, HS MAGNET FRAME ASSEMBLY. E35210C.

910
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

G2 SAME AS G1 EXCEPT
DIFFERENT P.E. BRG. ASM.

20
G3 SAME AS G2 EXCEPT
DIFFERENT P.E. BRG. ASM.
24 23

13
19 12
2
22.60 1.50

17.45 2.70
C
L OF B.H.

36.62 DIA.

33.365 DIA.
TORQUE P10 TO
30.440
DIA. 170
10 LB.FT.
14 15
11 10
AIR AIR
.205 GAP .360 GAP ELECT.
MECH. (COMM.)

6
L ARMATURE
C 3 CARBON BRUSHES
.75X2.25
16.625
DIA. 16 21

SPLINE 8/16 D.P.

7.75 35 TEETH

6.00 5.625
DIA. DIA.
4.938DIA.
9.0551DIA.

DIA.
5.1181 DIA.
230MM

130MM

G1
4.500

1.5748
40MM

FIG. 94. GE788DS1, ES2, FS, HS MAGNET FRAME ASSEMBLY. E35210C.

911
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

REF. DESCRIPTION
1 ARMATURE AND BEARING
2 COILED FRAME
3 BOLT, 1/213 X 1 1/2
4 HARDENED WASHER 1/2
5 BAFFLE ASSEMBL
6 CARBON BRUSH
7 AIR BAFFLE
8 BOLT, 3/816 X 3/4
9 LOCKWASHER
10 BOLT, GRD8 5/811 X 1 1/2
11 HARDENED WASHER, 5/8
12 AIR BAFFLE
7 13 BRUSHHOLDER ASSEMBLY

12

1 IN. TAPER ON DIA.

REDUCED 18.33
VIEW AT A

3
4
TORQUE P3 TO AIR
58
2 LB.FT. .197 GAP
(EXC)

SPLINE 8/16 D.P.

35 TEETH 19.25 DIA.

7.75

5.50 6.50 6.031

DIA. DIA. DIA.
ARMATURE SHAFT C
L
4.500
8.8583 DIA.

5.9055 DIA.

DIA. G1
150 MM
225 MM

1.378 14.905
35MM
38.140
58.71

FIG. 95. GE788DS2, ES1 MAGNET FRAME ASSEMBLY. E37728B.

912
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

7
5 12
2
22.60 1.50

17.45 2.70
C
L OF B.H.

36.62 DIA.

33.365 DIA.
TORQUE P10 TO
170
10 LB.FT.
30.440
9 8
DIA. 11 10

AIR 6 3 CARBON BRUSHES

.200 GAP .75X2.25
(COMM.)
A

L ARMATURE
C 13
16.625
DIA.

SPLINE 8/16 D.P.

35 TEETH
7.75
9.0551 DIA.

6.00 5.625
DIA. DIA.
4.938 DIA.
230MM

5.1181 DIA.

4.500DIA.
130MM

1.5748
40MM

FIG. 95. GE788DS2, ES1 MAGNET FRAME ASSEMBLY. E37728B.

913
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

PAINT END OF COMM. BARS & NOTE:

SPACE BETWEEN BARS & COMMUTATOR SURFACE SHALL MEET THE
TEFLON BAND WITH ONE COAT FOLLOWING:
OF VARNISH (P15) AFTER A) TOTAL INDICATED READ OUT WITH
REMOVING EXCESS RESIN
RESPECT TO THE AXIS CREATED BY THE
DO NOT PAINT THIS COMM. END & PINION END BEARING FITS
SURFACE UNTIL ALL NOTE FOR SPIRAL GROOVES:
SHALL NOT EXCEED 0.001 INCH
COMM. SEASONING HAS PITCH3 PER INCH. MAX. WIDTH 0.075 IN.
BEEN COMPLETED REMOVE ALL BURRS & SHARP EDGES B) VARIATION OF RADIAL HEIGHT OF
FROM GROOVES & BETWEEN ADJACENT BARS SHALL NOT EXCEED
BARS AFTER GROOVING 0.0001 INCH
C) WAVES OR LOBES, IF PRESENT, SHALL
NOT EXCEED 0.0004 INCH IN 20 BARS
MACHINE COMM. TO THESE MICA THK.=.060
DIMS. AFTER ARMATURE UNDER CUT=.046
IS WOUND 15.38
REF
+.02
9.87 .69
9, 20
10
6
REF .094
2.15
32 #

.046 250
.125
7 16.62 DIA. NEW +.015
15.62 DIA. MAX. WEAR LIMIT
13
A

19
10.12 DIA.

BREAK SHARP EDGES

TO TIGHTEN COMM. PRESS

AT THIS DIA. 80 TONS
AND TORQUE BOLTS TO
110 LB.FT. USING P21 SEAT COMM. WHILE PRESSING
OR APPROVED 90 TONS HERE
EQUIVALENT.
NOTE:
2. DYNAMIC BALANCE COMPLETE ARMATURE MAX. RESIDUAL IMBALANCE AT P.E. MUST
NOT EXCEED 17 GRAMS. MAX. IMBALANCE AT C.E. MUST NOT EXCEED 13 GRAMS.

.12
CLAMP P13 TO OUTSIDE
FLANGE & WELD AS
INDICATED

13
.20 LG. WELD HERE WITH P16
AFTER ALL SPINNING IS COMPLETED
& CAPSCREWS HAVE BEEN CHECK
TIGHTENED
VIEW A

FIG. 96. ARMATURE ASSEMBLY. E41203A.

914
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

20 FIRST 7 PUNCHINGS
EACH END

4 ASSEMBLE CONCAVE
SIDE FACING PUNCHINGS

5 9,
6 10

14
WELD P14 TO P3

3 .12

11,12 2

REF. DESCRIPTION
1 CORE ASSEMBLY
2 ARMATURE SHAFT
3 ARMATURE HEAD
4 END PUNCHING, FULL
5 MAIN PUNCHING
6 STEP PUNCHING
7 COMMUTATOR B, 16.62 DIA.
8 END PUNCHING, CUT BACK
10 ARMATURE INSULATION
11 COLLAR
12 COLLAR
13 BALANCE WEIGHT
14 BALANCE WEIGHT
15 VARNISH
17 TAPE
18 VARNISH
19 COLLAR
20 STEP PUNCHING
21 MOLYKOTE GN PASTE

FIG. 96. ARMATURE ASSEMBLY. E41203A.

915
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

FIG. 97. GE788B1 FIELD COIL CONNECTION

DIAGRAM. E28251A. FIG. 98. GE788BS1, BS3, BS4, CS, DS, ES, FS,
HS FIELD COIL CONNECTION DIAGRAM.
E28525A.

NOTES

916
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

SX SSX
SS
S

O
I
O

N
#1 #46
S I

O I #1
#2 #184
N AA
#22 O
A

#23 S I
EVERY BAR
EQUALIZED
I
#12
S

O N
#92 #94
#93 I O

S
I
N
I
O
O

COMMUTATOR END

FIG. 99. GE788BS2 FIELD COIL CONNECTION DIAGRAM. E38394.

917
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

918
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

NOTES

919
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

G1 APPLY P24 AT ALL BRAZED

CONNECTIONS. (18 TOTAL).
16 STAMP SX TAPE WITH 2 TAPINGS 1/2 LAPPED
6, OF P25 AND 1 TAPING 1/2 LAPPED
1 2 10 7 OF P26 THEN BRUSH WITH P27.
5
8
A
19 17 STAMP SS
17 STAMP S
18 STAMP SSX

15

19

P9BEP1
11 23
.06 TYP. ALL
20 4 TERMINALS
28,
29
3
2 12
16.625 DIA.
COMM.
19

14

22

9
19

19 TIE CABLE
TO STAPLE
21 13

19
COMMUTATOR END VIEW
LUBRICATE BOLTS
TORQUE TABLE
PT. NO. SIZE TORQUE, LB. FT. STAMP TERMINALS
6, 14 0.8759 293326 ON THIS SIDE
15 0.8759 215240 AS SHOWN VIEW A

NOTE:
HOT DRAW FIELD COILS, AFTER ASSEMBLY AND CONNECTIONS
ARE COMPLETED, AT 1200 AMPS UNTIL COIL TEMPERATURE
REACHES 100 oC. THEN RETORQUE BOLTS TO SPECIFIED VALUES.

FIG. 911. GE788BS2 FIELD COIL ASSEMBLY DIAGRAM. E38395A.

920
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

REF. DESCRIPTION
1 MAGNET FRAME
2 POLE AND COIL ASSEMBLY (EXCITING)
3 POLE AND COIL ASSEMBLY (COMMUTATING)
4 BRUSH HOLDER ASSEMBLY
5 BRUSH HOLDER SUPPORT
6 BOLT, 0.8759 X 2.75
7 LOCKWASHER, 0.875
8 CONNECTION STRAP
9 CONNECTION STRAP
10 CONNECTION STRAP
11 CONNECTION STRAP
12 CONNECTION STRAP
13 CONNECTION STRAP
14 BOLT, (EXCITING POLE) 0.8759 X 5.00
15 BOLT, (COMMUTATING POLE) 0.8759 X 2.25
16 CABLE
17 CABLE
18 CABLE
19 CABLE TIE
20 CABLE
21 CABLE
22 CABLE ASSEMBLY
23 BRAZING STRIP
24 FILLER
25 FIRST TAPING
26 SECOND TAPING
27 VARNISH
28 BOLT, (BRUSH HOLDER) 0.43814 X 1.00
29 WASHER, 0.438 NARROW

FIG. 911. GE788BS2 FIELD COIL ASSEMBLY DIAGRAM. E38395A.

921
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

TIE CABLE
19 TO STAPLE

STAMP TERMINALS
STAMP SX ON THIS SIDE VIEW A
16 6 AS SHOWN
1 2 7
5
A
19 17 STAMP SS
STAMP S 17 18 STAMP SSX
15
12
19
11
P9BEP1
23 31
.06 TYP.
9 4 28 ALL TERMINALS
3 29
2 3
16.625
DIA
COMM

14
3
30
2
22
21
19
13

12

8 19
2
NOTE;
COMM. END VIEW HOT DRAW FIELD COILS, AFTER ASSEMBLY
AND CONNECTIONS ARE COMPLETED, EXCITING
COILS AT 400 AMPS AND COMMUTATING
APPLY P24 AT ALL BRAZED COILS AT 1200 AMPS UNTIL COIL TEMPERATURE
CONNECTIONS. (18 TOTAL). REACHES 100_C. THEN RETORQUE BOLTS TO
TAPE WITH 2 TAPINGS 1/2 LAPPED OF SPECIFIED VALUES.
P25 & 1 TAPING 1/2 LAPPED OF P26
THEN BRUSH WITH P27.

LUBRICATE BOLTS
TORQUE TABLE
PT. NO. SIZE TORQUE, LB.FT.
6, 14 .8759 293326
15 .8759 215240

FIG. 912. GE788BS1, BS3, BS4, CS FIELD COIL ASSEMBLY DIAGRAM. E38396A.

922
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

REF. DESCRIPTION
1 MAGNET FRAME
2 GE788 POLE
3 COMMUTATOR/COIL POLE
4 BRUSH HOLDER ASSEMBLY
5 BRUSH HOLDER SUPPORT
6 BOLT, 7/89 X 2 3/4
7 LOCKWASHER, 7/8
8 CONNECTION STRAP
9 CONNECTION STRAP
11 CONNECTION STRAP
12 CONNECTION STRAP
13 CONNECTION STRAP
14 BOLT, 7/89 X 5.00
15 BOLT, NON MAGNETIC, 7/89 X 2 1/4
16 CABLE
17 CABLE
18 CABLE
19 CABLE TIE
21 CABLE ASSEMBLY
22 CABLE ASSEMBLY
23 BRAZING STRIP
24 PUTTY
25 FIRST TAPE
26 SECOND TAPE
27 VARNISH
28 BOLT, 7/1614 X 1.00
29 WASHER
30 COMMUTATOR/COIL POLE
31 BRAZING ROD

FIG. 912. GE788BS1, BS3, BS4, CS FIELD COIL ASSEMBLY DIAGRAM. E38396A.

923
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

G1 APPLY P24 AT ALL BRAZED JOINTS (16 TOTAL)

TAPE WITH 2 TAPINGS 1/2 LAPPED OF P25 AND
1 TAPING 1/2 LAPPED OF P26. THEN BRUSH
WITH ONE COAT OF P27.
CEMENT P39 IN 39
PLACE WITH P40
BRAZE P17 CABLE TO EXCITING COIL SO THAT
CABLE IS DRESSED TO THE COMMUTATING
SIDE OF CONNECTION STRAPS (P8 AND P11)
PINION END VIEW SHOWING
LOCATION OF P39
STAMP TERMINALS ON STAMP SX
THIS SIDE AS SHOWN 16 2
9
10

D 30 30

15 15
C

21
35
1
36 19
11 19
8 17 STAMP SS
3
19 3
2
2
17 STAMP S
13 8
12

14
19 14

36
30
SEE 10
NOTE 9 30

19
18 12
.12
MIN. 35

.12
B

15

3 31,32,34
15

13
9
NOTE FOR P30:
2 14 18 MINIMUM GAP BETWEEN AIR DEFLECTORS
STAMP SSX P30 AND COILS. ASSEMBLE P30 TOWARD
22,23 10
ALL TERMINALS P3 AND P13 TO ACHIEVE MAXIMUM AIR
VIEW OF COIL CONNECTIONS GAP WITH P2.
FROM COMMUTATOR END

FIG. 913. GE788DS, ES, FS, HS FIELD COIL ASSEMBLY. E35203C.

924
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

12

21 BRAZE P21 TO COMMUTATING COIL

SO THAT P21 IS PARALLEL TO C
L OF COIL
(AS SHOWN)
13
VIEW AT C

VIEW AT B

TORQUE TABLE
PT. NO. SIZE TORQUE, LB. FT.
6,14 .8759 293326
15 .8759 215240 3

NOTE;
HOT DRAW FIELD COILS, AFTER ASSEMBLY
AND CONNECTIONS ARE COMPLETED, EXCITING
COILS AT 400 AMPS AND COMMUTATING
COILS AT 1200 AMPS UNTIL COIL TEMPERATURE
REACHES 100_C. THEN RETORQUE BOLTS TO
SPECIFIED VALUES.
10

17

11

2
COMMUTATOR END
VIEW AT D

FIG. 913. GE788DS, ES, FS, HS FIELD COIL ASSEMBLY. E35203C.

925
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

6,
7
5
4 19
28,
1 29

21

.06 TYP.
28,29

COMMUTATOR
COIL TERMINAL

38 5
16.625 DIA.
COMMUTATOR
6,7

4 21

21 20
6,7 4

38

28,29
A

28,
29 38 TIE SPEED SENSOR CABLE
5
6, (NOT SHOWN) TO P21
20
7 4 38 TIE TWO CABLES TOGETHER
(3 PLACES)

VIEW OF BRUSHHOLDER CONNECTIONS

FROM COMMUTATOR END

FIG. 913. GE788DS, ES, FS, HS FIELD COIL ASSEMBLY. E35203C.

926
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

REF. DESCRIPTION
1 MAGNET FRAME
12 37 19 2 POLE AND COIL ASSEMBLY (EXCITING)
3 POLE AND COIL ASSEMBLY (COMMUTATING)
4 BRUSHHOLDER ASSEMBLY
5 BRUSHHOLDER SUPPORT
6 BOLT, 0.8759 X 2.75
7 LOCKWASHER, 0.875
8 CONNECTION STRAP
9 CONNECTION STRAP
10 CONNECTION STRAP
11 CONNECTION STRAP
20 12 CONNECTION STRAP
13 POLE AND COIL ASSEMBLY (COMMUTATING)
14 BOLT, 0.8759 X 5.00
28, 15 BOLT, MAGNETIC, 0.8759 X 2.25
29 16 CABLE
1 17 CABLE
18 CABLE
20 19 CABLE TIE
20 BRUSHHOLDER CABLE ASSEMBLY
21 BRUSHHOLDER CABLE ASSEMBLY
5 22 BRAZING ROD
23 BRAZING STRIP
12 24 FILLER
25 FIRST TAPING
6,7 26 SECOND TAPING
37 27 VARNISH
28 BOLT, 0.43814 X 1.00
4 29 WASHER, 0.438 NARROW
30 AIR DEFLECTOR
VIEW AT A
31 BOLT, 0.5013 X 1.00
32 LOCKWASHER, 0.50
34 WASHER, 0.50 NARROW
37 PAD
38 TIE WRAP
39 SEAL RING
40 CEMENT

FIG. 913. GE788DS, ES, FS, HS FIELD COIL ASSEMBLY. E35203C.

927
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
COMMUTATOREND
ARMATURE BEARING
NOTE: Do not reuse the old collar if it is of the
old design. The old collar has been superseded
by a new collar, 41A330161P1, designed to im-
prove bearing life. The new collar is shown in
2.
the bearing assembly drawing (Fig. 914).
1. Install collar (16) onto armature shaft as follows:
FIG. 914. ARMATURE BEARING ASSEMBLY (COMMUTATOREND). E28253D.
928
SECTION 9
a. Heat collar (16) in an oven or oil bath to
100_C (212_F).
b. Install hot collar onto armature shaft, cham-
fered edge inboard. Ensure collar is tight
against shoulder by holding pressure on the
collar for 30 seconds.
Install new ball bearing (3) and spacer (1) into
framehead as follows:
a. Heat framehead to 100_C (212_F).
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
b. Install ball bearing and spacer into hot frame-
head. When cool, seat with a soft steel bar
and a mallet.
3. Install framehead (with bearing and spacer) onto
armature shaft as follows:
a. When framehead has cooled, coat the pack-
ing groove (2) with epoxy, 497A806P9.
b. Install new packing (2) into groove.
c. Press packing into groove with a roller.
d. After epoxy has cured (24 hours), saturate
packing with D6B20H5 oil.
e. Pack inboard and outboard cavities of bear-
ing with 2.75 oz. of grease (5.5 oz. total). Also
pack grease in the spaces between the balls
of the bearing (approximately 12.5 oz.).
f. Smear 0.5 oz. of grease onto grease seals as
shown on Fig. 914.
g. Assemble bearing cap (6) to prevent bearing
movement when assembling to the shaft.
h. Heat bearing and framehead to 100_C
(212_F), then assemble to the armature
shaft. Ensure bearing goes tight against col-
lar by maintaining pressure on the framehead
for at least one minute.
4. Install speed sensor gear (9) onto armature shaft
as follows:
a. Remove bearing cap (6).
b. Heat speed sensor gear to 100_C (212_F).
c. Install hot gear onto armature shaft. Ensure
gear goes tight against bearing (3) by main-
taining pressure on the gear for one minute.
5. Install bearing cap (6) as follows:
a. Apply a 1/16 in. bead of sealant just under the
bolt hole circle on the framehead.
b. Install bearing cap (6) with bolts and washers
(7,8) and torque to 5156 lb.ft.
c. Install speed sensor. Screw in until sensor
bottoms on top of a gear tooth. Using a dial
indicator, back out sensor to give the
0.0100.034 in. gap or, back out 1/2 turn to
give 0.025 in. gap. Lock sensor in place with
locking nut.
PINIONEND ARMATURE
BEARING
1. Install bearing inner race (8, Fig. 915; 2, Fig.
916 or 917) and collars (1, 12, Fig. 915; 4, 13,
Fig. 916 or 917) onto armature shaft as fol-
lows:
a. Heat bearing inner race and both collars to
120_C (248_F).
b. Assemble hot collar (12, Fig. 915; 13, Fig.
916 or 917) tight against shaft shoulder.
c. Assemble hot bearing inner race tight against
collar.
d. Assemble hot collar (1, Fig. 915; 4, Fig.
916 or 917) tight against bearing inner
race.
e. Ensure all components are tight against their
respective fits by checking with a 0.001 in.
feeler gauge.
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
2. Install drive ring (65) onto armature shaft. Heat
drive ring (65) to 200_C (392_F), then install onto
armature shaft. Press tight against its shoulder.
Ensure that the end marked ARM is toward the
armature core.
929
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

CAUTION: Do not use copper bars for seating

SEE NOTE 3 MAGNET
6 FRAME bearings. Copper chips get into the bearing
causing bearing failures.
7 8
5 4. Install bearing rollers and outer race (59) into
SEE NOTE 2 bearing housing (57).
4

12 5. Install new packing (61) into bearing cap (62) as

SEE NOTE 1 SHAFT follows:
2, 9, 10

1 a. Coat the packing groove with epoxy

(497A806P9).

b. Install new packing (61) into groove.

c. Press packing into groove with a roller.

FILL BEARING SMEAR 0.5 OZ. d. After the epoxy has cured, saturate packing
COMPLETELY WITH OF P11 ON with D6B20H5 oil.
P11 (APPROX. GREASE SEAL.
6.25 OZ.).
6. Apply a 1/8 in. bead of #1473 Silmate sealer
USE 3.0 OZ. OF USE 3.0 OZ. OF
P11 IN THIS P11 IN THIS (497A806P60) to the bearing cap, just below the
CAVITY. CAVITY. circle of bolt holes.
SMEAR 0.5 OZ.
OF P11 ON 7. When cool, fill grease cavity in bearing housing
GREASE SEAL.
with 2.0 oz. grease. Also fill grease cavity in the
NOTES:
(1) COAT 3 SIDES OF GROOVE IN P3 WITH P9
bearing cap with 4.0 oz. grease (Fig. 916 or
AND ASSEMBLE P2 INTO GROOVE. SOAK 917).
EXPOSED SURFACE OF P2 WITH P10.
(2) TORQUE BOLTS P4 TO 5560 LB.FT. 8. Fill bearing completely (between rollers) with
(3) APPLY P6 TO SURFACES OF P7. KEEP P6
OUT OF BOLT HOLES. 6.25 oz. of grease (Fig. 916 or 917).
REF. DESCRIPTION
1 COLLAR
9. Align the bolt holes in the bearing cap with the
2 PACKING bolt holes in the bearing housing.
3 BEARING CAP
4 BOLT, 1/213 X 1 1/2 10. Install bolts and washers (56) and torque to
5 HARD WASHER, 1/2
6 SEALER (497A806P60) 5560 lb.ft.
7 BEARING HOUSING
8 ROLLER BEARING 11. On models GE78DS2, FS3, FS4, FS5, FS6,
9 CEMENT (497A806P9) FS7, FS8, FS9, HS3, HS4, HS5, HS6, HS7 and
10 OIL, D6B20H5
11 GREASE (SEE DATA SECTION) HS8 install a new oil seal (108) on bearing hous-
12 COLLAR ing (57). See Fig. 916. Tap seal into place (en-
sure seal is correctly oriented).
FIG. 915. GE788B, BS, CS, DS1, ES, FS1, FS2,
HS1, HS2 ARMATURE BEARING ASSEMBLY 12. Smear 1.75 oz. grease on bores of bearing cap,
(PINION END). E28254B.
bearing housing, and seal (Figs. 916 or 917).

13. Apply a bead of #1473 Silmate sealer to bearing

3. When cool, conduct a pulltest on the drive ring. housing, just below the bolt holes.
A pull of 16 tons must not remove the ring.
14. Install bearing assembly into magnet frame us-
NOTE: Heat the bearing housing to 100_C ing bolts and washers (56). Torque to 5560
(212_F) to ease installation. lb.ft.

930
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

2 FILL BEARING WITH

1 6.25 OZ. OF P10
TORQUE TO 7
5560 LB.FT.
8,
9 USE 4 OZ. OF P10
IN THIS CAVITY

6
USE 2 OZ. OF P10
IN THIS CAVITY
3
SEE NOTE 13
5
4

USE 1.75 OZ. OF P10 ON ALL

LABYRINTH AND SEAL
REF. DESCRIPTION SURFACES
1 BEARING HOUSING
2 ROLLER BEARING
3 BEARING CAP
4 COLLAR
5 PACKING
6 FORSHEDA SEAL NOTE FOR P5
7 SEALER, #1473 SILMATE COAT 3 SIDES OF GROOVE IN P3
8 BOLT, 1/213 X 1 1/2 BEARING CAP WITH P11 CEMENT
9 HARD WASHER, 1/2 AND ASSEMBLE P5 PACKING. SOAK EXPOSED
SURFACE OF P5 PACKING WITH P12 OIL.
10 GREASE (SEE DATA SECTION)
11 CEMENT
12 OIL, D6B20H5
13 COLLAR

FIG. 916. GE788DS2, FS3, FS4, FS5, FS6, FS7, FS8, FS9, HS3, HS4, HS5, HS6, HS7, HS8 ARMATURE
BEARING ASSEMBLY (PINION END). E39882C.

931
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

2 FILL BEARING WITH

1 6.25 OZ. OF P10
TORQUE TO 7
5560 LB.FT.
8,
9 USE 4 OZ. OF P10
IN THIS CAVITY

USE 2 OZ. OF P10

IN THIS CAVITY
3
13
SEE NOTE
5
4

USE 1.75 OZ. OF P10 ON ALL

LABYRINTH AND SEAL
SURFACES

REF. DESCRIPTION
1 BEARING HOUSING
2 ROLLER BEARING
3 BEARING CAP
4 COLLAR
5 PACKING NOTE FOR P5
COAT 3 SIDES OF GROOVE IN P3
7 SEALER, #1473 SILMATE BEARING CAP WITH P11 CEMENT
8 BOLT, 1/213 X 1 1/2 AND ASSEMBLE P5 PACKING. SOAK EXPOSED
9 HARD WASHER, 1/2 SURFACE OF P5 PACKING WITH P12 OIL.
10 GREASE (SEE DATA SECTION)
11 CEMENT
12 OIL, D6B20H5
13 COLLAR

FIG. 917. GE788FS3A, FS4A, FS5A, FS7A, FS8A, FS9A, HS3A, HS4A, HS6A, HS7A, HS8A ARMATURE
BEARING ASSEMBLY (PINION END). E40928A.

932
SECTION 9 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
ARMATURE
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Install the armature into the magnet frame as fol-
lows:
a. Place the magnet frame in a vertical position
with the pinion end down.
b. Check that the framehead and bearing hous-
ing are clear of all paint, varnish and nicks.
c. Grease the seal area of the armature collar
(60) with 1 oz. of grease.
d. Using a crane and an eyebolt in the armature
shaft, lower the armature into the magnet
frame slowly, being careful not to bump the
pole pieces or the pinion end bearing assem-
bly due to misalignment.
e. Align framehead bolt holes just before arma-
ture is fully seated.
f. Remove eyebolt.
g. Install bolts and washers (67) to secure the
framehead to the magnet frame (39). Tighten
to the torque value listed in SECTION 1,
DATA.
2. Install brushholders as follows:
a. Connect brushholder leads to brushholder.
b. Attach jumper cables.
c. Insert brushholders into magnet frame.
d. Before clamping into place, connect jumper
cables as well as commutating coil terminals.
e. Place brushholder studs in frame mount and
snug assembly into place with clamp and
bolts and washers.
f. Set brushholder clearance to commutator
with a 1/16 to 3/32 in. shim.
g. Torque clamp bolt to 293326 lb.ft.
h. Recheck clearance.
3. Connect cable to speed sensor (49). Tie the
cable as shown in Figs. 1011 through 1018.
4. Connect the thermal sensor cable (89).
SUN PINION
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
1. Install ring (81) by tapping gently in place with a
soft mallet.
2. Assemble retaining plate (63), snap ring (64) and
bolt and washer (68) into the end of the sun pin-
ion.
SLEEVE
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
Install wear bands (17). Refer to SECTION 8, page
84, for installation procedures.
OUTBOARD BEARING SEAL RING
NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
numbers may be different.
Install a new oil seal (94). Tap into place (ensure seal
is correctly oriented).
933
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 9

THRUST RING numbers may be different.

NOTE: Numbers in parentheses refer to items
listed in Fig. 1023 (Longitudinal Section draw-
ing for latest production models), unless other-
wise noted. Figs. 1019 through 1022 provide
similar views for older models but the item
Heat wear band (17) and install onto thrust ring (38).
To check the thrust ring for excessive wear on mod-
els GE788FS3 through FS9 and HS3 through HS8, re-
fer to Table 91.

TABLE 91. GE788 THRUST RING CONDEMNING LIMITS.

FRAME STRUCTURE OUTSIDE DIAMETER
FRAME/RING FIT
Maximum 36.520
Minimum 36.516
Maximum 0 008
0.008
THRUST RING BORE
Maximum 36.516 Wear Limit
Minimum 0 000
0.000
Minimum 36.512 36.518
RING FIT LENGTH
Maximum 0.765 Wear Limit
Minimum 0.761 0.750
LABYRINTH SEAL CLEARANCES
Thrust Ring Bearing Cap Clearance Clearance Limit
Maximum 37.500 37.580 0.085
Seal One 01
0.1
Minimum 37.495 37.575 0.075
Maximum 38.365 38.296 0.079
Seal Two 01
0.1
Minimum 38.355 38.286 0.059
Maximum 39.180 39.265 0.090
Seal Three 01
0.1
Minimum 39.175 39.255 0.075

934
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
SECTION 10. FINAL ASSEMBLY OF
COMPONENTS TO FRAME STRUCTURE
CONTENTS
Page
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SEAL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
PLANET GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SEAL RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1013
TORQUE TUBE/FLINGER . . . . . . . . . . . . . . . . . 1013
SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1014
WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1015
MAGNET FRAME/ARMATURE . . . . . . . . . . . . . 1016
SUN PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1017
BRAKE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1017
SCOPE
This section contains instructions for the final as-
sembly of the Motorized Wheel.
NOTE: Figs. 106 through 1010 provide out-
line drawings; Figs. 1011 through 1018 pro-
vide transmission/motor assembly drawings;
and Figs. 1019 through 1023 provide longitu-
dinal drawings of the GE788 Motorized Wheel.
All of these drawings are located at the back of
Section 10 and are referenced throughout this
Service Manual.
SEAL HOUSING
NOTE: Numbers in parentheses refer to items
listed in Figs. 101 and 102, unless otherwise
noted.
1. Place the frame structure in a cradle, flange end
up. The frame structure must be level.
2. Ensure that all old sealant is removed from
mounting flange of seal housing.
3. Apply a bead of new 497A806P60 sealer (42) to
the inside corner of the mounting flange and to
the threads of the assembly bolts (46).
4. Install seal housing (43) into the frame structure.
5. Assemble mounting bolts (46) and washer (11).
Torque bolts to 5560 lb.ft. Assemble lockwire
(47).
PLANET GEARS
NOTE: Numbers in parentheses refer to items
listed in Figs. 101 and 102, unless otherwise
noted.
1. Install outer race and rollers of gearend bear-
ings (6) into the frame structure by tapping lightly
with a soft mallet. Also, install appropriate bear-
ing cup and spacer of pinion end bearings.
CAUTION: Be sure not to mix parts of gear or pin-
ion bearings.
2. When the planet gear bearings are properly
seated, assemble bearing caps (9), bolts (96,
Fig. 101; or 45, Fig. 102) and washers (23).
Torque the bolts to 3046 lb.ft. Lockwire the
bolts in place.
3. Coat bearing rollers and inner races with oil. Us-
ing a crane, lower the planet gears into their fit in
the frame structure. Extra care is needed to get
pinion end bearings started squarely in bearing
bores.
4. Assemble bolts (92, Fig. 101; or 88, Fig. 102)
and washers (11) which fasten the pinionend
bearing caps (83 or 110, Fig. 101; or 83 or 96,
Fig. 102) to the frame structure. Torque the
bolts to 5560 lb.ft. Lockwire the bolts in place.
NOTE: Do not reuse old 1 in. long bolts (92, Fig.
101; or 88, Fig. 102). They have been super-
ceded by a longer (11/8 in.) Grade 8 bolt. The
bolt torque value remains the same.
5. Check planet gear endplay using the procedure
in SECTION 6. The endplay should be 0.0001
to 0.016 in. Change bearings as necessary to
bring the endplay within this range.
6. Remove the crane and eyebolts.
101
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

1,
97, NOTE FOR CUSTOMER OPTION:
114, FOR PERIODIC REGREASING OF DIRT
116 SEAL, USE 77 OZ. OF P35. FOR NO
PERIODIC REGREASING OF DIRT SEAL,
USE 108 OZ. OF P101.
42 SEE NOTE APPLY COAT
38, FILL 16 HOLES
OF P35 TO
49 100 WITH P35
WEAR SURFACE
PACK 72 OZ. OF P35 INTO
11, UPPER THREE CAVITIES SEE NOTE FOR
36 37 (G3G9) CUSTOMER OPTION.
PACK 108 OZ. OF P101 INTO
UPPER 6 CAVITIES (G3 & G4)
39 NOTE: (4) WASHERS PER
BOLT. ASM. WITH CONCAVE 4, 86
91 SEE NOTE 42 41 40, SIDE TOWARD P41. 5
94 35
SEE NOTE
31, 93 .06 CONTINUOUS BEAD
32, G1G5 ONLY 3,
2,90,112,113 33 83 84 108 14 87
13 86
INBOARD END

35
APPLY COAT OF P35
TO WEAR SURFACE
29
55 27 G1G5
NOTE FOR
P109: 26
G68 ONLY, 18,
INSTALL P109 98
WITH LARGE 109 7, G6G8
6 115
END OF CONE
93 SEE NOTE
FACING
OUTWARD 9 .06 CONTINUOUS BEAD
23,
APPLY TO 42 96
3 BOSSES
111 110
G68 ONLY
49
11,47,92 WIRE LOCK
BOLTS

42 APPLY A BEAD OF
P42 BEFORE ASM.
43
WIRE LOCK 47
BOLTS 11,42,46
APPLY TO THDS.
OF P46
47
LOCK WIRE BOLTS IN PAIRS PER
VIEW AT INBOARD END
ENLARGED
SECTION AA

NOTE FOR P18 OR P98:

P18 OR P98 MUST BE SEATED AGAINST SHOULDER OF P1,97 OR 114. G1
ALIGN WINDOWS IN P18 OR 98 WITH 4 SLOTS IN P1,97 OR 114.

N0TE FOR P25: G2 SAME AS G1 EXCEPT

ADJUST SHIM PACK TO OBTAIN .025.030 DIFFERENT PLANET GEAR
BRG. END PLAY. SAME AS G1 EXCEPT DIFFERENT FRAME STRUCTURE
G3
NOTE FOR P42: SLEEVE AND GREASE AND ADDITION OF
APPLY .18 CONTINUOUS BEAD OF P42 TO P36,P48 & P91 O RING AND PIPE PLUG
ON BOLT CIRCLE & BELOW BOLT HOLES. SAME AS G2 EXCEPT DIFFERENT FRAME STRUCTURE
G4
NOTE FOR P31, 32 & 33: SLEAVE AND GREASE AND ADDITION OF
APPLY P33 TO P39. O RING AND PIPE PLUG
ASSEMBLE FELT SEAL PER INSTRUCTIONS THEN SATURATE
FELT SEAL WITH OIL P32. G7 SAME AS G3 EXCEPT
DIFFERENT GEARING

NOTE FOR P56: G8 SAME AS G4 EXCEPT

LUBRICATE ALL FITTINGS AND LABYRINTH SEALS WITH P56 DIFFERENT GEARING
EXCEPT AS OTHERWISE SHOWN SAME AS G7 EXCEPT DIFFERENT
G9
FRAME STRUCTURE (P116)

G10 SAME AS G8 EXCEPT DIFFERENT

FRAME STRUCTURE (P116)

FIG. 101. GE788BS, CS, ES1, FS1, FS3, FS6, FS8, HS TRANSMISSION ASSEMBLY. E28598F.

102
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

19 ASSEMBLE SO THAT SLOT

FILL AREA BETWEEN IN P19 LINES UP WITH SLOT
ROLLERS WITH P56 USE 102 OZ. OF P56 IN P17.
(APPROX. 61 OZ.) IN THIS CAVITY
USE 43 OZ. OF P56 USE 55 OZ. OF P56
IN THIS CAVITY USE 102 0Z. OF P56 17
IN THIS CAVITY IN THIS CAVITY

20
21

OUTBOARD END
22,23
28

35

26
20
REMOVE 3 PIPE PLUGS (BOTH ENDS) 16 24
15 AND FILL HOLES WITH P56.
99 REASSEMBLE PIPE PLUGS. FILL AREA BETWEEN 25 SEE NOTE
ASSEMBLE P99 WITH ROLLERS WITH P56
JOINT AT TOP (APPROX. 61 OZ.)
VERTICAL POSITION

TOP
VERTICAL CL
NOTE FOR P35:
FOR TYPE OF GREASE
SEE DATA SECTION
NOTE FOR P101:
FOR TYPE OF GREASE
SEE DATA SECTION

P25 SHIMS P1,2,3, & 4

AS REQUIRED
(4 PLACES)

G1 = BS1, BS2, BS3

G2 = CS1, CS2
G3 = BS4, ES1, HS2, HS4
G4 = CS3, HS1, HS3
G5 = FS1, FS3 NO
G6 = FS6 SHIMS
G7 = HS5 P25 SHIMS P5,6,7, & 8
G8 = HS6 AS REQUIRED
G9 = HS7
G10 = HS8
G11 = FS8

SHIM LOCATION DIAGRAM

FIG. 101. GE788BS, CS, ES1, FS1, FS3, FS6, FS8, HS TRANSMISSION ASSEMBLY. E28598F.

103
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

LOCATE DIAMOND MARKINGS ON STAMP CONN. STRAPS WITH

GEARS (P2,90,112 OR 113) AS SHOWN TO 50 .38 HIGH LETTERS WITH
INSURE PROPER TIMING A PROPER IDENTIFICATION
82 AAASSSSXSSX AS SHOWN.

79
B
1,97,114,116
F

AA E
C
SSX

F 69, SX 49
A 70, 69,
70, SS
73
67 73 E S
13 28.25 R. MAX.
C REF. OVER CABLES
67

S1S2S3
43
59
11,46
GT1T2T3

47

D
51

50

49
54

53

52

VIEW AT INBOARD END

FIG. 101. GE788BS, CS, ES1, FS1, FS3, FS6, FS8, HS TRANSMISSION ASSEMBLY. E28598F.

104
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

WHEN ASSEMBLING P68,

WHEN ASSEMBLING P80, APPLY P102 ON ALL THDS OF
APPLY P102 ON ALL THDS OF STUD AND ASSEMBLE P68
STUD AND ASSEMBLE P80 WITH 23
1 LBSFT TORQUE 79 68 44
WITH 44
1 LBSFT TORQUE
73,74,107 68
44
68 73,74
69,70,73
80
67
71,72 72

79
73, 69,70,73
76, 74, 68 44
78, 107 67
81 68
82
TORQUE P81 TO
44 ENLARGED ENLARGED
VIEW AT B SECTION FF
67
ENLARGED
68 SECTION EE

69,70,73
65,
66 64 103
60,
75,76 61

105,
77,78 59 104 106
69,70,73
61

63 62
68
ENLARGED
VIEW AT D

67
ENLARGED G5 SAME AS G4 EXCEPT DIFFERENT WHEEL
SECTION CC HUB, BRG CAP AND HDWR

G6 SAME AS G5 EXCEPT PARTS

108 THRU 112.

G11 SAME AS G6 EXCEPT DIFFERENT

FRAME STRUCTURE (P116)

3 58 3 58 17
TORQUE TABLE
TORQUE
PART NO. SIZE FT. LBS.
22,49,81 .37516 23
1
90 o 96 .37516 38
8
37,40,46,60,75,92 .5013 58
2
20 .62511 115
5
4 1.0014 827
36
CL VERTICAL 13 3.13712 85
5
62 .2520 7
1
ASSEMBLE P58 AS SHOWN
(FLATS TO BE HORIZONTAL AT VERT. C) 106 .7510 198
12
L
LUBRICATE BOLTS

FIG. 101. GE788BS, CS, ES1, FS1, FS3, FS6, FS8, HS TRANSMISSION ASSEMBLY. E28598F.

105
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

REF. DESCRIPTION REF. DESCRIPTION

1 FRAME STRUCTURE 62 BOLT, 1/420 X 1 1/2
2 GEAR/PINION 63 LOCKWASHER, 1/4
3 TORQUE TUBE 64 WASHER, 1/4 REGULAR
4 BOLT, 1 1/4 X 5 1/2 65 NUT, 1/420
5 HARDENED WASHER 66 WASHER, 1/4 NARROW
6 ROLLER BEARING 67 CONNECTION STRAP
7 SLEEVE 68 INSULATOR
9 BEARING CAP 69 NUT, 3/816
11 HARDENED WASHER, 1/2 70 WASHER, 3/8 REGULAR
12 BEARING 71 BOLT, 3/816 X 1.00
13 BEARING NUT 72 WASHER, 3/8 NARROW
14 BEARING LOCKWASHER 73 LOCKWASHER, 3/8
15 BEARING 74 JAM NUT, 3/816
16 BEARING 75 BOLT, 1/213 X 1 1/2
17 WHEEL HUB 76 WASHER, 1/2 REGULAR
18 SEAL RING 77 JAM NUT, 1/213
19 BEARING CAP 78 LOCKWASHER, 1/2
20 SOCKET HEAD BOLT, 5/811 X 1 1/2 79 SHUNT
21 RING 80 INSULATOR
22 BOLT, 3/816 X 1 3/4 81 NUT, 1/213
23 HARDENED WASHER, 3/8 82 JUMPER
24 RING 83 BEARING CAP
25 SHIMS 84 COLLAR
26 WEAR BAND 86 OIL SEAL
27 WEAR BAND 87 RING
28 OIL SEAL 90 GEAR/PINION
29 OIL SEAL 91 PLANET COVER
31 PACKING 92 BOLT, 1/213 X 1 1/8
32 OIL, D6B20H5 93 SEALER
33 CEMENT 94 WASHER
35 GREASE, D50E16 95 SPACER
36 SEAL RING 96 BOLT, GRD8, 3/816 X 2.00
37 BOLT, 1/213 X 3.00 97 FRAME STRUCTURE
38 FITTING 98 SEAL RING
39 FLINGER 99 ORING
40 BOLT, 1/213 X 1 1/4 100 PLUG, 1/8 NPT
41 CLAMP 101 GREASE (SEE NOTE)
42 SEALER, NO. 1473 SILMATE 102 LOCKTITE
43 SEAL HOUSING 103 WHEEL HUB
46 BOLT, 1/213 X 1 1/4 104 BEARING CAP
47 LOCKWIRE 105 HARDENED WASHER, 3/4
49 BOLT, 3/816 X 3/4 106 BOLT, 3/410 X 2 1/2
50 PIPE PLUG (PLASTIC) 107 HARD WASHER, 3/8
51 PIPE PLUG, 1 1/4 NPT 108 TORQUE TUBE
52 DRAIN PLUG, 1 1/4 MAGNETIC 109 RING
53 PIPE CAP 110 BEARING CAP
54 FILL CAP 111 COLLAR
55 RING 112 GEAR/PINION
56 GREASE (SEE DATA SECTION) 113 GEAR/PINION
58 LOCATING PIN 114 FRAME STRUCTURE
59 TERMINAL BLOCK 115 SLEEVE
60 BOLT, 1/213 X 1 3/4 116 FRAME STRUCTURE
61 WASHER, 1/2 NARROW

FIG. 101. GE788BS, CS, ES1, FS1, FS3, FS6, FS8, HS TRANSMISSION ASSEMBLY. E28598F.

106
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

NOTES

107
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

102 100 1

42 SEE NOTE

FILL 16 HOLES
49 38 WITH P35

11
36 37

39 PACK 108 OZ. OF P10 INTO

48 UPPER 6 CAVITIES
NOTE: (4) WASHERS 5
SEE NOTE 86
42 41 57 PER BOLT. ASM. WITH 4
97 40 APPLY COAT
2 SEE NOTE CONCAVE SIDE TOWARD P41 35 OF P35 TO
31 .06 CONTINUOUS BEAD WEAR SURFACE
89
INBOARD END

32 G1 & G2 98
33 3 87
83 12 14 13
84 86
35 APPLY COAT OF P35
TO WEAR SURFACE

29

55 27
G1 & G2

26 18
SEE
99 NOTE
6 7 101 G3
SEE 89
NOTE
9 .06 CONTINUOUS BEAD
23
42 45

SEE 95 96
NOTE G3 ONLY

49 47 WIRE LOCK
88 BOLTS
11

WIRE LOCK 42 APPLY A BEAD OF

BOLTS P42 BEFORE ASM.
43 G1
47
46
11
42 APPLY TO THDS. SAME AS G1 EXCEPT DIFFERENT WHEEL HUB &
OF P46 G2
GREASE IN WHEEL BEARINGS
ENLARGED
47 LOCK WIRE BOLTS IN PAIRS PER
SECTION AA G3 SAME AS G2 EXCEPT COARSE PITCH
VIEW AT INBOARD END GEARING PARTS 95, 96, 97, & 98.

NOTE FOR P99:

G4 SAME AS G3 EXCEPT DIFFERENT
G3 ONLY,
FRAME STRUCTURE (P102)
INSTALL P99
WITH LARGE NOTE FOR P18:
END OF CONE P18 MUST BE SEATED AGAINST SHOULDER OF P1 OR P100.
3 3 58 17
FACING 58 ALIGN WINDOWS IN P18 WITH 4 SLOTS IN P1 OR P100.
OUTWARD
N0TE FOR P25:
NOTE FOR P42: ADJUST SHIM PACK TO OBTAIN .015.020
APPLY TO BRG. END PLAY.
3 BOSSES NOTE FOR P42:
APPLY .18 CONTINUOUS BEAD OF P42 TO P36 & P48
o ON BOLT CIRCLE & BELOW BOLT HOLES.
90
NOTE FOR P31, 32 & 33:
APPLY P33 TO P39.
ASSEMBLE FELT SEAL PER P7CEP36 THEN SATURATE
FELT SEAL WITH OIL P32.
VIEW SHOWING METHOD OF
C
L VERTICAL ASSEMBLING P58 BETWEEN NOTE FOR P56:
ASSEMBLE P58 AS SHOWN TORQUE TUBE & WHEEL HUB LUBRICATE ALL FITTINGS & LABYRINTH SEALS WITH P56.
(FLATS TO BE HORIZONTAL AT VERT. C)L
G5 SAME AS G4 EXCEPT DIFFERENT
WHEEL HUB (P17)

FIG. 102. GE788DS, ES2, FS2, FS4, FS5, FS7, FS9 TRANSMISSION ASSEMBLY. E35206B.

108
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

FILL AREAS BETWEEN ROLLERS REMOVE 3 PIPE PLUGS (BOTH ENDS)

WITH APPROX. 61 OZ. OF: AND FILL HOLE WITH 1 OZ. OF P56 (G1) OR
P56 (G1) OR P91 (G2 & G3) P91 (G2 & G3). REASSEMBLE PIPE PLUGS, SO
USE 43 OZ. OF: USE 102 OZ. OF: THEY ARE BELOW O.D. OF WHEEL HUB.
P56 (G1) OR USE 102 OZ. OF: 92 P56 (G1) OR
P91 (G2 & G3) P56 (G1) OR 17 P91 (G2 & G3)
IN THIS CAVITY P91 (G2 & G3) IN THIS CAVITY
USE 43 OZ. OF:
IN THIS CAVITY P56 (G1) OR
P91 (G2 & G3)
IN THIS CAVITY

19 8
20

OUTBOARD END
21
23
22
28

35

26

90
ASSEMBLE P30 WITH 16 24
JOINT AT TOP 15
30
VERTICAL POSITION 25 SEE NOTE

FILL AREAS BETWEEN ROLLERS

TORQUE TABLE
WITH APPROX. 61 OZ. OF:
TORQUE P56 (G1) OR P91 (G2 & G3)
PART NO. SIZE
FT. LBS.
22,49,81,85 .37516 23
1 TOP
VERTICAL CL
45 .37516 38
8

37,40,46,60,75,88 .5013 58
2

20 .7510 198
12

4 1.0014 820
43

13 3.13712 85
5

62 .2520 7
1 41B535930 P1,2,3 & 4

AS REQUIRED
90 .62511 115
5 (4 PLACES)

LUBRICATE BOLTS

68
94
74 79 44
73

NO
SHIMS

41B535930 P5,6,7 & 8

AS REQUIRED
G1 = DS1, DS2
G2 = ES2, FS2, FS4
G3 = FS5
G4 = FS7
G5 = FS9
44
68
67 SHIM LOCATION DIAGRAM
ENLARGED
SECTION FF

FIG. 102. GE788DS, ES2, FS2, FS4, FS5, FS7, FS9 TRANSMISSION ASSEMBLY. E35206B.

109
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

STAMP CONN. STRAPS WITH

STAMP PLANET COVER .38 HIGH LETTERS WITH
50
WITH .38 HIGH LETTERS A PROPER IDENTIFICATION
82 AAASSSSXSSX AS SHOWN.
(S1 S2 S3 & G T1 T2 T3)
102
79 100
B 1

LOCATE DIAMOND
MARKINGS ON GEARS F
(P2) AS SHOWN TO
INSURE PROPER
TIMING

E
C
AA
SSX

F 69 SX 49
A 70 69 SS
67
73 70 E S
13_ 73 28.25 R MAX.
C REF. OVER CABLES
67

S1S2S3
43

59

11 46
G T1T2T3

47

30_
D
51
30_
A 50

49
54

53

52
VIEW AT INBOARD END

FIG. 102. GE788DS, ES2, FS2, FS4, FS5, FS7, FS9 TRANSMISSION ASSEMBLY. E35206B.

1010
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

68 73
70
69
WHEN ASSEMBLING P80, APPLY P93 ON
ALL THREADS OF STUDS. ASSEMBLE P80
ON STUD WITH 43 +
2 LB.FT. TORQUE WHEN ASSEMBLING P68, APPLY P93 ON
ALL THREADS OF STUDS. ASSEMBLE P68 76
ON STUD WITH 23 + 44
1 LB.FT. TORQUE 75

68
80
73
67 78 77 70
69

79
73

76 74 68
ENLARGED
78 94
VIEW AT B
81
TORQUE P81 T0
43 +
2 LB.FT. 67

ENLARGED
SECTION CC

68

66
74
64 69 73
65 73 70
61
60

71 72
72
59
61

69
70
73
63 62
68
82
ENLARGED
VIEW AT D

67
ENLARGED
SECTION EE

FIG. 102. GE788DS, ES2, FS2, FS4, FS5, FS7, FS9 TRANSMISSION ASSEMBLY. E35206B.

1011
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

REF. DESCRIPTION 52 DRAIN PLUG, 1 1/4 MAGNETIC

1 FRAME STRUCTURE REF. DESCRIPTION
2 GEAR/PINION 53 PIPE CAP
3 TORQUE TUBE 54 FILL CAP
4 BOLT, 1 1/4 X 5 1/2 55 RING
5 HARDENED WASHER 56 GREASE (SEE DATA SECTION)
6 ROLLER BEARING 57 WASHER
7 SLEEVE 58 LOCATING PIN
8 HARDENED WASHER, 3/4 59 TERMINAL BLOCK
9 BEARING CAP 60 BOLT, 1/213 X 1 3/4
10 GREASE, D6A2C10 61 WASHER, 1/2 NARROW
11 HARDENED WASHER, 1/2 62 BOLT, 1/420 X 1 1/2
12 BEARING 63 LOCKWASHER, 1/4
13 BEARING NUT 64 WASHER, 1/4 REGULAR
14 BEARING LOCKWASHER 65 NUT, 1/420
15 BEARING 66 WASHER, 1/4 NARROW
16 BEARING 67 CONNECTION STRAP
17 WHEEL HUB 68 INSULATOR
18 SEAL RING 69 NUT, 3/816
19 BEARING CAP 70 WASHER, 3/8 REGULAR
20 BOLT, 3/410 X 2 1/2 71 BOLT, 3/816 X 1.00
21 RING 72 WASHER, 3/8 NARROW
22 BOLT, 3/816 X 1 3/4 73 LOCKWASHER, 3/8
23 HARDENED WASHER, 3/8 74 JAM NUT, 3/816
24 RING 75 BOLT, 1/213 X 1 1/2
25 SHIMS 76 WASHER, 1/2 REGULAR
26 WEAR BAND 77 JAM NUT, 1/213
27 WEAR BAND 78 LOCKWASHER, 1/2
28 OIL SEAL 79 SHUNT
29 OIL SEAL 80 INSULATOR
30 ORING 81 NUT, 1/213
31 PACKING 82 JUMPER
32 OIL, D6B20H5 83 BEARING CAP
33 CEMENT 84 COLLAR
35 GREASE, D50E16 86 OIL SEAL
36 SEAL RING 87 RING
37 BOLT, 1/213 X 3.00 88 BOLT, 1/213 X 1 1/8
38 PLUG, 1/8 NPT 89 SEALER
39 FLINGER 90 SOCKET HEAD BOLT, 5/811 X 1 1/2
40 BOLT, 1/213 X 1 1/4 91 GREASE (SEE DATA SECTION)
41 CLAMP 92 WHEEL HUB
42 SEALER, NO. 1473 SILMATE 93 LOCKTITE
43 SEAL HOUSING 94 HARDENED WASHER, 3/8
44 SPACER 95 COLLAR
45 BOLT, 3/816 X 2.00 96 BEARING CAP
46 BOLT, 1/213 X 1 1/4 97 GEAR/PINION
47 LOCKWIRE 98 TORQUE TUBE
48 PLANET COVER 99 RING
49 BOLT, WHIZLOCK, 3/816 X 3/4 100 FRAME STRUCTURE
50 PIPE PLUG (PLASTIC) 101 SLEEVE
51 PIPE PLUG, 1 1/4 NPT 102 FRAME STRUCTURE

FIG. 102. GE788DS, ES2, FS2, FS4, FS5, FS7, FS9 TRANSMISSION ASSEMBLY. E35206B.

1012
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
7. After properly aligning timing marks on planet
gears, clamp gears with a clamping tool (Fig.
103).
8. Check that there is no adhesive remaining on
planet cover (91, Fig. 101; or 48, Fig. 102) or
its mating surface on the frame structure.
9. Run a 0.18 in. continuous bead of 497A806P60
sealer (42) around the planet cover bolt circle
just below the bolt holes.
10. Apply 497A806P60 sealer (42) to three bosses
in the gearcase.
11. Install the planet cover, then bolts (49). Torque
the bolts to 2124 lb.ft.
12. Reconnect the power cables, speed sensor
cable and the thermal sensor cable to the planet
cover insulators and terminal blocks.
NOTE: Observe special torque requirements on
shunt mounting bolts and cable connections.
See SECTION 1, DATA for torque values.
FIG. 103. PLANET GEAR CLAMPING TOOL.
E28945.
SEAL RING
NOTE: Numbers in parentheses refer to items
listed in Figs. 101 and 102, unless otherwise
noted.
1. Place the frame structure on blocking with the
flange down. The frame must be level.
2. Clean the mating surfaces of the seal ring (36)
and the frame structure of any remaining oil or
adhesive. Also remove any nicks.
3. Run a 1/16 in. continuous bead of 497A806P60
sealer (42) on the seal ring bolt circle just below
the bolt holes.
4. Using a crane and two opposing eyebolts, lift the
seal ring into place on the frame structure, align-
ing the bolt holes in the process.
5. Remove the eyebolts.
6. Start assembly square using a soft hammer.
7. Install bolts (37) and washers (11). Torque the
bolts to 5560 lb.ft.
8. When the assembly of the flange end seal ring is
completed, prevent future ingress of dirt by filling
the four puller/lifter holes with grease and install-
ing bolts and washers of suitable length to plug
the holes. This prevents the need to clean out or
retap these holes at future disassemblies.
TORQUE TUBE/FLINGER
NOTE: Numbers in parentheses refer to items
listed in Figs. 101 and 102, unless otherwise
noted.
1. Pack 108 oz. of grease into the seal ring/flinger
cavity. See SECTION 1, DATA for grease type.
See NOTE on Fig. 101 regarding customer op-
tion.
2. Using the overhead crane, slowly lower the
torque tube/flinger assembly down onto the
frame structure.
3. As the torque tube lowers, rotate it slightly to
ease the assembly of the seals into place and
also to mesh the gear teeth of the planet pinion
and ring gears.
1013
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
NOTE: If a clamping tool is not used to lock the
planet gears during the assembly process, be
careful not to alter the relative positioning of
the planet gears. To do so will destroy required
gear timing.
4. After the dirt seal has been assembled, pump
grease into grease fitting holes to ensure the as-
sembly is 100 percent full.
NOTE: At customer option, D6A2C10 grease
may be used on older models instead of D50E16
grease. If this option is exercised, no further
greasing of the dirt seal is required until the
next overhaul.
5. On DS models using D6A2C10 grease, remove
all grease lines and install pipe plugs to avoid in-
advertent application of a different grease into
the dirt seal area.
SLEEVE
NOTE: Numbers in parentheses refer to items
listed in Figs. 101 and 102, unless otherwise
noted.
1. Measure and record the dimension in three
places from the outboard end of the frame to the
inboard shoulder of sleeve (seal ring). This will
be Dimension A, Fig. 104.
FIG. 104. DIMENSIONS FOR CHECKING CORRECT SLEEVE INSTALLATION. E28946A.
1014
SECTION 10
2. Measure and record the sleeve thickness. This
will be Dimension B.
3. Subtract Dimensions B from A to obtain Dimen-
sion C. This should be the same as the dimen-
sion measured in Step 7 below.
4. Apply a liberal coating of grease to the oil seals
(86) to facilitate assembly of sleeve.
5. Remove the Nomex cover from the set screw (in
frame) before assembling sleeve.
NOTE: It is necessary to ensure that oil picked
up by the paddle pump is returned to the oil
sump. If the sleeve openings are mislocated,
the drain openings will be blocked.
6. Position the hot sleeve over the frame and above
the torque tube with the wear bands down. Make
sure that the sleeve openings are located over
the oil drain grooves in the frame by positioning
the 1/4 in. diameter hole at the top. Gently tap the
sleeve into the torque tube using a steel bar and
a mallet as necessary. Ensure that the sleeve is
tight against its shoulder fit.
7. Measure and record the dimensions from the
end of the frame to the sleeve in four places.
These four dimensions should be the same as
that measured in Step 3 above within 0.003 in.
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
8. Install a new Oring into the sleeve. To avoid cut-
ting the Oring, press it into place with a dull tool.
9. Heat the sleeve and the inboard wheel hub bear-
ing cone with rollers in an oven to 80_C (176_F)
rise.
10. Assemble the hot bearing cone and bearings,
setting them tightly against the sleeve. Seat the
bearing cone with a steel bar or mallet. When
cool, pack the rollers with 61 oz. of grease. See
SECTION 1, DATA for grease type.
11. Using a 0.001 in. feeler gauge, check that there
are no gaps in the fit of the bearing cone.
WHEEL HUB
NOTE: Numbers in parentheses refer to items
listed in Figs. 101 and 102, unless otherwise
noted.
1. Pack 43 oz. of grease into the cavity between the
inboard wheel hub bearing cone and the sleeve.
See SECTION 1, DATA for the grease type.
2. Install two eyebolts into the wheel hub (17 or 103,
Fig. 101; or 17 or 92, Fig. 102).
3. Lift the wheel hub and lower it over the frame
structure. Try to keep the hub level.
4. If the hub binds while lowering it, raise and rotate
it slightly before lowering it again. This may com-
pensate for the hub not being perfectly level.
5. When the outboard end of the hub is about even
with the end of the frame structure, rotate the hub
to align the locating pin in the hub with the locat-
ing pin hole in the torque tube. Then lower the
hub completely. Remove the crane.
6. Lubricate threads of bolts (4) and washers (5)
with oil.
7. Install at least four bolts and washers with one or
two bolts on either side of the locating pin. Tight-
en these bolts evenly to bring the torque tube up
into position against the hub.
8. Install the rest of the bolts and washers. Torque
all of the hub bolts to 777863 lb.ft. (Tightening
can be done at this time or later in the test stand.)
9. Place three polypropylene spacers (41A286415)
120 degrees apart on the race of the outboard
bearing cup (Fig. 105). Each spacer measures
approximately 10 x 2 x 0.105 in.
NOTE: The use of these spacers is very impor-
tant in assuring that a positive amount of initial
bearing endplay is obtained.
10. Heat the outboard bearing cone and rollers to
100_C (212_F).
11. Carefully install the hot bearing cone into posi-
tion over the frame structure and lower onto the
plastic spacers.
12. When the bearing cone has cooled, remove the
plastic spacers and pack 61 oz. of grease be-
tween the rollers of the bearing. See SECTION
1, DATA for the type of grease to use.
13. Install the thrust ring (24) with shims (25) onto
the frame structure.
NOTE: All shim packs should be measured
prior to assembly to verify that they are of equal
thickness (within 0.005 in.).
POLYPROYLENE
STRIP
FRAMEHEAD
OUTBOARD
WHEELHUB
BEARING
WHEEL
HUB
FIG. 105. WHEEL HUB OUTBOARD BEARING
ASSEMBLY SPACERS. E25161.
1015
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
14. If the wheel hub, wheel hub bearing, magnet
frame, thrust ring or adapter ring have not been
replaced during overhaul or repair, it is permissi-
ble to use the original shim packs. Otherwise, in-
stall a shim pack approximately 0.190 in. thick.
This will assure sufficient endplay for the initial
assembly. The shims are installed between the
thrust ring and the frame structure.
15. Install bolts (20, Fig. 101; or 90, Fig. 102) and
torque to 110120 lb.ft.
16. Pack 55 oz. (Fig. 101) or 43 oz. (Fig. 102) of
grease into the cavity over the outboard bearing.
17. Preassemble the bearing cap (19 or 104, Fig.
101; or 19, Fig. 102) and the seal ring (21), us-
ing bolts (22) and washers (23). Torque to 2124
lb.ft.
18. Assemble bearing cap/seal ring assembly to
wheel hub using bolts (106, Fig. 101; or 20, Fig.
102). Torque bolts to 185210 lb.ft.
19. Check the wheel hub bearing endplay by per-
forming the following:
a. Place two magneticbase dial indicators dia-
metrically opposite on the outboard edge of
the wheel hub. The indicator pointer should
rest on the thrust ring. Mark the pointer loca-
tions. All readings must be taken with the indi-
cator pointers at these locations.
b. Set the indicators to zero. Allow for 0.060 in.
of indicator travel.
c. Using the sun pinion rotating tool
(41E908727G1, Fig. 36), rotate the wheel
hub until the dial indicators show repetitive
readings as the marked locations pass be-
neath the pointers. This usually takes 10 to 15
revolutions.
d. Shut off the rotating tool and with the indica-
tors at their marked locations, reset them to
zero.
e. Attach cables of proper size to the wheel hub
lifters. Using a swivel hook and a crane of suf-
1016
SECTION 10
ficient capacity (25,000 lb.), raise the wheel
clear of the floor to approximately 1/2 in.
f. With the wheel in the raised position, again
rotate the wheel using the sun pinion rotating
tool. Rotate the wheel at least 15 revolutions
then stop the wheel, aligning the marks with
their dial indicator pointers.
g. Before lowering the wheel, read the dial indi-
cators to determine the amount of endplay.
Refer SECTION 1, DATA for correct end
play value.
h. If the endplay is not within limits, the wheel
hub bearing shims must be adjusted. After
readjustment, repeat this endplay test.
NOTE: If a Motorized Wheel frame is sent into
the shop for repair without its motor, it also
should have wheel hub bearing endplay
checked before shipping the wheel back to the
customer. The above method can be used.
MAGNET FRAME/ARMATURE
NOTE: Numbers in parentheses refer to items
listed in Figs. 1017 and 1018 (Transmission
and Motor Assembly drawings for latest pro-
duction models), unless otherwise noted. Figs.
1011 through 1016 provide similar views for
older models but the item numbers may be dif-
ferent.
1. Check to ensure that the mating surfaces for seal
(16, Fig. 1023) are clean on the pinion end of
the magnet frame.
2. Install a new seal into the magnet frame. See
page 84 for details.
3. Lift the magnet frame into the frame structure,
positioning the magnet frame to align its keyway
with the key in the frame structure.
NOTE: Lubricate the outside surface of the
magnet frame lightly to ease the assembly and
future disassembly process. Use Molytex oil.
4. When the magnet frame is completely lowered in
place, install capscrews (3) and washers (13).
Torque bolts to 790863 lb.ft.
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

5. Megger the bus bars at this point to ensure that SUN PINION
bus bar insulation was not damaged during the
NOTE: Numbers in parentheses refer to items
assembly process.
listed in Figs. 1017 and 1018 (Transmission
6. Connect the thermal sensor cable connectors. and Motor Assembly drawings for latest pro-
duction models), unless otherwise noted. Figs.
7. Bolt the motor connection straps to the frame 1011 through 1016 provide similar views for
structure connection straps. older models but the item numbers may be dif-
ferent.
8. Insulate the bolted connections (all except A and
1. Place the frame structure in a horizontal position.
AA).
2. Install the sun pinion (2 or 7, Fig. 1017; or 7 or
a. Apply compound 41A239176P443. 29, Fig. 1018) into the drive ring (8). Tighten bolt
(14) to 5560 lb.ft.
b. Wrap with insulation 41A239176P112.
3. Apply a new gasket (6) to the sun pinion cover.
c. Wrap with outside tape 41A239176P15.
4. Install the sun pinion cover (4) using bolts (5).
d. Brush thoroughly with varnish Torque the bolts to 21 24 lb.ft.
41A239176P487.
BRAKE HUB
9. Insulate the A and AA bolted connections: NOTE: Numbers in parentheses refer to items
listed in Figs. 1017 and 1018 (Transmission
a. Apply compound 41A239176P443.
and Motor Assembly drawings for latest pro-
duction models), unless otherwise noted. Figs.
b. Wrap with insulation 41A239176P112.
1011 through 1016 provide similar views for
c. Wrap with outside tape 41A239176P20. older models but the item numbers may be dif-
ferent.
d. Brush thoroughly with varnish
1. Heat the brake hub (21) to 275_C (527_F) and
41A239176P487.
install on the armature shaft tight against its col-
lar.
10. Connect the speed sensor cable.
2. When the hub is cool, conduct a pull test. It
11. If applicable (GE788B, BS, CS), assemble the should withstand a test of 16 tons.
adapter ring (32) to the magnet frame with bolts
(3) and washers (31). Torque the bolts to 3. Assemble the end plate (22) with bolt (16) and
530575 lb.ft. washer (13). Torque the bolt to 440495 lb.ft.

NOTES

1017
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

A A S

SS

CP CP
2.25 GEAR CASE
COVER AA
JUMPER
S SX AA SX

.59 SS SSX SSX

TROLLEY STATEX

#1032 CONNECTIONS ON CONNECTION SCHEMATIC

1000 AMP CURRENT SHUNT 1.16

VIEW AT C
45 o
MOUNTING
FACE

GEAR BOX BREATHER HOLES JUMPER PROVIDED FOR USE

1.25 STD. PIPE TAP WITH WITH STATEX APPLICATION
PLASTIC PLUGS ENLARGED
VIEW AT E
SHOWING BRAKE
LINE TERMINATION
C
.406 DIA. 2 HOLES
EACH CONNECTION
STRAP

4 FITTINGS
SPEED SENSOR .562518 UN2B INT. THD.
LEADS (FROM THIS POINT BRAKE
LINE PARTS ARE FURNISHED
NAMEPLATE BY CUSTOMER)
.2520
NUTS
E

GEAR BOX BREATHER HOLES

THERMAL SENSOR 1.25 STD. PIPE TAP WITH
LEADS PLASTIC PLUGS

GEAR BOX BREATHER

HOLE. 1.25 STD. PIPE TAP MAGNETIC
WITH STD. PIPE PLUG DRAIN PLUG

OIL FILL CAP, MAINTAIN

OIL LEVEL TO TOP OF OPENING
(OIL SUMP CAPACITY APPROX.
40 QTS.) AIR IN BETWEEN
GEAR CASE AND FLANGE

1.25 STD. PIPE TAP 1.00 NPT WITH

WITH MAGNETIC PIPE CAP FOR
PIPE PLUG OIL DRAIN

FIG. 106. GE788BS, CS OUTLINE. E28528C.

1018
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

NOTES:
1. MOTORIZED WHEEL MUST BE MOUNTED
AND INSTALLED ON TRUCK PER 41A239442.
2. FLAT ON BOTTOM OF MOUNTING FLANGE o
MUST BE PARALLEL TO GROUND WITHIN 3
WHEN MOUNTED UNDER ALL CONDITIONS OF
LOADING.
3. REFERENCE SERVICE MANUAL GEK84745.

1.65R

.125 PIPE PLUGS AVAILABLE

FOR GREASING OF DIRT SEAL
MOUNTING (16 PIPE PLUGS EQ. SP.)
FACE GREASE SPECIFICATION VIEW AT D
D5OE16 MOLYBDINUM
CHASIS GREASE MAINTAIN .50 MIN. CLEARANCE
BETWEEN WHEEL RIM AND TWO
SETS OF BOLT HEADS.
30.90 MIN.
.020 .070
.000 D 27.146 3.454
.005
64.500 59.00 CENTERLINE FOR
DIA. 59.00 53.25 DUAL TIRES
DIA.
DIA. DIA.
MAX.
.000
.375 50.50 .005
(CONN. DIA. 41.813
.625 DIA. 4 HOLES
IN SUPPORTS FOR STRAP) 44.50 DIA.
DIA. (FOR BRAKE
BRAKE LINES MOUNTING)
SPACE REQUIRED 39.50
FOR REMOVAL OF DIA.
SUN PINION
39.002 .006
DIA. .000

13.25 9.34
DIA.
C
L BRAKE
LINES

.000
.002
6.750
.000 .000 DIA.
.030 .030
27.62 45.140
46.750 DIA.
DIA.

63.00

o
28
2.10 C
L LOAD

16.48 13.12
LENGTH REQUIRED
37.731 TO REMOVE MOTOR

47.90
.068
64.877

73.60

FIG. 106. GE788BS, CS OUTLINE. E28528C.

1019
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

2.00
40.00 DIA. .052
4.132
39.62 DIA. .62511 TAP THRU 1.50
6 HOLES ON 15.125 DIA. B.C.
.562518 THD. FOR PARKING BRAKE
(SIZE #6) 17.18 TO LC
4 PLACES .20

6.94

.19 5.95 DIA.

5.50 DIA.
.000
.003
.75 13.000
DIA.

SECTION AA SECTION BB
ENLARGED ENLARGED

1.062 DIA. HOLE VALVE AND DRIVER

5.75 DEEP AND SLOT SEE VIEW AT D
1.0014 TAP 2.75 DEEP
27 HOLES SPACED AS SHOWN
ON 35.00 DIA. B.C. FOR
BRAKE MOUNTING
1.0014 CLASS 38 TAP 1.69 DEEP
46 HOLES ON 43.25 DIA. B.C.
FOR BRAKE MOUNTING

1.375 DIA. THRU

48 HOLES TOTAL o
21 SPACES AT 7.5
ON 61.75 DIA. B.C.
(BOTH SIDES)
o .7510 TAP THRU
157.5 2 SETS OF 5 HOLES
1.0014 TAP SPACED AS SHOWN
6 HOLES ON FOR BRAKE MOUNTING
35.00 DIA. B.C.
(FOR MOTOR JACKOUT)

B
1.257 TAP THRU
2 HOLES FOR
JACKOUT

.62511 TAP THRU

16 HOLES EQ. SPACED ON
8.375 DIA. B.C.
B
A
A
OPEN AREA IN END OF
1.0014 TAP MOTOR FOR BRUSH
3 HOLES ON ACCESSIBILITY
35.00 DIA. B.C. (BOTH ENDS)
FOR JACKOUT

1.62 DIA.
.25 DEEP
(4 PLACES)

.8759 TAP THRU 7.88

2 SETS OF 4 HOLES 2 ROLLER SLOTS FOR
AS SHOWN FOR 15.75 ASSEMBLING MOTOR
BRAKE MOUNTING
(15 HOLES ON 3.94
2 ROLLER SLOTS FOR CENTERS. 3.00 DIA.
ASSEMBLING MOTOR S.F. TO DIM.
KEY FOR POSITIONING
MOTOR AT ASSEMBLY

FIG. 106. GE788BS, CS OUTLINE. E28528C.

1020
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

NOTES

1021
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

CONNECTION SCHEMATIC
1.16

A A
GEAR CASE S MOUNTING
2.25 COVER SS FACE
CP CP
AA JUMPER
.59 AA
S SX SX
SS SSX SSX
ENLARGED
VIEW AT C VIEW AT E
TROLLEY STATEX
#1032 CONNECTIONS ON SHOWING BRAKE
1000 AMP CURRENT SHUNT LINE TERMINATION

JUMPER PROVIDED FOR USE

WITH STATEX APPLICATION
GEAR BOX BREATHER HOLES
1.25 STD. PIPE TAP WITH
PLASTIC PLUGS
.406 DIA. 4 FITTINGS
2 HOLES EACH .562518 UN2B INT. THD.
CONN. STRAP. (FROM THIS POINT BRAKE
LINE PARTS ARE FURNISHED BY
CUSTOMER)
C
SPEED SENSOR
LEADS

SSX
AA
SX
NAMEPLATE A SS
S
.2520
NUTS E

S1S2S3

G T1T2T3
THERMAL
SENSOR 13.25
LEADS DIA.

MAGNETIC
DRAIN PLUG

GEAR BOX BREATHER

HOLE. 1.25 STD. PIPE TAP
WITH STD. PIPE PLUG
OIL FILL CAP. MAINTAIN
OIL LEVEL TO TOP OF OPENING
(OIL SUMP CAPACITY APPROX.
40 QTS.) AIR IN BETWEEN
1.00 NPT WITH GEAR CASE & FLANGE
1.25 STD. PIPE TAP PIPE CAP FOR
WITH MAGNETIC OIL DRAIN
PIPE PLUG

FIG. 107. GE788DS, ES2, FS1FS6 OUTLINE. E38384A.

1022
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

REF.
61.575
REF.
6.766

5_
17.43 R.
18.00 .12

MOUNTING .125 PIPE PLUGS AVAILABLE

FACE FOR GREASING OF DIRT SEAL
(16 PIPE PLUGS EQ. SP.)
GREASE SPECIFICATION
D50E16 MOLYBDINUM VIEW SHOWING HUB CAP DIMENSIONS
CHASSIS GREASE
PIPE PLUGS FOR GREASING
MAINTAIN .50 MIN. CLEARANCE WHEEL BEARINGS THE HEAD OF A 1.00 STD. BOLT
2.75 MUST BE ALTERED TO CLEAR .38 R.
BETWEEN WHEEL RIM & TWO SETS
.12 R OF BOLT HEADS.
.054

.015 LATCHING BAIL
.000 24.194 6.766
.005 6.70 1.61 CENTERLINE FOR FOR HUB CAP
64.500 (DS1 ONLY)
DUAL TIRES
DIA. 59.00
59.00 53.25 DIA.
DIA. DIA.
MAX. 46.00 DIA .000
50.50 47.813 .005
DIA. DIA.
44.50 (FOR BRAKE
.375 DIA. MTG.)
(CONN. 39.50 DIA.
STRAP) 39.002 .006 DIA.
.625 DIA. 4 HOLES .00 .000
24.28
IN SUPPORTS FOR .03 2.717 .052
BRAKE LINES TO C
51.14 1.00
DIA L .50
7.18
CL BRAKE
LINES
13.25 1.06 7.77 9.34
DIA.

27.62
46.80 DIA 47.38 +.000
6.750 .002
DIA DIA.
SPACE REQUIRED .00
FOR REMOVAL OF .03 .81
SUN PINION 52.75
DIA.
44.50 DIA.

63.00

28.50 28_ 4.33

2.10 16.15 5.36

16.48 13.12 CENTER OF GRAVITY

C
L LOAD
37.381
48.125

.078
61.575
73.60
NOTES:
1.) MOTORIZED WHEEL MUST BE MOUNTED
LENGTH REQUIRED TO
AND INSTALLED ON TRUCK PER 41A239442.
REMOVE MOTOR
2.) FLAT ON BOTTOM OF MOUNTING FLANGE
MUST BE PARALLEL TO GROUND WITHIN 3
WHEN MOUNTED UNDER ALL CONDITIONS OF
LOADING.
3.) REFERENCE SERVICE MANUAL. GEK84745

FIG. 107. GE788DS, ES2, FS1FS6 OUTLINE. E38384A.

1023
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

.25 PIPE PLUG (3 EQ. SP. EACH

END) FOR GREASING WHEEL BRGS.
1.0014 CLASS 3B TAP 1.69 DEEP
1.062 DIA HOLE 22 HOLES ON 49.25 DIA. B.C.
24 EQ. SP.WITH HOLES 1.019 DIA. THRU
5.75 DEEP AND 24 HOLES EQ. SP. ON 49.25 DIA. B.C.
MISSING AT
1.0014 TAP 2.75 DEEP (FOR WHEEL RIM WEDGE BLOCKS) DS1 MODEL
DRIVER SLOT & 90
27 HOLES SPACED AS SHOWN ONLY
IN AUXILIARY VIEW (FOR BRAKE MOUNTING)
1.0014, CLASS 3B TAP, 1.69 DEEP
ON 35.00 DIA. B.C. FOR 24 HOLE EQ. SP. ON 49.25 DIA. B.C.
BRAKE MOUNTING (ES2 & FS MODELS)

1.375 DIA. THRU

48 HOLES TOTAL VALVE AND
DRIVER SLOT
21 SPACES AT 7.5
ON 61.75 DIA. B.C.
(BOTH SIDES)
1.0014 TAP
6 HOLES ON
35.00 DIA. BC.
157.5_
(FOR MOTOR JACKOUT)
.7510 TAP THRU
2 SETS OF 5 HOLES
SPACED AS SHOWN
FOR BRAKE MOUNTING

B 1.257 TAP THRU

2 HOLES FOR
JACKOUT

.62511 TAP THRU

SPEED 16 HOLES EQ. SPACED ON
B SENSOR 8.375 DIA. B.C.
A

A
OPEN AREA IN END OF
MOTOR FOR BRUSH
ACCESSIBILITY
(BOTH ENDS)

1.0014 TAP
3 HOLES ON
35.00 DIA. B.C.
FOR JACKOUT

7.88
15.75 KEY FOR POSITIONING
.8759 TAP THRU MOTOR AT ASSEMBLY
2 SETS OF 4 HOLES (5 HOLES ON 3.94
AS SHOWN FOR BRAKE MOUNTING CENTERS. 3.00 DIA.
S.F. TO DIM.)

.62511 TAP THRU

.56 REF 6 HOLES ON 15.125 DIA. B.C.
FOR PARKING BRAKE
.562518 THD.
(SIZE #6)
4 PLACES 2.14 6.94

ENLARGED
SECTION BB
ENLARGED
SECTION AA

FIG. 107. GE788DS, ES2, FS1FS6 OUTLINE. E38384A.

1024
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

NOTES

1025
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

CONNECTION SCHEMATIC

A A S
o
45
SS
CP
CP
JUMPER
GEAR CASE
COVER AA

S SX AA SX
MOUNTING
SS FACE
SSX SSX
NO. 1032 CONNECTIONS ON
1000 AMP CURRENT SHUNT
VIEW AT C TROLLEY STATEX
ENLARGED
VIEW AT E
SHOWING BRAKE LINE
TERMINATION

GEAR BOX BREATHER HOLE

1.25 STD. PIPE TAP WITH
PLASTIC PLUG

JUMPER PROVIDED FOR USE

WITH STATEX APPLICATION
C
.406 DIA.
2 HOLES EACH
CONN. STRAP

.2520 NUTS

4 FITTINGS
.562518 UN2B INT. THD.
SPEED SENSOR (FROM THIS POINT BRAKE
LEADS LINE PARTS ARE FURNISHED
BY CUSTOMER)

NAMEPLATE E

THERMAL SENSOR
LEADS

GEAR BOX BREATHER GEAR BOX BREATHER HOLE

13.25 1.25 STD. PIPE TAP WITH
HOLE. 1.25 STD. PIPE TAP DIA. PLASTIC PLUG
WITH STD. PIPE PLUG

MAGNETIC MAGNETIC
DRAIN PLUG DRAIN PLUG

OIL FILL CAP. MAINTAIN

OIL LEVEL TO TOP OF OPENING
(OIL SUMP CAPACITY APPROX. 1.25 STD. PIPE TAP 1.00 NPT WITH PIPE AIR IN BETWEEN
40 QTS.) WITH MAGNETIC CAP FOR OIL DRAIN GEAR CASE AND FLANGE
PIPE PLUG

FIG. 108. GE788ES1, HS1HS6 OUTLINE. E37731B.

1026
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

1.65 R

VIEW AT D

.125 PIPE PLUGS AVAILABLE MAINTAIN .50 MINIMUM CLEARANCE

FOR GREASING OF DIRT SEAL BETWEEN WHEEL RIM AND TWO
(16 PIPE PLUGS EQ. SP.) SETS OF BOLT HEADS
D5OE16 MOLYBDENUM
MIN.
CHASSIS GREASE 30.90
+ + .070
MOUNTING .020
FACE 27.146 3.454

PIPE PLUGS FOR

GREASING WHEEL
BEARINGS
D
CENTERLINE FOR
DUAL TIRES
59.00
59.00 DIA.
DIA. 53.25
MAX. DIA.

+.000 .375
.005 (6 CONN.
64.500 STRAPS) 50.50 39.50
DIA. DIA. 44.50 DIA.
DIA. +.000
+.006 .005
. 625 DIA. 4 HOLES .000
IN SUPPORTS FOR 39.002 41.813
BRAKE LINES DIA. DIA.
(FOR BRAKE
MOUNTING)
11.84 11.06
13.25 9.34
DIA.
CL BRAKE + .030
LINES
46.75
27.62 DIA. +.000
.030 +.000
45.140 .002
SPACE REQUIRED DIA. 6.750
FOR REMOVAL DIA.
OF SUN PINION

CENTER OF
GRAVITY o 63.00
2.10 28
16.48 CL LOAD
13.12
APPROX.
27.00

37.731

47.90
+ .068

64.877

73.60

LENGTH REQUIRED TO
REMOVE MOTOR

FIG. 108. GE788ES1, HS1HS6 OUTLINE. E37731B.

1027
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

VALVE AND
1.062 DIA. HOLE DRIVER SLOT
5.75 DEEP AND SEE VIEW AT D
1.0014 TAP 2.75 DEEP 1.0014 CLASS 3B TAP 1.69 DEEP
27 HOLES SPACED AS SHOWN IN 46 HOLES ON 43.25 DIA. B.C.
AUXILIARY VIEW FOR TIRE RIM & BRAKE MOUNTING
ON 35.00 DIA. B.C. FOR
BRAKE MOUNTING 34 EQ. SP. AT 7.5_
(35 HOLES)
3.30
1.375 DIA. THRU MIN.
48 HOLES TOTAL .25 PIPE PLUG (3EQ.
SP.EACH END) FOR
21 SPACES AT 7.5_
GREASING WHEEL HUB
ON 61.75 DIA. B.C. BEARINGS
(BOTH SIDES)
.7510 TAP THRU
2 SETS OF 5 HOLES
10 EQ. SP. AT 7.5_
SPACED AS SHOWN
(11 HOLES) FOR BRAKE MOUNTING
1.0014 TAP
6 HOLES ON 12.343 R.
35.00 DIA. BC.
(FOR MOTOR 1.257 TAP THRU
JACKOUT) B 2 HOLES FOR
10.688 R.
JACKOUT

28.00
DIA.

.62511 TAP THRU

B 16 HOLES EQ.
SPACED ON
8.375 DIA. B.C.
A

A
OPEN AREA IN END OF
1.0014 TAP MOTOR FOR BRUSH
3 HOLES ON ACCESSIBILITY (BOTH
35.00 DIA. BC. SIDES)
FOR JACKOUT

SPEED
SENSOR 28.50

.8759 TAP THRU

2 SETS OF 4 HOLES
AS SHOWN FOR BRAKE MOUNTING 7.88

15.75 KEY FOR POSITIONING

(5 HOLES ON 3.94 MOTOR AT ASSEMBLY
CENTERS. 3.00 DIA.
S.F. TO DIM.)

FIG. 108. GE788ES1, HS1HS6 OUTLINE. E37731B.

1028
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

.37516 TAP THRU

4 SETS OF 2 HOLES
EQ. SP.

32_

.25 DEEP POCKET

(4 PLACES)

AUXILIARY VIEW OF BRAKE ADAPTER

2.00

.562518 THD. .56 REF. 1.50

(SIZE #6) 4.132 + .052
4 PLACES
.62511 TAP THRU
6 HOLES ON 15.125 DIA. B.C.
6.94
FOR PARKING BRAKE
2.14 .20
17.18 TO C L
5.95 DIA.

5.50 DIA.

.75

ENLARGED
SECTION AA ENLARGED
SECTION BB

FIG. 108. GE788ES1, HS1HS6 OUTLINE. E37731B.

1029
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

GEAR CASE
2.25 COVER A A S

SS

.59 CP CP
.62
MOUNTING AA
#1032 CONNECTIONS ON FACE JUMPER
1000 AMP CURRENT SHUNT S SX AA SX
VIEW AT C
SS SSX SSX
o
45 ELL WITH .562518
UN2B MALE THREAD
(4 FITTINGS WITH ORING)
(FROM THIS POINT, BRAKE LINE TROLLEY STATEX
PARTS ARE FURNISHED BY CUSTOMER)
CONNECTION SCHEMATIC

VIEW AT E
ENLARGED
(SHOWING BRAKE
LINE TERMINATION)

.406 DIA.
2 HOLES EACH
CONNECTION GEAR BOX BREATHER HOLE
STRAP 1.25 STD. PIPE TAP WITH
PLASTIC PLUG

JUMPER PROVIDED FOR USE

C WITH STATEX APPLICATION

SPEED SENSOR
LEADS

NAMEPLATE

.2520
NUTS E

THERMAL SENSOR
LEADS

GEAR BOX BREATHER

HOLE 1.25 STD. PIPE TAP
WITH STD. PIPE PLUG

GEAR BOX BREATHER HOLE

OIL FILL CAP. MAINTAIN 1.25 STD. PIPE TAP WITH
OIL LEVEL TO TOP OF OPENING PLASTIC PLUG
(OIL SUMP CAPACITY APPROX.
4 QTS.

1.25 STD. PIPE TAP

WITH MAGNETIC AIR IN BETWEEN
PIPE PLUG GEAR CASE AND
MAGNETIC FLANGE
1.00 NPT WITH DRAIN PLUG
PIPE CAP FOR
OIL DRAIN

FIG. 109. GE788FS7FS9 OUTLINE. E41537.

1030
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

NOTES:
1.) MOTORIZED WHEEL MUST BE MOUNTED
AND INSTALLED ON TRUCK PER 41A239442.
2.) FLAT ON BOTTOM OF MOUNTING FLANGE MODEL D
MUST BE PARALLEL TO GROUND WITHIN 3
WHEN MOUNTED UNDER ALL CONDITIONS OF 1.0014, CLASS 3B TAP
GE788FS7 & 8 1.69 DEEP
LOADING.
GE788FS9 1.019.003 DIA. THRU
3.) REFERENCE SERVICE MANUAL. GEK84745

.125 PIPE PLUGS AVAILABLE MAINTAIN .50 MIN. CLEARANCE

FOR GREASING OF DIRT SEAL BETWEEN WHEEL RIM AND
(16 PIPE PLUGS EQ. SP. ) 2 SETS OF BOLT HEADS
GREASE SPECIFICATION .054
D50E16 MOLYBDINUM .015
CHASSIS GREASE 24.194 6.766
MOUNTING
FACE PIPE PLUGS FOR
GREASING WHEEL
BEARINGS

CENTERLINE FOR
DUAL TIRES
.000
.005
64.500 59.00 59.00
DIA. DIA. 53.25 DIA.
MAX. DIA.
.000
.005
.375 50.50 47.813
(CONN. DIA. DIA.
STRAP) 44.50 39.50 (FOR BRAKE
DIA. DIA. MOUNTING)
.006
.625 DIA. 4 HOLES .000
IN SUPPORTS FOR 39.002
BRAKE LINES DIA.

13.25

.00
27.62 .03
52.75
DIA.
SEE DETAIL
F
SPACE REQUIRED
FOR REMOVAL OF
SUN PINION

63.00

2.10 CENTER OF
GRAVITY 28o
16.48 13.12 CL LOAD

28.50
37.381

48.125
.078
61.575

74.45

LENGTH REQUIRED TO
REMOVE MOTOR

FIG. 109. GE788FS7FS9 OUTLINE. E41537.

1031
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

.56 REF

6.355 .052
.562518 THD. 1.17
(SIZE #6) 6.94
4 PLACES 2.14
.35 .62511 TAP THRU
6 HOLES ON A 15.125 B.C.
FOR PARKING BRACK

.20

6.00
DIA
5.50

SECTION AA
ENLARGED 13.000+.000
.003 DIA.
1.0014 CLASS 3B TAP 1.69 DEEP
22 HOLES ON 49.25 DIA. B.C. .75
24 EQ. SP.WITH HOLES MISSING AT
DRIVER SLOT & 90 CCW
(FOR BRAKE MOUNTING) D HOLES
24 HOLES EQ. SP. ON A 49.25 DIA B.C.
.25 PIPE PLUG (3 EQ. SP. EACH
END) FOR GREASING WHEEL BRGS.
SECTION BB
1.062 DIA HOLE VALVE AND ENLARGED
5.75 DEEP AND DRIVER SLOT
1.0014 TAP 2.75 DEEP
27 HOLES SPACED AS SHOWN
IN AUXILIARY VIEW
ON 35.00 DIA. B.C. FOR
BRAKE MOUNTING
o
157.5
1.375 DIA. THRU .7510 TAP THRU
48 HOLES TOTAL 2 SETS OF 5 HOLES
21 SPACES AT 7.5
SPACED AS SHOWN
ON 61.75 DIA. B.C.
(BOTH SIDES) FOR BRAKE MOUNTING

1.0014 TAP
6 HOLES ON 1.257 TAP THRU
35.00 DIA. BC. B 2 HOLES FOR
(FOR MOTOR JACKOUT) JACKOUT

A OPEN AREA IN END OF

MOTOR FOR BRUSH
ACCESSIBILITY
A (BOTH ENDS)

SPEED
SENSOR

1.0014 TAP
3 HOLES ON
35.00 DIA. B.C.
FOR JACKOUT

KEY FOR POSITIONING

MOTOR AT ASSEMBLY
.8759 TAP THRU
2 SETS OF 4 HOLES
AS SHOWN 7.88
FOR BRAKE MOUNTING

15.75
(5 HOLES ON 3.94
CENTERS. 3.00 DIA.
S.F. TO DIM.)

FIG. 109. GE788FS7FS9 OUTLINE. E41537.

1032
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

.35 .62511 TAP THRU, 6875

DIA CBORE X .85 DEEP,
12 HOLES EQ. SP. ON A
12.75 DIA B.C. (NO ANGULAR
RELATIONSHIP WITH OTHER HOLES)
+.000
11.200
.002 DIA
14.00
DIA
7.000 +.000
.002
DIA APPROX. WEIGHT= 22,650 LBS.
AIR FLOW FOR MOTOR= 2800 CFM.
.75010 TAP THRU, .812 DIA
CBORE X 1.10 DEEP, 8 HOLES
EQ. SP. ON A 8.375 DIA B.C.
DETAIL F
SHOWING DETAIL OF BRAKE HUB

61.575
REF.

REF.
6.766

4.00R 5

17.43R.
18.00 .12
.37516 TAP THRU
4 SETS OF 2 HOLES
EQ. SP.

VIEW SHOWING HUB CAP DIMENSIONS

.25 DEEP POCKET

(4 PLACES)

AUXILIARY VIEW OF BRAKE ADAPTER

FIG. 109. GE788FS7FS9 OUTLINE. E41537.

1033
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

A A S
GEAR CASE
2.25 COVER SS

CP CP

AA
JUMPER
.59 S SX AA
SX
SS SSX SSX

TROLLEY STATEX
#1032 CONNECTIONS ON
1000 AMP CURRENT SHUNT CONNECTION SCHEMATIC
VIEW AT C
45 ELL WITH .562518
MALE THREAD .62 MOUNTING
(4 FITTINGS WITH ORING) FACE
(FROM THIS POINT BRAKELINE
PARTS ARE FURNISHED BE
CUSTOMER)

JUMPER PROVIDED FOR USE

GEAR BOX BREATHER HOLE WITH STATEX APPLICATION
.406 DIA. 1.25 STD. PIPE TAP WITH
2 HOLES EACH
CONN. STRAP. PLASTIC PLUG

ENLARGED
SPEED SENSOR
LEADS VIEW AT E
SHOWING BRAKE
LINE TERMINATION

NAMEPLATE

GEAR BOX BREATHER HOLE

1.25 STD. PIPE TAP WITH
THERMAL SENSOR PLASTIC PLUG
LEADS

MAGNETIC
GEAR BOX BREATHER DRAIN PLUG
HOLE. 1.25 STD. PIPE TAP
WITH STD. PIPE PLUG

OIL FILL CAP. MAINTAIN

AIR IN BETWEEN
OIL LEVEL TO TOP OF OPENING
(OIL SUMP CAPACITY APPROX. GEAR CASE & FLANGE
40 QTS.)

1.25 STD. PIPE TAP

WITH MAGNETIC 1.00 NPT WITH
PIPE PLUG PIPE CAP FOR
OIL DRAIN

FIG. 1010. GE788HS7, HS8 OUTLINE. E41538.

1034
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

NOTES:
1.) MOTORIZED WHEEL MUST BE MOUNTED
AND INSTALLED ON TRUCK PER 41A239442.
2.) FLAT ON BOTTOM OF MOUNTING FLANGE
MUST BE PARALLEL TO GROUND WITHIN 3
WHEN MOUNTED UNDER ALL CONDITIONS OF
LOADING.
3.) REFERENCE SERVICE MANUAL. GEK84745

APPROX. WEIGHT= 21,050 LBS.

.125 PIPE PLUGS AVAILABLE AIR FLOW REQUIRED FOR MOTOR=
FOR GREASING OF DIRT SEAL 2600 CFM MINIMUM
(16 PIPE PLUGS EQ. SP.)
GREASE SPECIFICATION
D50E16 MOLYBDENUM
CHASSIS GREASE.

VIEW AT D
MAINTAIN .50 MIN. CLEARANCE
MOUNTING BETWEEN WHEEL RIM AND TWO
FACE SETS OF BOLT HEADS.
30.90 MIN.
.070
27.146 .020 3.454
D PIPE PLUGS FOR
.000 GREASING WHEEL
.005 BEARINGS CENTERLINE FOR
64.500 59.00 DUAL TIRES
DIA. DIA.
59.00 53.25
DIA. DIA.
MAX.

.375 50.50
(6CONN. DIA. 39.50
STRAPS) 44.50 DIA.
DIA. .000
.006 .005
.625 DIA. 4 HOLES .000 41.813
IN SUPPORTS FOR 39.002 DIA.
BRAKE LINES DIA. (FOR BRAKE
MTG.)

+.000
.000 .030
13.25 .030 45.140
46.75
DIA. DIA.
CENTER OF GRAVITY

27.62

SPACE REQUIRED
FOR REMOVAL OF SEE
SUN PINION DETAIL
F

63.00

28
2.10
16.48 13.12

APPROX
27.00

37.731

47.90

64.877.068

74.45

LENGTH REQUIRED TO
REMOVE MOTOR

FIG. 1010. GE788HS7, HS8 OUTLINE. E41538.

1035
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

.56 REF

.562518 THD.
(SIZE #6)
4 PLACES 6.355 .052
1.17
2.14 .35 .62511 TAP THRU
6.94 6 HOLES ON A 15.125 B.C.
FOR PARKING BRACK

.20

6.00
DIA
5.50

SECTION AA 1.062 DIA HOLE 13.000+.000 DIA.

5.75 DEEP AND .75 .003
ENLARGED
1.0014 TAP 2.75 DEEP
27 HOLES SPACED AS SHOWN VALVE AND
IN AUXILIARY VIEW DRIVER SLOT SECTION BB
ON 35.00 DIA. B.C. FOR SEE VIEW AT D
ZONE B11(SH.1) ENLARGED
BRAKE MOUNTING
1.375 DIA. THRU 1.0014 CLASS 3B TAP 1.69 DEEP
48 HOLES TOTAL 46 HOLES ON 43.25 DIA. B.C.
21 SPACES AT 7.5 FOR TIRE RIM & BRAKE MOUNTING
ON 61.75 DIA. B.C.
(BOTH SIDES)

o .25 PIPE PLUG (3 EQ. SP.EACH END)

157.5 FOR GREASING WHEEL HUB BEARINGS

.7510 TAP THRU

2 SETS OF 5 HOLES
SPACED AS SHOWN
FOR BRAKE MOUNTING
1.0014 TAP
6 HOLES ON 1.257 TAP THRU
35.00 DIA. BC. B 2 HOLES FOR
(FOR MOTOR JACKOUT) JACKOUT

OPEN AREA IN END OF

MOTOR FOR BRUSH
ACCESSIBILITY
(BOTH SIDES)

A B

1.0014 TAP
3 HOLES ON
35.00 DIA. B.C.
FOR JACKOUT

.8759 TAP THRU

2 SETS OF 4 HOLES
AS SHOWNFOR BRAKE MOUNTING
7.88

KEY FOR POSITIONING

15.75 MOTOR AT ASSEMBLY
(5 HOLES ON 3.94
CENTERS. 3.00 DIA.
S.F. TO DIM.)

FIG. 1010. GE788HS7, HS8 OUTLINE. E41538.

1036
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

.35
.62511 TAP THRU, 6875
DIA CBORE X .85 DEEP,
12 HOLES EQ. SP. ON A
12.75 DIA B.C. (NO ANGULAR
RELATIONSHIP WITH OTHER HOLES)

+.000
11.200 DIA
.002
14.00
DIA
+.000
7.000 DIA
.002

.75010 TAP THRU, .812 DIA

CBORE X 1.10 DEEP, 8 HOLES
EQ. SP. ON A 8.375 DIA B.C.
DETAIL F
SHOWING DETAIL OF BRAKE HUB

.37516 TAP THRU

4 SETS OF 2 HOLES
EQ. SP.

.25 DEEP POCKET

(4 PLACES)
AUXILIARY VIEW OF BRAKE ADAPTER

FIG. 1010. GE788HS7, HS8 OUTLINE. E41538.

1037
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

BEARING I.D.8.0012
GEAR TEETH (74) O.D.12.2047
2.9083 D.P. WIDTH3.228

BEARING I.D.36.614
RING GEAR O.D.41.732

ARMATURE
111 TEETH WIDTH3.622
2.9410 D.P.
BEARING I.D.3.3465
O.D.5.9055
WIDTH3.622

C
L
6

PINION 21 TEETH
5 2.941 D.P.

TORQUE TO
2124 FT.
LBS. A

17 CEMENT P17 IN PLACE IN

MAGNET FRAME WITH P29.
14
7 NOTE FOR P38
15 SPLINE BEFORE ASSEMBLING MOTOR (P2) TO
PINION 15 TEETH 8 35 TEETH G1 TRANSMISSION ASSEMBLY (P1),APPLY
2.9083 D.P. 8/16 D.P. A UNIFORM COAT OF P38 TO
MATING SURFACES OF BOTH. ALIGN
8 KEY IN FRAME STRUCTURE WITH
KEYWAY IN MAGNET FRAME.
7 SAME AS G1 EXCEPT MOTOR (P33)
G2
AND TRANS. ASM. (P36).
G3 SAME AS G2 EXCEPT MOTOR (P37).

NOTE:
TORQUE TO
15 14 5560 FT. LBS.
INSULATE ALL BOLTED ELECTRICAL
CONNECTIONS WITH P25 PER
ENLARGED VIEW AT A P6GEP50. WRAP WITH P26 & P27
& BRUSH THOROUGHLY WITH P28

FIG. 1011. GE788B, BS2, BS3, BS4 TRANSMISSION AND MOTOR ASSEMBLY. E41523.

1038
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

40

BEARING: I.D.36.535 39
36
1 O.D.41.732
WIDTH3.622
C ARMATURE
L

3 31 G4 SAME AS G1 EXCEPT MOTOR (P39)

AND TRANS. ASM. (P40).
2 33 37

SPLINE 35 TEETH
8/16 D.P.
TORQUE TO
440495 FT. LB.
31
30

22
21
THERMAL
SENSOR CABLE#

CONNECT SPEED SENSOR CABLE

TO SPEED SENSOR AND CONNECT
THERMAL SENSOR CABLE TO
COMM. COIL AT THE
4 OCLOCK POSITION

18

32

FIG. 1011. GE788B, BS2, BS3, BS4 TRANSMISSION AND MOTOR ASSEMBLY. E41523.

1039
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

32

2 33 37
23
24

ENLARGED SECTION BB (G1, G2 & G3)

ENLARGED SECTION CC (G1 ONLY)
C 36
1
31 3
TORQUE TO
530575 FT. LB.

C
37 33 2
B

21

32
32

34
35 S, SX SS, SSX
33
SX, SSX 37
S, SS
ENLARGED SECTION CC
(G2 & G3 ONLY)
FIG. 1011. GE788B, BS2, BS3, BS4 TRANSMISSION AND MOTOR ASSEMBLY. E41523.

1040
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

G1 = GE788B1
G2 = GE788BS3
G3 = GE788BS2
G4 = GE788BS4

G4 G3 G2 G1 REF. DESCRIPTION
1 1 TRANSMISSION ASSEMBLY
1 2 MOTOR ASSEMBLY
9 9 9 9 3 BOLT, SOCKET HEAD, 114 X 5
1 1 1 1 4 COVER
6 6 6 6 5 BOLT
1 1 1 1 6 GASKET
1 1 1 1 7 PINION SHAFT AND RING GEAR ASSEMBLY
1 1 1 1 8 DRIVE RING
1 1 1 1 14 BOLT, 0.513 X 4
1 1 1 1 15 WASHER
1 1 1 1 17 SEAL
3 3 3 3 18 TIE WRAP
1 1 1 1 19 NAME PLATE
2 2 2 2 20 ESCUTCHEON PIN NO. 12 X 3/8
1 1 1 1 21 BRAKE HUB
1 1 1 1 22 END PLATE
4 4 4 8 23 BOLT, 0.37516 X 1
4 4 4 8 24 LOCKWASHER, 0.375
AR AR AR AR 25 COMPOUND
6 6 6 6 26 INSULATION, 3 X 5
6 6 6 6 27 OUTSIDE TAPE, 2 FT. (1T 1/2L)
AR AR AR AR 28 VARNISH
AR AR AR AR 29 CEMENT
1 1 1 1 30 BOLT, 18 X 2.5
10 10 10 10 31 WASHER
1 1 1 1 32 ADAPTER RING
1 33 MOTOR ASSEMBLY
4 4 4 34 BOLT/WASHER, 0.3118 X 0.62
4 4 4 35 LOCKWASHER, 0.31 MED.
1 1 36 TRANSMISSION ASSEMBLY
1 37 MOTOR ASSEMBLY
16oz. 16oz. 16oz. 16oz. 38 COATING
1 39 MOTOR ASSEMBLY
1 40 TRANSMISSION ASSEMBLY

FIG. 1011. GE788B, BS2, BS3, BS4 TRANSMISSION AND MOTOR ASSEMBLY. E41523.

1041
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

NOTE FOR P6:

APPLY .18 CONTINUOUS BEAD OF P6 ON P4
BOLT CIRCLE & BELOW BOLT HOLES.
BEARING I.D.8.0012
GEAR TEETH (74) O.D.12.2047
2.9083 D.P. WIDTH3.228

42.06

BEARING I.D.36.614
RING GEAR O.D.41.732

ARMATURE
111 TEETH WIDTH3.622
2.9410 D.P.
BEARING I.D.3.3465
O.D.5.9055
WIDTH3.622

C
L
SEE
6 NOTE

PINION 21 TEETH
5 2.941 D.P.
TORQUE TO
2124 FT.
LBS.
A

CEMENT P17 IN PLACE IN

17 FRAME STRUCTURE WITH P29.
16 7 9 14
10
15 G1 BEFORE ASSEMBLING MOTOR (P31) TO
PINION 15 TEETH 8 SPLINE TRANSMISSION ASSEMBLY (P30), GREASE
2.9083 D.P. 35 TEETH UNDERSIDE OF MAGNET FRAME. ALIGN
PRICK PUNCH P11 8/16 D.P. KEY IN FRAME STRUCTURE WITH KEYWAY
11 TO P7 AFTER IN MAGNET FRAME.
8 TIGHTENING 13
12
G2 SAME AS G1
9 EXCEPT AS SHOWN

7 G3 SAME AS G2
EXCEPT AS SHOWN

10
NOTE:
TORQUE TO INSULATE ALL BOLTED ELECTRICAL
15 14 5560 FT. LBS. CONNECTIONS WITH P25 PER
P6GEP50. WRAP WITH P26 & P27
ENLARGED VIEW AT A & BRUSH THOROUGHLY WITH P28

FIG. 1012. GE788BS1 TRANSMISSION AND MOTOR ASSEMBLY. E41524.

1042
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

ARMATURE

1
30
BEARING: I.D.36.535
C
L

O.D.41.732
WIDTH3.622

3
38
41
31

SPLINE 35 TEETH
8/16 D.P.
TORQUE TO
440495 FT. LB.
37
38

35

34
40
TERMINAL
SENSOR CABLE

REMOVE SPEED SENSOR CABLE

FROM POCKET IN FRAME STRUCTURE
AND CONNECT TO SPEED SENSOR

TIE SPEED SENSOR CABLE 18

TO STAPLE WITH P18 &
PAINT P18 WITH 2 COATS
OF P28.

32
39

FIG. 1012. GE788BS1 TRANSMISSION AND MOTOR ASSEMBLY. E41524.

1043
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

21 S, SX SS, SSX
30
22 23 24
31
SX, SSX TORQUE TO
2124 FT.LBS.
S, SS ENLARGED SECTION BB 33
(G1 & G2)

41 38 3
31 32 36
TORQUE TO
790863 FT. LB. ENLARGED SECTION BB
(G1 ONLY) 1
30

B
31
C

VIEW WITH HUB CAP ADAPTER (P33)

AND HUB CAP (P36) REMOVED

31
24 23

ENLARGED SECTION CC

FIG. 1012. GE788BS1 TRANSMISSION AND MOTOR ASSEMBLY. E41524.

1044
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

G3 = GE788BS1

G3 G2 G1 REF. DESCRIPTION
1 1 TRANSMISSION ASSEMBLY
9 3 BOLT, SOCKET HEAD, 112 X 6
1 1 1 4 COVER
6 6 6 5 BOLT
1 1 1 6 SEALER
1 1 1 7 PINION SHAFT AND RING GEAR ASSEMBLY
1 1 1 8 DRIVE RING
1 1 1 9 PILOT SLEEVE
1 1 1 10 RETAINING RING
1 1 1 11 NUT
1 1 1 12 SLEEVE
1 1 1 13 ORING
1 1 1 14 BOLT, 0.513 X 4
1 1 1 15 WASHER
1 1 1 16 RING
1 1 1 17 SEAL
1 1 1 18 TIE WRAP
1 1 1 19 NAME PLATE
2 2 2 20 ESCUTCHEON PIN NO. 12 X 3/8
4 4 2 21 BOLT/WASHER, 0.3118 X 0.62
4 4 2 22 LOCKWASHER, 0.31
4 4 16 23 BOLT, 0.37516 X 1
4 4 16 24 LOCKWASHER, 0.375
AR AR AR 25 COMPOUND
6 6 4 26 INSULATION, 3 X 5
6 6 4 27 OUTSIDE TAPE, 2 FT. (1T 1/2L)
AR AR AR 28 VARNISH
AR AR AR 29 CEMENT
1 1 30 TRANSMISSION ASSEMBLY
1 1 1 31 MOTOR ASSEMBLY
1 32 ADAPTER RING
1 33 HUB CAP ADAPTER
1 34 BRAKE HUB
1 1 1 35 END PLATE
1 36 HUB CAP
1 1 1 37 BOLT, 18 X 2.5
10 10 10 38 WASHER
1 1 39 ADAPTER RING
1 1 40 BRAKE HUB
9 9 41 BOLT, SOCKET HEAD, 112 X 5

FIG. 1012. GE788BS1 TRANSMISSION AND MOTOR ASSEMBLY. E41524.

1045
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

BEARING I.D.8.0012
GEAR TEETH (74) O.D.12.2047
3.000 D.P. WIDTH3.228

42.06

BEARING I.D.36.614
RING GEAR O.D.41.732
111 TEETH

ARMATURE
WIDTH3.622
2.9410 D.P.
BEARING I.D.3.3465
O.D.5.9055
WIDTH3.622

C
L
6

PINION 21 TEETH
5 2.941 D.P.

TORQUE TO
2124 FT.
LBS. A
4

17 CEMENT P17 IN PLACE IN

MAGNET FRAME WITH P29.
7 14
15 NOTE FOR P36
SPLINE BEFORE ASSEMBLING MOTOR (P2 ) TO
8
35 TEETH TRANSMISSION ASSEMBLY (P1), APPLY
PINION 18 TEETH
8/16 D.P. G1 A UNIFORM COAT OF P36 TO
3.000 D.P.
MATING SURFACES OF BOTH. ALIGN
8 KEY IN FRAME STRUCTURE WITH
KEYWAY IN MAGNET FRAME.
7
SAME AS G1 EXCEPT DIFFERENT
G2 MOTOR(P33)

15 14 TORQUE TO
5560 FT. LBS.
ENLARGED VIEW AT A

FIG. 1013. GE788CS TRANSMISSION AND MOTOR ASSEMBLY. E41525.

1046
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

40

39
APPLY LIGHT FILM OF OIL
(P36) BEFORE ASSEMBLY
BEARING: I.D.36.535
O.D.41.732
1
WIDTH3.622

G3
SAME AS G1 EXCEPT MOTOR (P39)
AND TRANS. ASM. (P40).
TORQUE TO
530575 FT. LB.
3 31
33
2

SPLINE 35 TEETH
8/16 D.P.
TORQUE TO
440495 FT. LB.
31
30

THERMAL 22
SENSOR CABLE
21

REMOVE SPEED SENSOR CABLE

FROM POCKET IN FRAME STRUCTURE
AND CONNECT TO SPEED SENSOR
AND CONNECT THERMAL
SENSOR CABLE TO COMM.
TIE SPEED SENSOR CABLE 18 COIL AT 4 OCLOCK
TO STAPLE WITH P18 & POSITION#
PAINT P18 WITH 2 COATS
OF P28.

32

FIG. 1013. GE788CS TRANSMISSION AND MOTOR ASSEMBLY. E41525.

1047
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

32

34
S, SX SS, SSX
35
33 ENLARGED SECTION CC
SX, SSX
2
S, SS

C 1

TORQUE TO
530575 FT. LB.
3 31

C
2
B

21

32
32

2
A, AA 23 33
24
ENLARGED SECTION BB

FIG. 1013. GE788CS TRANSMISSION AND MOTOR ASSEMBLY. E41525.

1048
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

G1 = GE788CS1
G2 = GE788CS2
G3 = GE788CS3

G3 G2 G1 REF. DESCRIPTION
1 1 1 TRANSMISSION ASSEMBLY
1 2 LONGITUDINAL ASSEMBLY
9 9 9 3 BOLT, SOCKET HEAD, 114 X 5
1 1 1 4 COVER
6 6 6 5 BOLT, WHIZLOCK, 0.37516 X 0.75
1 1 1 6 GASKET
1 1 1 7 PINION SHAFT AND RING GEAR ASSEMBLY
1 1 1 8 DRIVE RING
1 1 1 14 BOLT, 0.513 X 4
1 1 1 15 HARD WASHER, 0.5
1 1 1 17 SEAL RING
1 1 1 18 TIE WRAP
1 1 1 19 NAME PLATE
2 2 2 20 ESCUTCHEON PIN NO. 12 X 3/8
1 1 1 21 BRAKE HUB
1 1 1 22 END PLATE
4 4 4 23 BOLT, 0.37516 X 1
4 4 4 24 LOCKWASHER, 0.375
AR AR AR 25 PUTTY
6 6 6 26 TAPE
4 4 4 27 TAPE
AR AR AR 28 VARNISH
AR AR AR 29 CEMENT
1 1 1 30 BOLT, 18 X 2.5
10 10 10 31 HARD WASHER, 1
1 1 1 32 ADAPTER RING
1 33 LONGITUDINAL ASSEMBLY
4 4 4 34 BOLT/WASHER, 0.3118 X 0.62
4 4 4 35 LOCKWASHER, 0.31
16oz. 16oz. 16oz. 36 COMPOUND
2 2 2 37 TAPE
1 39 LONGITUDINAL ASSEMBLY
1 40 TRANSMISSION ASSEMBLY

FIG. 1013. GE788CS TRANSMISSION AND MOTOR ASSEMBLY. E41525.

1049
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

BEARING I.D.8.0012
GEAR TEETH (74) O.D.12.2047
2.9083 D.P. WIDTH3.228

42.06

BEARING I.D.36.614
RING GEAR O.D.41.732

L ARMATURE
111 TEETH WIDTH3.622
2.9410 D.P.
BEARING I.D.3.3465
O.D.5.9055
WIDTH3.622

C
D

PINION 21 TEETH
5 2.941 D.P.
TORQUE TO
2124 FT.
LBS.
A

7 14
NOTE FOR P9
15 SPLINE BEFORE ASSEMBLING MOTOR (P2) TO
PINION 15 TEETH 8 35 TEETH G1 TRANSMISSION ASSEMBLY (P1),APPLY
2.9083 D.P. 8/16 D.P. A UNIFORM COAT OF P9 TO
MATING SURFACES OF BOTH. ALIGN
8 KEY IN FRAME STRUCTURE WITH
KEYWAY IN MAGNET FRAME.
7

G2 SAME AS G1 EXCEPT DIFFERENT

MOTOR AND TRANS. ASSEMBLY

G3 SAME AS G1 EXCEPT MOTOR

NOTE:
15 14 TORQUE TO INSULATE ALL BOLTED ELECTRICAL
5560 FT. LBS. CONNECTIONS WITH P25 PER
ENLARGED VIEW AT A P6GEP50. WRAP WITH P26 & P27
& BRUSH THOROUGHLY WITH P28
FIG. 1014. GE788DS, ES2 TRANSMISSION AND MOTOR ASSEMBLY. E41526.

1050
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

26 3.00 X 5.00

27 1 TAPING, 1/2 LAP

33
1
L ARMATURE

TORQUE P31 TO
BEARING: I.D.36.535 3036 FT.LB.
O.D.41.732 31 G1 ONLY
WIDTH3.622
C

30 G1 ONLY

3 13

35
32
2

SPLINE 35 TEETH
8/16 D.P.
TORQUE TO
440495 FT. LB.
13
TIE CABLES TOGETHER 16
WITH P34 AT 6.00 &
14.00 FROM
CABLE CLAMP

TIE CABLE SETS

TOGETHER WITH P34
AT 3.00 & 8.00 FROM 22
CABLE CLAMPS
21
THERMAL
SENSOR CABLE#

CONNECT SPEED SENSOR CABLE

T3
T2 TO SPEED SENSOR AND CONNECT
THERMAL SENSOR CABLE TO
COMM. COIL AT THE
4 OCLOCK POSITION
REDUCED
PARTIAL VIEW 18
AT D

12

FIG. 1014. GE788DS, ES2 TRANSMISSION AND MOTOR ASSEMBLY. E41526.

1051
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

12

10
S, SX SS, SSX
1 11 2 32 35
SX, SSX
S, SS ENLARGED SECTION CC

12 C

30
13 3
TORQUE TO
530575 FT. LB. 31

C
35
2 32
B

21

12

2
32
35
23
24
B.H. CABLES(P2)
ENLARGED SECTION BB
FIG. 1014. GE788DS, ES2 TRANSMISSION AND MOTOR ASSEMBLY. E41526.

1052
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

G1 = GE788DS1
G2 = GE788ES2
G3 = GE788DS2

G3 G2 G1 REF. DESCRIPTION
1 1 1 TRANSMISSION ASSEMBLY
1 2 LONGITUDINAL ASSEMBLY
9 9 9 3 BOLT, SOCKET HEAD, 114 X 5
1 1 1 4 COVER
6 6 6 5 BOLT, WHIZLOCK, 0.37516 X 0.75
1 1 1 6 GASKET
1 1 1 7 PINION SHAFT AND RING GEAR ASSEMBLY
1 1 1 8 DRIVE RING
16oz. 16oz. 16oz. 9 COMPOUND
4 4 4 10 LOCKWASHER, 0.375
4 4 4 11 BOLT, 0.37518 X 0.625
1 1 1 12 BRAKE ADAPTER
10 10 10 13 HARD WASHER, 1
1 1 1 14 BOLT, 0.513 X 4
1 1 1 15 HARD WASHER, 0.5
1 1 1 16 BOLT, 18 X 2.5
3 3 3 18 TIE WRAP
1 1 1 19 NAME PLATE
2 2 2 20 ESCUTCHEON PIN NO. 12 X 3/8
1 1 1 21 BRAKE HUB
1 1 1 22 END PLATE
4 4 4 23 BOLT, 0.37516 X 1
4 4 4 24 LOCKWASHER, 0.375
AR AR AR 25 PUTTY
6 6 6 26 INSULATION
6 6 6 27 OUTSIDE TAPE
AR AR AR 28 VARNISH
4 4 30 HUB CAP BA
8 8 31 BOLT
1 32 LONGITUDINAL ASSEMBLY
1 33 TRANSMISSION ASSEMBLY
6 6 6 34 CABLE TIE
1 35 LONGITUDINAL ASSEMBLY

FIG. 1014. GE788DS, ES2 TRANSMISSION AND MOTOR ASSEMBLY. E41526.

1053
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

BEARING I.D.8.0012
GEAR TEETH (74) O.D.12.2047
2.9083 D.P. WIDTH3.228
(G1,3,5,7&9)
GEAR TEETH (74) 42.06
3.000 D.P.
(G2,4,6&8) BEARING I.D.36.614
RING GEAR O.D.41.732

ARMATURE
111 TEETH G1G5,G8&9 WIDTH3.622
2.9410 D.P.
BEARING I.D.3.3465
87 TEETH O.D.5.9055
2.320 D.P. G6&7 WIDTH3.622

L
C
D

16 TEETH
PINION 21 TEETH2.320 D.P.(G6&7)
5 2.941 D.P.
(G15,8&9)
TORQUE TO
23 1 FT.
LBS.
A

4
NOTE FOR P9
BEFORE ASSEMBLING MOTOR (P2 OR P31) TO
G1 TRANSMISSION ASSEMBLY (P1 OR P30),APPLY
A UNIFORM COAT OF P9 TO
7 14 MATING SURFACES OF BOTH. ALIGN
15 KEY IN FRAME STRUCTURE WITH
32 8 SPLINE KEYWAY IN MAGNET FRAME.
PINION 15 TEETH
35 TEETH G2 SAME AS G1 EXCEPT
2.9083 D.P.
(G1,3,5,7&9) 8/16 D.P. FOR P30,31 & 32#
PINION 18 TEETH 8 G3 SAME AS G1 EXCEPT FOR P31
32 3.000 D.P.
(G2,4,6&8) G4 SAME AS G2 EXCEPT MOTOR
7
G5 SAME AS G3 EXCEPT MOTOR
G6 SAME AS G4 EXCEPT TRANS ASM

G7 SAME AS G5 EXCEPT TRANS ASM

G8 SAME AS G4 EXCEPT MOTOR
G9 SAME AS G5 EXCEPT MOTOR
15 14 TORQUE TO
58 2 FT. LBS. G10 SAME AS G7 EXCEPT MOTOR
ENLARGED VIEW AT A

FIG. 1015. GE788ES1, HS1HS6 TRANSMISSION AND MOTOR ASSEMBLY. E41527.

1054
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

TIE CABLES TOGETHER

WITH P33 AT 6.00 &
14.00 FROM
CABLE CLAMP TIE CABLE SETS
TOGETHER WITH P33
AT 3.00 & 8.00 FROM
CABLE CLAMPS

36 T3
T2
35
L ARMATURE

30
1 BEARING: I.D.36.535
O.D.41.732 REDUCED
WIDTH3.622 PARTIALAT D
VIEW
C

3 13

37
2 31 34

SPLINE 35 TEETH
8/16 D.P.
TORQUE TO
468 27 FT. LB.
13
16

22

21
THERMAL
SENSOR CABLE#

CONNECT SPEED SENSOR CABLE

TO SPEED SENSOR AND CONNECT
THERMAL SENSOR CABLE TO
COMM. COIL AT THE
4 OCLOCK POSITION

18

12

FIG. 1015. GE788ES1, HS1HS6 TRANSMISSION AND MOTOR ASSEMBLY. E41527.

1055
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

12

10 S, SX
11 SS, SSX
2 31
SX, SSX 34
S, SS ENLARGED SECTION CC NOTE:
INSULATE ALL BOLTED ELECTRICAL
1 30 35 36 CONNECTIONS(6 TOTAL) WITH P25 PER
P6GEP50. WRAP WITH P26(3.00 X 5.00 PC)
12 C AND P27 (1T. 1/2 L.)
& BRUSH THOROUGHLY WITH P28

13 3
TORQUE TO 26 3.00 X 5.00
553 22 FT. LB.

C
37
2 31 34
B

21

12

2
31
23 34
24 B.H. CABLES(P2)
ENLARGED SECTION BB

FIG. 1015. GE788ES1, HS1HS6 TRANSMISSION AND MOTOR ASSEMBLY. E41527.

1056
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

G1 = GE788ES1 G6 = GE788HS5
G2 = GE788HS1 G7 = GE788HS6
G3 = GE788HS2 G8 = GE788HS3A
G4 = GE788HS3 G9 = GE788HS4A
G5 = GE788HS4 G10 = GE788HS6A

G10 G9 G8 G7 G6 G5 G4 G3 G2 G1 REF. DESCRIPTION

1 1 1 1 1 TRANSMISSION ASSEMBLY
1 2 LONGITUDINAL ASSEMBLY
9 9 9 9 9 9 9 9 9 3 BOLT, SOCKET HEAD, 114 X 5
1 1 1 1 1 1 1 1 1 1 4 COVER
6 6 6 6 6 6 6 6 6 6 5 BOLT, WHIZLOCK, 3/816 X 3/4
1 1 1 1 1 1 1 1 1 1 6 GASKET
1 1 1 1 1 1 7 PINION SHAFT AND RING GEAR ASSEMBLY
1 1 1 1 1 1 1 1 1 1 8 DRIVE RING
16oz. 16oz. 16oz. 16oz. 16oz. 16oz. 16oz. 16oz. 16oz. 16oz. 9 COMPOUND
4 4 4 4 4 4 4 4 4 4 10 LOCKWASHER, 5/16
4 4 4 4 4 4 4 4 4 4 11 BOLT/WASHER, 5/1618 X 5/8
1 1 1 1 1 1 1 1 1 1 12 BRAKE ADAPTER
10 10 10 10 10 10 10 10 10 10 13 WASHER, 1
1 1 1 1 1 1 1 1 1 1 14 BOLT, 1/213 X 4
1 1 1 1 1 1 1 1 1 1 15 HARDENED WASHER, 1/2
1 1 1 1 1 1 1 1 1 1 16 BOLT, 18 X 2 1/2
3 3 3 3 3 3 3 3 3 3 18 TIE WRAP
1 1 1 1 1 1 1 1 1 1 19 NAME PLATE
2 2 2 2 2 2 2 2 2 2 20 ESCUTCHEON PIN NO. 12 X 3/8
1 1 1 1 1 1 1 1 1 1 21 BRAKE HUB
1 1 1 1 1 1 1 1 1 1 22 END PLATE
4 4 4 4 4 4 4 4 4 4 23 BOLT, 3/816 X 1
4 4 4 4 4 4 4 4 4 4 24 LOCKWASHER, 3/8
AR AR AR AR AR AR AR AR AR AR 25 PUTTY, SILASTIC
6 6 6 6 6 6 6 6 6 6 26 INSULATION
6 6 6 6 6 6 6 6 6 6 27 OUTSIDE TAPE
AR AR AR AR AR AR AR AR AR AR 28 VARNISH
1 1 1 30 TRANSMISSION ASSEMBLY
1 1 31 LONGITUDINAL ASSEMBLY
1 1 1 1 32 PINION SHAFT AND RING GEAR ASSEMBLY
6 6 6 6 6 6 6 6 6 6 33 CABLE TIE
1 1 1 1 34 LONGITUDINAL ASSEMBLY
1 35 TRANSMISSION ASSEMBLY
1 1 36 TRANSMISSION ASSEMBLY
1 1 1 37 LONGITUDINAL ASSEMBLY

FIG. 1015. GE788ES1, HS1HS6 TRANSMISSION AND MOTOR ASSEMBLY. E41527.

1057
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

GEAR: BEARING I.D.8.0012

74T 2.9083 DP (G2,G4,G5,G8) O.D.12.2047
74T 3.0000 DP (G1,G3,G6,G7) WIDTH3.228

42.06
BEARING I.D.36.614
RING GEAR O.D.41.732
111 TEETH

L ARMATURE
WIDTH3.622
2.9410 D.P.} G1G4,G7,68
87 TEETH
2.320 D.P. } G5,G6
BEARING I.D.3.3465
O.D.5.9055
WIDTH3.622

C
D

PINION 21 TEETH, 2.941 D.P. (G1G4,G7,G8)

16 TEETH, 2.320 D.P. (G5,G6)
5

TORQUE TO
23 1 FT.
LBS.
A

4
NOTE FOR P9
BEFORE ASSEMBLING MOTOR TO
G1 TRANSMISSION ASSEMBLY, APPLY
A UNIFORM COAT OF P9 TO
7 14 MATING SURFACES OF BOTH. ALIGN
32 15 SPLINE KEY IN FRAME STRUCTURE WITH
8 35 TEETH KEYWAY IN MAGNET FRAME.
PINION
15T 2.9083 DP (G2,G4,G5,G8) 8/16 D.P. G2 SAME AS G1 EXCEPT AS NOTED
18T 3.0000 DP (G1,G3,G6,G7)
8 G3
32 SAME AS G1 EXCEPT MOTOR

7 G4 SAME AS G2 EXCEPT MOTOR

G5 SAME AS G4 EXCEPT TRANS. ASM.
G6 SAME AS G3 EXCEPT TRANS. ASM.
G7 SAME AS G3 EXCEPT MOTOR
G8 SAME AS G4 EXCEPT MOTOR
15 14 TORQUE TO
G9
58 2 FT. LBS. SAME AS G5 EXCEPT MOTOR
ENLARGED VIEW AT A

FIG. 1016. GE788FS1FS6 TRANSMISSION AND MOTOR ASSEMBLY. E41528.

1058
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

TIE CABLES TOGETHER

WITH P34 AT 6.00 &
14.00 FROM
TIE CABLE SETS
CABLE CLAMP
TOGETHER WITH P34
AT 3.00 & 8.00 FROM
CABLE CLAMPS

37
36
T3
T2
33
30
L ARMATURE

BEARING: I.D.36.535 REDUCED

O.D.41.732 PARTIAL VIEW AT D 26 3.00 X 5.00
WIDTH3.622
C

3 13

35 38
31

SPLINE 35 TEETH
8/16 D.P.
TORQUE TO
468 27 FT. LB.
13
16

22
21
THERMAL
SENSOR CABLE

CONNECT SPEED SENSOR CABLE

TO SPEED SENSOR AND CONNECT
THERMAL SENSOR CABLE TO
COMM. COIL AT THE
4 OCLOCK POSITION

18

12

FIG. 1016. GE788FS1FS6 TRANSMISSION AND MOTOR ASSEMBLY. E41528.

1059
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

12

37 10 S, SX
11 SS, SSX
36 31
SX, SSX
33 35
S, SS
30
ENLARGED SECTION CC
12 C

13 3
TORQUE TO
553 22 FT. LB.

C
31
B

21

12

31 35

24 23
B.H. CABLES(P2)
ENLARGED SECTION BB

FIG. 1016. GE788FS1FS6 TRANSMISSION AND MOTOR ASSEMBLY. E41528.

1060
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

G1 = GE788FS1 G6 = GE788FS6
G2 = GE788FS2 G7 = GE788FS3A
G3 = GE788FS3 G8 = GE788FS4A
G4 = GE788FS4 G9 = GE788FS5A
G5 = GE788FS5

G9 G8 G7 G6 G5 G4 G3 G2 G1 REF. DESCRIPTION
9 9 9 9 9 9 9 9 9 3 BOLT, SOCKET HEAD, 114 X 5
1 1 1 1 1 1 1 1 1 4 COVER
6 6 6 6 6 6 6 6 6 5 BOLT, WHIZLOCK, 3/816 X 3/4
1 1 1 1 1 1 1 1 1 6 GASKET
1 1 1 1 7 PINION SHAFT AND RING GEAR ASSEMBLY
1 1 1 1 1 1 1 1 1 8 DRIVE RING
16oz. 16oz. 16oz. 16oz. 16oz. 16oz. 16oz. 16oz. 16oz. 9 COMPOUND
4 4 4 4 4 4 4 4 4 10 LOCKWASHER, 5/16
4 4 4 4 4 4 4 4 4 11 BOLT/WASHER, 5/1618 X 5/8
1 1 1 1 1 1 1 1 1 12 BRAKE ADAPTER
10 10 10 10 10 10 10 10 10 13 WASHER, 1
1 1 1 1 1 1 1 1 1 14 BOLT, 1/213 X 4
1 1 1 1 1 1 1 1 1 15 HARDENED WASHER, 1/2
1 1 1 1 1 1 1 1 1 16 BOLT, 18 X 2 1/2
3 3 3 3 3 3 3 3 3 18 TIE WRAP
1 1 1 1 1 1 1 1 1 19 NAME PLATE
2 2 2 2 2 2 2 2 2 20 ESCUTCHEON PIN NO. 12 X 3/8
1 1 1 1 1 1 1 1 1 21 BRAKE HUB
1 1 1 1 1 1 1 1 1 22 END PLATE
4 4 4 4 4 4 4 4 4 23 BOLT, 3/816 X 1
4 4 4 4 4 4 4 4 4 24 LOCKWASHER, 3/8
AR AR AR AR AR AR AR AR AR 25 PUTTY, SILASTIC
6 6 6 6 6 6 6 6 6 26 INSULATION
6 6 6 6 6 6 6 6 6 27 OUTSIDE TAPE
AR AR AR AR AR AR AR AR AR 28 VARNISH
1 1 1 30 TRANSMISSION ASSEMBLY
1 1 31 LONGITUDINAL ASSEMBLY
1 1 1 1 1 32 PINION SHAFT AND RING GEAR ASSEMBLY
1 1 1 33 TRANSMISSION ASSEMBLY
6 6 6 6 6 6 6 6 6 34 CABLE TIE
1 1 1 1 35 LONGITUDINAL ASSEMBLY
1 1 36 TRANSMISSION ASSEMBLY
1 37 TRANSMISSION ASSEMBLY
1 1 1 38 LONGITUDINAL ASSEMBLY

FIG. 1016. GE788FS1FS6 TRANSMISSION AND MOTOR ASSEMBLY. E41528.

1061
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

GEAR: BEARING I.D.8.0012

74T 3.0000 DP (G2&4) O.D.12.2047
74T 2.9083 DP (G1&3) WIDTH3.228

42.06
BEARING I.D.36.614
O.D.41.732

L ARMATURE
WIDTH3.622
RING GEAR
87 TEETH
2.320 D.P.
BEARING I.D.3.3465
O.D.5.9055
WIDTH3.622

C
D

5 PINION 16 TEETH, 2.320 D.P.

TORQUE TO
23 1 FT.
LBS. A

NOTE FOR P9
14 BEFORE ASSEMBLING MOTOR TO
7 G1 TRANSMISSION ASSEMBLY, APPLY
2 15 SPLINE A UNIFORM COAT OF P9 TO
8 35 TEETH
PINION MATING SURFACES OF BOTH. ALIGN
18T 3.0000 DP (G2&4) 8/16 D.P. KEY IN FRAME STRUCTURE WITH
15T 2.9083 DP (G1&3) KEYWAY IN MAGNET FRAME.
2 8 G2 SAME AS G1 EXCEPT DIFFERENT
SUN PINION (P7) AND TRANS. (P1)
7
G3 SAME AS G1 EXCEPT DIFFERENT
MOTOR.
G4 SAME AS G2 EXCEPT DIFFERENT
MOTOR.
G5 SAME AS G1 EXCEPT DIFFERENT
WHEEL HUB.
15 14 TORQUE TO G6 SAME AS G3 EXCEPT DIFFERENT
58 2 FT. LBS.
WHEEL HUB.
ENLARGED VIEW AT A
FIG. 1017. GE788FS7FS9 TRANSMISSION AND MOTOR ASSEMBLY. E41529.

1062
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

TIE CABLES TOGETHER

WITH P17 AT 6.00 &
14.00 FROM
CABLE CLAMP TIE CABLE SETS
TOGETHER WITH P17
AT 3.00 & 8.00 FROM
CABLE CLAMPS

36
T3
T2
1
30

BEARING: I.D.36.535 REDUCED

O.D.41.732 PARTIAL VIEW AT D
WIDTH3.622

3 13

35
31

SPLINE 35 TEETH
8/16 D.P.

TORQUE TO
468 27 FT. LB.
13
16

22

THERMAL 21
SENSOR CABLE#

CONNECT SPEED SENSOR CABLE

TO SPEED SENSOR AND CONNECT
THERMAL SENSOR CABLE TO
COMM. COIL AT THE
4 OCLOCK POSITION

18

12

FIG. 1017. GE788FS7FS9 TRANSMISSION AND MOTOR ASSEMBLY. E41529.

1063
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

12

26 3.00 X 5.00

10
11 S, SX SS, SSX
36 31
SX, SSX
1 35
S, SS
30 ENLARGED SECTION CC

12 C
NOTE:
INSULATE ALL BOLTED ELECTRICAL
CONNECTIONS (6 TOTAL) WITH P25 PER
P6GEP50. WRAP WITH P26 (3.00 X 5.00 PC.)
13 3 AND P27 (1T1/2L)
& BRUSH THOROUGHLY WITH P28
TORQUE TO
553 22 FT. LB.

C
31
B

21

12

31
35
23
24
B.H. CABLES(P2)
ENLARGED SECTION BB

FIG. 1017. GE788FS7FS9 TRANSMISSION AND MOTOR ASSEMBLY. E41529.

1064
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

G1 = GE788FS7
G2 = GE788FS8
G3 = GE788FS7A
G4 = GE788FS8A
G5 = GE788FS9
G6 = GE788FS9A

G6 G5 G4 G3 G2 G1 REF. DESCRIPTION
1 1 1 TRANSMISSION ASSEMBLY
1 1 1 1 2 PINION SHAFT AND RING GEAR ASSEMBLY
9 9 9 9 9 9 3 BOLT, SOCKET HEAD, 114 X 5
1 1 1 1 1 1 4 COVER
6 6 6 6 6 6 5 BOLT, WHIZLOCK, 3/816 X 3/4
1 1 1 1 1 1 6 GASKET
1 1 7 PINION SHAFT AND RING GEAR ASSEMBLY
1 1 1 1 1 1 8 DRIVE RING
16oz. 16oz. 16oz. 16oz. 16oz. 16oz. 9 COMPOUND
4 4 4 4 4 4 10 LOCKWASHER, 5/16
4 4 4 4 4 4 11 BOLT/WASHER, 5/1618 X 5/8
1 1 1 1 1 1 12 BRAKE ADAPTER
10 10 10 10 10 10 13 WASHER, 1
1 1 1 1 1 1 14 BOLT, 1/213 X 4
1 1 1 1 1 1 15 HARDENED WASHER, 1/2
1 1 1 1 1 1 16 BOLT, 18 X 2 1/2
6 6 6 6 6 6 17 CABLE TIE
3 3 3 3 3 3 18 TIE WRAP
1 1 1 1 1 1 19 NAME PLATE
2 2 2 2 2 2 20 ESCUTCHEON PIN NO. 12 X 3/8
1 1 1 1 1 1 21 BRAKE HUB
1 1 1 1 1 1 22 END PLATE
4 4 4 4 4 4 23 BOLT, 3/816 X 1
4 4 4 4 4 4 24 LOCKWASHER, 3/8
AR AR AR AR AR AR 25 PUTTY, SILASTIC
6 6 6 6 6 6 26 INSULATION
6 6 6 6 6 6 27 OUTSIDE TAPE
AR AR AR AR AR AR 28 VARNISH
1 1 30 TRANSMISSION ASSEMBLY
1 1 1 31 LONGITUDINAL ASSEMBLY
6 6 6 6 6 6 34 CABLE TIE
1 1 1 35 LONGITUDINAL ASSEMBLY
1 1 36 TRANSMISSION ASSEMBLY

FIG. 1017. GE788FS7FS9 TRANSMISSION AND MOTOR ASSEMBLY. E41529.

1065
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

BEARING I.D.8.0012
GEAR TEETH (74) O.D.12.2047
2.9083 D.P. WIDTH3.228
(G1&3)
GEAR TEETH (74) 42.06
3.000 D.P.
(G2&4) BEARING I.D.36.614
O.D.41.732

L ARMATURE
WIDTH3.622
RING GEAR BEARING I.D.3.3465
87 TEETH O.D.5.9055
2.320 D.P. WIDTH3.622

C
D

16 TEETH
5 2.320 D.P.
TORQUE TO
23 1 FT.
LBS. A

7 14
15 SPLINE
29 8
PINION 15 TEETH 35 TEETH
2.9083 D.P. 8/16 D.P.
(G1&3)
PINION 18 TEETH 8
29 3.000 D.P. G1 NOTE FOR P9
(G2&4) BEFORE ASSEMBLING MOTOR (P2) TO
7 TRANSMISSION ASSEMBLY (P1),APPLY
A UNIFORM COAT OF P9 TO
MATING SURFACES OF BOTH. ALIGN
KEY IN FRAME STRUCTURE WITH
KEYWAY IN MAGNET FRAME.
G3 SAME AS G1 EXCEPT
FOR MOTOR
TORQUE TO G2 SAME AS G1 EXCEPT
15 14 FOR P29 & P30
58 2 FT. LBS.
ENLARGED VIEW AT A G4 SAME AS G2 EXCEPT
FOR MOTOR

FIG. 1018. GE788HS7, HS8 TRANSMISSION AND MOTOR ASSEMBLY. E41530.

1066
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

TIE CABLES TOGETHER

WITH P17 AT 6.00 &
14.00 FROM
TIE CABLE SETS
CABLE CLAMP
TOGETHER WITH P17
AT 3.00 & 8.00 FROM
CABLE CLAMPS

T3
T2
L ARMATURE

30
1 BEARING: I.D.36.535
O.D.41.732 REDUCED
WIDTH3.622 PARTIAL VIEW AT D
C

3 13

31
2

SPLINE 35 TEETH
8/16 D.P.

TORQUE TO
468 27 FT. LB.
13
16

22

THERMAL
SENSOR CABLE 21

CONNECT SPEED SENSOR CABLE

TO SPEED SENSOR AND CONNECT
THERMAL SENSOR CABLE TO
COMM. COIL AT THE
4 OCLOCK POSITION

18

12

FIG. 1018. GE788HS7, HS8 TRANSMISSION AND MOTOR ASSEMBLY. E41530.

1067
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

12

10
11 S, SX
SS, SSX
2
SX, SSX 30
S, SS 1 ENLARGED SECTION CC
12 C
NOTE:
INSULATE ALL BOLTED ELECTRICAL
CONNECTIONS(6 TOTAL) WITH P25 PER
P6GEP50. WRAP WITH P26(3.00 X 5.00 PC)
13 3 AND P27 (1T. 1/2 L.)
TORQUE TO & BRUSH THOROUGHLY WITH P28
553 22 FT. LB.

C
2
B

22

21

12

23
24
B.H. CABLES(P2)
ENLARGED SECTION BB

FIG. 1018. GE788HS7, HS8 TRANSMISSION AND MOTOR ASSEMBLY. E41530.

1068
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

G1 = GE788HS7
G2 = GE788HS8
G3 = GE788HS7A
G4 = GE788HS8A

G4 G3 G2 G1 REF. DESCRIPTION
1 1 1 TRANSMISSION ASSEMBLY
1 1 2 LONGITUDINAL ASSEMBLY
9 9 9 9 3 BOLT, SOCKET HEAD, 114 X 5
1 1 1 1 4 COVER
6 6 6 6 5 BOLT, WHIZLOCK, 3/816 X 3/4
1 1 1 1 6 GASKET
1 1 7 PINION SHAFT AND RING GEAR ASSEMBLY
1 1 1 1 8 DRIVE RING
16oz. 16oz. 16oz. 16oz. 9 COMPOUND
4 4 4 4 10 LOCKWASHER, 5/16
4 4 4 4 11 BOLT/WASHER, 5/1618 X 5/8
1 1 1 1 12 BRAKE ADAPTER
10 10 10 10 13 WASHER, 1
1 1 1 1 14 BOLT, 1/213 X 4
1 1 1 1 15 HARDENED WASHER, 1/2
1 1 1 1 16 BOLT, 18 X 2 1/2
6 6 6 6 17 CABLE TIE
3 3 3 3 18 TIE WRAP
1 1 1 1 19 NAME PLATE
2 2 2 2 20 ESCUTCHEON PIN NO. 12 X 3/8
1 1 1 1 21 BRAKE HUB
1 1 1 1 22 END PLATE
4 4 4 4 23 BOLT, 3/816 X 1
4 4 4 4 24 LOCKWASHER, 3/8
AR AR AR AR 25 PUTTY, SILASTIC
6 6 6 6 26 INSULATION
6 6 6 6 27 OUTSIDE TAPE
AR AR AR AR 28 VARNISH
1 1 29 PINION SHAFT AND RING GEAR ASSEMBLY
1 1 30 TRANSMISSION ASSEMBLY
1 1 31 LONGITUDINAL ASSEMBLY

FIG. 1018. GE788HS7, HS8 TRANSMISSION AND MOTOR ASSEMBLY. E41530.

1069
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

1 5
5 4

74 2
6
78 3

80 8 23
97 17 18 20
24
7 82 19
50 14
22 25
9 10 11
13 15
79

70

87

12
77

56
76

99

74 95 96

73

75

57
58 5
101 71 62
12 59
81 69 66 64 16 60
72 61
65 63
68 67 GE788B & BS3 MOTOR

103

102
83

101
85

104
86
84 GE788CS MOTOR

FIG. 1019. GE788B, BS3, CS1 MOTORIZED WHEEL LONGITUDINAL. E41518.

1070
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

27
28 30 29 32 33
26
31
36 88
34

100
17

38

33 37

40
41

42 43

45
44
90
46

91

92

47
54

53 49
55
48
52 51
108 55
105 68
35

56

39

89
106 107

GE788B, BS3, CS WITH

ONE PIECE DRIVE RING

FIG. 1019. GE788B, BS3, CS1 MOTORIZED WHEEL LONGITUDINAL. E41518.

1071
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

REF. DESCRIPTION REF. DESCRIPTION

1 FRAME STRUCTURE 54 COLLAR
2 SEAL RING 55 ARMATURE
3 BOLT AND WASHER 56 BOLT AND WASHER
4 CONNECTOR 57 BEARING HOUSING
5 SEALER 58 COLLAR
6 PACKING 59 ROLLER BEARING
7 OIL SEAL 60 COLLAR
8 FLINGER 61 PACKING
9 BLOT AND WASHERS 62 BEARING CAP
10 CLAMP 63 SLEEVE
11 TORQUE TUBE 64 O RING
12 SEALER 65 DRIVE RING
13 ROLLER BEARING 66 NUT
14 BEARING LOCKWASHER 67 RETAINING PLATE
15 BEARING NUT 68 BOLT AND WASHER
16 SEAL 69 PILOT SLEEVE
17 WEAR BAND 70 RING
18 OIL SEAL 71 SEAL HOUSING
19 BOLT AND WASHER 72 SUN PINION
20 SLEEVE 73 COVER
22 ROLLER BEARING 74 BOLT AND WASHER ASSEMBLY
23 EXCITER COIL 75 BOLT, WASHER AND LOCKWIRE
24 EXCITER POLE BOLT 76 BEARING CAP
25 EXCITER POLE 77 ROLLER BEARING
26 COMMUTATING POLE BOLT 78 WEAR BAND
27 COMMUTATING POLE 79 PLANET GEAR AND PINION
28 COMMUTATING COIL 80 PLANET COVER
29 WHEEL HUB 81 RING
30 BAFFLE 82 SLEEVE
31 ROLLER BEARING 83 FILLER CAP
32 BEARING CAP 84 SUMP
33 CAP SCREW 85 MAGNETIC PLUG
34 SEAL RING 86 PIPE CAP
35 FRAME HEAD 87 SLEEVE
36 BOLT AND LOCKWASHER 88 BRAKE ADAPTER RING
37 CAP SCREW 89 THERMAL SENSOR CABLE
38 THRUST RING 90 BRAKE HUB
39 MAGNET FRAME 91 END PLATE
40 SHIMS 92 BOLT AND WASHER
41 BRUSHHOLDER CLAMP 95 BEARING CAP
42 BOLT AND WASHER 96 BOLT AND WASHER
43 BRUSH 97 PADDLE PUMP
44 BRUSHHOLDER 99 GASKET
45 BOLT AND WASHER 100 OIL SEAL
46 BEARING CAP 101 MAGNETIC PLUG
47 GEAR 102 COVER
48 SPACER 103 PLANET GEAR AND PINION
49 SPEED SENSOR 104 SUN PINION
50 BOLT, WASHER AND LOCKWIRE 105 SUN PINION
51 SPEED SENSOR CABLE 106 RETAINING PLATE
52 BALL BEARING 107 DRIVE RING
53 PACKING 108 RETAINING RING

FIG. 1019. GE788B, BS3, CS1 MOTORIZED WHEEL LONGITUDINAL. E41518.

1072
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

NOTES

1073
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

1 5
5 4

74 2 22
6
78 3 21
23

80 8
97 17 18 20

7 82 19
50 14 24
25
9 10 11
13 15
79

70

87

12
77

56
76

98

74 95 96

73

75

57
58 5
93 71 62
12 59
81 64 16 60
72 61

68 63 65
GE788BS4 MOTOR

67

69
83

93
85

66
GE788CS3 MOTOR
86
84

FIG. 1020. GE788BS4, CS3 MOTORIZED WHEEL LONGITUDINAL. E41519.

1074
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

99

27
28 30 29 32 33
26
31
36 88
34

94
17

38

33 37

40
41

42 43

45
44
90
46

91

92

47
55
54
53 49

48
52 51

35

56

39

89

FIG. 1020. GE788BS4, CS3 MOTORIZED WHEEL LONGITUDINAL. E41519.

1075
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

REF. DESCRIPTION REF. DESCRIPTION

1 FRAME STRUCTURE 51 SPEED SENSOR CABLE
2 SEAL RING 52 BALL BEARING
3 BOLT AND WASHER 53 PACKING
4 PIPE PLUG 54 COLLAR
5 SEALER 55 ARMATURE
6 PACKING 56 BOLT AND WASHER
7 OIL SEAL 57 BEARING HOUSING
8 FLINGER 58 COLLAR
9 BLOT AND WASHERS 59 ROLLER BEARING
10 CLAMP 60 COLLAR
11 TORQUE TUBE 61 PACKING
12 SEALER 62 BEARING CAP
13 ROLLER BEARING 63 RETAINING RING
14 BEARING LOCKWASHER 64 RETAINING RING
15 BEARING NUT 65 DRIVE RING
16 SEAL 66 SUN PINION
17 WEAR BAND 67 PLANET GEAR AND PINION
18 OIL SEAL 68 BOLT AND WASHER
19 BOLT AND WASHER 69 COVER
20 SLEEVE 70 RING
21 O RING 71 SEAL HOUSING
22 ROLLER BEARING 72 SUN PINION
23 EXCITER COIL 73 COVER
24 EXCITER POLE BOLT 74 BOLT AND WASHER ASSEMBLY
25 EXCITER POLE 75 BOLT, WASHER AND LOCKWIRE
26 COMMUTATING POLE BOLT 76 BEARING CAP
27 COMMUTATING POLE 77 ROLLER BEARING
28 COMMUTATING COIL 78 WEAR BAND
29 WHEEL HUB 79 PLANET GEAR AND PINION
30 BAFFLE 80 PLANET COVER
31 ROLLER BEARING 81 RING
32 BEARING CAP 82 SLEEVE
33 CAP SCREW 83 FILLER CAP
34 SEAL RING 84 SUMP
35 FRAME HEAD 85 MAGNETIC PLUG
36 BOLT AND LOCKWASHER 86 PIPE CAP
37 CAP SCREW AND WASHER 87 SLEEVE
38 THRUST RING 88 BRAKE ADAPTER RING
39 MAGNET FRAME 89 THERMAL SENSOR CABLE
40 SHIMS 90 BRAKE HUB
41 BRUSHHOLDER CLAMP 91 END PLATE
42 BOLT AND WASHER 92 BOLT AND WASHER
43 BRUSH 93 MAGNETIC PLUG
44 BRUSHHOLDER 94 OIL SEAL
45 BOLT AND WASHER 95 BEARING CAP
46 BEARING CAP 96 BOLT AND WASHER
47 GEAR 97 PADDLE PUMP
48 SPACER 98 GASKET
49 SPEED SENSOR 99 PIPE PLUG
50 BOLT, WASHER AND LOCKWIRE

FIG. 1020. GE788BS4, CS3 MOTORIZED WHEEL LONGITUDINAL. E41519.

1076
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

NOTES

1077
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

1 5
5 4
2 21
74 6
17
78 3 20 23
19 25
100 18
80 8 69
97
24
22 102
7 82
50 14
9 10 11
13 15
79

70

87
99
12
77

56
76

98

74
95 96

73

75

57
93
58 5
71 62
12 59
81 64 16 60
72 61

68 63 65

56 107 56

109

83 110 108
106

111
85 59

GE788DS2

86
84

FIG. 1021. GE788DS, ES2 MOTORIZED WHEEL LONGITUDINAL. E41520.

1078
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

69
101 29
17
27
28 30 32 66
26
31
36 88
34
103
94

104
38

33 37

40
41

42 43

45
44
90
46

91

92

47
55 54
53 49

48
52 51

67 35

39
ARMATURE(ES2)
89
105

FIG. 1021. GE788DS, ES2 MOTORIZED WHEEL LONGITUDINAL. E41520.

1079
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

REF. DESCRIPTION REF. DESCRIPTION

1 FRAME STRUCTURE 57 BEARING HOUSING
2 SEAL RING 58 COLLAR
3 .BOLT AND WASHER 59 ROLLER BEARING
4 PIPE PLUG 60 COLLAR
5 SEALER 61 PACKING
6 PACKING 62 BEARING CAP
7 OIL SEAL 63 RETAINING RING
8 FLINGER 64 RETAINING RING
9 BLOT AND WASHERS 65 DRIVE RING
10 CLAMP 66 BOLT AND WASHER
11 TORQUE TUBE 67 BOLT AND WASHER
12 SEALER 68 BOLT AND WASHER
13 ROLLER BEARING 69 PIPE PLUG
14 BEARING LOCKWASHER 70 RING
15 BEARING NUT 71 SEAL HOUSING
16 SEAL 72 SUN PINION
17 WEAR BAND 73 COVER
18 OIL SEAL 74 BOLT AND WASHER ASSEMBLY
19 BOLT AND WASHER 75 BOLT, WASHER AND LOCKWIRE
20 SLEEVE 76 BEARING CAP
21 O RING 77 ROLLER BEARING
22 ROLLER BEARING 78 WEAR BAND
23 EXCITER COIL 79 PLANET GEAR AND PINION
24 EXCITER POLE BOLT 80 PLANET COVER
25 EXCITER POLE 81 RING
26 COMMUTATING POLE BOLT 82 SLEEVE
27 COMMUTATING POLE 83 FILLER CAP
28 COMMUTATING COIL 84 SUMP
29 WHEEL HUB 85 MAGNETIC PLUG
30 BAFFLE 86 PIPE CAP
31 ROLLER BEARING 87 SLEEVE
32 BEARING CAP 88 BRAKE ADAPTER RING
33 CAP SCREW 89 THERMAL SENSOR CABLE
34 SEAL RING 90 BRAKE HUB
35 FRAME HEAD 91 END PLATE
36 BOLT AND LOCKWASHER 92 BOLT AND WASHER
37 CAP SCREW AND WASHER 93 MAGNETIC PLUG
38 THRUST RING 94 OIL SEAL
39 MAGNET FRAME 95 BEARING CAP
40 SHIMS 96 BOLT, WASHER AND LOCKWIRE
41 BRUSHHOLDER CLAMP 97 PADDLE PUMP
42 BOLT AND LOCKWASHER 98 GASKET
43 BRUSH 99 AIR DEFLECTOR
44 BRUSHHOLDER 100 BOLT AND LOCKWASHER
45 BOLT AND WASHER 101 BOLT AND WASHER
46 BEARING CAP 102 POLE SEAT
47 GEAR 103 HUB CAP BAIL
48 SPACER 104 CAP SCREW
49 SPEED SENSOR 105 ARMATURE (ES2)
50 BOLT, WASHER AND LOCKWIRE 106 BEARING CAP
51 SPEED SENSOR CABLE 107 BEARING HOUSING
52 BALL BEARING 108 COLLAR
53 PACKING 109 SEAL
54 COLLAR 110 SEAL
55 ARMATURE (DSI) 111 COLLAR
56 BOLT AND WASHER

FIG. 1021. GE788DS, ES2 MOTORIZED WHEEL LONGITUDINAL. E41520.

1080
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

NOTES

1081
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

1 5 4
5
74 2 6
17 21
78 3 24
100 18
8 102
80 22
97
25
7 82 19 20
50 119 14 23 69

9 10 11
13 15
79

70

87
99

12
77

56
76

98

74
95 96
73

75

93 57
58 5
71 62
12 59 GE788ES1,FS2,HS2
81 64 16 60
72 61
68 118
63 65

104

105
83 117
116
93

GE788FS5 OTHERWISE SAME AS FS3

85
GE788FS6 OTHERWISE SAME AS FS4
GE788HS5 OTHERWISE SAME AS HS3
GE788HS6 OTHERWISE SAME AS HS4
103

86
84 GE788FS1, 3 & 5 MOTOR
HS1, 3 & 5

FIG. 1022. GE788ES1, FS1FS6, HS1HS6 MOTORIZED WHEEL LONGITUDINAL. E41521.

1082
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

69 107
101 114 17
27
28 30 29 32 66
26
31
106 36 88
34

94

38

33 37

40
41

42 43

45
44
90
46

91

92

16 55 47
110 112
54
108
56
56 111 53 49

62
48
52 51
61
89 35
67

59
60

GE788FS3 OTHERWISE SAME AS FS1 39

GE788FS4 OTHERWISE SAME AS FS2
GE788HS3 OTHERWISE SAME AS HS1
GE788HS4 OTHERWISE SAME AS HS2
GE788FS3A
GE788FS4A
GE788FS6A SAME AS ABOVE
EXCEPT OMIT P112
GE788HS3A
GE788HS4A

FIG. 1022. GE788ES1, FS1FS6, HS1HS6 MOTORIZED WHEEL LONGITUDINAL. E41521.

1083
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

REF. DESCRIPTION REF. DESCRIPTION

1 FRAME STRUCTURE 59 ROLLER BEARING
2 SEAL RING 60 COLLAR
3 BOLT AND WASHER 61 PACKING
4 CONNECTOR 62 BEARING CAP
5 SEALER 63 RETAINING RING
6 PACKING 64 RETAINING RING
7 OIL SEAL 65 DRIVE RING
8 FLINGER 66 CAP SCREW
9 BLOT AND WASHERS 67 BOLT AND WASHER
10 CLAMP 68 BOLT AND WASHER
11 TORQUE TUBE 69 PIPE PLUG
12 SEALER 70 RING
13 ROLLER BEARING 71 SEAL HOUSING
14 BEARING LOCKWASHER 72 SUN PINION
15 BEARING NUT 73 COVER
16 SEAL 74 BOLT AND WASHER ASSEMBLY
17 WEAR BAND 75 BOLT, WASHER AND LOCKWIRE
18 OIL SEAL 76 BEARING CAP
19 BOLT AND WASHER 77 ROLLER BEARING
20 SLEEVE 78 WEAR BAND
22 ROLLER BEARING 79 PLANET GEAR AND PINION
23 EXCITER COIL 80 PLANET COVER
24 EXCITER POLE BOLT 81 RING
25 EXCITER POLE 82 SLEEVE
26 COMMUTATING POLE BOLT 83 FILLER CAP
27 COMMUTATING POLE 84 SUMP
28 COMMUTATING COIL 85 MAGNETIC PLUG
29 WHEEL HUB 86 PIPE CAP
30 BAFFLE 87 SLEEVE
31 ROLLER BEARING 88 BRAKE ADAPTER RING
32 BEARING CAP 89 THERMAL SENSOR CABLE
33 CAP SCREW 90 BRAKE HUB
34 SEAL RING 91 END PLATE
35 FRAME HEAD 92 BOLT AND WASHER
36 BOLT AND LOCKWASHER 93 MAGNETIC PLUG
37 CAP SCREW 94 OIL SEAL
38 THRUST RING 95 BEARING CAP
39 MAGNET FRAME 96 BOLT, WASHER AND LOCKWIRE
40 SHIMS 97 PADDLE PUMP
41 BRUSHHOLDER CLAMP 98 GASKET
42 BOLT AND WASHER 99 AIR DEFLECTOR
43 BRUSH 100 BOLT AND LOCKWASHER
44 BRUSHHOLDER 101 BOLT AND WASHER
45 BOLT AND WASHER 102 POLE SEAT
46 BEARING CAP 103 SUN PINION
47 GEAR 104 PLANET GEAR AND PINION
48 SPACER 105 COVER
49 SPEED SENSOR 106 AIR BAFFLE
50 BOLT, WASHER AND LOCKWIRE 107 BOLT AND LOCKWASHER
51 SPEED SENSOR CABLE 108 ARMATURE (FS,HS)
52 BALL BEARING 110 BEARING HOUSING
53 PACKING 111 COLLAR
54 COLLAR 112 SEAL
55 ARMATURE 114 WHEEL HUB (FS)
56 BOLT AND WASHER 116 PLANET PINION
57 BEARING HOUSING 117 BEARING CAP
58 COLLAR 118 SLEEVE

FIG. 1022. GE788ES1, FS1FS6, HS1HS6 MOTORIZED WHEEL LONGITUDINAL. E41521.

1084
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

NOTES

1085
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

1
5 4
5 2 6 21
74 3
78
17
24 25
8 18
80 20 23
97 102
7 69
82 19
14 22
50
9 10 11
13
15
104
79

70

87

77
100
76
56 99
98 12
16

74
95 96 56
75

73

105 57

93 58 5
71 62 108
12 59
81 64 60
72 61

103 68 63 65
SAME AS ABOVE EXCEPT
OMIT FACE SEAL

83

85

GE788FS7A
GE788FS8A
86
GE788HS7A
84
GE788HS8A

FIG. 1023. GE788FS7FS9, HS7, HS8 MOTORIZED WHEEL LONGITUDINAL. E41522.

1086
SECTION 10 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

69 107 17
101
27
29 32
28 30 66
26
31
106 36 88
34

94

38

37
33

41 40

42 43

44
46 45

90

92
55
91
54
53

52 48 47
35

89 51
49
67

39

FIG. 1023. GE788FS7FS9, HS7, HS8 MOTORIZED WHEEL LONGITUDINAL. E41522.

1087
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 10

REF. DESCRIPTION REF. DESCRIPTION

1 FRAME STRUCTURE 55 ARMATURE
2 SEAL RING 56 BOLT AND WASHER
3 BOLT AND WASHER 57 BEARING HOUSING
4 PIPE PLUG 58 COLLAR
5 SEALER 59 ROLLER BEARING
6 PACKING 60 COLLAR
7 OIL SEAL 61 PACKING
8 FLINGER 62 BEARING CAP
9 BLOT AND WASHERS 63 RETAINING RING
10 CLAMP 64 RETAINING RING
11 TORQUE TUBE 65 DRIVE RING
12 SEALER 66 CAP SCREW
13 ROLLER BEARING 67 BOLT AND WASHER
14 BEARING LOCKWASHER 68 BOLT AND WASHER
15 BEARING NUT 69 PIPE PLUG
16 SEAL 70 RING
17 WEAR BAND 71 SEAL HOUSING
18 OIL SEAL 72 SUN PINION
19 BOLT AND WASHER 73 COVER
20 SLEEVE 74 BOLT AND WASHER ASSEMBLY
21 O RING 75 BOLT, WASHER AND LOCKWIRE
22 ROLLER BEARING 76 BEARING CAP
23 EXCITER COIL 77 ROLLER BEARING
24 EXCITER POLE BOLT 78 WEAR BAND
25 EXCITER POLE 79 PLANET GEAR AND PINION
26 COMMUTATING POLE BOLT 80 PLANET COVER
27 COMMUTATING POLE 81 RING
28 COMMUTATING COIL 82 SLEEVE
29 WHEEL HUB 83 FILLER CAP
30 BAFFLE 84 SUMP
31 ROLLER BEARING 85 MAGNETIC PLUG
32 BEARING CAP 86 PIPE CAP
33 CAP SCREW 87 SLEEVE
34 SEAL RING 88 BRAKE ADAPTER RING
35 FRAME HEAD 89 THERMAL SENSOR CABLE
36 BOLT AND LOCKWASHER 90 BRAKE HUB
37 CAP SCREW AND WASHER 91 END PLATE
38 THRUST RING 92 BOLT AND WASHER
39 MAGNET FRAME 93 MAGNETIC PLUG
40 SHIMS 94 OIL SEAL
41 BRUSHHOLDER CLAMP 95 BEARING CAP
42 BOLT AND LOCKWASHER 96 BOLT, WASHER AND LOCKWIRE
43 BRUSH 97 PADDLE PUMP
44 BRUSHHOLDER 98 GASKET
45 BOLT AND WASHER 99 AIR DEFLECTOR
46 BEARING CAP 100 BOLT AND LOCKWASHER
47 GEAR 101 BOLT AND WASHER
48 SPACER 102 POLE SEAT
49 SPEED SENSOR 103 SUN PINION
50 BOLT, WASHER AND LOCKWIRE 104 PLANET GEAR AND PINION
51 SPEED SENSOR CABLE 105 COVER
52 BALL BEARING 106 AIR BAFFLE
53 PACKING 107 BOLT AND LOCKWASHER
54 COLLAR 108 SEAL

FIG. 1023. GE788FS7FS9, HS7, HS8 MOTORIZED WHEEL LONGITUDINAL. E41522.

1088
 SECTION 11 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

SECTION 11. INPROCESS AND FINAL TESTS

CONTENTS
Page
FINAL WHEEL HUB ENDPLAY
(Rotating Method) . . . . . . . . . . . . . . . . . . . . . . . . 111
BRAKE LINE TEST . . . . . . . . . . . . . . . . . . . . . . . . 112
THERMAL SENSOR . . . . . . . . . . . . . . . . . . . . . . . 112
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 112
ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
ARMATURE TEST . . . . . . . . . . . . . . . . . . . . . . . . 112
ARMATURE SURGE TEST . . . . . . . . . . . . . . . . 113
TESTING DURING OVERHAUL . . . . . . . . . . . . . 113
FIELD COIL IMPEDANCE, MEGOHMMETER
AND HIGHPOTENTIAL TESTS . . . . . . . . . . . 113
Impedance Test . . . . . . . . . . . . . . . . . . . . . . . . . 113
Megohmmeter Test . . . . . . . . . . . . . . . . . . . . . . 113
TESTING AFTER OVERHAUL . . . . . . . . . . . . . . 113
GEARCASE PRESSURIZATION DURING
FINAL RUNNING TEST . . . . . . . . . . . . . . . . . . . 113
Equipment Needed . . . . . . . . . . . . . . . . . . . . . . 113
Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

FINAL WHEEL HUB ENDPLAY

FIG. 111. GE788 TEST CONNECTIONS.
(Rotating Method) E28947.
1. Using appropriate lifting fixture, lift the Motorized
Wheel and place it on suitable blocking with the 6. Shut off the power source and with the indicators
gearcase end down. at their marked locations, reset them to zero.

7. Attach cables of proper size to lifters. Using a

2. Place two magneticbase dial indicators diamet-
rically opposite on the outboard edge of the
wheel hub. The indicator pointer should rest on
the thrust ring. Mark the pointer locations. All
readings must be taken with the indicator point-
ers at these locations.
3. Set indicators to zero. Allow for 0.060 in. of indi-
cator travel.
4. Connect motor leads to power source capable of
supplying 30 to 40 amps at 20 to 25 vdc (such as
a dc welder). This should rotate the wheel hub at
approximately 3 rpm. Connect dc power source
as shown in Fig. 111.
5. Using the power source, rotate the wheel hub un-
til the dial indicators show repetitive readings as
the marked locations pass beneath the pointers.
This usually takes 10 to 15 revolutions.
swivel hook and crane of sufficient capacity
(25,000 pounds), raise wheel clear of floor (ap-
proximately 1/2 in.).
8. With the wheel in the raised position, rotate the
wheel using a welder, then return to align marks
and indicator pointers.
9. Before lowering the wheel, read the dial indicator
to determine the amount of endplay, which
should be the average of the two indicator read-
ings as indicated in SECTION 1, DATA.
NOTE: If the reading is less than 0.025, it cannot
be increased by simply adding shims. The out-
board bearing must be moved axially outboard
by hydraulically jacking the wheel hub up.
10. If endplay is not within limits for this final check,
the motor must be removed to readjust the

111
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
shims. Reinstall motor and repeat Steps 1
through 9.
BRAKE LINE TEST
1. Visually inspect the flared end of the brake line
tubes to see that they are free of splits and any
surface defects. This must be done before as-
sembly.
2. Before brake is assembled, plug the inboard
hose end with a plug equipped with a bleeder.
Connect the pump to the outboard hose.
3. Fill the system with hydraulic brake fluid and
bleed all air.
NOTE: If the brake system is B.F. Goodrich Cat.
No. 21080, use mineral oil.
4. Maintain a pressure of 4000 psi for not less than
10 seconds nor more than 25 seconds and in-
spect for leaks. Watch pressure gauge for leaks.
5. Any parts with uncorrectable leaks must be re-
placed.
6. Purge brake lines after testing with compressed
air. Purge such that residual brake fluid does not
drop into the motor.
THERMAL SENSOR
1. Test four leads of the thermal sensor cable to
ground with connector grounded. Use a Simp-
son multimeter or equivalent. The readings must
be infinity.
2. Test the thermal sensor plug pins to armature cir-
cuit. Readings must be infinity.
3. Check between individual pins as follows:
a. White to Black leads 100
15 ohms
b. White to Red leads 100
15 ohms
c. Black to Red leads 0 ohms.
SPEED SENSOR
Test sensor cable resistance to ground with the con-
nector grounded (three circuits). Use Simpson multime-
ter or equivalent. Circuit leads must be infinity to ground.
112
SECTION 11
ARMATURE
Handle the armature carefully during overhaul oper-
ations to avoid damage to the core, banding, end turns
and shaft fits. Support the armature in a saddle to pro-
tect the commutator and coil ends. Keep the commuta-
tor covered with heavy paper.
ARMATURE TEST
1. With 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/or rewind the armature. In-
structions for creepage band replacement are
found in SECTION 8. Instructions for rewinding
the armature are not provided in this publica-
tion.
2. Perform highpotential test. When new, re-
wound or reinsulated armatures are tested, test
insulation to ground at 3500 vac for one minute.
When reconditioned armatures are tested, sepa-
rate fields SSS and SXSSX, then test insu-
lation to ground at 2500 vac for one minute.
3. Measure and record armature resistance using a
double bridge or digital ohmmeter. See SEC-
TION 1, DATA for values.
4. If there are no armature coils grounded, perform
a bartobar voltage comparison test to check
for open or shortcircuited armature coils.
a. Pass a regulated dc 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 five percent of
the average, a defective or shortcircuited
coil may be indicated.
SECTION 11 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
ARMATURE SURGE TEST
WARNING: Surge testing is considered hazard-
ous. Strict safety precautions must be taken to
protect personnel from serious or fatal injury.
Newly wound armatures experience a small percent-
age of insulation defects which can be either a direct
short or a near short which will not fail until the armature
has been placed in service with heat, centrifugal force
and voltage present. The best method of identifying and
locating these defects for correction is with a surge tes-
ter. It is therefore recommended that all rewound arma-
tures receive a 750 peak volt surge between all adjacent
commutator bars. The peak surge voltage must be mea-
sured with a separate oscilloscope and shielded coax
circuit with the pick up made at the two adjacent commu-
tator bars. This method of metering is necessary be-
cause of the very high voltage drop in the surge tester
leads caused by the high peak current (3000 amperes).
This test method is the result of many years of testing
experience in locating the near short type of armature
defect, and it takes about 750 peak volts across arma-
ture turntoturn insulation to exceed the normal in
service operating condition of voltage stress. This volt-
age value is confirmed by the laws of physics.
NOTE: For used armatures, use 500 volts.
TESTING DURING OVERHAUL
FIELD COIL IMPEDANCE,
MEGOHMMETER AND
HIGHPOTENTIAL TESTS
Impedance Test
Coiled Frame Without Armature
60 Hz, ac Voltage Drop
with Current Through Fields Voltage Drop
Min. Max.
Exciting (shunt) Field 12 amps 87.0 99.0
Commutating Field 24 amps 6.8 7.5
Megohmmeter Test
With frame at room temperature 25_C (77_F), use a
500 or 1000 vdc megohmmeter and make a dielectric
test of the coil insulation. A reading of one megohm or
higher should be obtained. If necessary, perform addi-
tional cleaning and baking operations to obtain this val-
ue before proceeding.
Highpotential test coiled frame without armature.
WARNING: Highpotential testing is considered
hazardous. Strict safety precautions must be tak-
en to protect personnel from serious or fatal inju-
ry.
When new, rewound or reinsulated coils are tested:
Test insulation to ground, of AAA: Commutating field,
at 3500 vac for one minute. SSS: Shunt field should
be highpotential tested to ground at 2500 vac.
When reconditioned coils are tested: Test insulation
to ground, of AAA: Commutating field, at 2000 vac for
one minute. SSS: Shunt field should be highpoten-
tial tested to ground at 1500 vac.
TESTING AFTER OVERHAUL
WARNING: The following tests are performed
with the motor energized and the armature rotat-
ing. Extreme care should be taken to avoid con-
tact with energized components and to avoid be-
ing struck by rotating elements and/or loose ma-
terial.
GEARCASE
PRESSURIZATION DURING
FINAL RUNNING TEST
The oil seal is tested under pressure during final run-
ning test to assure that it has been properly assembled.
To duplicate factory testing, a static pressure of five
inches of water (5 in. WC) should be applied at the
twelve oclock 11/4 in. pipe plug. If shop air is used, it
must be dry.
Equipment Needed
1. 010 in. water column pressure gauge such as
Magnehelic Model 201000. Available from:
Dwyer Instruments Inc.
Highway 212 at 12
P.O. Box 373
Michigan City, IN 46360
2. Pressure regulator with a range from 1 in. WC
(water column) to shop air pressure.
113
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 11

3. Air hose PVC nylon braided reinforced tubing to view the area between the torque tube and
1/4 in. inside diameter, 1/2 in. outside diameter frame to detect possible oil leaks at the oil seal.
Nylobrade. Available from:
After the Motorized Wheel has been completely as-
U.S. Plastic Corp.
sembled, proceed to test as follows:
1390 Newbrecht Road
Lima, OH 45801
1. Bolt the Motorized Wheel to a test stand in the
4. Reducer for 11/4 in. standard pipe thread down horizontal position.
to 1/4 in. pipe thread.
2. Fill the gearcase with lubricating oil.
5. 1/4 in. standard thread pipe union.
3. Lubricate the inboard dirt seal area.
6. Necessary pipe hardware to connect hose to 1/4
in. pipe union (or quick disconnect) to the 11/4
4. See Figs. 97 and 98 for identification of motor
in. x 1/4 in. standard pipe thread reducer.
leads.
7. See Fig. 112 for location of gear box breather
hole (11/4 in. pipe thread). 5. Connect the shuntfield leads to a separate
source of power capable of exciting the field with
Process 300 amps.

1. The gearcase should be pressurized to 5 in. WC 6. Connect the armature leads to a source of power
during the entire final running test. capable of supplying 800V.
2. After completion of the running test, rotate the
7. Close the contactor or switch to apply power to
torque tube so that the pipe plug is in the 6
excite the field at 225 amps.
oclock position. A dental mirror should be used
8. Close the contactor or switch to apply power to
the motor armature. Increase the voltage to
350V.

9. Gradually reduce field current to 62 amps to pro-

duce a motor speed of approximately 1000 rpm.

WARNING: For the safety of personnel during

brush seating operations, the following safety
precautions must be adhered to:
1. Remove any rings, watches or loose clothing.
2. Do not wear gloves.
3. Do not come in contact with commutator and
wheel frame simultaneously.

10. Seat the commutator brushes with a brush seat-

er stone. Continue to seat the brushes until they
are seated 100 percent.

WARNING: When using compressed air for

cleaning purposes, an environment potentially
hazardous to personnel in the immediate area is
created. To prevent injury by flying debris, ob-
FIG. 112. GEARCASE PRESSURIZATION TEST. serve all safety regulations.
E28600.

114
SECTION 11 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D
WARNING: Observe all the following safety pre-
cautions 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 pow-
ersupply control to quickly remove power
from the traction motor should an emergency
arise.
3. Wear rubberinsulated gloves and goggles
while air curing. Stand on an insulated plat-
form.
4. Avoid contact with the cable terminals.
11. Air cure the commutator, using dry, compressed
air as follows:
a. Use a hose with a rubber or fiber nozzle (nev-
er use a metal nozzle).
b. Direct a stream of air back and forth across
the commutator surface. Hold the nozzle ap-
proximately 11/2 in. away from the commu-
tator surface.
c. Increase the armature voltage in 100V incre-
ments and repeat Step b. Never proceed to a
higher voltage until the sparking has stopped
at each voltage increase.
d. Proceed with the air curing until the armature
voltage has reached 800V. When all sparking
has stopped, the air curing is complete.
12. Perform field excitation curve check as follows:
a. Decrease the armature voltage to 350V.
b. Set field current as specified in the following
listing and read the rpm. The value of rpm
should be approximately as shown in the list-
ing for each current setting:
Field Current RPM
Settings (Amps) Calculated
225 503
137 586
62 943
c. Stop the Motorized Wheel and reverse polar-
ity of the armature or field connection and
perform test as in Step b for the opposite ro-
tation. Speed difference between clockwise
(CW) and counterclockwise (CCW) should
not exceed
4 percent.
CAUTION: Do not maintain field current at 250
amps longer than necessary. The motor leads
may overheat. Stop test and allow the motor to
cool if field shows signs of overheating.
13. Increase armature voltage to 800V. Gradually re-
duce field until 2320 rpm is obtained. Field cur-
rent will be approximately 50 amps at this speed.
14. Hold 2320 rpm for two minutes and perform the
following checks:
a. Measure vibration. The maximum permissi-
ble vibration is 0.002 in. at the commutator
end.
b. Check for oil leaks.
c. Check commutator for roughness using an
insulating fiber rod.
15. During the entire test, listen for noisy bearings
and any unusual gear noise.
16. Stop the Motorized Wheel. Attach an indicator to
the frame with a flattipped pointer against the
commutator. Slowly rotate the armature by hand
and measure the commutator runout; measure
at all three brush paths. Maximum runout per-
mitted in any brush path is 0.001 in. TIR. Rate of
change is 0.0003 in. within any group of six bars.
WARNING: Highpotential testing is considered
hazardous. Strict safety precautions must be tak-
en to protect personnel from serious or fatal inju-
ry.
17. Measure insulation resistance to ground at 1000
vdc. If the reading (with Motorized Wheel hot) is
greater than two megohms, highpotential test
the commutating fields, brushholders and arma-
ture to ground at 3500 vac for one minute. S
SS and SXSSX shunt fields should be high
potential tested at 1750 vac for one minute.
NOTE: Step 17 applies to Motorized Wheels that
are new, rewound or reinsulated. When a recon-
ditioned motor is being tested, measure insula-
tion to ground at 2000 vdc. If reading (with Mo-
torized Wheel hot) is greater than two
megohms, highpotential test the commutat-
115
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
ing fields, brushholders and armature to
ground at 2000 vac for one minute. SSS sep- mutator end. Use an IRD vibration meter or equivalent.
arate field should be highpotential tested at
1050 vac for one minute.
18. Check for excessive temperatures.
The following checks are temperature measure-
ments taken for select components of the Motorized
Wheel. These checks which should be performed after
wheel overhaul, are to determine how high operating
temperatures will rise above ambient. If test results for a
given component are higher than that given below, it is a
sign that insufficient lubrication or cooling air is avail-
able. Such conditions must be rectified before placing
the Motorized Wheel into service, even if the wheel must
be dismantled to find the cause.
Temperature
Rise Above
Component Ambient
Commutator End Armature Bearing 45_C
Thrust Ring Dirt Seal 30_C
Frame Structure 10_C
Gearcase (including sun pinion cover) 15_C
NOTES
116
SECTION 11
Also, check armature bearing vibration at the com-
The maximum allowable vibration is 0.002 in.
Finally, after shutting down the running test, remove
the magnetic drain plugs in the sun pinion cover and
clean. Check for abnormally large or excessive quanti-
ties of metal particles.
19. Drain oil from the gearcase and inspect for metal
particles. Inspect the sump magnetic plug for
particles.
20. Tag the Motorized Wheel to show that oil must be
put in the gearcase before operating.
NOTE: While rotating motor tests are being
completed, the motor should be observed for:
1. Excessive gear noise
2. Oil leaks
3. Abnormal conditions at contact seals.
SECTION 12 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

SECTION 12. AFTER OVERHAUL PROCEDURES

NOTE: Numbers in parentheses refer to Fig.
CONTENTS 121. The particular group listing to be used is
Page by model number as follows:
ARMATURE LOCKING ARRANGEMENT . . . . . 121 G1 Models GE788B, BS, CS, DS, ES, FS1
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 through FS6, and HS1 through HS6A.
INSTALLATION OF MOTORIZED
WHEEL TO TRUCK . . . . . . . . . . . . . . . . . . . . . . . 122 G2 All other GE788FS and HS models not
GEARCASE VENTING . . . . . . . . . . . . . . . . . . . . . 123 listed in G1.
SHIPPING REQUIREMENTS . . . . . . . . . . . . . . . . 123
1. Remove hub cap from motor.

2. Install a shipping bolt (1 or 5) with a jam nut (2 or

ARMATURE LOCKING 6) assembled on the bolt through the brake hub.
ARRANGEMENT 3. Tighten the shipping bolt (1 or 5) against the
CAUTION: Do not rotate the armature when the bearing cap.
locking bolt is in place. Bearing and commutator
4. Tighten the jam nut (2 or 6) so it is tight against
damage may result.
the brake hub.

5. Attach WARNING tag (3) to shipping bolt with

NOTE: If assembled Motorized Wheel is to be
lockwire (4).
transported any distance, the armature must be
locked. 6. Install hub cap.

G2 G1 REF. DESCRIPTION
1 1 BOLT, 5/811x4
1 2 JAM NUT, 5/811
1 1 3 TAG
1 1 4 LOCKWIRE, 0.08 DIA. x 1 FT.
1 5 BOLT, 3/410x6.4
1 6 JAM NUT, 3/410
6
2

1 5

4
3

G1 ATTACH P3 TO
P1 WITH P4

G2 ATTACH P3 TO
P5 WITH P4

FIG. 121. ARMATURE LOCKING ARRANGEMENT. E37883B.

121
GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL
STORAGE
Motorized Wheels not installed on vehicles must be
stored in a warm, dry, climatecontrolled environment.
Do not store outside. If installed on vehicles, refer to
STORAGE INSTRUCTIONS, GEK61793.
INSTALLATION OF MOTORIZED
WHEEL TO TRUCK
Since the Motorized Wheel is the principle compo-
nent of the driving, load bearing axle of the vehicle, the
vehicle is designed to support the loads transmitted
through the Motorized Wheel.
As such, when mounting the Motorized Wheel to the
axle box, attention must be paid to the following:
1. The mounting face must be a flat surface to with-
in 0.011 in.
2. The surface finish of 250 microin. or better is re-
quired.
FIG. 122. VEHICLE FRAME REQUIREMENTS FOR MOUNTING MOTORIZED WHEEL. E28601A.
122
SECTION 12
3. The bottom flat must be parallel to the ground
within 3 degrees when mounted under all condi-
tions of loading (Fig. 122).
4. The tapped holes used in mounting the wheel
motor to the axle box must be within 0.015 in. of
true position.
5. The lip or flange that supports the vertical shear
load at the bolted joint interface should be 64.515

0.015 in. diameter. (In some cases, the lip may
only encompass the top half of the Motorized
Wheel flange.)
6. The forty eight (48) 11/47 x 51/2 in. min.
Grade 8 bolts are torqued to 12501400 lb.ft.
(Bolt threads and heads must be lubricated prior
to assembly.)
7. Hardened (RC4048) flat ground washers
0.250 thick, 1.313 I.D., 2.500 O.D. with a surface
finish of 250 microin. or better must be used in
conjunction with bolts in Step 6 (washers must
also be lubricated before assembly).
SECTION 12 GE788 MOTORIZED WHEEL SERVICE MANUAL, GEK84745D

GEARCASE VENTING
The Motorized Wheel obtains forced ventilation for
motor cooling from a blower unit in another part of the
system. A plenum chamber (axle box) is provided on the
gearcase side of the Motorized Wheel so that air flows
freely into the air passages along the periphery of the
gearcase cover, through the magnetic frame, exhaust-
ing at the hubcap vents.

The air flow requirement is 2600 cfm per motor (4.5

in. of water pressure drop across the motor). The static FIG. 124. GEARCASE VENT CONNECTIONS.
pressure varies between trucks of different manufactur- E23971A.
ers. Contact your truck builder for correct values.
2. The vent system connect to the 11/4 in std. pipe
To prevent leaks, the gearcase must be vented to the connections should have no size restriction at
atmosphere. This is done to minimize the pressure dif- any point in the system.
ferential across the oil seals; thus, eliminating a cause of
oil leaks. 3. Each gearcase must be vented to a separate
breather.
Three 11/4 in. NPT connections are provided on the
gearcase cover (Fig. 123) at 12, 4 and 8 oclock for this 4. Breathers must be a low restrictive, filteredtype
purpose. Fig. 124A shows the 12 oclock and one of the and have a 11/4 in. NPT connection. It should
lower connections (4 or 8 oclock) positions joined to- be of a design which sheds rain water rather than
gether before venting to the atmosphere. This is an ap- allowing it to enter the breather pipe.
proved arrangement.
5. The breather should be mounted in a location
The following criterion is to be followed in installation: which is accessible for maintenance and free
from dirt buildup.
1. Flexible hoses are recommended to avoid distor-
tion of the gearcase cover. Care must be taken to
avoid low spots in the piping, which can form a SHIPPING REQUIREMENTS
trap and block air flow (Fig. 124B). Sharp To prepare the Motorized Wheel for shipping, per-
bends which can relax with time, kink and block form the following:
air flow, must be avoided.
1. Drain oil from sump.

2. Plug all open threaded holes and cap threaded

male fittings.

3. Install armature locking device.

4. Protect exposed armature shaft spline from

weather and damage.
FIG. 123. GEARCASE COVER VENT HOLES.
E34042A. 5. Weather protect the Motorized Wheel.

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GEK84745D, GE788 MOTORIZED WHEEL SERVICE MANUAL SECTION 12

GE Transportation
Systems
2901 East Lake Road
REV 0386, WLF Erie, Pennsylvania 16531
REV 0388, WLF
PRINTED
REV 0791, WLF IN
REV 0894, KAP U.S.A.
E

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