INSTRUCTIONS

ROTATING EQUIPMENT

CONTENTS

Page

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . .IV-1
TRACTION ALTERNATOR
DESCRIPTION . . .. .. . . . . . . . . . . . . . . . . . . . . . . . IV .1
DATA . . . . . . . ..... . . . . . . . . . . . . . . . . . . . . . . . IV-2
LUBRICATION ... . . . . . . . . . . . . . . . . . . . . . . . . .IV-2
INSPECTION . . .. . .. . . . . . . . . . . . . . . . . . . . . . . .IV-2
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . IV-4
AUXILIARY GENERATOR/EXCITER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . .. IV-7 . . . . .
DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. IV-7 . . . . .
SPECIAL TOOLS AND EQUIPMENT . . . . . . . .. IV-7 . . . . .
LUBRICATION . . . . . . . . . . . . . . . . . . . . . ..IV-7 . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-H
COMMUTATOR RESURFACING . . . . . . . . . . . . . . . . IV-H
TRACTION MOTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. IV-10
DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-l0 FIG . IV-1 . TRACTION ALTERNATOR
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-12 WITH AUXILIARIES .
REPLACING AXLE LININGS ON THE
LOCOMOTIVE . . . . . . . . . . . . . . . . . . . . IV-13 TRACTION ALTERNATOR
RESURFACING COMMUTATOR IN . THE . . . . . .
LOCOMOTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-13 DESCRIPTION
COMMUTATOR MAINTENANCE The Type GTAI I Traction Alternator is a salient-pole,
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-15
CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-17 three-phase, Y-connected alternating-current generator
SURFACE CONDITIONS . . . . . . . . . . . . . . . . . IV-17 which converts the mechanical energy of the locomotive
RESURFACING THE COMMUTATOR . . . . . . . . . . . . IV-23 diesel engine into the electrical power required for
locomotive propulsion. The a-c output of the alternator is
converted to d-c by means of a rectifier panel and used as
the power supply for the d-c traction motors.
INTRODUCTION The GTA11 alternator is a single-bearing, separately-
excited machine which is directly connected to
This section is a brief description of electrical rotating the diesel engine. The engine crankshaft supports
apparatus on a locomotive such as the traction alternator, approximately half the weight of the alternator rotor. The
the auxiliary generator/exciter and the traction motor. For other half is supported at the outboard end by means of a
a detailed analysis, refer to the applicable maintenance roller bearing which is splash-lubricated from the
manual furnished with the locomotive . auxiliary-drive gear unit.

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 maintenance. Should further information be desired or should particular problems
arise which are not covered sufficiently for the purchaser's purposes, the matter should be referred to the General Electric Company.
Verify numbers for parts, tools, or material by using the Renewal Parts or Tool Catalogs, or contact your General
Electric representative for assistance . Do not order from this publication .
GEK-30150, SECTION IV, ROTATING EQUIPMENT

Excitation is supplied by an exciter, Fig. IV-1, mounted

on and driven by the alternator through the auxiliary-drive
gear system . Also shown in Fig. IV-1 is the auxiliary
generator which supplies power for the control system .

A simplified schematic diagram of the GTA11 alternator

is shown in Fig. IV-2.

DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GTAII
Classification . . . . . . . 10-pole, three-phase, Y-connected
a-c generator FIG . IV-2 . SCHEMATIC DIAGRAM FOR
GTAII ALTERNATOR .
Rotation (facing collector-ring end) . . . . . . . . . . . . CCW
Brushes
Quantity per machine . . . . . . . . . . . . . . . . . . . . . . . 6 INSPECTION
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speer 524
Minimum Length (length at which brush In general, the inspection schedule of the alternator
becomes inoperative) (in .) . . . . . . . . . . . . . . . 1-3/16 should conform to the inspection schedule established for
Brush-Arm Pressure (new brush) (lb .) . . . . . 4-1/4 to 4-3/4 the overall locomotive, but may be modified as required by
Brushholder actual operating experience .
Clearance to Collector Ring (in .) . . . . . . . . . 3/32 to 1/8
Lubrication The following information is offered as a general
Auxiliary-Drive Gear Case Capacity inspection guide which calls attention to what should be
(initial filling, approximately) (pt.) . . . . . . . . . . . . . 5 inspected and what to look for when making the
Lubricant (low-foam type) . . . . . SAE-40 Engine Lube Oil inspection . If the inspection results call for corrective
GE-D6B-18D maintenance to be performed, the procedures for carrying
out such maintenance are covered in the Maintenance
LUBRICATION Procedures section .

The alternator roller bearing is splash-lubricated from the

auxiliary-drive gear unit. No other lubrication is required. General

Check the oil level in the auxiliary-drive gear unit by Make a visual inspection for evidence of loose or missing
means of the dipstick located on the lower right-hand side auxiliary and auxiliary gear-case mounting bolts, bolts
of the gear case (facing collector end) between the exciter which hold the electrical connection box cover in place,
and the alternator framehead . loose, damaged or missing latches in inspection covers . Also
check for oil leakage from the auxiliary-drive gear unit and
If the engine is shut down, read the oil level on the side around the auxiliary mounting flanges. Make sure the gear
of the dipstick marked Generator Stopped . If the engine is unit oil-drain plug is tight.
idling, read the oil level on the side of the dipstick marked
Generator Running . Maintain the oil level between the
FULL and ADD marks on the dipstick . Brushes

l . Inspect for wear, and replace brushes which have

reached their minimum permissible length of
CAUTION : Do not overfill gear case. Overfilling 1-3/16 in., or which may be too short to run until the
may result in oil being drawn through the alternator next inspection . When checking brush length, measure
bearing onto the collector rings and windings, and from the top of the brush clip to the center of the
cause serious operating difficulty . curved surface that is in contact with the collector
ring.

Drain the gear case once a year or after 180,000 miles of 2. Look for chipped or broken brushes, brushes with
operation, whichever occurs first, and refill with SAE-40 loose or frayed pigtails, and replace such brushes as
engine lube oil, GE Specification D6B-I8B. necessary .

IV-2
 FIG . IV-4 . BRUSHHOLDER ASSEMBLY .

following information is offered as an inspection

guide. Ideally the collector ring surface should have a
FIG . IV-3. CORRECT POSITION OF BRUSH PIGTAIL uniform, chocolate-brown color and be free of
AND TERMINAL.
etching, threading or grooving. Conditions
encountered in service, however, including oil vapors,
3. Make sure the pigtail terminals are positioned as adverse humidity conditions and air contaminants of
shown in Fig. IV-3 and that pigtail terminal screws are various kinds add to the difficulty of maintaining an
tight . ideal collector ring surface .

4. Move brushes up and down several times in the If dark spots appear on the ring surface, they will
brushholders to release carbon dust or foreign matter likely be at uniform brush spacing. These spots later
from the carbonways, which may prevent free turn to a grayish color accompanied by etching of the
movement of the brushes. collector ring surface . If appropriate action is taken at
this point, that is, as soon as the dark spots appear or
Brushholders no later than the first evidence of the grayish, etched
condition, more serious problems can be avoided later
1 . Check for loose, broken, bent or overheated pressure by removing the distressed areas with a brush seater
arms. Overheating will cause arms to become stone as described under Maintenance Procedures
discolored and result in improper brush-arm pressure . section .

2. Make sure the thumb loop on the coiled brush Without corrective action, severe arcing and grooving
pressure spring is in the position shown in Fig. IV-4. of the collector ring with resultant rapid brush wear,
follow quickly until the grooving extends over
3. Inspect brushholder mounting and make sure the 180 degrees or more of the ring surface . This requires
studs are tight . the rings to be ground in order to remove the burned
spots and grooving, and to restore the ring surface to
4. Check brushholder-to-collector ring clearance (3/32 a true circle .
to 1/8 in.) and adjust as necessary.

Collector Rings Bus Rings and Field Leads

1 . Wipe off insulation between rings with a clean, dry Check for cracked, frayed or damaged insulation .
cloth and inspect for evidence of physical damage .

2. Check the surface of the collector rings for evidence Field Coil Connection Straps
of discoloration, etching, grooving, threading or other
signs of distress that may require corrective action . To Inspect insulation for evidence of cracks or physical
help determine the need for such action, the damage that may require corrective action .

IV- 3
GEK-30150, SECTION IV, ROTATING EQUIPMENT

MAINTENANCE PROCEDURES 6. With engine running at idle speed, clean collector ring
surfaces by use of clean, dry compressed air .
Resurfacing Collector Rings
7 . Shut down engine and reinstall brushes .
When inspection reveals that corrective maintenance is
required, resurface the collector rings by one of the 8. Sand brushes to remove metal which may have
following two methods depending on the severity of the transferred from collector ring to the brush contact
burned spots or grooving: surface . Use a strip of 2-in. wide by 24-in. long
Brush Seater Stone fine-grit sandpaper for this operation .

1 . With engine shut down, remove all collector ring WARNING : When using compressed air for cleaning
brushes . purposes, an environment potentially hazardous to
personnel in the immediate area is created. To prevent
2. Tape seater stone to the end of a stick for use as physical injury by flying debris, observe all Railroad
shown in Fig. IV-5 . and OSHA safety regulations.

WARNING : Projections from the end of the 9. Blow out carbon dust with clean, dry compressed air.
rotating field leave insufficient clearance above the
rear (inboard) collector ring for use of a hand-held Collector Ring Grinder
stone . To avoid serious injury, resurface rings only
with a stone taped to the end of a stick. See Fig. IV-6 for collector ring grinder drawing.

3 . Start the engine and run it at idle speed. 1 . With engine shut down, remove all brushes from
brushholder .
4. Apply enough pressure to the seater stone to produce
the cutting action required to remove the dark or 2. Remove the two collector bus rings (with field leads
burned spots . attached) so they will not interfere with the grinder
installation or the grinding operation .
5. Shut down the engine to inspect the ring surface . If
further stoning is required, repeat Steps 2 and 3 and 3. Remove the two brushholders (Nos. 5 and 6) from
continue doing this until ring surfaces are clean. the brushholder yoke located on the right-hand side
of the alternator facing the collector end . Mark or
WARNING : When using compressed air for cleaning label the studs to reduce the possibility of
purposes, an environment potentially hazardous to reassembling them in the incorrect position .
personnel in the immediate area is created. To prevent
physical injury by flying debris, observe all Railroad 4. Attach the grinder (without stones installed) to the
and OSHA safety regulations. brushholder yoke in the No. 6 brushholder position
by means of the No. 6 brushholder stud capscrew as
shown in Fig. IV-7. The grinder mounting bracket is
designed so that once it is attached to the yoke, no
further alignment is required.

5. Adjust the radial-feed stop to prevent the grinder way

from damaging the collector ring if the stone wears
too short.

6. Install stone in right-hand (inboard) support and a

dummy stone in left-hand (outboard) support . Clamp
stone at the proper angle to permit full travel of the
stone across the ring surface . If burning or grooving is
severe, start with a medium-grade stone and change to
a fine-grade stone for the finishing operation.

NOTE : Grind only one ring at a time. Final ring

diameters need not be the same .
 FIG . IV-6 . COLLECTOR RING GRINDER .

7. Start engine and run it at idle speed .

WARNING : When using compressed air for cleaning
purposes, an environment potentially hazardous to
8. Feed the stone radially inward by means of the feed
personnel in the immediate area is created. To prevent
screw until the stone makes contact with the collector
physical injury by flying debris, observe all Railroad
ring surface .
and OSHA safety regulations.

9. Traverse the stone back and forth across the ring

12. Restart the engine and, with alternator running at
surface by means of traverse knob. Alternately
continue feeding the stone inward slowly as it wears, engine idle speed, blow out the alternator with dry
and traversing the ring. compressed air. Direct the air so as to remove
grinding dust from the stator windings and field
coils .
10. Periodically shut down the engine to check progress
of the grinding operation. Repeat Steps 7, 8 and 9 as 13. Shut down the engine and reinstall brushholder
many times as necessary to remove burned spots or studs in their original position.
grooving . Change to fine-grade stone for the
finishing operation. CAUTION: Failure to install brushholder studs in
their correct position will result in short circuiting the
11 . With the grinding operation completed and the collector rings when excitation is applied.
engine shut down, remove the grinding fixture . Be
careful not to nick or scratch the rings. 14. Reinstall the bus rings and field leads.

IV-5
 Seating New Brushes

Because new brushes are already contoured to the

collector ring it is not necessary to seat them when they are
first installed . Simply install them as described previously,
and they are ready for operation .

Adjusting Brushholder Clearance

Maintain clearance between the brushholders and the

collector rings at 3/32 to 1/8 in. If the clearance is not
within this range, readjust the brushholders as follows :

1 . Remove brush from the holder.

2. Loosen the capscrew located on the brushholder

yoke.

3. Place a fiberboard shim of the proper thickness

between the bottom of the brushholder and the
collector ring.

FIG . IV-7 . SET-UP FOR GRINDING 4. Move the brushholder down against the fiberboard
COLLECTOR RINGS . shim and tighten the brush stud capscrew .

15. Reinstall brushes removed for the resurfacing 5 . Remove the fiberboard shim and replace brush in the
operation, or install new ones if necessary. holder . Make sure the pigtail terminal screw is tight
and the pigtail is in the correct position shown in
16. If brushes removed for the resurfacing operation are Fig. IV-3.
reused, sand them to remove metal which may have
transferred from the collector ring to the brush Reversing Brush Polarity
contact surface . Use a strip of fine-grit sandpaper
2-in. wide by 24-in. long for this operation. To increase life expectancy of the collector rings and
brushes, periodically reverse the polarity of the brushes by
Installing New Brushes
interchanging the two exciter leads inside the alternator
connection box or at the brushholder.
CAUTION: When installing new brushes use the GE
recommendedgrade. Do not mix brush grades. Mixing
Because conditions which adversely affect collector ring
brush grades in the same alternator or changing to
and brush life vary so widely, brush polarity reversals
another grade can seriously affect the collector-ring
should be made every six months until operating experience
surface film and result in short brush life.
indicates that satisfactory wear rates can be obtained by
reversing the polarity less frequently.
Install new brushes as follows, see Fig. IV-4:

1 . Insert brushes in the holder with the pigtail High-Potential Testing

connection on the side farthest away from the pigtail
terminal screws. It is customary to apply an annual ICC high-potential
test to the complete locomotive power circuit which
2. Position the pigtail terminal under the terminal screw includes all traction motors, the traction alternator,
so that the terminal is parallel to the brush pressure auxiliaries, locomotive wiring and associated switching
arm . apparatus . For the procedure to be followed in making this
test and the precautions to be taken to protect equipment
3. Tighten terminal screw and latch the brush pressure and personnel, refer to the appropriate section in the
spring . overall locomotive maintenance manual .

IV-6
 ROTATING EQUIPMENT, SECTION IV, GEK-30150

AUXILIARY GENERATOR/EXCITER Classification . . . . . . . . . . . four-pole, commutating pole,

force-ventilated, shunt-wound, d-c generator
DESCRIPTION Nominal Rating . . . . . . . . . . . . 12 kw, 75 v at 850 rpm
51 kw, 250 v at 2400 rpm
The Type GY27 Auxiliary Generator/Exciters are Resistances at 25 C (Ohms)
force-ventilated, shunt-wound, d-c machines . The GY27 Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 .0229
located at the four o'clock position on the traction Shunt Field . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 .05
alternator, Fig . IV-8, is used as an auxiliary generator to Commutating Field . . . . . . . . . . . . . . . . . . . . . 0 .00872
supply regulated 75-vdc power to the control equipment, Starting Field . . . . . . . . . . . . . . . . . . . . . . . . 0 .00665
lights and to charge the battery . The GY27 at the Brush Data
eight o'clock position, is used as an exciter to control the Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GE-T-583
field current of the traction alternator . Type . . . . . . . . . . . . . . . . . . . Duplex with Rubber Pad
Pressure (oz .) . . . . . . . . . . . . . . . . . . . . . . . . 43 to 53
Both have cranking windings, and the two are used to Size (in .) . . . . . . . . . . . . . . . . . . . . . . . . . 0 .50 x 1 x 2
start the diesel engine . The two models are the same except Minimum Length (length at which brush
for the arrangement of the commutator covers for external becomes inoperative) (in .) . . . . . . . . . . . . . . . . . . 1
ventilation connections . Brushholder Clearance to
Commutator (in .) . . . . . . . . . . . . . . . . . 0 .06 to 0.10
Principal parts of the auxiliary generator/exciters are the Pole Bores (Average)
armature assembly, commutator and pinion end bearings, Exciting Poles (in .) . . . . . . . . . . . . . . . . . . . . . . 9 .844
brushholders, field coils, and magnet frame . Commutating Poles (in .) . . . . . . . . . . . . . . . . . 10.098
Commutator Data
The auxiliary generator/exciters are mounted on the Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Arch-Bound
traction alternator gear box . A drive gear, mounted on the Side Mica - Thickness (Nominal) (in .) . . . . . . . . . 0 .022
traction alternator shaft extension, meshes with a pinion - Grooving Depth (in.) . . . . . . . . . . . . 0 .047
gear on the auxiliary generator/exciter shaft to drive each Saw Width (in .) . . . . . . . . . . . . . . . . . . . . . . . . 0 .024
auxiliary generator/exciter machine . Diameter - New (in .) . . . . . . . . . . . . . . . . . . . . . 8 .00
- Minimum Permissible (in .) . . . . . . . . . . 7 .50
Grease Capacity of Bearing
Commutator End (oz .) . . . . . . . . . . . . . . . . . . . . 3-1/8
DATA
Type Lubricant . . . . . . . . . . . . . . . . . . . . GE-D6A2C4
Pinion End . . . . . . No grease required (splash lubricated)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GY27
Weight (lb .) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 695
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CW
Max . Speed (rpm) . . . . . . . . . . . . . . . . . . . . . . . . 2900
Full Speed (rpm) . . . . . . . . . . . . . . . . . . . . . . . . 2400 WARNING : Electric shock can cause serious or
fatal injury. To avoid such injury, personnel should
take and observe proper precautions during
high potential testing.

SPECIAL TOOLS AND EQUIPMENT

The following items are required to maintain, repair and

overhaul the auxiliary generator/exciter .

GE Part No .
Commutator Grinder . . . . . . . . . . . . . . . . 8843613G3
Resurfacing Stones . . . . . . . . . . . . . . . . . . 8828492P4

LUBRICATION

The pinion-end bearing is lubricated by oil splashed in

the traction-alternator gear box . Maintain the oil level in
the gear box between the HIGH and ADD marks on the
dipstick .

IV- 7
GEK-30150, SECTION IV, ROTATING EQUIPMENT

Periodically repack the CE bearing as follows : Resurfacing On Locomotive

1 . Remove the bearing cap and examine the old grease WARNING : An environment potentially hazardous
for evidence of steel chips. This would indicate to personnel in the immediate area is created when
bearing damage . resurfacing . To prevent physical injury by flying
debris, observe all Railroad and OSHA safety
2. Repack the bearing cap with approximately 2 oz. of regulations.
D6A2C4 grease .
1 . Remove any oil and dirt from the exposed insulation
3 . Replace the bearing cap . surfaces around the commutator, using an approved
method .

INSPECTION 2. Remove the four o'clock brushholder assembly and

the Al connection strap on the generator, Fig. IV-8,
1 . Inspect brushes to be sure they are not worn near the or the two o'clock brushholder assembly on the
minimum length, chipped or broken. Replace worn or exciter . Lift all the other brushes on the machine
damaged brushes . Also replace others in same being resurfaced .
brushholders since longer brushes are probably
defective (did not share load equally) . 3. Install the commutator grinder in the auxiliary
gene rator/exciter as follows, Fig . IV-9 :
a. Assemble the grinder to the mounting bracket
CAUTION : When replacing brushes, use the GE with two 3/8-16 by 1-3/8 in. hex bolts and
recommended grade. Mixing of brush grades in the lockwashers .
same machine or changing brushes to another grade is
not recommended as this will seriously affect b. Bolt this assembly in the machine where the
commutation, surface film, commutator and brush brushholder was removed . The key on the end of
life . the bracket fits into the keyway on the end of
the frame . Then insert the 5/8-11 by 1-1/2 in.
2. Inspect brushholders for damage from burning or hex bolt through the frame (with the flat washer
arcing . Check for damaged pressure springs or levers ; under the head), screw the hex bolt into the hole
replace parts as necessary. in the bracket and tighten.

3. Inspect the condition of the commutator . Be sure it c. Install two resurfacing stones on the grinder .
has a smooth, polished surface . Clean and resurface Space them far enough apart to cover the entire
when necessary. See section on Commutator width of the commutator surface when the
Resurfacing . carriage is moved from side to side. For small
commutators, use only finish-grade stones .
4. Inspect all leads and connections. Be sure the
connections are tight. d. Adjust the holder on the bracket so each stone
travels parallel to the surface of the commutator.
5 . Measure the insulation resistance of the armature and To adjust, slightly loosen the two 3/8-16 hex
field coils with a megohmmeter. bolts. Check by inserting a feeler gage between
the surface of the commutator and each stone at
each end of their travel along the commutator.
COMMUTATOR RESURFACING This check should be made at unworn sections of
the commutator and at both ends or between the
When the commutator becomes worn, grooved, or brush paths. After adjustment, back the stones
burned, it may be resurfaced with a commutator grinder away from the commutator and tighten the two
without removing the machine from the locomotive or the mounting bolts.
armature from the machine . Rotate the armature in its own
bearings . 4. Place the locomotive Reverse handle in the OFF
position . Have the Generator Field Breaker in the
Resurfacing of a commutator is done with commutator OPEN position so no current will pass through the
grinder assembly, Part 8843613G3 and stones listed in machine being resurfaced . The engine can be started
Special Tools and Equipment section . by cranking with one machine only.

IV-8
 ROTATING EQUIPMENT, SECTION IV, GEK-30150

is not the same, readjust the grinder until the cut is

approximately even at both ends of the commutator.

7 . Traverse the grinder and advance the stones until the

commutator is clean. Begin with light pressure and
increase it no more than necessary . Do not take too
deep a cut, for this will result in an excessive amount
of copper being dragged over the edges of the
commutator bars. If possible, use a vacuum-cleaning
device to collect the copper and abrasive dust during
the grinding operation.

8. Make a light finishing cut. Then, without changing the

feed, traverse the commutator several times to obtain
a good, smooth finish .

9. Shut down the engine and remove the grinder from

the auxiliary machine .

10. Using an engraving tool, remove any ragged edges

from the commutator bars and fins of copper which
have dragged over the slots .

11 . If necessary, undercut the slot mica between the

segments with a 0.024 in. thick saw .

12. Clean the commutator slots to remove mica and

grinding dust with a stiff nylon bristle brush. A new
paint brush or stencil brush with bristles cut short
for added stiffness is satisfactory .

WARNING : When using compressed air for cleaning

purposes, an environment potentially hazardous to
REF . DESCRIPTION
personnel in the immediate area is created. To prevent
1 TRAVERSING HANDLE
2 FEED HANDLE physical injury by flying debris, observe all Railroad
3 RESURFACING STONES and OSHA safety regulations.
4 GRINDER
5 BRACKET
5/8-11 CAPSCREW WITH WASHER 13. Start the engine and run it at IDLE . Thoroughly
6
blow the commutator and interior of the machine
with dry, compressed air to remove all copper filings
FIG . IV-9 . COMMUTATOR GRINDER INSTALLED IN
and dust. Polish the commutator with fine
GY27 MACHINES .
sandpaper .
5 . Start the engine and let it run at IDLE until it runs 14. Shut down the engine and measure the commutator
smoothly . This operation may be performed runout with a dial indicator mounted on the frame.
immediately after a locomotive returns from a run, The indicator should have a sensitivity of 50
while the engine is still warm. divisions, 0.001 in. or smaller, for one revolution of
the pointer. Maximum allowable runout after
6. Advance the stones to take a light cut across the stoning is 0.001 in.
commutator surface and to check alignment before
proceeding with the operation. Stones should cut 15. Replace the brushholder assembly that was removed
approximately the same amount at the front and the and the Al connection strap, if it was removed .
riser ends of the commutator where the brush paths Replace brushes, as necessary, with the GE
are not worn in the surface . If the amount of the cut recommended grade .

IV-9
GEK-30150, SECTION IV, ROTATING EQUIPMENT

TRACTION MOTOR

DESCRIPTION

The Type GE752 Traction Motor, Fig . IV-10, is a

four-pole, commutating-pole, series-wound d-c motor
designed for locomotive propulsion . Its normal function is
to convert the electrical energy supplied by the traction
generator into mechanical power for driving the locomotive
wheels .

The traction motor is coupled to the locomotive axle

through a reduction gear system housed in a gear case . The
gear case is attached to the traction motor and surrounds a I I
pinion and gear . The gear case excludes dirt and moisture FIG . IV-10. TRACTION MOTOR .
and holds the necessary gear lubricant .
End-Play
Armature Bearings - New (in .) . . . . . . . . 0 .005-0 .014
Locomotives equipped with dynamic braking use the Axle Bearings
traction motors as generators to retard the rate of travel New Linings (in .) . . . . . . . . . . . . . . . . . . . . . 1/16
when descending grades or slowing down the train . Worn Linings (1/8 in . max . wear
per lining flange) (in .) . . . . . . . . . . . . . . . . 5/16
Impedance of Field Circuits
DATA Measure before assembly of
armature : 60 cycles a-c Volts
to hot field coils only Amps _Max . _Min .
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GE752
Exciting Field . . . . . . . . . . . . . . 24 14 .8 13 .7
Maximum Permissible Speed . . . . . . . . . . . . . . . . . 2445
Commutating Field . . . . . . . . . . . 24 9 .6 8 .3
Resistances at 25 C (Average) (Ohms)
Measure with brushes lifted
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . .0 .01002
and armature assembled :
Exciting Field . . . . . . . . . . . . . . . . . . . . . . . . 0 .00555
60 cycles a-c
Commutating Field . . . . . . . . . . . . . . . . . . . . . 0 .00592
Exciting Field . . . . . . . . . . . . . . 24 17 .6 15 .6
Brush Data
Commutating Field . . . . . . . . . . . 24 12 .7 11 .0
Pressure (lb .) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Weights
Size (Duplex) (in.) . . . . . . . . . . . 3/4 by 2-1/4 by 21ong
Motor with Pinion (lb .) . . . . . . . . . . . . . . . . . . . . 7000
Minimum Lenght (length at which brush
Armature (lb .) . . . . . . . . . . . . . . . . . . . . . . . . . . 2170
becomes inoperative) (in .) . . . . . . . . . . . . . . . 1-3/32
Brushholder Clearance to Commutator . . . . . . 1/16-3/32
INSPECTION
Commutator
Side Mica - Thickness (in .) . . . . . . . . . . . . . . . . 0 .060
1 . Inspect the commutator and wipe off the string band .
- Grooving Depth (in .) . . . . . . . . . 3/64-5/64
The commutator surface must be free of copper beads
Diameter - New Commutator (in .) . . . . . . . . . . . 16-5/8
and have a smooth, polished surface . Clean and
- Minimum Permissible (in .) . . . . . . . . . 15-3/8
resurface the commutator when necessary .
Riser - Width Minimum Permissible (in .) . . . . . . . . . 5/8
Pole Bores (Nominal - measured at center of poles)
2 . The brushholder mechanisms must operate properly .
Exciting Poles (in .) . . . . . . . . . . . . . . . . . . . . . 19 .640
Shunts and terminals must be tight and insulators
Commutating Poles (in .) . . . . . . . . . . . . . . . . . 19 .970
clean .
Bearings (Assembled)
Diametrical Clearance
3 . Inspect the brushes for physical appearance and
Armature Bearings
amount of wear . Replace any which are chipped,
Commutator End (in .) . . . . . . . . . . 0.0017-0 .0057
broken or worn near the minimum length of
Pinion End (in .) . . . . . . . . . . . . . . . 0.0025-0 .008
1-3/32 in .
Axle Bearings
Minimum New (in .) . . . . . . . . . . . . . . . . . . 0 .014 Brushes must move freely in their holders and be free
Maximum Worn (in .) . . . . . . . . . . . . . . . . . 0 .060 of dirt, carbon dust or other foreign material .

IV-10
 ROTATING EQUIPMENT, SECTION IV, GEK-30150

CAUTION : When replacing brushes, use the GE CAUTION : Do not apply insulating varnish over
recommended grade. Mixing of brush grades in the dirt. Dirt or other contaminants will provide a current
same machine, or changing brushes to another grade, leakage path under, as well as over, varnish.
could seriously affect commutation, surface film and
brush life. 10. Measure end-play of the motor on the axle and
diametrical clearance of the axle linings. See Data
4. Check and adjust the spring pressure . Inspect the section for permissible limits of wear . Measure as
clearance between the bottom of the brushholder and follows:
the commutator support. See Data section.
a. To measure the end-play, move the motor toward
5 . Examine the armature and field coils for cracked, the gear by barring between the nose suspension
charred or broken insulation . See that field coil and truck bolster. Measure the end-play (lateral
connections are tight. clearance) through the drain hole in the
axle-flange dust guard located at the commutator
6. Examine the flash ring for damage . Keep the flash end. Use feeler or go-no-go gage as shown in
ring clean and free of paint or insulation . Fig. IV-11 . If gear lubricant has frozen the pinion
to the gear so the motor cannot be barred
7 . Measure the insulation resistance with a sidewise, add clearance at each end of the motor
megohmmeter. If a reading of less than one megohm to get the total lateral clearance . Clearance at the
is indicated, a further inspection to determine pinion end can be measured between the gear
insulation failure or excessive moisture should be hub and the axle-lining flange by inserting a
made . Correct the cause of low megohmmeter feeler through the drain hole in the gear-case seal .
readings before placing a motor back in service .

WARN ING : When using compressed air for cleaning b. Another method of measuring end-play is to
purposes, an environment potentially hazardous to clamp an indicator to the commutator end of the
personnel in the immediate area is created. To prevent axle cap so that the pointer rests against the
physical injury by flying debris, observe all Railroad wheel, Fig. IV-12. Force the motor as far as it
and OSHA safety regulations . will go one way along the axle . Set the indicator
at zero. Force the motor in the other direction as
8. Blow out the motor thoroughly, in both directions, far as it will go and read the lateral clearance or
with dry compressed air. end-play . When this clearance equals or exceeds
the permissible amount, install new linings. See
9. Clean the string band and paint it with insulating Fig. IV-13 for a method of measuring diametrical
varnish A15B17A if needed . clearance of axle linings .
v
FIG . IV-14 . CONDEMNING LIMIT FOR FELT
FIG . IV-12 . USING DIAL INDICATOR TO MEASURE WICK LUBRICATOR .
END-PLAY .

LUBRICATION

Armature Bearings
11 . Remove the felt-wick lubricators and examine them
Roller bearings are packed at the time of motor assembly
for the following defects :
with ball-bearing grease GE Spec . D6A2C4 . No access is
provided for the addition of grease during the operation of
the motor between overhaul periods .
a. Wear in excess of 1/4 in ., Fig. IV-14 .

Axle Bearings
b. Burned or hardened wick surface which is no
longer absorbant . The motor is equipped with large oil capacity axle caps
having felt-wick lubricators to conduct the oil to the axle
c. Damaged wick or wick holder . and bearing .

FIG . IV-13 . MEASURING DIAMETRICAL CLEARANCE OF LININGS .

 suspected,
maintain
be
truck,
THE
guard
remove
Use
Remove
replace
Loosen
Insert
Lift
Rest
Remove
done
cause
spur
of
will
the
and
aLOCOMOTIVE
removal
case
the
GE
apply
position
place
side
aitReplace
around
the
out
1bar
presence
examination
be
pinch
the
force
axle
two
readily
gearing
the
the
the
in
free
change
cause
AXLE
the
Spec
motor
the
halves
together
of
oil
Never
Do
extreme
the
gear
flange
enough
Install
level
linings
three
bolts
motor
end
of
from
inner
3/4-in
bar
over
well
the
asnot
bar
top
D50E8C
bearing
truck
pinion-end
weight
by
the
LININGS
(one
of
permit
compound
follows
isagainst
so
to
gear-case
motor
that
the
dust
and
overfill
to
the
lining
water,
with
wear
of
new
without
drawing
with
leverage
of
oil
lubricated
clearance
the
pieces
piece
over
failure
top
force
allow
off
axle
the
the
hold
contained
guard,
Use
lining
the
jacks
of
aby
the
away
dirt
bottom
of
lining
the
aat
mounting
oil
piece
gear
lining
axle
removing
gears
AAR
to
rotating
out
inner
the
pit,
the
the
of
against
each
gear
isor
will
axle
enter
To
by
from
with
and
axle
recommended
wood
two
bottom
aother
motor
of
drain
Check
in
to
Spec
free
flange
Then,
rotating
of
be
end)
case
caps
by
sample
the
pinion
the
glass
run
itthe
bolts
the
axle
sections
maintained
athe
supporting
away
contaminants
the
oil
M-906-56
between
gear
to
and
Doing
armature
towards
dry
of
gear
roll
journals
heavy
motor
half
by
tubing
hold
filler
from
inner
from
the
teeth
case
the
from
the
to
using
The
case
of
wheel
so
from
them
This
drop
gear
axle
cap
axle
the
axle
half
the
for
the
oil
the
for
Iftoa THE
Install
Tighten
Place
Axles
Raise
If
must
cap
the
and
with
the
rotated
the
aLOCOMOTIVE
drawn
caps
qt
degrees
corresponding
case
the
cap
Axle
use
in
magnet
and
equipped
Replace
Preparation
outside
the
clear
isare
always
diesel
by
space
airwhich
the
axle
of
tie
locomotive
out
motor
loose
stamped
shims
This
down
locomotive
duct
maintenance
wheels
not
axle
bolts
the
are
AAR
EQUIPMENT,
caps
Lock
air
placing
COMMUTATOR
bars
The
the
cap
engine
the
apart
half
frame
itbrakes
Jack
interchangeable
be
diameter
tightly
the
axle
linings
so
will
caps
rails
was
until
with
block
between
and
bolts
Spec
are
with
air
the
on
dust
assembled
with
of
dust
serial
up
which
destroy
are
originally
isaover
capto
the
machined
brakes
the
on
the
cannot
roller
atto
bolts
clamped
should
the
new
M-906-56
wooden
will
aAxle
white
the
prevent
of
guards
lb
the
journal
number
8001b
after
atight
face
be
faces
SECTION
axles
end
the
pit
not
will
journal
serial
lining
the
with
other
run,
on
tobe
linings,
move
of
machined
fit
with
linings
giving
lead
of
be
of
and
not
between
with
be
the
movement
clamping
GE
block
the
boxes
car
thick
insert
wire
the
blown
number
magnet
locomotive
torque
in
fill
other
being
bearings
used
motor
IV,
cap
and
oil
truck
when
Spec
the
itAxle
truck
position
enough
the
of
through
abetween
GEK-30150
and
athe
Replace
about
The
baffle
motors
worked
to
magnet
oil
the
frame
effect
thorough
of
caps
frame
Lubricate
correctly
and
cap
requiring
until
the
magnet
may
axle
run
trucks
axle
the
before
toin
bolts
wear
with
face
bolt
and
and
the
fill
on
be
the
to

ROTATING

Where 8. outer
is . reassemble
can cleaning .
bottom .
contaminated, . . NOTE :
to frame .
opening . Each
frame .
Gearing cap
having .
The
compound . . Never
axle .
CAUTION : . result .
result . assembled,
frame
CAUTION : . on .
may are
bearing . of .

REPLACING 9. .-ft. .
ON axle
To tightening.
the heads .
caps, four . . .
: gear and add 12 . of . D50E8C
dust .
lubricant .
1.
commutator RESURFACING
easy . IN

2. . Locomotive
1. .
3.
gear a. Cut
about . motor .

4. . . b. Block
gear-case so .
apart .
c. Set .
5.
axle . 2.
lining, raised
jimmy . pedestal
be .
6. all .
and wheels .
raise .
lining . 3. all the brushes except the two, located
180
7. traction .
key .
roughness . 4.
into . motor .

IV-13
GEK-30150, SECTION IV, ROTATING EQUIPMENT

WARNING : An environment potentially hazardous

to personnel in the immediate area is created when
resurfacing . To prevent physical injury by flying
debris, observe all Railroad and OSHA safety
regulations .

5. Install commutator grinder, Part 8837582G1, in the

bottom commutator opening located on the
suspension side . This is the safest place and will allow
most of the grinding dust to fall out. See Fig. IV-15 .
The grinder assembly consists of a "Midget" grinder,
K-8828708G1 (Part 100X371), mounting bracket,
Part 8843149P6, resurfacing stones, Part 8824492P8,
and various capscrews and set screws as indicated on
Fig. IV-16 . Install the grinder as follows:

a. Bolt the grinder to mounting bracket with four

capscrews (6), Fig. IV-16.

b. Remove the cover from the bottom inspection

hole on the suspension side . REF . DESCRIPTION
1 COMMUTATOR GRINDER
2 MOUNTING BRACKET
c. Install the grinder in the motor by bolting it into RESURFACING STONE
3
the cover bolt holes. Use two capscrews and 4 CAPSCREW
lockwashers (4 and 5) provided with the fixture. 5 LOCKWASHER
6 CAPSCREW
The base of the mounting bracket will be on the 7 LOCKWASHER
outside of the frame . 8 SET SCREW
9 JAM NUT
d. Place the two jam nuts (9) on the set screws (8)
and screw them into the tapped holes in corners FIG . IV-16 . COMMUTATOR GRINDER
of the base of the mounting bracket. These adjust PART 8837582G1 .
the position of the grinder with respect to the
commutator . f. After the stones are installed, traverse the grinder
to one end of the commutator and check
e. Install medium-grade resurfacing stones in the clearance between the commutator surface and
grinder, Fig. IV-15. one stone with a feeler gage . Traverse the grinder
to the other end of the commutator and check
the clearance under the same stone. The
clearance should be the same at both ends. If the
clearance is different, adjust the mounting
bracket by means of the set screws (8) until the
clearances are the same at both ends . When
clearances are the same, tighten the jam nuts (9)
on the set screws to maintain adjustment while
grinding.

g. Turn the feed control to back the stones away

from the commutator while the motor is being
started.

6. Connect the motor to a source of controlled power to

drive it at a speed of 1000 to 1500 rpm. This power
can be obtained from an outside source of power or
from the locomotive power plant.
 ROTATING EQUIPMENT, SECTION IV, GEK-30150

9. Grind the commutator until a uniformly smooth

surface is obtained and all flat spots have been
removed . Do not remove more copper than necessary .

10. After the final cut, traverse the stones back and
forth longitudinally without changing the feed until
there is no more cutting action .

11 . Remove power from the motor and remove the

grinding fixture .
FIG . IV-17. DIAGRAM OF CONNECTIONS TO RUN
TRACTION MOTOR FROM WELDING SET.
12. Scrape the slots between the bars to remove
a. Disconnect the motor leads from the locomotive projecting mica fins or copper whiskers.
wiring and connect motor as a series motor to an
outside source of power such as a 3 to 5 kw at WARNING: When using compressed air for cleaning
100 v welding set if an outside power supply is to purposes, an environment potentially hazardous to
be used. See Fig. IV-17. personnel in the immediate area is created. To prevent
physical injury by flying debris, observe all Railroad
b. The motor can also be run from the and OSHA safety regulations.
diesel-electric locomotive power plant. With all
wheels blocked except those connected with the 13. Run the motor again at 1000 rpm and polish the
motor to be worked on, the motor can be run for commutator with 00, or finer, sandpaper . Blow dust
stoning the commutator without disturbing from the commutator and interior of the motor with
locomotive connections by placing the Throttle dry compressed air. Hold the end of the hose about
handle in the first operating position . Current one or two inches from the commutator surface and
required to run the motor is so low no damage sweep longitudinally to blow away copper chips and
will result to the blocked stationary motors loose mica.
through which current will flow.
14. Remove power and make the necessary mechanical
WARNING : To protect personnel from physical and electrical changes to place the motor back in
harm, following safety precautions must be adhered service on the locomotive.
to :
15. Install new brushes.
Block the locomotive wheels to protect the
locomotive from moving during the grinding NOTE : Do not grind the commutator to a depth
operation. Make blocking positively secure. where the mica undercut has been removed.

A second person must be at the power control station

ready to shut-off power in case of an emergency COMMUTATOR MAINTENANCE
during the grinding operation .
DESCRIPTION
The grinding operator should wear goggles and a dust
mask when grinding or blowing out the commutator. The commutator, Fig. IV-18, is a vital part of every d-c
motor and generator ; therefore, it deserves the very best
7. Apply power to the traction motor and gradually care . The fact that a commutator usually shows signs of
bring the speed up to 1000 to 1500 rpm. distress before trouble actually occurs, is a big help to the
8. Move the fixture back and forth along the maintainer . If you can recognize these signs and know what
commutator while slowly advancing the stones to do, you can often correct the trouble before it becomes
toward the commutator surface . Use extreme caution serious .
in advancing the stones to obtain a fine cut and to
avoid chatter . A commutator has three functions :

NOTE : Use the medium stones for the rough cuts . 1 . It provides the required sliding electric contact
For finishing, use fine stones and run the motor in the between the fixed brushes and the moving armature
opposite direction . to remove or apply electrical energy to the machine .

IV-1 5
 FIG . IV-18. CUTAWAY SECTION OF FIG . IV-19. ARCH-BOUND COMMUTATOR ASSEMBLY .
THE COMMUTATOR .
Mica cones, contoured to fit between the shell and cap,
2. It acts as a reversing switch . As the ends of the insulate the bars from ground (armature).
armature coils pass the brush positions, the
commutator switches them from one circuit to A Teflon* creepage band, applied on the exposed cone
another where the current is flowing in the opposite insulation, protects the mica from damage and presents a
direction . Thus all the coils have current flowing smooth creepage surface that is easy to keep clean.
through them in the proper direction at all times.
SURFACE CONDITIONS
3. It also brings the voltage of each armature coil in the A commutator cannot work properly unless the brushes
circuit to the brush surface . These voltages add up bar make good electrical contact . This requires a smooth,
by bar between brushes. As a result, the total polished, cylindrical surface that runs true with its center .
operating voltage of the machine appears at the
brushes . Surface Film

CONSTRUCTION The successful operation of all d-c machines depends on

maintaining a proper film on the surface of the
A commutator, Fig. IV-18, is formed of alternate copper commutator, Fig. IV-20 . This film of carbon, graphite,
segments and mica plates . Copper segments are often called copper oxide and water vapor is deposited on the
bars so hereafter, in this publication, we will use the term commutator surface by electrochemical action . It is formed
bar instead of segment . by the wiping action of the brush against the commutator
and by the normal current flow between the brush and the
The mica plates physically separate and electrically commutator.
insulate the bars and provide arch pressure essential to
commutator stability . The plates are undercut below the The importance of maintaining a proper commutator
commutator surface to prevent interference with the sliding surface film cannot be overemphasized . With this film
action of the brushes on the surface of the commutator . established and properly maintained, good brush
performance (reduced brush and commutator wear) and
The bars are wedge shaped and form a cylinder when satisfactory commutation (no destructive sparking) is
assembled . Each bar has a riser at one end to make assured . Changes in color from copper to deep brown or
armature coil connections . chocolate should give no cause for worry, as long as the
surface is smooth and has a polished glossy appearance.
The bars are held in position by the clamping action of a
steel cap bolted to a steel shell, Fig. IV-19. *E .I. du Pont de Nemours and Co ., Inc.

IV-16
 FIG . IV-20. GOOD COMMUTATOR FILM OF
UNIFORM COLOR .

Color Pattern FIG . IV-21 . ONE LIGHT-TWO DARK, THREE-COIL

PER SLOT COLOR PATTERN .
This term indicates only that the color of the
commutator bars is not uniform and a definite pattern 6. Incorrect brush spacing
exists. The pattern is almost always related to the
arrangement of coils in the armature slots. In itself, this 7. Incorrect brush shift .
condition is not a sign of damage . The color pattern may
show up in several sequences, Figs. IV-21 and IV-22 . As
long as there is a definite pattern around the whole
commutator, do not be concerned .

A check for surface damage should be made at scheduled

commutator inspection periods . If no damage exists, no
further action is required.

Marking, Etching and Flat Spots

The following conditions indicate discoloration and/or

etching of commutator bars - but in varying degrees .
Possible causes of etching and discoloration include :

1 . Excessive load on the machine

2. Electrical adjustment off ; such as, wrong shims

behind commutating poles or wrong interpole gap

3 . Wrong brush grade

4. Uneven or rough commutator surface

FIG . IV-22 . ONE DARK-TWO LIGHT, THREE-COIL
5. Contaminated atmosphere PER SLOT COLOR PATTERN .

IV-17
GEK30150, SECTION IV, ROTATING EQUIPMENT

The best way to overcome these conditions is to

determine the cause and make the necessary corrections . If
damage has not progressed too far, it may clear itself once
the cause has been eliminated . If it is determined that some
resurfacing of the commutator is necessary, it should be
done sparingly .

Marking

This condition appears as an opaque darkened surface or

black deposit on the bars, usually at their trailing edge, with
no etching or corrosion of copper underneath.

Check for this condition quickly by using a common

pencil eraser to remove the deposit; then examine the
copper surface for roughness or pitting . If none is seen, the
condition is marking, which can readily be removed with a
canvas cloth. See Fig. IV-23 .

Bar Surface Etching

This condition gives the appearance of severe marking s_

and a pencil eraser uncovers pitting, eroded or burned bar
surfaces . Such a condition results from arcing between the FIG. IV-24. HEAVY ETCHING ON A TWO-COIL PER
brush and the copper commutator bars and the etching is SLOT COMMUTATOR .
usually visible with the naked eye when the marking is Bar Corner Etching
removed . See Figs. IV-24 and IV-25 . When this condition prevails, the corner of the bar is
eroded leaving a chamfered corner but little or no evidence
of marking or bar surface etching.

FIG . IV-23. COMMUTATOR FILM REMOVED WITH A

PENCIL ERASER TO SHOW A SMOOTH COPPER FIG. IV-25. IRREGULAR FILM AND ETCHING
SURFACE UNDERNEATH . CAUSED BY A ROUGH COMMUTATOR .
 ROTATING EQUIPMENT, SECTION IV, GEK-30150

Bar corner etching may be best seen by holding a light

source at an angle which will reflect light from a chamfered
corner to the eye.

Flat Spots

If etching is not corrected and progresses too far, flat

spots will develop . Flat spots may also develop from a
mechanical disturbance, such as the vibration from a
defective bearing. As a rule, however, flat spots result from
failure to correct some faulty condition which is first
indicated by burned bars. See Fig. IV-26.

Threading
Threading is a commutator surface condition that shows
as circumferential grooves on the commutator . Threading is
the result of abrasive or electro-chemical action of the FIG . IV-27. HEAVY THREADING OF COMMUTATOR .
brushes.

In light threading, grooves may be just barely apparent

where the surface film or color is disturbed or different . In Possible causes of threading include:
heavy threading, a rippled surface can be felt if you rub a
fingernail along the surface of a bar. See Figs. IV-27 and 1 . Low current-density in the brush (machine is not
IV-28. heavily loaded) .

The brush faces wear to fit these grooves . When the 2. Abrasive dirt or other foreign material imbedded in
commutator shifts due to armature end-play, the brushes the face of the brush .
are lifted out of the grooves . Then contact between the
brush and the commutator is disturbed, sparking occurs and 3. Mica flakes or copper imbedded in the brush face .
commutation is disrupted .
4. Wrong brush grade.

FIG. IV-26. FLAT SPOT ON A COMMUTATOR THAT FIG. IV-28. ILLUSTRATION OF THREADING OF
ALSO SHOWS FLASHOVER DAMAGE . COMMUTATOR SURFACE.

IV-19
GEK-30150, SECTION IV, ROTATING EQUIPMENT

Copper Drag

Under certain conditions copper is dragged over the

trailing edges of the commutator bars and has the
appearance of small metal flakes or feathers. Copper drag is
caused by particles of copper, copper oxide and
contaminates that do not bond firmly to the surface of the
commutator. As the commutator rotates, the brushes shove
small flakes of this material toward or into the commutator
slots. This decreases the distance between the bars. An arc
formed at any brush can then be more easily carried over to
an adjacent brush resulting in a flashover . FIG . IV-30 . ILLUSTRATION OF COPPER DRAG .
Copper drag should not be confused with bar corner
etching. See Figs. IV-29 and IV-30. Possible causes of banding include :

Possible causes of copper drag include: 1. Brush film too heavy (film tears from surface)
2. One brush is the wrong grade
1. Contaminated atmosphere
3. Hard spot in a brush .
2. Copper imbedded in brush face
3. Hard spot in brush
Banding can be corrected by hand-stoning after the cause
4. Wrong brush grade
has been eliminated.
5. Excessive vibration
6. Low current density.
Eccentricity
A temporary solution to copper drag is to clean the
commutator occasionally with a light brush-seater stone . If Even though a commutator surface is smooth, it can be
drag has progressed too far, the slots must be raked and running off center . This is a common fault and is usually
cleaned. the easiest of all surface variations for the brushes to
follow. They simply rise and fall in the holders with each
Banding revolution . However, as speed goes up, this eccentric
motion becomes faster. Finally, the brushes begin to break
Banding is a surface defect in the form of bands around
contact and gradually burn the commutator surface . As this
the commutator in which the surface film has been partially continues, the burning causes still further surface
or completely removed. These bands may be quite narrow destruction . See Fig. IV-32 .
(not to be confused with threading) or they may extend
over a sizeable percentage of the brush path. See Fig . IV-31

FIG . IV-29 . COPPER DRAG ON TRAILING EDGE OF

COMMUTATOR BARS . FIG . IV-31 . EXAMPLE OF BANDING .

IV-20
 FIG. IV-33. EFFECTS OF DEPRESSED BARS AND
REVERSAL OF ROTATION .

Possible causes of surface breaks include bumping of

commutator surface during handling or striking
commutator with a heavy tool, etc .

Resurface the commutator with a rigidly-mounted

grinding fixture to remove the surface break .

FIG . IV-32 . EXAMPLE OF ECCENTRIC COMMUTATOR High Bars

(EXAGGERATED FOR PURPOSES
OF ILLUSTRATION) . If a motor armature does not rotate while power is
applied, the commutator bars under the brushes will
Possible causes of eccentricity include: overheat and expand . Expansion will cause these bars to
rise above the adjacent bars. When the armature rotates, the
1 . Bent shaft high bars kick the brushes which, in turn, arc and burn the
commutator surface . If this condition is not corrected, the
2. Bearings not running true brushes may shatter and a flashover could occur . See
Figs. IV-34 and IV-35 .
3. Commutator machined on bad shaft centers

4. Distortion caused by wide temperature changes and

high speed

5 . An offset coupling in single bearing traction

generators.

Determine the cause of eccentricity and resurface the

commutator using a rigidly-mounted grinding fixture .
Eccentricity cannot be corrected by hand-stoning.

Surface Breaks

Sometimes a sharp step occurs on a commutator surface .

This may be caused by a bump or blow to the commutator.
Though the change in surface level may be very small, not
even a heavy spring load will keep the brush in contact with
the depressed bars. The brush may "ski-jump" from the
higher level or, if rotation is reversed, the step strikes the
brushes and "kicks" them away from the surface . This
causes sparking, followed by electrical erosion and flat
spots on the surface of the commutator . At high speed this
kick may be hard enough to shatter the brushes . See FIG. IV-34. EXAMPLE OF A SOFT COMMUTATOR
Fig. IV-33 . BAR WHICH HAS LIFTED AT HIGH SPEED.

IV-21
GEK-30150, SECTION IV, ROTATING EQUIPMENT

Feather edge mica results from the incorrect

undercutting of high mica, Fig. IV-36-C, which leaves
feather edges of mica level with the commutator surface .

Either form of high mica disrupts the process of

commutation . This, in turn, increases wear on the
commutator bars and the brushes to expose more mica to
further disrupt commutation .

Flashover Damage

Any condition or defect which causes arcing on the

surface of the commutator must be regarded as a potential
cause for a flashover . When arcing becomes severe enough,
the surrounding air changes into a conductive gas and
FIG . IV-35. EFFECTS OF HIGH BARS ON BRUSHES. allows power to spill over between the brushes in a
flashover . A flashover is the commutator's final protest
against neglect and abuse. Evidence that a machine has
In severe cases, bar temperature may rise high enough to flashed over will be found in the form of copper splatter on
anneal the copper and destroy the binder in the mica plates. the surface and ends of the commutator bars, on the
When this happens, flakes of mica will shift from the brushholders and nearby insulation and on the frame as
pressure areas and reduce the clamping action on the bars. shown on Fig. IV-37.
Annealed bars wear differently than normal bars and being
loose, will lift at high armature speed . If a flashover occurs, clean the commutator, the Teflon
creepage band, and the brushholders . Examine these parts
Annealed bars can be detected with a scleroscope or for damage and check the condition of the brush faces.
some equivalent means. Sometimes they can be spotted by Repair or replace damaged parts as necessary.
discoloration of the bar ends outside the brush track.

High mica refers to the height relationship between the

surface of the mica plate and the surface of the
commutator bars. See Fig. IV-36-A for correct relationship.

In normal use, the surface of the commutator is

gradually worn down. As the copper is worn away, the
depth of the undercut (slots) is reduced until the edges of
the mica plates are even with (or slightly higher than) the
surface of the commutator, Fig. IV-36-B . At this point, the
mica is called high mica.

High mica can be the result of either normal

electro-mechanical wear, or failure to undercut the mica
after resurfacing operations.

FIG . IV-37. EQUIPMENT BADLY DAMAGED

FIG . IV-36. HIGH OR FEATHER-EDGE MICA . BY FLASHOVER.

IV-22
 ROTATING EQUIPMENT, SECTION IV, GEK-30150

RESURFACING THE COMMUTATOR

WARNING : An environment potentially hazardous

to personnel in the immediate area is created when
resurfacing . To prevent physical injury by flying
debris, observe all Railroad and OSHA safety
regulations .

Commutator troubles may often be corrected by

resurfacing. This is the name given to any process which
restores a true, cylindrical, polished surface to the
commutator .

Polishing

FIG . IV-39 . PROPER USE OF HANDSTONE .

If the commutator surface is merely smudged, you can
clean it by polishing with canvas . When this is not
sufficient, or if the commutator is slightly rough, crocus
cloth or fine (4/0) sandpaper may be used . This should be Hand stoning will not correct an out-of-round
mounted on a wooden block curved to fit the surface of the commutator . It is a fairly difficult operation and should be
commutator as shown in Fig . IV-38 . performed only by knowledgeable, skilled personnel.

CAUTION : Never use emery cloth on a

Undercutting
commutator. The abrasive particles not only scratch
the surface, but they are conductive and lodge
After a commutator has been resurfaced, check the
between commutator segments. This leads to short
depth of the undercut of the mica between bars . If
circuits .
undercutting is necessary, it should be done carefully with a
proper tool of correct size . The tool must have a sharp edge
Stoning
to cut the mica freely . A dull blade or saw produces small
If the commutator surface is mildly grooved, etched, or cracks in the mica into which dirt or moisture may find its
way and break down the insulation between commutator
burned, and only a small amount of copper has to be
bars .
removed to correct the defect, a hand stone is most
suitable . The stone should have a surface curved to fit the
Some common mistakes are shown in Fig. IV-40. Avoid
commutator . Also, it should be long enough to bridge the
these mistakes, refer to the device instruction book for the
defect to be removed ; otherwise, the stone will ride in and
slot width and depth dimensions .
out of the defect and do nothing to correct it. The length
of the stone will usually be limited by the space between
brushholders . If there is not enough space, a brushholder
should be removed to make room for a larger stone,
Fig. IV-39 .

A. MICA PROPERLY UNDERCUT .

B. UNDERCUTTING TOOL TOO NARROW, LEAVING
FIN AT ONE SIDE OF SLOT .
C. UNDERCUTTING TOOL VERY NARROW, LEAVING
FINS AT BOTH SIDES OF SLOT .
D. SLOT IMPROPERLY INDEXED. PART OF BAR CUT
AWAY AND FIN OF MICA LEFT .
E. TOOL TOO WIDE . PART OF BAR CUT AWAY .
F. UNDERCUTTING TOO SHALLOW. SERVICE LIFE
SHORTENED.
G. UNDERCUTTING TOO DEEP . POCKET COLLECTS
CARBON AND COPPER DUST, SHORT-CIRCUITING
BARS.

FIG . IV-38 . FINE GRAIN SANDPAPER ON A SHAPED FIG . IV-40 . COMMON MISTAKES IN UNDERCUTTING
WOODEN BLOCK. THE MICA BETWEEN COMMUTATOR SEGMENTS .

IV-23
GEK-30150, SECTION IV, ROTATING EQUIPMENT

Slot Raking and Brushing If resurfacing has produced considerable copper-drag on

the bar edges, a "V" shaped slot-raking tool should be used
to remove fins and ragged edges from the bars. Insert the
Resurfacing operations usually leave copper particles and point of the tool in the slot so the sides of the tool will
slivers on the edges of the commutator bars and in the slots. scrape the edge of the bar on each side of the slot as the
These must be removed before the machine is placed in tool is dragged along the slot.
service as they could cause a flashover . Use a brush with
stiff nylon bristles, a piece of fiberboard or a special tool After the slots have been cleaned, it may be necessary to
ground to fit the slot, Fig. IV-41-B, C, and clean the slots use very fine sandpaper or crocus cloth to remove small
thoroughly . Use a slot raking tool, Fig. IV-41-A, and break burrs and slivers from the edges of the bars. Don't use
the sharp edges of the bars. emery cloth.

(B) CLEANING OUT SLOTS IN INNER (C) CLEANING OUT SLOTS ON OUTER
BRUSH PATH . BRUSH PATH .

FIG. IV-41 . CLEANING COMMUTATOR SLOTS .

IV-24