i/J/l ‘)

SERVICE DEPARTMENT M.I. 3950-3

EMM Maintenance Instructi;

T R A C T I O N M O T O R O V E R H A U L i , in’ ‘-- - . _ ,-:a ;
-.- . - A-. .~i_ -“-. _..
- t “..~*‘~~~:...“. I.. ._. . ,,. . . .

Traction motor overhaul instructions are presented in seven sections, each under separate cover, and
contain detailed instructions to completely disassemble, inspect, overhaul, assemble, and test the traction
motor. Refer to Maintenance Instruction 3900 for general or “running” maintenance of the traction
motor and also for procedures to remove the traction motor from the locomotive truck. These
instructions apply to Models D37, D47, D57, D67, D75, and D77 traction motors unless specifically
identified.

Section No. Title

1 Disassembly
2 Bearing Component Inspection
,3 Stator Inspection And Reconditioning - Mechanical
4 Stator Inspection And Reconditioning - Electrical I
5 Armature Inspection And Reconditioning
6 Armature Overhaul
7 Motor Assembly

SECTION 3
STATOR lNSPECTlON AND
RECONDITIONING -MECHANICAL
INTRODUCTION STATOR CLEANING
During traction motor overhaul, the stator should Clean the inside and outside of stator assembly
be cleaned and inspected to determine mechanical by blowing out dirt, dust, and other contami-
and electrical quality to ensure satisfactory per- nants using high volume, low pressure, clean, dry,
formance during subsequent operation. Visual and compressed air. Avoid excessive air pressure
electrical inspections are required to determine which could cause insulation damage.
what type of repair, if any, is needed.
Remove remaining dirt by wiping frame and
The inspections should be carefully made and all
insulation with a clean cloth dampened with a
rework performed according to the outlined
suitable solvent such as Stoddards Solvent.
procedures.
This section is divided into five major parts:
WARNING : Provide adequate ventilation when
Frame Inspection - Coils Intact using solvents. The usual precautions
should be observed when handling
Frame Inspection - Coils Removed inflammable fluids such as Stoddards
Solvent which has a flash point of
Minor Frame And Axle Cap Repairs 46” C (115” F).

Major Frame Repairs - Coils Intact In the event that the stator is extremely dirty or
oily, the inside and outside. may be cleaned using
Major Frame Repairs - Coils Removed hot water to which a small amount of caustic has

*This bulletin is revised and supersedes previous issues of this number.

E-L January 1978

M.I. 3950-3
been added. The hot water and caustic solution 2, Check oil filler caps on support bearing caps
may be applied with a pump and hose using a and replace with new caps if required.
pressure of 300-350 kPa (45-50 psi). After such 3. Check that internal condition of support
washing, the stator should be thoroughly rinsed bearing caps is satisfactory.
with clear, clean water to remove all traces of the
caustic. 4. Check commutator inspection cover felt seals,
Replace with new felt seals if required.
After washing and rinsing, dry the stator by
placing it in a 145” C (293” F) oven. Insulation 5. Check the tack weld of field pole bolts on
resistance readings should be checked while the support side of frame. Tack weld if cracked.
drying process is going on. The drying out should 6. Inspect for cracks in the frame and frame
be continued until both the insulation resistance welds. Closely check the following areas:
and the temperature have become constant and
remain stable for several hours. This procedure a. Between the pinion end bore and the axle
usually takes 6 to 8 hours. bore
FRAME INSPECTION - b. Corners of the commutator opening and
COI LS INTACT cover openings
FRAME INSPECTION C. Upper brush holder support web.
Refer to Fig. 1 during inspection of traction Repair all cracks by welding. Refer to Welding
motor frame. Procedure in this section.
1. Check that ventilating screens (if used) are
not broken and have no cracked welding. 7. Inspect and recondition felt wicks and carriers
Replace screens or tack weld as required. as follows.
Main Field Coil Nut

lnterpole Coil Bolt ,

enti I ,g Screer IS
Commutator Inspection
Cover

Support Cap Bolt

Felt Wick
Lubricating
Windows

Bearing Bore

21930

Fig. 1 - Traction Motor

 M.I. 3950-3

FELT WICK LUBRICATORS Wick Should Not Touch

Bench When Test

Clean the felt wick lubricators using oil heated to

a temperature between 49” C and 60” C (120” F
and 140” F) and a soft bristled brush. The use of
a scraper or wire bristle brush is not recom-
mended. Refer to Maintenance Instruction M.I.
1756 for correct type of oil.
After cleaning, the felt wick assemblies should be
inspected to determine if the wicks are in satis-
factory condition for continued service. Observe
the following points:
1. Felt wicks should be discarded if they have Fig. 2 - Testing Wide Window Wick
hardened, glazed, or burned contact surfaces. Lubricator Springs
Normal service tends to pack the upper
portion of the wick, which is permissible
unless the wick no longer can absorb oil.
Check wick by applying oil and observing
how rapidly the oil is absorbed. If a pool of
oil remains on the surface of the wick or is
absorbed slowly, replace with a new wick.

2. The wick contact surface should be free of

major irregularities. Slight depressions are
permissible provided the depressions do not
extend the full length of the wick.

Check contact surface of the wick with a

straight edge. If any depression exceeds 3 mm
(l/8”) or if a regular “saw tooth” pattern is
observed, replace with a new wick.

3. The narrow window type wick should be

replaced with a new wick when the wick Fig. 3 - Testing Narrow Window
contact surface is worn down to within 6 mm Wick Lubricator Springs
(l/4”) of the metal wick carrier. This wick 6. All early style fiat or constant-pressure-type
should also be replaced with *a new wick narrow window support bearing wick lubri-
when the felt has elongated the rivet holes cator springs should be inspected for cracks
and is loose in the carrier. near rivet point. If any defective or cracked
springs are found, the assembly should be
4. Visually inspect the metal wick carrier assem- replaced with a wick conversion kit. Refer to
bly for warping, distortion, or cracks. Replace Service Data for part number.
carrier if required. Check carrier pins and
pinholes. Replace parts if worn more than 7. New and used wicks must be impregnated
0.30 mm (.012”) over a new assembly. with oil prior to use. Refer to Maintenance
Instruction M.I. 1756. Impregnate wicks as
5. Check wide window support bearing lubri- follows :
cator spring pressure by placing a weight on
the wick as shown in Fig. 2. Use a 3 kg (7 lb) a. Soak wicks for a minimum of 20 minutes
weight for new assemblies and a 2 kg (5 lb) in oil at room temperature or 10 minutes
weight for used assemblies. The narrow in oil heated to 71’ C (160” F). Wicks
window support bearing lubricator spring should not be allowed to touch bottom of
should be able to raise a 0.9 kg (2 lb) weight container when soaking in heated tank.
placed on the contact surface after the wick
is depressed, Fig. 3. The test should be made b. Allow to drain for 10 minutes to facilitate
with the wick saturated with oil and with all handling and installation. Use care to keep
sliding parts clean and lubricated. wicks clean while handling.

-3
M.I. 3950-3

8. If there is evidence that water has been GEAR CASE MOUNTING

absorbed into the wick, remove moisture as
follows: Measure the distance from the centerline of the
axle bore to the centerline of the gear case 27.0
a. Submerge wicks in oil heated to 104” C mm (l-l/l 6”) diameter mounting hole in the axle
(220” F) for 8 hours. cap arm, Fig. 4. This dimension shall be within
435.0 mm f 1.6 (17-l/8” + l/16). Wall thick-
b. Allow to cool, while still submerged, until ness of axle cap arm from center of 27.0 mm
oil cools to room temperature. (l-1/16”) diameter gear case mounting hole and
inner edge of arm should not be more than 32
c. Remove wick from tank and allow to mm (l-1/4”).
drain for 24 hours before use.
AXLE CAP TO FRAME
AXLE CAP MOUNTING TO FRAME SPLINE CONNECTION
The two axle caps are machined and line bored The axle caps should be assembled to the traction
when mounted on the traction motor with a 0.46 motor frame with the 0.46 mm (.018”) shims
mm (.018”) shim inserted between the caps and between the caps and motor frames.
the motor frame. Line boring of the caps is
necessary to achieve the accuracy of bearing fit CAUTION: The 0.46 mm (.018”) shim is placed
required. between the axle cap and the motor
frame before machining operation.
When the traction motor is mounted in a truck, During final assembly to locomotive,
the 0.46 mm (.018”) shims are removed and 0.25 a 0.25 mm (.OlO”) shim is used.
mm (.OlO”) shims are used, giving a 0.20 mm
(.008”) clamp fit or squeeze to the axle bearing Tighten securely in place and check the spline fit
shell. on each side with a feeler gauge. This measure-
The caps are not interchangeable with each other ment is taken between the support cap and its
on a given motor or with caps of the other junction with the traction motor frame. Total the
motors. To ensure the caps are properly matched, top and bottom readings taken on each side of
the caps are stamped with a serial number individual caps. This measured total clearance
matching the motor frame. During assembly, the should not exceed 0.38 mm (.015”) or the
numbers on the support bearing caps should be interference should not exceed 0.18 mm (.007”).
checked to ensure the cap matches the number
stamped on the motor frame. The interference fit, if present, can be determined
by measuring individual components with micro-
NOTE: The lockwasher used with axle cap bolt meters and determining the dimensional differ-
has been replaced by hardened flat steel ence. The tolerance of the frame spline is 260.17
washer 8495681 on current model mm to 260.53 mm (10.243” to 10.257”). The
traction motors. The flat washer provides tolerance of the support cap spline is 260.15 mm
a larger and smoother seating area which to 260.35 mm (10.242” to 10.250”).
enables bolt to develop a higher clamp
load at a given torque. The new flat AXLE BORES
washer is directly interchangeable with
the split washer after spot face of the 1. With the 0.46 mm (.018”) shim in place
area under the washer. between the axle cap and the motor frame,
and the support bearing caps drawn up tight,
Axle caps that have been removed should be
measure the axle bore diameter in four places
checked as follows:
as shown in Fig. 5. Ensure frame is at room
1. Thoroughly clean with a suitable solvent and temperature.
dry.
The average of the four readings must be
2. Paint outside of axle cap with chalk dust within 234.92 mm and 235.13 mm (9.249”
mixed with water and allow to dry.
to 9.257”), providing “A” diameter in Fig. 5,
3. Fill axle cap with kerosine and allow to stand is not less than 234.82 mm (9.245”).
for one hour. Check outside for leaks. If
leakage ~cl~-~~-oiL_~rajn-hoJe, repair- threads 2. Axle bore must be parallel to armature bore
and replace drain plug if required. within 0.31 mm (.012”).

-4-
 M.I. 3959-3

Top‘Spline

II +0.0045

Refer to Axle Cap Bores paragraphs

in this section for procedure to
measure bore diameter and bore limits.

2. The centerline of axle cap arm is

determined by a line from the centerpoint
of the armature housing bore through the
centerpoint of the axle bore.

1 -l/l 6” Diameter
Max. l/64” Oversize

METRIC CONVERSION CHART 1

(inch) mm (inch) mm (inch) mm

0.001 0.03 l-1/16 27 5-l/8 130.2

0.002 0.05 I-3116 30.2 55/16 134.9
0.003 0.08 l-114 32 9.249 234.92
0.007 0.18 l-112 38 9.250 234.95
0.010 0.25 2 51 9.257 235.13
1 I64 0.4 2-314 10.242 260.15
518 15.9 3-l l/64 ::6 10.250 260.35
35164 13.9 3-31132 106.8 17-I/8 435.0
1 25.4 4 102
21933

Fig. 4 - Pinion End Axle Cap

-5-
M.I. 3950-3
1 AXLE CAP THREADS
3 Axle cap frame threads are acceptable if no more
than three turns of class 2B no-go gage enter the
threads. Axle cap bolt threads must be class 2A.

FRAME THREADS
Threads in the motor frame are acceptable if a
class 1B no-go thread gage will enter the hole
with an easy fit, but not loose. Threads which are
recut must be class 2B.

SE SUSPENSION LUGS
AND WEAR PLATE
The dimension between the nose suspension
lower lug and the wear plate, Fig. 6, shall not
exceed 307.85 mm (12.120”).

COMMUTATOR END ARMATURE

HOUSING BORE
21704
Fig. 5 - Axle Bore Measurement 1. To check the commutator end housing bore
diameter, Fig. 8, measure the diameter at four
3. Axle bore centerline on pinion end to be places 45” apart. The readings must be be-
parallel and concentric with axle bore center- tween 307.92 mm and 308.08 mm (12.123”
line on commutator end within 0.13 mm and 12.129”), with an average maximum of
(005”). 308.05 mm (12.128”).
4. Distance between axle bore centerline and
2. Maximum out-of-round is to be 0.13 mm
armature bore centerline at the pinion end
(.005”). Housing bore inside face must be
shall be 434.34 mm (17.100”) minimum and
perpendicular to axial centerline within 0.08
434.75 mm (17.116”) maximum, Fig. 6.
mm (.003”).
When pinion end is at minimum of 434.34
mm (17.1 OO”), it is permissible for distance 3. Minimum housing bore wall thickness is 27
between centerlines at the commutator end to
mm (l-1/16”).
be 434.14 mm (17.092”).
4. Housing bore bolt holes to be within 1.04
AXLE BORE FACES
mm (.041 I’) of nominal location with respect
The distance between axle bore faces for frames to the bore.
with new axle caps shall be 1063.63 mm rt 0.13
(41.875” I .005”) and 1062.10 (41.815”) mini- 5. Housing bore bolt holes should be 22.2 mm
mum for all others, Fig. 7. (7/8”) diameter.
NOTE: An 0.8 mm (l/32”) step is permissible
between the pinion end armature bore ARMATURE HOUSING
face and the pinion end axle bore face. BORES AND FACES
AXLE CAP MOUNTING 1. Minimum acceptable dimension between the
BOLT SPOTFACE pinion end housing bore face and commutator
end housing bore face, Fig. 8, is 1044.37 mm
Check axle cap mounting bolt spotface, View A
(41 .l 17”).
of Fig. 4. The minimum thickness is 25 mm (1 I’).

AXLE BORE KEY AND KEYWAY 2. Pinion end housing bore and commutator end
housing bore to be concentric to each other
Check the axle cap bore key and keyway, Fig. 7. w i t h i n 0 . 1 3 m m (.005”) t o t a l i n d i c a t o r
Maximum keyway depth is 7.62 mm (.300”). reading. Refer to Pinion End To Commutator
Minimum keyway depth is 6.35 mm (.250”). End Armature Bore Concentricity Check
Maximum key protrusion is 6.35 mm (.250”). Procedure which follows.

-6
 M.I. 3950-3

'-13-114 "-r---17-1/8"
+-10-l/4"+ --I c 2523/32"- - 2 2 - 3 1 8 ” - -
-~8-15/16" - 1 9 - 1 / 3 2 ” - - - + 1
l-l/4"+
l-l /4”- +-8-l/8”-
5-l 12” &
2-314” Z
0

-lYtiE!f- bii4i iiWri

NOTES:
1. 17.111” between axle bore centerline and
armature bore centerline. Refer to Axle Bore
section of text for min. and max. dimensions.

2. The centerline of axle cap arm is determined

by a line from the centerpoint of the armature
bore through the centerpoint of the axle bore.

I METRIC CONVERSION CHART 1

(inch) mm (inch) mm (inch) mm

l/8 3.2 4 102 10-l/4 260.4

314 19.0 4-7116 112.7 12-I/16 306.4
I-114 31 5-I/2 140 13-l/4 336.55
2 50.8 5-27132 148.4 14-I/2 368
2-314 69.8 7 -518 193.7 14-19132 370.7
3-7116 87.3 8-118 206.4 17-l/8 435.0
3-I/2 89 8-15116 227.0 31-21132 804.1
35-1 l/16 906.5

21935

Fig. 6 - Traction Motor Outline

-7-
M.I. 3950-3

COMMUTATOR END PINION END

81 mm
(3-3/l 6”)
I+ 3 mm (l/8”)
+7

New106363mm+-013 b
(41.8j5” I!I 0.006)
I Min. 1062.10 mm
(41.815”)

NOTE: Max. keyway depth 7.62 mm (0.300”)

Min. keyway depth 6.35 mm (0.250”)
Max. key protrusion 6.35 mm (0.250”) 21934

Fig. 7 - Axle Side Of Motor Frame

PINION END TO COMMUTATOR insert is centered in the bore to assure

END ARMATURE BORE FACE true indicator readings.
CONCENTRICITY CHECK PROCEDURE
5. Slide alignment bar (Item 2, Fig. 9) through
The following procedure can be used to check pinion end bore and into the commutator end
the concentricity between the commutator end bore insert as shown in Fig. 11.
and pinion end armature bore faces using a
concentricity gauge. Refer to Service Data for 6. Apply stabilizer (Item 3, Fig. 9) to com-
gauge file number. mutator end of alignment bar as shown in
Fig. 9.
1. Remove axle caps and clean splines on both
axle caps and frame. Remove all burrs.
7. Position pinion end spider on alignment bar
2. Reassemble axle caps to frame with a 0.46 so the spokes are horizontal and vertical in
mm (.018”) shim inserted between the axle the bore, Fig. 11. Snug spider in position.
cap and frame.
8. Engage I.D. indicator, Fig. 11, in pinion end
3. Clean pinion end and commutator end arma- bore and align bar to the centerline of the
ture housing bores, commutator end armature bore. Adjust the spoke adjusting screws to
bore inner face, and pinion end armature obtain a “Zero” reading around the bore.
housing bore outer face with a wire brush. Disengage the indicator.
Ensure surfaces are free of rust, residue, and
burrs.
9. Engage pinion end face indicator, Fig. 11,
4. Apply concentricity gauge commutator end between the outer edge of the face and outer
bore insert (Item 1, Fig. 9) into commutator edge of the pinion end housing mounting
end bore as shown in Fig. 10. Line up insert holes. Start at point “A” of Fig. 11, and
so the bronze land is located at the bottom, sweep the face clockwise. Record indicator
Gently tap insert in place to seat firmly and readings at 45” intervals up to point “B”. Do
tighten the two clamps. not run indicator into axle bore area. Total
face runout is the sum of the greatest neg-
NOTE: If the armature bore is oversize, shim ative reading plus the greatest positive
insert to compensate for oversize. Ensure reading.

-8-
 M.I. 3950-3

Pinion end bore and commutator end bore to be concentric to each other within 0.13 mm (0.005”). Bore faces must be perpendicular
to axial centerline within 0.08 mm (0.003”) total indicator reading for commutator end and 0.15 mm (0.006”) for pinion end.

4-25132” rt 0.015
Limit + 5/64” I

New 12.125” ~~$$

See Note + New 22.875” ‘:zi:

See Note

COMMUTATOR END / PINION END

I New 41.125” f 0.003

-Min 41.117”

II* 42-5116 “I

METRIC CONVERSION CHART

NOTE: Refer to Commutator End
and Pinion End Housing Bore (inch) mm (inch) mm (inch) mm
-
sections of text for bore
diameter limits. 0.001 0.03 1 25 15-7116 392.1
0.002 0.05 l-1/16 27.0 20-l/16 509.6
0.003 0.08 I-3116 30.2 22.875 58 1.03
0.015 0.38 4-25132 121.4 23-I/16 585.8
Ill6 1.6 7-314 197 41.117 1 044.37
5164 2.0 12.125 307.98 41 .I25 1 044.58
l/8 3.2 12-7/l 6 315.9 426/l 6 1 074.7

21936

Fig. 8 - Traction Motor Frame Cross-Section

-9-
M.I. 3950-3

Item 3 22215

Fig. 9 - Armature Housing Bore Face Concentricity Gauge

22216

Fig. 10 - Concentricity Gauge Commutator End Insert

- lo-
 M.I. 3950-3

22217

Fig. 11 -- Concentricity Gauge Installed On Pinion End Frame

10. Engage the commutator end face indicator, 1. To check the pinion end housing bore diam-
Fig. 12, on the face between the housing bolt eter, Fig. 8, measure the diameter at four
holes and the outer edge of the face. Do not places 45” apart. The average reading must be
let indicator drop into bolt holes. Record between + 0.13 mm to - 0.03 mm (+ .005”
indicator readings at 45” intervals. Total face to - .OOl”).
runout is the sum of the greatest negative
reading plus the greatest positive reading. 2. If the stator is to have the axle cap renewed,
the pinion end armature bore may be mea-
PINION END ARMATURE sured without the old axle cap assembled on
HOUSING BORE the frame. If the bore is more than 0.53 mm
There are five nominal sizes of pinion end arm- (.021”) out-of-round, assembled axle cap (or
ature housing bores. simulator) and remeasure the bore. If bore is
then within 0.38 mm (.015”), bore is accept-
Standard size 581.03 mm + 0.051 - 0.025 able. Refer to Service Data for axle cap
(22.875” + .002” - .OOl”) simulator tile number.
0.8 mm (l/32”) oversize 581.81 mm + 0.051 -
NOTE: Maximum pinion end armature housing
0.025 (22.906” + .002” - .OOl”)
bore out-of-round on stator frames with-
1.59 mm (l/16”) oversize 582.70 mm + 0.05 1 - out coils is 0.30 mm (.012”).
0.025 (22.941” + .002” - .OOl”)
3. The outer bore face must be perpendicular to
2.38 mm (3/32”) oversize 583.46 mm + 0.05 1 - the axial centerline within 0.15 mm (.006”).
0.025 (22.971” + .002” - .OOl ”
Check measurement at the solid nortion of
3.18 mm (l/.8”), oversize 584.23 mm + 0.051 - the face,. or opposite the main pole pads of
0.025 (23.001” + .002” - .OOl”) the frame.

-ll-
MI. 3950-3

22218

Fig. 12 - Concentricity Gauge Installed On Commutator End Frame

4. Pinion end housing bolt holes must be within 3. Old style brush holder blocks (8300158)
1.04 mm (.041”) of nominal location in should be reworked to have a 57 mm
respect to the bore. (2-l/4”) counterbore and a 27 mm (l-1/16”)
bolt hole.
5. Cracks in the bore side of the housing bolt
holes are acceptable.
BRUSH HOLDER CLEANING
6. A maximum of 0.8 mm (l/32”) is permissible
between the pinion end armature bore face HEAVY CLEANING
and the pinion end axle bore face. When the
armature bore face is welded, the axle bore 1. To remove heavy carbon deposits, oil, grease,
face should be welded. Both faces should and severe burn marks, place the brush
then be machined to “new“ dimensions. holders in a tank charged with one part
emulsion soak cleaner such as Clifco No. 1
BRUSH HOLDER BLOCKS BH or equivalent mixed with four parts of
AND BOLT HOLES water. Soak the brush holders at room tem-
1. Dimension from commutator end armature perature without agitation for 3 to 5 hours
housing inner face to the 12 1.4 mm depending upon the condition of the brush
(4-25/32”) block centerline and to the 197 holders.
mm (7-3/4”) brush holder block centerline,
Fig. 8, is acceptable at + 2 mm (+ 5/64”). CAUTION: Observe safety precautions when
handling emulsion soak cleaner and
2. Top brush holder blocks must have a 27 mm store in a safety-type container.
(l-1/16”) diameter bolt hole. Blocks with the Cleaner as received from supplier has
23.8 mm (15116”) bolt holes should be re- a flash point of 38” C (100” F).
worked to 27 mm (l-1/16”) diameter. Mixed with water, it has no flash

- 12-
 M.I. 3950-3

point. Rubber gloves should be used When carbonways are worn or distorted beyond
when using cleaner to prevent drying acceptable limits and the wear is not too great, it
out the skin or possible irritation. is possible to rework the slots. Insert gauge into
Keep cover on tank when not in use slot and gently peen the outer surface of the slot
and while brush holders are soaking. to close it in. By peening and filing, the slot size
can be reduced.

2. Steam clean brush holders using a steam

cleaner such as Dober Chemical Corporation BRUSH HOLDER
Cleaner 6006 or Turco Chemical Company INSULATOR STUDS
Steamfas. Operate steam cleaning gun nozzle
from 25 mm to 150 mm (1” to 6”) from Brush holder insulator studs should be kept clean
surfaces being cleaned. and free of defects. The polyester insulated type
insulator studs, Fig. 13, are unusually resistant to
CAUTION: Protect skin and clothing while steam flashover damage. If flashover damage should
cleaning. Operator should wear rubber occur, the insulator studs usually can be restored
apron, boots, gloves, and a plastic to satisfactory condition by polishing them with
face shield. fine sandpaper. Polyester glass material should
never be subjected to alkaline cleaning solutions.
3. Hose off brush holders with clear water.

LIGHT CLEANING NOTE: Early model brush holder insulator studs

were insulated with porcelain and should
For light cleaning, brush holders should be be replaced with the polyester insulated
cleaned by washing in a non-toxic solvent such as studs. Polyester is more durable and does
Stoddards Solvent. A solvent with a fast rate of not become permanently carbon tracked.
evaporation is preferred.

CAUTION: Adequate ventilation and safety P r--- ,

--m-J h
precautions are necessary when /- - - _----- I
I ’ I
handling inflammable fluids such as I
j[
Stoddards Solvent which has a flash I
t
.---- ---- --- L -, 2
point of 46” C (115” F). \-----
\ /
BRUSH HOLDER INSPECTION
OLDER MODELS
AND REPAIR
1. Inspect brush holder terminal lug seat for
roughness and rework as required.

2. Check dowel securing the brush holder pins

to ensure the casting is peened over at both
ends.
CURRENT MODELS
22379
3. Remove all arc burns and file off surfaces
facing the commutator if metal buildup has Fig. 13 - Polyester Brush Holder Stud
occurred.

CARBONWAYS (BRUSH SLOTS) Older model brush holder insulator studs have a
silicone rubber insulated sleeve over the base of
Check carbonways for wear with gauge. Refer to the studs, Fig. 14. When replacing or recondi-
Service Data for gauge part number. The carbon- tioning brush holder assemblies, ensure insulated
way should be between 15.90 mm (.626”) and sleeves are in place.
16.13 mm (.635”) in each brush slot. The length
of the short brush slot should be within 50.90
mm to 51.13 mm (2.004” to 2.013”). The long The current model brush holders have a silicone
brush slot should be within 101.70 mm to rubber boot which fits over the base of the stud
101.93 mm (4.004” to 4.013”). and brush holder, Fig. 14.

- 13-
M.I. 3950-3

Max. Clearance 0.79 mm

Retaining Pin -. -Do Not Bottom t.031")
\ II Min. Clearance 0.13 mm
t.005")

Silicone Rubber Sleeve

Brush Holder
MODELS

n
I’
2’ - - --- -----_
,
+ Silicone

Brush Holder y

CURRENT MODELS
NOTE: Fill gap between insulator pin and
casting with a small excess of sili-
cone compound. Immediately in-
stall silicone rubber boot, seating
,boot i n w e t s i l i c o n e c o m p o u n d
tightly against casting.
22390

Fig. 14 - Brush Holder Insulator Installation

Replacement polyester glass insulated studs are The oversize studs may be identified by the
available in the following sizes: number 2, 8, 31, 33, 62, or 65 stamped on the
bottom of the stud. The number is in reference
Standard size - 8 159003 to the amount oversize in thousandths of an inch.
For example, the number 2 identifies the 0.05
To be used in new brush holders or when mm (.002”) oversize stud. The number 65 identi-
stud holes are within 25.235 mm + 0.013 fies the 1.65 mm (.065”) oversize stud.
mm (.9935” f .OOOS”>.
JNSULATOR STUD INSTALLATION
0.05 mm (.002”) Oversize - 8209068
A sleeve-type tool made of half-hard brass, Fig.
0.20 mm (.008”) Oversize - 8219773 15, should be used for pressing the studs into the
brush holder.
For stud holes which have had a standard size
pressed out. To replace the brush holder insulator studs, per-
form the following procedure:
The following studs can be used for extensivelv
scored stud holes which have been reamed out. 1. Press out brush holder insulator stud, shearing
retaining pins.
0.79 mm (.03 1”) Oversize - 8209069
2. Clean up stud holes of brush holder, if
0.84 mm (.033”) Oversize - 8222653 required.

1.57 mm (.062”) Oversize - 8222652 3. Select proper oversize stud. Ensure that 0.05
mm + 0.025 mm (.002” + .OOl ‘I) press fit is
1.65 mm (.065”) Oversize - 8222654 obtained. Press in stud using sleeve-type tool,

14-
 M.I. 3950-3
31.80 mm
(I 252”)
31.90 mm 41.28 mm
(I .256” ) / (1.625”)

~8~;f$g-q- i?Ti?zx,6”
(3.i50”) 21132

Fig. 15 - Insulator Stud Installation Tool

Fig. 15. Clearance between the stud shoulder

L5.187”k0.002 -1
and brush holder must be maintained to
insure the insulation does not get damaged
against the brush holder. Max. 0.635”

4. On older model brush holders, drill and pin

brush holder and stud. Use a No. 23 drill,
(. 1540”), and refer to Service Data for pin iston
Above
part number. Peen over hole on both ends
after installing pin. I
Brush Holder Finger
On current model brush holders, fill the gap
between the insulator pin insulation and the
casting with a small excess of silicone com-
pound. Immediately install silicone rubber
boot, seating boot in wet silicone compound
tightly against the casting. Refer to Service
Data for silicone compound part number.
0.125” 2;:::Dia. 2 Holes
COIL SPRING TYPE
BRUSH HOLDER
METRIC CONVERSION CHART
All motors since the D57 have been equipped
(inch) mm (inch) mm
with constant pressure spring cell brush holders.
The D67 and D77 motors use a brush holder 0.002 0.05 l/8 3.2
which will accept a longer brush. This longer 0.003 0.08 0.628 15.95
brush reduces maintenance by extending the 0.020 0.51 0.635 16.13
period between brush changeouts. The D37 and 0.125 3.18 5.187 131.75
D47 model traction motor brush holders can be 21938
modified to use the constant pressure spring cell
Fig. 16 - Coil Spring Type Brush
but if the longer brush is desired, the new style
Holder Assembly
brush holder should be used. All early model
traction motors rebuilt at the factory are
equipped with the latest model brush holder. of the pin protruding into the hole directly
below the spindle hole. It may be necessary
SPINDLE AND THIMBLE REMOVAL to alternately bend the pin back and then
down to accomplish removal, or a drift and
When inspection indicates it is necessary to hammer may be used to drive the pin out.
remove the spindle to replace thimble or brush
holder finger, Fig. 16, perform the following.
NOTE: If pin is driven out with a drift, use care
1. Remove the groove pin at either end of the so as not to damage the reamed hole.
spindle by slightly bending back the portion Ensure drift is smaller than reamed hole.

- 15-
M.I. 3950-3

2. Remove cotter pins holding the thimbles. Resolder shunt connection at brush holder with
Hold thimble to prevent it from turning while 63-37 solder or with pure tin solder.
cotter pin is removed. Insert a small drift into
one of the adjusting holes in the thimble. After the shunts have been soldered in place,
Hold the drift firmly as the finger spring is reassemble the thimble and spindle assembly to
under tension. brush holder. Install two groove pins at both ends
of the spindle to anchor spindle to brush holder.
3. Release the spring tension on the thimble by
Stake upper ends of the pin holes.
removing the drift pin after the cotter pin is
removed. The spindle can then be driven out NOTE: When the groove pin holes are oversize so
of the brush holder body.
that the pin is loose in the hole, rework
4. If the spring, shunt, and thimble assembly are the hole by filling the hole with silfos
to be removed, heat the soldered end of the brazing alloy (do not overheat brush
shunt with a soldering iron. The spring, shunt, holder) and redrill to drawing size, Fig.
and thimble assembly can then be removed. 16.
5. Inspect all component parts for wear and SPRING TENSION
damage. Replace any defective parts with new
parts. If spindle has cracks or has wear in Check brush spring tension. This pressure is
excess of 0.25 mm (.OlO”), replace spindle measured with a spring tension scale with the
with a new part. New spindle measures 9.462 brush spring lifted 3.2 mm (l/8”) above top
mm -~9.525 mm (.3725” - .3750”). inside edge of the brush box, as shown in Fig.
6. Inspect spindle holes in brush holder. If holes 17. The minimum spring pressure limit on a
have excessive wear or clearance between completely worn brush, is 3.2 kg (7 lbs). Spring
spindle and brush holder is beyond the limits pressure should always be set high enough, 4 to 5
shown in Fig. 16, repair hole as follows: kg (9 to I 1 lbs) to compensate for the loss of
pressure that results as the brush wears.
a. Ream or drill worn spindle holes to 12.77
Spring Scale

grr4’“” kg
m m t o 1 2 . 8 8 m m (.503” t o .507”)
diameter. fi Initial Pressure n
(9 to 11 Ibs)
b. Clean and flux the drilled holes and plugs z- ’
E Low Pressure Limit
to be used. Refer to Service Data for plug z 3.2 kg (7 Ibs)
part number.

C. Insert plug in drilled hole and silver braze

in place.

CAUTION: Use care not to overheat and warp

brush holder during brazing.

d. Clean in hot water.

e. Redrill the holes to 9.35 mm (.368”)

maintaining the 36.5 mm (l-7/16”) and
61.9 mm (2-7/16”) dimensions.
20629

f. Ream the 9.35 mm (.368”) drilled holes Fig. 17 - Measuring Coil Spring Pressure
to 9.57 mm - 9.65 mm (.377” - .380”).

SPRING SHUNTS Spring tension can be regulated by removing the

cotter pin locking the thimble to spindle and
Inspect brush holder spring shunts for wear and
turning the thimble and the spindle. The adjust-
for condition of soldered joint at brush holder.
ing collar on the thimble can be set every half
When shunt and/or tip shows excessive wear, notch by using alternately two cotter pin holes in
replace shunt and tip assembly. If only slight the spindle. This will give a variation of tension
wear on tip is found, shunt surface may be from 0.57 to 0.68 kg (l-1/4 to l-1/2 lbs) for
cleaned by filing. each half notch.

- 16-
 M.I. 3950-3

CONSTANT PRESSURE 1. Place brush holder fingers in “cocked”

BRUSHHOLDER position.
2. Pry lower end of each pin (visible in the holes
SPRING CELL REMOVAL directly below and at each end of the spindle)
slightly upward until pin protrudes from the
top of the holder. Pull pin out of hole.
When inspection indicates it is necessary to
remove the spring cell assemblies from the brush 3. Drive spindle out of brush holder to free
holder, Fig. 18, perform the following. spring cell assemblies.

Cocked Position

OLDER MODELS

9.5 III; (3/8”$

“--Cocked Position

CURRENT MODELS

22391

Fig. 18 - Constant Pressure Brush Holder And SpringCell Tolerances

- 17-
M.I. 3950-3

SPRING CELL REPLACEMENT spindle. Continue to drive the spindle through

until the spindle is centered in the brush
Before replacing spring cell assemblies, inspect holder.
brush holder casting and insulator pins. Replace
any defective parts with new parts. Repair all 7. If old spindle is used, the two 3.2 mm (l/8”)
defects. diameter holes in the ends, “D” of Fig. 19,
should be aligned with the matching holes of
1. Insert the spindle in the spindle hole with the the brush holder. If new spindle is used, drill
spindle pushed up against the top of the hole. two 3.2 mm (l/8”) diameter holes at area
Check the distance from the bottom of the “D” of Fig. 19. Insert groove pins in each
spindle to the inside surface of the bottom hole at area “D.” Peen casting lightly into
web of the brush holder casting, as shown in each hole to lock pins.
Fig. 18. If this dimension is greater than
19.69 mm (.775”) or if the hole is more than 8. Ensure each spring cell is tight in the brush
5 1 mm (.020”) oversize, the hole must be holder. If cells are properly installed, the cells
plugged and relocated. will be held firmly at contact points “E” and
“F” of Fig. 20. If required, adjust rear spring
2. Check rear spring tab to ensure that offset of tab so that spring cell is anchored tightly in
tab is 9.5 mm (3/8”), Fig. 18. Bend rear assembly at points “E” and “F” when spindle
spring tab as required. Place brush holder “G” is driven in place. Points “E” and “F”
fingers in “cocked” position. must have definite contact with holder.

3. Place cell assembly in brush holder spring

pocket with fingers centered in slot “A” as
shown in Fig. 19. Spring Cell Assembly

l-
Rear Spring ’ E
Tab 21941

Fig. 20 -Position Of Spring Cell Assembly In Holder

9. After assembly, release brush holder fingers

21940
from “cocked” position to prevent handling
Fig. 19 - Installing Spring Cell In Brush Holder damage and to prepare assembly for instal-
lation.
4. Insert aligning tool through spindle hole and
spring cell. Add necessary washers at areas FRAME INSPECTION -
“B” and “C” as shown in Fig. 19. Check COILS REMOVED
alignment of spring cell with finger slot “A”
and, if cell is out of line, remove alignment All inspections and qualifications are the same as
tool and reassemble. for a stator with coils intact, except for the
following inspection of the main field and inter-
5. Follow same procedure with center and left- pole seat dimensions.
hand cells. Use as many washers in the lineup
as possible. After each cell is assembled, re- MAIN FIELD POLE SEATS
check the alignment with finger slot “A.” AND COIL PADS-
6. When all cells have been installed, drive the 1. Main pole seat diameter, Fig. 21, acceptable
aligning tool out of the assembly with the to 605.99 mm (23.858”).

- 18-
 M.I. 3950-3

NOTE: If dimension is at To be concentric about axial

305.49 mm (12.027”), centerline within 0.51 mm
main pole shield 8353542 (0.020”) total indicator reading.
must be used under pole.
These pad faces are to be concentric
about axial centerline within 0.89 mm
(0.035”) total indicator reading.
22219

Fig. 21 - Frame Cross-Section

2. Main pole seat diameter concentricity accept- MINOR FRAME AND

able to 0.51 mm (.020”) total indicator AXLE CAP REPAIRS
reading. Concentricity total indicator readings
between pinion end and commutator end This portion of the section covers minor frame
ends of pole seat need not be compared, but repair and axle bores which require only a partial
the individual readings must be within 0.51 weld rebuild of not more than two inches on the
mm (.020”). bottom and three inches on the top of the axle
bore.
3. Dimension from centerline of armature to
main field coil pads, Fig. 21, acceptable from If there is evidence of armature bearing failure,
306.63 mm to 305.49 mm (12.072” to armature housing bore or face which requires
12.027”). If dimension is at 305.49 mm machining, or if axle bore requires complete
(12.027”), main pole shield 8353542 must be remanufacture, refer to Major Frame Repair of
used under pole. this section.

INTER-POLE PADS WELDING PROCEDURE -GENERAL

1. Interpole seat diameter, Fig. 21, acceptable All welding referred to in this section should be
from 761.87 mm to 762.25 mm (29.995” to done in accordance with the following procedure.
30.010”).
1. For weld buildup, the use of A.W.S. Class
2. Interpole pad diameter must be concentric E-601 2 or E-6013 electrodes of 3 mm to 5
w i t h i n 0 . 8 9 m m (.035”) t o t a l i n d i c a t o r m m (l/8” to 3116”) diameter is recom-
reading between opposite pads. mended.

- 19-
M.I. 3950-3

For repair of cracks, use A.W.S. Class E-6010 or Scarfing may be done from one or both
E-601 1 electrodes for all root passes. The diameter sides depending upon the thickness of the
of the electrode must be small enough to reach piece being repaired. The root opening
into the root of the groove preparation. should be 3 mm (l/8”) minimum, except
on thick sections. Where casting shrink
cracks have not progressed through the
2. Observe the following cautions:
full thickness, removal of the crack is
sufficient providing there is enough parent
a. Do not plug weld the eleven bolt holes of
metal remaining to act as a back-up for
the commutator end housing bore face.
welding.
Welding sets up considerable stresses in
the commutator end endplate.
Magnetic particle inspect the groove
preparation to assure complete removal of
b. No weld buildup is permitted for the sole
the crack.
purpose of counteracting shrinkage due to
welding.
d. Often it is of an advantage to employ
When nickel plated surfaces are en- back-up plates, especially if a thin section
C.
countered, the plating must be removed is repaired and scarfed from one side
prior to welding. only.

Back-up plates must be fabricated of

d. Do not peen root passes.
welding quality steel of 3 mm (l/8”)
minimum thickness, length and width to
3. All weld deposits should be free of slag suit the application.
inclusions, undercuts, or crater cracks.
After the weld repair on one side has
4. Proper welding sequence, such as back step been completed, the back-up plate must
sequence or staggering of weld passes is be removed by flame cutting or chipping.
important to minimize distortion associated The root pass should then be chipped out
with weld shrinkage. to remove entrapped slag or insufficient
fusion and a back-up bead (weld pass)
5. Peening should be done with an air hammer applied.
and blunt nosed tools to partially relieve
stress of the welded area. Peening should be NOTE: It is always good practice to magnetic
done immediately after laying a weld bead particle inspect initial root weld passes.
and while the metal is still hot. Peening also Never cover up a root bead crack by
helps to control shrinkage. For example, applying additional weld beads, without
during weld buildup of axle bores, shrinking first removing the defective weld. All
or closing-in of bore at the split line can be weld repairs of cracks must pass final
controlled by peening. Caution should be magnetic particle inspections.
taken not to peen excessively.
AXLE CAP SPLINES
6. Observe the following to repair cracks.
If the axle cap bore is acceptable, but the cap
a. Magnetic particle inspection should be spline fits are out-of-tolerance, the spline fits may
employed to detect cracks. be restored with the following procedure.
b. Preparation for weld repair requires com-
plete removal of crack. This should be 1. Build up the 16 mm (5/8”) wide surface on
done by chipping, grinding or flame the top of the spline completely with weld.
cutting. Flame cutting should be held to a Cover the full area, approximately 292 mm
minimum to avoid excessive distortion (1 l-1/2”) long.
due to the additional heat input associ- 2. The bottom spline area is approximately 51
ated with the burning operation. mm (2”) wide. Apply a 22 mm (7/8”) wide
weld build up to the area next to the cap
C. During the removal of the cracks, scarfing
bore, across the full length of the cap.
to a single (45”) or double (60”) bevel
should be incorporated during the same 3. No peening of any weld metal deposit on the
operation. axle caps is required.

- 20 -
 M.I. 3950-3

4. Machine welded areas of the cap to provide a the bottom or 76 mm (3”) is required on the
fit with the frame spline that is between 0.18 top of the bore, a complete reweld is
mm (.007”) tight (interference) and 0.33 mm required.
(.013”) loose (clearance). This step should be CAUTION : If stator frame requires complete axle
taken after the frame spline has been properly bore welding, loosen No. 4 main coil
rebuilt or determined to be dimensionally assembly and prop away from frame
satisfactory. during welding operation to prevent
NOTE: If old caps are used, serial numbers must damage to coil insulation.
correspond with numbers on the frame. 2. Apply weld build up in increments of two
New caps must be marked to correspond passes over the full 248 mm (9-3/4”) length
with frame numbers. of the bore.
5. Machine a light cut from the axle cap Pe en each increment immediately after
(vertical) mounting face on frame, if required, deposition. Peening should cover the full weld
in order to allow machine stock in axle bore. area of each increment. Additional peening in
Maintain “new tolerance” of Fig. 4 between the axle bore may be required after weld
upper and lower mounting faces, and on deposit has cooled to maintain spline or axle
depth of spline surface. cap mounting hole spacing dimensions.
3. Machine light cut from axle cap mounting
FRAME AXLE BORE AND SPLINE FITS surface on frame, if required. Remachining
spline on the frame should be brought back
If the frame axle bore and spline fits are out-of- to new tolerance of 260.35 mm, + 0.15, -
tolerance, the bore and spline fits may be 0.18 (10.250”, + .006, - .007).
restored with the following procedure.
CAUTION: Before removing stock from spline
1. Depending on the extent of wear or distor- mounting faces on pinion end frame,
tion, either completely weld or partial weld a check must be made of both cap
the frame portion of the axle bore, Fig. 22. If and frame to hold accumulative
more than 51 mm (2”) of weld is required in machining on these mating faces to a

VIEW B-B

METRIC CONVERSION CHART

(inch) mm (inch) mm

I-114 32 3 76
l-314 44 5 127
2 51 9-314 248
2-l/2
2-l/2 64 1 I-112 292 22220

Fig. 22 - Frame Axle Bore Rebuild Welding

-21-
M.I. 3950-3

maximum of 1.6 mm (l/16”). The axle bore must be parallel to pinion end axle
4 3 4 . 9 7 m m (17-l/8”) d i m e n s i o n bore within 0.13 mm (.005”).
between the gear case mounting bolt
and axle bore centerline must be not 3. The centerline of the axle bore and centerline
less than 432.99 mm (17-3/64”) after of pinion end axle cap gear case support arm
machining mating face for the pinion bolt hole must be held to a maximum var-
end cap. The accumulative machining iation of not more than 0.76 mm (.030”).
of mating faces for the commutator
end cap must not exceed 3 mm 4. Upon completion of axle bores, the spline
(l/8”). dimension must be remeasured. If the spline
has not been reworked, the spline dimension
4. A minimum of 18.03 mm (.710”) must be must correspond to preliminary measure-
maintained between the cap mounting surface ments. If the splines have been reworked, the
and the vertical portion of the top spline. A spline dimension must be within “new”
1.2 mm (3/64”) radius or chamfer will be tolerance.
permitted at the frame side of the splines,
providing tolerance is maintained on the 5. A mandrel check shall be made on all frames
mounting surfaces of the axle caps. which have had any work performed on axle
5. Assemble axle caps to frame with a 0.46 mm bores or splines.
(.018”) shim. Serial number on axle caps
must correspond with serial number on frame. 6. Rebored axle bores occasionally do not clean
Rebore axle bore to new print dimension. up completely. Rebuilt axle bores not re-
Refer to Axle Bore Reboring Tolerances of quiring complete weld build up may have an
this section for bore tolerances. “uncleaned” area of up to 5 162 mm2 (8 sq.
in.) any place in the frame half of the bore.
6. When axle bores have been welded and re- However, at the parting line, an additional
machined, the keyway can change depth, due uncleaned area may extend the full length of
to a shift in bore location to gain machine the bore. Measure the width of the uncleaned
stock. A maximum keyway depth of 7.62 area. Width must be within the limits of Fig.
mm (.300”) is permitted. Minimum keyway 23.
depth is 6.35 mm (.250”). Maximum key 44 mm (l-3/4”)
protrusion is 6.35 mm (.250”). 38 mm (1 -l/2”)

FRAME AXLE BORE OUTER FACE

To buildup axle bore outer face, welding should

be started on one end of the 180” arc, at the
largest diameter of the semi-circle.

1. Apply weld metal buildup in increments of

two passes over the full length of the semi- 22221
circle.
Fig. 23 - Frame Axle Cap “Unclean”
2. Peen each increment immediately after Maximum Tolerance
welding. Peening should cover the full welded
area. 7. Frames requiring new axle caps should have
the 1063.63 mm f 0.13, (41.875” + .005”)
AXLE BORE REBORE TOLERANCE dimension restored. A 0.8 mm (l/32”) step is
permissible between the pinion end armature
1. Center distance between frame bores and axle bore and the pinion end axle bore.
bores condemning limit is 434.19 mm
(17.094”) at the pinion end, however 433.88 NOSE SUSPENSION LUG
mm (17.082”) will be acceptable at the AND WEAR PLATE
commutator end when the pinion end is at
the low limit of 434.19 mm (17.094”). If the distance between wear plate and lower
suspension lug machined surface is more than
2. Axle bores must be parallel to armature bores 307.2 mm (12-3/32”), refer to Fig. 24 and
within 0.30 mm (.012”). Commutator end perform the following procedure.

- 22 -
 M.I. 3950-3

9.5 mm

F:-
(3/8”)

I
00 Jack Hydraulic 0 0 0
0

45” Chamfer
I
\ I
w

-Horizontal Q Of Motor

400 mm

Vertical Q- Of Motor

22222

Fig. 24 - Nose Suspension Lug And Wear Plate

- 23 -
M.I. 3950-3

1. Check the lower suspension lug dimension AXLE CAP MOUNTING

from horizontal centerline of motor. If BOLT SPOTFACE
dimension is greater than limits of Fig. 24,
area should be milled to dimension of Fig. 24 If the mounting bolt spotface on the axle cap is
and a 6.35 mm (.250”) wear plate welded to galled or beyond the 25 mm (1”) minimum
suspension lug. Refer to Wear Plate Welding thickness, the spotface should be welded and
Procedure which follows. It is not necessary machined to the “new” dimensions shown in
to maintain the 45” chamfer on lower suspen- View A of Fig. 4. The washer spotface and the
sion lug as shown in Fig. 24, but maintain the area around the spotface may be built up to 3
374.6 mm (14-3/4”) dimension from vertical mm (l/8”) to add support to the mounting
centerline of motor as shown in Fig. 24. flange. The weld at the lower end of the weld
area is to blend into the cap and not have a weld
2. If the lower suspension lug is within toler-
undercut or abrupt stop. After welding, machine
ance, the 19.05 mm (.750”) upper suspension
to “new” dimensions of Fig. 4.
lug wear plate must be replaced. If upper
suspension lug is undersize, build up with
PINION END AXLE CAP
weld and re-machine to dimension of Fig. 24.
Use only A.W.S. E-7016 stick electrode. Refer GEAR CASE MOUNTING
to Wear Plate Welding Procedure which
1. Check location of the 27 mm (l-1/16”)
follows.
diameter mounting hole in the pinion end
NOTE: Upper suspension lug is not a normal axle cap arm using combination gauge and
wear area, but if for any reason such as a drill jig as shown in Fig. 25. Refer to Service
loose wear plate pounding lug, the suspen- Data for combination gauge and drill jig file
sion lug must be welded and re-machined. number.

WEAR PLATE WELDING 2. If the 27 mm (l-l/l 6”) diameter mounting

PROCEDURE hole is off location, apply heat from a torch
to the elbow section of the axle cap arm.
The proper preparation of motor frame surface is
After sufficient heating, apply pressure to the
very important to successful application of the
arm and straighten arm to obtain proper hole
wear plates. The frame surface must be smooth
location.
and flat. Remove any weld beads or high spots. If
the nose bracket face dimension is not within
3. If the mounting hole dimensions are out-of-
tolerance of Fig. 24, the surface must be welded
tolerance, or were thrown out-of-line when
and re-machined. Perform the following proce-
straightening arm, perform the following
dure to install wear plates if required.
procedure.
1. Position wear plates on frame and hold in
place with a hydraulic jack which exerts a a. Plug weld the 27 mm (l-1/16”) gear case
force of 4.5 to 7.3 tonnes (5 to 8 tons). mounting hole in the axle cap.

2. Check wear plate fit to frame with a 0.08 b. Remove excess weld from top and bottom
mm (.003”) shim. Shim should not enter gear case mounting surfaces.
more than 13 mm (l/2”) at any point be-
tween the frame and the pad. Excess gap can c. Reassemble combination gauge and drill
cause weld to fatigue. jig and redrill 27 mm (l-1/16”) diameter
hole. Hole location is 434.98 mm + 0.8
3. Weld wear plates to frame using E-Fe-Mn-A m m (17-l/8” * l/32”) f r o m a x l e b o r e
welding electrode. Ensure good penetration is centerline to the 27 mm (l-l /16”) diam-
obtained on both the frame and the wear e ter hole centerline.
plate.

4. Allow weld to cool for a few minutes before 4. Needle peen gear case support arm as shown
removing jack. Check the plate fit to frame in Fig. 26, using axle cap needle peening
with a 0.08 mm (.003”) shim. fixture. Needle peen with twelve 3 mm,
round end peening wire needles at 517 to 655
5. Check the distance between the wear plates. kPa (75 to 95 psig) for 30 to 35 seconds to
The distance should be a nominal 306.70 mm obtain 100% coverage. Refer to Service Data
(12.075”). for needle peening fixture file number.

- 24 -
 M.I. 3950-3
Armature Bore Locator +

22236

22223
Fig. 25 - Pinion End Axle Cap Arm And Mounting Hole Locator Gauge And Drill Jig
-25 -
M.I. 3950-3
The area shown to be needle peened in Fig. bolt hole will provide to be within the limits of
26 must have a 3 mm (l/8”) corner radius. A Fig. 8, the tapped hole in the frame must be
radius smaller than 3 mm (l/8”) or irregular relocated to bring the blocks within tolerance.
notched surface will require grinding with a
high speed pencil type grinder to produce a MAJOR FRAME REPAH -
smooth, blended surface. Any grinding or
welding in this area necessitates re-needle COI LS INTACT
peening of the entire area using peening NOTE: If welding is required, refer to General
fixture. Welding Procedure in the Minor Frame
And Axle Cap Repairs part of this
instruction.

PINION END ARMATURE

Needle Peen Shaded HOUSING BORE
NOTE: If pinion end armature housing bore
requires reboring, commutator end
armature housing bore must be welded
and machined to limits of Fig. 8.

When it is necessary to rebore one or

both armature housing bores and/or re-
face one or both armature housing bore
faces, it will be necessary to line bore
22224 both bores and machine both bore faces
Fig. 26 - Pinion End Axle Cap Gear Case in the same set up.
Support Arm Needle Peening
Pinion end armature housing bore may be welded
BRUSH HOLDER BLOCKS to the standard size of 581.03 mm, f 0.051,
- 0.025 (22.875”, -t .002”, - .OOl”), Fig. 8 and
Reassemble brush holder blocks to frame. If the Fig. 27, or may be machined to any of the
block requires more space than 27 mm (l-1/16”) following approved oversizes, without welding.

22.2 mm (7/8”)

19 mm (3/4”)

New 1044.5!, mm
(41.125 )
Min 1 044.37,mm
. (41.117 1
innerface Outer Diameter Must
Be 390.5 mm (15-3/8”) Min. TO
AS Required I Provide Housing Clearance

Reql Jired

COMMUTATOR END
PINION END
22225

Fig. 27 - Pinion End And Commutator End Armature Bousing Bore Welding

- 26 -
 M.I. 3950-3

0.8 mm (l/32”) oversize 581.81 mm f 0.051 - PINION END ARMATURE

0.025 (22.906” + .002” - .OOl”) BORE OUTER FACE
1.59 mm (l/16”) oversize 582.70 mm + 0.051 -
0.025 (22.941” -I- .002” - .OOl”) NOTE: When it is necessary to rebore one or
both armature housing bores and/or re-
2.38 mm (3/32”) oversize 583.46 mm f 0.051 - face one or both armature housing bore
0.025 (22.971” + .002” - .OOl “) faces, it will be necessary to line bore
both bores and machine both bore faces
3.18 mm (l/8”) oversize 584.23 mm + 0.051 - in the same set up.
0.025 (23.001” + .002” -.OOl “)
When pinion end armature bore outer face
If the pinion end armature housing bore requires requires a complete weld build-up, either of two
rewelding, perform the following procedure. methods can be used.
1. Pinion end armature housing bore may be
build up with weld as shown in Fig. 27. Plug 1. Weld the complete outer face and then peen
housing bolt holes with ceramic plugs to the entire welded area.
prevent weld splatter on bolt threads. Weld
one-half (180”) of the bore and then peen the 2. Weld the area around the pinion end
weld deposit. repeat this procedure for the mounting bolt holes as shown in Fig. 28.
other half. Refer to Service Data for ceramic Peen the entire welded area. Protect the
plug file number. threaded bolt holes during welding and ensure
the unwelded area is free of weld splatter.
2. To machine the armature housing bore, refer
to Pinion End Armature Housing Bore
paragraphs of Inspection And Qualification COMMUTATOR END ARMATURE
part of this instruction for size and concen- BORE INNER FACE
tricity tolerance.
NOTE: When it is necessary to rebore one or
COMMUTATOR END ARMATURE both armature housing bores and/or re-
HOUSING BORE face one or both armature housing bore
faces, it will be necessary to line bore
both bores and machine both bore faces
NOTE: If commutator end armature housing bore in the same set up.
requires reboring, pinion end armature
housing bore must be welded and
machined to limits of Fig. 8. The complete surface of the commutator end
inner armature bore face may be built up with
When it is necessary to rebore one or weld if necessary, but check the following to
both armature housing bores and/or re- ensure weld build up is required.
face one or both armature housing bore
faces, it will be necessary to line bore 1. Recheck bore face. When the commutator
both bores and machine both bore faces end armature bore has been welded, the com-
in the same set up. mutator end armature bore face usually pulls
inward approximately 0.13 mm to 0.25 mm
If the commutator end armature housing bore (005” to .OlO”) which usually provides
requires rewelding, perform the following. sufficient machining stock.

1. Commutator end armature housing bore may

be built up with weld as shown in Fig. 27. 2. Check commutator end plate to determine if
plate is thick enough to permit relocation of
the 1 044.58 mm (41.125”) dimension of
2. To machine the armature housing bore, refer Fig. 27.
to Commutator End Armature Housing Bore
paragraphs of Inspection And Qualification No peening of weld is required. Peening increases
part of this instruction for size and concen- stresses of the commutator end plate already
tricity tolerance. induced by the heat input of the weld build-up.
- 27 - I
MI. 3950-3
Weld Spot As
Required (3 Places)
31.8 m m (l-1/4”) \ 144.5 mm (5-11/16”)
Dia.

J
,44 mm (l-3/4”)

89 mm
(3-l/2”)

22226

Fig. 28 - Pinion End Armature Housing Bore Face Welding

COMMUTATOR END ARMATURE MAJOR FRAME REPAIR -

BORE OUTER FACE COILS REMOVED
NOTE: When it is necessary to rebore one or MAIN FIELD POLE SEATS
both armature housing bores and/or re- AND COIL PADS
face one or both armature housing bore
1. The frame main pole seat diameter, 605.64
faces, it will be necessary to line bore
mm (23.844”), Fig. 21, is to be processed
both bores and machine both faces in the
during frame line boring operation to remove
same set up.
random high spots that may exist. However,
the 605.64 mm (23.844”) diameter is not to
Enlarge commutator end 20.6 mm (13/l 6”) exceed 605.99 mm (23.858”). Maximum
armature housing bolt holes to 22.2 mm (7/8”), difference between opposite main pole seats is
Fig. 29. Holes must be within 1.0 mm (0.041”) not to exceed 0.38 mm (.015”) total indica-
of nominal location with respect to armature tor reading when checked from the housing
bore. bore centerline.

- 28 -
 M.I. 3950-3

Enlarge 20.6 mm (13/16”) dia. holes to 22.2 mm (7/8”) dia.

Locate within 1 .O mm (0.041”) with respect to armature bore.

22227

Fig. 29 - Commutator End Armature Housing Bore Face Welding

2. Main pole seat diameter is acceptable to 6. If a main coil pad diameter dimension from
605.99 mm (23.858”), Fig. 21. If main pole housing bore centerline is at the minimum
seat diameter is greater than 605.99 mm 305.49 mm (12.027”) main pole shield
(23.858”), machine oversize to 608.58 mm 8353542 must be used in the coil and pole
(23.960”) and add 1.5 mm (.058”) shims assembly to obtain proper air gap.
8329728 to each pole seat to obtain 605.64
mm (23.844”). Shims not to exceed 1.6 mm INTERPOLE PADS
(l/16”). Weld shims to each pole seat.

3. Main coil pad diameter is acceptable, without 1. The interpole pad dimension is acceptable at
machining, from 306.63 mm to 305.49 mm 762.00 mm, + 0.25, - 0.13 (30.000”, + .OlO”,
(12.072” to 12.027”), when checked from - .OOS”). If the dimension exceeds the 762.00
the frame housing centerline, Fig. 21. The mm, but by not more than 3.2 mm (l/8”),
main pole coil pads on each side of the pole any combination of the following shims may
seat must be equalized within 0.51 mm be used.
(.020”) using any combination of the follow-
ing adhesive backed shims. Shim Part No. Shim Thickness
8353501 0.13 mm (.005”)
Shim Part No. Shim Thickness 8329727 1.47 mm (.058”)
8353502 0.25 mm (.OlO”) 8342703 3.05 mm (.120”)
8353499 0.38 mm (.015”)
8353500 0.51 mm (.020”) 2. Interpole pad diameter must be concentric
w i t h i n 0 . 8 9 m m (.035”) t o t a l i n d i c a t o r
4. Coil pads on each side of pole seats must be reading between opposite pads.
parallel to centerline by no more than 0.51
mm (.020”). NOTE: Frames with main and interpole coil pads
that cannot be corrected by shimming or
5. Coil pads requiring use of adhesive backed straightening should be returned to the
shims must have pad areas thoroughly cleaned Electra-Motive Division for machining due
and all rust, paint, and varnish removed to to special tooling and facilities required to
provide good contact for shims. make corrections.

- 29 -
M.I. 3950-3

SERVICE DATA

EQUIPMENT
............................ 8305181
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8166383
. . . . . . . . . . 8415805
. . . . . . . . . . . . . . . . . . . . . . . 8259133
. . . . . . . . *File No. 884
g Hole . . . . *File No. 885
. . . . . . . . . . . . . . . . . . . . . . . . . . *File No. 886
. . . . . . . . . . . . . . . . . . . *File No. 888
. . . . . . . . . . . . . . . . . . *File No. 889
. . . . . . . . . . 8453256

MATERIAL
Solder, Flux . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8116442
Solder, 63-37 . . , . . . . . . . . . . . . . . . . . . . . . . . . , . . . , . . . . . . . . . . 8004403
Solder, Sil-Fos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8004440
Solder, Tin Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8225761

* File numbers represent facility drawings that are available (at no charge) from EMD Service
Department. These drawings include construction details of tooling that can be manufactured.

- 30 - Litho in U.S.A.