~ ( MAIN GENERATOR . should be replaced with new or recondl- ‘loned assemblies. Main pole and tntorpote assemblies are only serviced as a unit, 4 mms sanaparecweiad nouraniermmrnce Suaacsene sae sant oo sass, Premera imtond Suomeees mith meres meena at oe em sate ase enews mate wagons ae eee Rotate St oot =e ean pay aoa Field poles or interpoles should be re~ moved as a complete assembly, and the defective assemblies shouldbe returnedto Bleotro-Motive. Bain polo and intorpole asgomblies are only serviced as camplete units, ‘When replacing feld poles, line up pole ‘washer and spring assembly before tight- fening the pole bolts, Reassemble all {nterpolo shims tn thetr original posttion, Before soldering or brazing connector straps or oable connections, align the enerator pole spacing as follows: 1, The pole spacing between the side of the interpole core and the adjacent sides of the mein pole cores bas =nominal spacing of 127/64", The total variation between these spactngs shall not exceed .050", Every intorpolo air gap on any one ‘machine shall be within plus or minus 010" of the average intorpole air ‘gp of that machine. 3. The spacing from the centerline of ono ‘main pole to the centerline of the ad- jncont main pole shall not vary from 4 nomingl centerline by more than 1/33", Models D12 and D22 have all cable and ‘connection jolnts other than interpoles, shunt fletd, battery fHeld and compensating fleld connectors soldered with Hi-Temp solder 8004398, Battery field and compen= ‘ating field connectors aro soldered with ‘in base solder 8004402, (Flux with Noko- rode soldering paste before soldering). Shunt field coll lead connections ave Pressure applied crimp type connectors, [Braze all interpole connector Joints using brazing tongs and Sil~Fos solder 6004440, Care should be taken to prevent solder from running down the fleld conductors when performing any of the soldering operations, Fig. 15 — p12 And Da2 Generator Field Assembly Model DS2 gonerator has all cable and connection joints other than the shunttleld and battery field connectors brazed, Bat- tery field connectors are soldered withtin base solder 8004402. (Plux withNokorede soldering paste before soldering). Shunt fleld coll lead connections have pressure applied crimp type connections. Care should be taken to provent solder fram running down the field connectors when performing any soldering operations, Fig, 15 shows a D12 and 22 gonerator teld assembly and Fig. 16 shows a D32 gen- erator field assembly. NOTE: Due to special tooling required for brazing operations it is recom- ‘mended that D82 generators which ‘require extensive stator repair be retumed to Elestro-Motive for overhaul, Insulation of D12, D22 and D32 Connections Connections, straps and cable leads to coils should be inspected to determine if they are electrically and mechantonlly secured, Pig, 16— 33 Gonerator Field Assembly 4overlapped and 2 layers of friction tape half overlapped, Insulate all battery field connections with 2 layers of vinyl tape half overlapped and 2 layers of adhesive tape (8168002) half overlappet. Starting and differential field connectors are not insulated, but are painted with red atr-drying enamel after soldering or bra= ing. Ingulate all brazed interpole connections, except those next to the frame, with 2 layera of riayl tape half overlapped and 2 lnyers af friction tape half overlapped. Insulate all interpole connector aasem- bites next to the frame with 2 layers of vinyl tape half overlapped and 2 layers of ‘glass adhesive tape half overlapped. All loose lead connectors should be tied with 1/16" torpedo twine and fish paper insulators tled-in where necessary; paint with red air drying enamel, ‘Do2 compensating field connectors have ‘been changed from a radial plane as on Di2 and D2 generators, Fig. 17, toa oylindrical plane as shown in Fig. 19, ‘The 52 compensating fleld connections are brazedinstend of eoldered as they were fon the Di? and D22 generators, Theeo ‘connections, whether brazed or soldered, are not insulated with vingl or friction ‘tape, but are sprayed or painted with red air drying enamel. ‘The D22 gmnerators use rubber damping strips between compensatingfield connoe- tors on both ends of the stator. Thedamp- ng strips are tied in place with two turns of treated lass tapo as shown tn Pig. 17. ‘The D12 gmorator uses rubber spacers between the compensating field connectors which mus: be tled in place with 1/16” torpedo twine. Pig. 17 — Da2 Compensating Fickt ‘Connection After assembly, the stator should be var- nish trested using varnish 8160879 thlaned with Xylol 8089758 to maintain visoseity at 100-190 seconds Ford Cup#4at2.2°C. 1, Preheat tho stator assembly ina convection oven so that the average steel frame and coll copper compenent temperature is maintalnod at 130° C, {for one hour, 2, After removing the het stator assembly from the convection oven immerse tt completely in the varnish for fire sminatos. 8. Drain the varnish and allow the excess to drain from the assembly for five minutes.= Fig, 19 — D32 Compensating Field ‘Connection lean varnish off stator frame bore face, all tapped holes and mounting pads. Pole bolt holes ahove the horizontal cen- terline should have the gap in pole bolt lockwashors sealed with a small bell of caulking compound, The frame and spaces around pole bolts should be palnted with Bray locomotive enamel. Apply 4 high potential test of 4200 volts for 10 soconds on the main field and shunt fleld cfreutts, Apply a high potential test of 1200 volts on the battery fleld oirouit for 10 seconds, NOTE: Ground both sides of battery fleld clroult when hy-potting the shunt sn weseeny gree ane ig shunt field circuit when the battery field clroutt, Make & resistance tost of the folds and Interpoles with Kelvin Bridge, sce wiring diagram, Pig. 18 and 20, Refer to Mato tenance Data for valuee, ARMATURE ‘The armature should be closely inspected for the condition of bands, wedgee, coll ingulation, general assembly and comm tator. Armature bands and core wedges should be tight and secure, On older models watch use wire bands, the soldering should be intact, If solder has been thrown off, the cause should be determined and com rected, and bands replaced. Unless proper faollities for banding are available, the generator should be returned to Electro- Motive, ‘The coll insulation should be clean and free from blisters, flakes, or oracks on tho insulating varnish eurface, When the Condition of the insulating varnish on the armature requires treatment, and tho proper facilities for vacuum impregnating fare not available, retum the generator to Eloctro-Motive, If solder has boon thrown out of the com- mutator risers, tho armature may haveto be rewound, Commutator Polishing ‘The surface of the commutator should Present an even, smooth appearance, free from pitting. Under normal conditions ‘where split type brushes are used, olean- ing of the commutator with « cleaning ‘stone should not be necessary. Commutators, that havo accumulated a grayish black film, which may reault in the burning of the ‘commutator bars, can be cleaned with an improved commutator cleaning stone 8149435, This stone will n13-Graser and doos not affect the face of the brush or the commutator. After grinding, the stone can also be used to remove alight imperfections. Commutator Grinding In the event that the commutator is etched, burned or pitted to the extent that 1 surfacing is required, grinding will be necessary. The following procedure is suggested to grind a commutator, using ‘erinder 5052924. 1f a new act of brushes is to be installed after grinding, remove all brushes except two adjacent sets, which will be used £or starting the ongise, These two sets can be left in, while grinding, provided new brushes are installed after grinding, The next step ia to remove 2 brush holder (it ‘ss suggested that the first holder above the horizontal plane af the generator on the right side, looking into the commutator cond, be removed). ‘The grinding fixture is made up of two parts, the supporting adapter and grinier. ‘Mount the grinder onthe supporting adapt- for and install as 2 unit in place of the ‘brush holder, and securely clamp in the brush holder blocks, as shown in Fig. 21, Square the grindsr with the commutator 80 that the grinder eross-feed will mun parallel with the commutator bars, Check this, using grinder alignment bar 8210141, Before grinding use a short stiff stencti brush and remove any grease ordirt from the commutator slots, ‘The use of vacuum ‘cleaner 8210140 1s recommended toctfeo- tively collect copper and stone dust during, grinding and final clean up, Pig. 21. ‘Mount stones so they are seated squarely on the commutator, With radial feed, pull ‘stones away from commutator and start ‘engine (run at idle speed for grinding). Food stones onto commutator slowly until ight contact is made, then run stones across commutator. To finish, runstones Fig, 21 — Commutator Grinding Fixture across commutator several times without feeding radially. Remove stones and grinding fixture, Clean commutator slots with slot file 8217141 and commutator cloning stones 149435. After grinding the commutator, the gener ‘ator should be cleaned thoroughly. Firat remove all of the loose copper from the Inside of the generator. Using dry com- pressed alr, blow the generator out thor~ ‘oughly. To Complete the removalat copper ‘from commulator slots, runtheengine and dlrect the alr hose at the face ofthe com~ mutator. Any copper remaining in slots, ‘either in the form of dust or slivers, will result in flash-overs. ‘The slote between the commutator bars ‘should be cleaned whenever examination shows that bright mice ts not vistbie, To loan, use @ hacksaw blade that bas tho tooth set ground off, and is of the proper thickness, If the commutator is badly wornar burned, the ‘should be removed and re fumed to Electro-Motive for service, 15+NOTE: Emery cloth or emery paper should NEVER be used on the commutator, tis unnecessary to use any lubri- cant on the commutator asthereis 4 suffiolent amount of graphite in ‘the brushes to supply all the lubri- cation required, Commutator Turning If the commutator is damaged to auch ex- tent that grinding the commutator 1s not cetfective, the armature should be placed 4m @ latho and the commutator turned just enough to give a uniform surface, Before turning the commutator, 2 aultable cover~ {ng should be placed over the end winding to prevent chips working into the armature. For a light machine out, the speed of the ‘armature should be 181 RPM of 16654 feet Per minute, Use a carboloy-tipped lathe cutting tool when making a Light cut, and ‘nish with fine grinding stones Round off the ends of the commutator ‘segments to at least 1/16" radius with « ‘ine mil fle, Commutator Wear Limits Qverall Diameter — The generator com- ‘mutator Is designed for 8/8" radial wer, which gives a minimum diameter of 4-1/4", Neck Width — When reworking the commu~ ‘tor, the face ofthe commutator is cleaned up by a light machine turned out, When ‘ls operation has to be repoateda number of times, the minimum neck width allow- able is 3/4, Nook Diameter ~The minimum diameter for cleaning up the outside diameter of the ‘commutator neck is limited by the location. of the top eiige of the armature coil: ‘The ‘commutator neck diameter should not be ‘machined below that point, Commutator Undereutting After the commutator has been turned, and then ground with fine stones, or after 16 checking the commutator surface and the surface 1s found to be in good condition, ‘the mfoa should be underout to a depth of 9/64" to 6/64" and a width of .030". When undercutting the width of the mica, 030" ‘undercutting saw 8085255 should be used, After undercutting, burr the commutator with hand scraper to remove shazpedgss from commutator bara, Then apply croous ‘loth lightly around the commutator. Re= ‘move all mioa and copper cuttings with ary compressed atx, Commutator Overhaul ‘The duty performed by a commutator ona ‘heavily loaded generator in railroad sery- {oe ts very exacting and oalla for acommu- talor of a definite design, as wellas highly acourste workmanship in assembling, ‘which is done in a speolal alr conditioned yom. After a commutator has been ‘assembled, there is a definite period of seasoning that requires many hours topre- are it for service, Al of this work requires spoctal machin~ cory that a customer would not be warranted in buying for the few commutators he might have to rebuild, Therefore, itis our Tecommendation that armatures be sentto our plant if the commutators have been damaged to the extent that they must be rebuilt, 4m addition to the work and equipment required to rebuild a commutator, tt is algo necessary that the core be properly Delanced after the commutator has been rebullt, Such repairs should be handled on ‘repair and return isis, Creepage Surfaces 4. Sandpaper the aurfaces marked "A", "x" and "¥" with 00 grade sandpaper, Sand amooth applying a light pressure whon sanding over the commutator string band, See Fig. 22,Vid 45" Chomfor Pig, 22 — Croopage Surfacs 2 Clean surfaces thoroughly with al- ‘cohol. CAUTION: Do not paint over carbonized ‘insulation with insulating palnt or varnishes. When the ineu~ orortoada, surface creepage through wn- cleaned insulation, moisture or improper use of hy-pot ms chine, the generator should be removed if proper repairs can not be mad in the locomotive, ° Do nat run the genoretor while Paint is wet, Tho paint howd fir dry in approximately one ency with aa thin a coat as possible, leaving no dabs or overlappingmarks, 4. Extra care must be taken to see that ‘no paint gets into the commutator slots or the relief at the bottom of commutator neck, or surface marked "A." This problem will be expori- fenced if care is not taken in applying the paint or if the machine 1s run ‘while paint la wot, Plintflex Red (153-0896) is recommended {or painting commutators because of tte fast drying property. ‘Thinner 1s not reniired for Flintflex, if container is opt tightly covered and brushes aro ‘lean and free of old paint, Generator armatures may be cleaned 6. Temove all carbon dust, grease and abi) hy the granulated corn cob process aa“! outlined for cleaning stator assembly, ‘When the granulated oor cob prooess is not available, Apco #42 (Stoddard) solvent may be used. This solvent is gunerally used by wiping the insulation with a cloth ‘dampened with the cleaning fiud. CAUTION: Use tho usual safety precau- ‘ions that apply totnflammable fluids, Provide adequate ven- tiation when any type of sol~ vent 1s being used. After cleaning with Apoo #42 solvent the armature assembly must be thoroughly ried out by placing it in a 115°-126° c. ‘convection type oven from 3 to 6 hour NOTE: Drying will not bo necessary after cleaning if a dry cleaning process ‘has been used, unless mogobm= meter check should so warrant, Insulation Resistance And High Potential Test Perform an insulation resistance test on the armature using a mogobmmeter test set. If a mogohmmetor reading of lees than 3 mogohme ts found, bake armature for four hours at 110° C, tn a convection type oven. Recheck armature megohm Treading after cooling armature to room temperature, If the reading te still low, > strip and rewind armature, ‘ ‘When armature passes the megekmmeter test, spply = high potential test at 3200 volts at umbiont temperature, Iermatire {falls on high potential test and the ground oF short 1s located in one of the upper ‘armature cofls and the armature s ter wise sound, the top section ofthat coll eam be raised out of the coro slot and «:néw -ar-‘ground insulation (or cell) should be applied. Wf ground or sorte are located {in bottom section of coll or cannot be located, the armature must be stripped ‘and rewound. When the armature passes high potential test, apply a bar-to-bar resistance com~ parison test (ductor test) witha low restet- ‘ance oimmeter tost set, If the tost indi~ cates resistance readings are 104% or more above normal on 20 or more connections, ‘hand solder all coll leads to commutator neck connections, If teat indlostes resistance readings of 1/28 or more below normal, thie will {nd cate a short which must be eliminated, or the armature must be stripped and re- wound, After soldering and clearing of shorts, apply & second duotor test to insure that tho faults have been corrected. Vacuum Impregnating Armature ‘Armatures which pass the above electrical tpat should be varnish treated using var- alah 8316868 thinned with Xylol 8089758 to ‘maintain viscosity at 43 to 62 seconds Ford Cup Mat 211° C, The vacuum impregnation should be performed follow 1, Clean core section thoroughly with Xylol or petroleum solvent and wipe dry with a clean dry cloth. 2, Proheat armature until average gore temperature stabilizes at 125° C. "5° Be sure oven temperature doos not exoeed 175° C, at any time. Remove armature from oven and place 4m vacuum impregnation tank. Do not allow armature to ooal below 110° C. before placing it in taal 4. apply 26" to 15 minutes. * vaomum to tank for itn vacuum still on tank, runvarnish {nto tank to level of commutator riser. If varnish tends to boll, bleed insmall amount of COg until boiling stops. Do not, however, open release valve to permit entry of atmospherioair, When varnish reaches proper level, spily 30 to 40 Ibs, COg pressure for at east 15 minutos, 6, Aftor 15 minutes reduce COzpressure to 10 ~ 12 Ib, and run varnish out of vacuum tank into @ storage tals 1. Apply 28” to 80" vacuum immediately ‘and hold for $0 minutes, 8, Remove armature from impregnation ‘tank and place in convection oven, 9 After average core temperature reaches 158° C. bake for 9houre being ‘oareful that the oventemporature does not excead 175" C, 110, Within 15 minutes after baking, tighten commutator bolts to 300 ft. Ibe, and tack weld in placo, NOTE: Commutator bolts should not be tightoned or disturbed unless ‘major work has been performedon the armature such as coil replace- ment, resolder, etc, High Potential Test On Armature ‘While armature is still hot, 60° C, + 10°, apply @ high potential ground teat at 2400, volts for one minute, Armature Shaft Magnaflux armaturo shaft for olrétiifor- tential and longitudinal cracks, df.any are found, the shaft must be replaced. Production tolerance for armature ahett bearing seat diameter is 5.1197" + .0000" 0008".ai Dynamic Balancing ‘The generator armature and the altornator rotor are dynamically balanced individ~ ually (the alternator rotor at 600 RPM and the generator armature at 875 RPM) and ag a generator armature and alternator rotor assembly at 375 RPM, After dynamic balancing. the assembly tn floated thresigh ‘and checked at tho critical speed of balane~ ing machine, When balancing generator armature as- ‘sembly, comterweighte are added to the ‘spider on the rear end of armature and to the inside diameter of the cammutator "V" ing. Whon balancingslternator rotor assembly, counterweights are added toeach end of the Inside diameter of the rotor spider. When balancing generator armature and alternator rotor assembly, counterweights are added to outside diameter of the al- termator rotor spider and the inside diam- ter of the commutator "'V" ring ‘ARMATURE BEARING INSPECTION ‘The roller bearing should be thoroughly inspected for possible evidence of im- ending failure, If there 1a any evidence that the bearing shows signs of distress, it should be replaced with a new bearing. ‘The following procedure may be helpful in ‘inspecting bearings, Cleaning Before attempting to make aay inspection, 4 bearing must be thoroughly cleaned. A. mixture of 50% carbon tetrachloride and 50% benzine has been found eultable for this purpose. After inspection, bearings should be dipped in hot oll to prevent cor~ osion unless they are to be used imme~ lately. A good grade of bearing oll should be used, or grease that is used for its Iubrication in service, Wear A properly lubricated bearing not subjected. to misalignment, dirt or distortion will show no evidence of wear, The internal radial clearance of the bearing may be checked by passing a fealer gauge bo- tween the rollers and race onthe unloaded side. Do not roll a feeler through a bear~ ing. For Limits see Maintenance Data, Fatigue Failure Sign of bearing fatigue will most uaually ‘appear on the bearing surface, Patigue failure is usually evidenced as ragged craters, and may be of aay size, Any bearing showing signs of oracks ar eratera of any size, regardless of how small they may be, should be replaced, ‘This type of faiture 1a more lkely to ‘occur on either the rollers oF inner race, Dents Dents are caused by hard particles of foreign mattor being rolled between the aces and rollers, causing slight deprea- ‘sions where the ‘bearing eurfaces have eon permanently deformed, They are ‘istinguished from fatigue failures by thelr ‘smooth surface with a slightly ralsed edge around the dent. ‘Small donte in themselves cause ttle damage and are usually evident on the earings which have been run, However, should the bearing show signe of more than normal distress, and should there be ‘any question as to whether they are dents cor fatigue fatlures, or should there be any doubt as to thelr effect on the Ife of the bearing, the bearing should be replaced, Soratches In general, soratches due to mishandling sare not serious provided they are emall, Scratches on the bearing surface, parallel to the Tength of the bearing are more -1-Soratches are difficult to differentiate ‘from cracks, and for this reason, if there ‘is any doubt as ‘o their character, they should be treated es oracks due to fatigue failure, Heat Any bearing shoving evidence of having been overheated should be replaced, Cages Bearing cages which show excessive wear should be replaced, Honing When it is neosssary to free up the fit of the bearing, a hone should be Used in the housing, An inside and outside micro- ‘meter should be used for checking the Dearing and the housing dimensions. ARMATURE BEARING ASSEMBLY Before shrinking armature bearing to shaft, it is very important that the bear~ ing be tried tn ts housing before aa- sembly. Place bering housing on floor and try bearing through bore of housing. Care must be taken to see that the bearing ‘enters the housing bore squazely and 1s not cocked. Ifthe outer race 1s tight, then At As necessary the: housing bore be honed to give a push fit having a olearance from 002" to .003", Ma new armature hearing and housingaze to be applied, it may be necessary at assembly to hone tho housing bore to obtain the recommended 002!" to .00: clearance between sousing bore and bear ing race. If a bearing race were at the ‘maximum allowable tolerance, and the housing bore at the minimum allowable tolerance, the recommended clearance ‘would not prevail, See Maintenance Data for bearing dimensions and tolerances. Assembly To Shaft 1. Remove old grease from bearing eap and cover. Clean bearing cap and cover, Repaint with erankoase paint and allow to dry. 2. Apply an unwelghed amount of grease, same type as specified in the Grease Chart at the end of this ML, Sato the Dearing cap and cover grooves, 8, Fill the lower portion of the bearing cap and cover with the type and quan- tity of grease az shown in the Main tenance Data, Grease cavity should be filled 180° to 200° for additive earings, and 240° to 270* for sealed bearings, refer to Fig. 23. 4. Clean armature chaft and remove burrs or gall marks, Place bearing cap on shaft. 5. Het the iner off throwor in an ofl Dath or electric oven for half sn hour at 248° F. or 120° C. Han induction hhoator 1s used, only heat up to 248° F or 120° C. If an oll bath is used for heating, remove the olf from the ofl ‘thrower with clean bound edge cloths prior to shrinking to the shaft. Whea lusing an induction heater, pyrometer readings (with current off) should be taken periodically. After heating, ih Va BAG Fer Cover Fig. 28 — Application Of Grease To (Cap And Bearing” Fig. 24 — Cross-Section Of D12 And D22 Generator fearink the oll thrower to the shaft. ‘Spo Fig. 24 and 25 for proper position 1 shaft. Let the oll thrower cool to room temperature, NOTE: Care should be used when heating bearing assembly parts. Over- hosting may xesult in warping oF metallurgical upsetting of the parts, pyrometer readings (with current off) at outside face of inner race only. Also, see note in Step 5, Shrink bearing to shaft with the bearing part ‘umber toward the outside, Do not cook the bearing when placing it on shaft. Use a brass pipe to push bear- {ng on shaft up to and against inner oll thrower. Let bearing oool to room temperature, 6. Paok the bearing rollers andthespeee Check. tne at tas Kone between the two rows of rollers com= Pietely with the quantity and type of srease specified in the Grease Chart. ‘T.Hout roller bearing with an induction 9, heater to 248° P. oF 120°C. Take oa aoe. Runout should be within 0,002" total indicator reading, 3. Apply two studs 8159226, Pig. 26, 160° apart to the 1/2"=20 N.P, 3 threadPig, 25 — Cross-Section Of D32 Generator spline nut whch is pressed into the 11, oaring cap. Purpose of atuda is to {guide tho bozring housing to the bear ing cap, Before applying housing be sure to apply 2 new gasket to the Dearing cap. Geskot must be lined up to clear bolt holes and may be held {in placo by applying a spot of grease to the gasket, 10, Hest the outer off thrower in an oft bath or electric oven for half an hour at 249°, or 120°C, Hf an induction hhoater Js used, heat up to 248°. or 1200. Then proceed as per Step 5. -2a- - Clean bearing housing hore with APCO tnd apply Molykcote 1400,6108822 wit 4 brush or spray; allow to dry, Place aligning toot 8159227 cn the sheft, Fig. 26, to hold the bearing outer race stationary and to assist in placing the fend housing over roller bearing. if the bearing 1s an additive type, fil. ‘grease pipe and grotee grooves in hhousing and housing core with recom= ‘mended grease. For soaled bearings, {Ul grease grooves and holes in bear {ing and bearing housing. Install metal tag with screws near lop of cover to read "DO NOT GREASE." Apply endhousing OVeF we Ui, yung rousing drain with the cap drain. 12, Pit the outer bearing cover pocket ‘with grease around the lower 180° to the level indicated by Fig. 23. For fadattive type hearings fill the lubri~ cating tube with grease and apply to Apply 2 now gasket to the {or aligning assembly parts. 18, Heat armature shaft sleeve on induo~ ‘ion heater to 260° F., oF 127° Cu, and shrink to shaft. 14, Install alternator brush holder asser~ ies on poste pressed in bearing cover. Set brush holder assemblies 90 that 2 1/8" clearance 1s obtained ‘between bottom of each brush holder and slip ring. 16, Measure spring tension with the spring 1/8" shove top of brush holder, should be 1-1/2 to 1-3/4 pounds, Applying Ind Housing Fig. 28 “to Armature Assombly “iting the spring tension beouuse fof spring and finger friction. Two methods may be used to eliminate friction. a. Wiggle the finger and spring ‘while holding the tension scale fn place. b. Take an average of readings ‘obtained while raising and Low- fering fingers withtensionscale. 16, Install brushes in brush holders, 11, Place alternator collector ring as sembly on induction heater to expand pore. Heat to 248°F., or 120°C. taking pyrometor readings on slip rings. Clean keyway and asoemble key to shaft, Shrink collector ring assembly to shaft. For posttion of aswembly on shaft see Fig. 24, 118, On generators which drive compres~ ‘sors, apply compressor coupling to ‘collector ring and bolt in place. ‘Asgemble conduit bushing on cables fand insert into end of shaft, Bolt ‘shaft flange to end of shaft, 20,1 new cables are used, ou and sin to allow enough slack in oables to clear bolt heads, Solder terminal gs to cables. ‘21, Apply 6/8" loom insulation over cable fand tie cables with torpedo twine, ‘Apply cables with terminals to posts ‘with brass studs, Cables are not ‘marked for any particular post. Paint ‘cables and Tom with red alr-drying ‘insulating enamel. 22, Connect drain pipe to bearing cover fand bolt with pipe clamp to end housing. GENERATOR-ALTERNATOR ASSEMBLY Lif alternator rotor assembly was re moved from generator rotor, bolt -a3-sixteen 7/8"-9 bolts tightoned to a torque value of 375 to 400 ft-lbs. Bolt alternator stator assembly to generator stator frame. 8. Apply coupling disc to alternator rotor fnub using six 1-1/2"=12 "D" head bolts with hardened washers and self ooking nuts and torque to 1500 f-Ibs, Any Di2 or D22 generator using the old style bolt and mut should be ‘torqued to 1200 ft-Ibe, NOTE: On D12 and D22 generators if the now self looking aut is replacing an old atyle nut the rotor hub diameter must be ‘machined from 1-3/8" to 7” to allow clearance for the now ut, 4. Placo gonerator stator assembly and armature assembly on their stands ‘close enough to oach other #o that, ‘hon the arbor fixture ia placed inthe flango hore of tho alternator rotor ‘spider, the end of the arbor fixture protrudes through tho stator assembly 8. ‘6 chown in Fig. 27, 5, Using two wire cable lope, place one Joop through the generator énd housing ‘and the other loop around the arbor fixture, With the ald of two cranes, lift and guide the armature and alter nator assembly into the stator assem~ bly a8 shown in Fig, 27. Guide the armature assembly slowly and care- fully 60 a8 not to damage the coils or Ansulation. Install bolts through end hhousing to frame and torque to 200 tithe. 6. Pinos fish paper stripsi/16"x3"x36" 9, {in alr gap botwoen armature and field polos. Do not apply any fish papor oF other material in atr gap between Pig, 27 — Installing Armature Into Stator alternator rotor and stator, Remove wire cable loops and arbor fixture after fish paper has been applied, Install split brushes, and bott shunts from brushes to brush holder. Make sure brushes are properly seated, With a clean, dry, intloss, bound edge cloth, clean carbon dust from commutator riser, string bund and porcelain insulato Prior to assembly of bus bar, bar must be clean and free of burrs, Balt the starting fleld connector bus bar to the starting bus. Bolt the generator negative bua bar to tho generator negative bus. Bolt the brush holder negative bus to the bus which ties in the compensating and differential field ‘connections. After tightening all bolted ‘connections, insulate connections with one layer of Empire cloth, one layer of vinyl tape one-half overlapped, and two layers of friction tape one-half overlapped. Paint the ingwlabéd.con- neotion with red atr-drying enamel, Attach bus bar to generator frame by insorting molded cleat (8325547 for Daz and 8325548 for D12 and D32) ‘under bus bar. Place molded clamp(6395649 tor Ost ana wszs000 LwE wie and D22) over bus bar andbolt assem hy to ganaratar frame. NOTE: ¥ old style clamp 8081908 is ‘used with wood block 8084169 under bu bar, use phenolic ‘looks 8092355 ae inaulator bo~ ‘tween bus bar andmetal clamp. 20, Apply alr box assembly and commu- {ator covers 11, Apply compressor coupling guard as~ sembly, i applicable, and bolt in Place, Connect collector ing brash holder cables to terminal block on guard assembly. CAUTION: Connect the cable leads from brush holders of same polarity to the same ter- ‘minal post, otherwise tho rotor field’ will be short clrculted and a direct short clroult placed on tho aux- {lary generator. HIGH POTENTIAL TEST Refer to Maintenance Instruction 6800 for ‘tasting the generator in the locomotive. Before high potential teste are made tt is Highly dostrable to check first with meg- dunmeter, A megohmmeter reading of 1 megobm, when tested with a 1000 V. mogger, is satisfactory for hy-pot teat. 4n acoumulation of dirt and motsture sometimes 1s autfioient to cause leakage, and if high potontial 1s applied it will ‘cause an actunl breakdown on the insula~ tion, ‘The condition may be aggravated by sudden temperature changos. Ifthe equlp- ‘ent hag been standing outside during cold weather before being brought inside ‘4 warm building, the equipment wil tend to awoat and the condensed moisture will ald the Leakage effect. tors 1s 600 volts. ‘Therefore, tho min mum test voltago should be: Gonerator. .- sees 950 volts High voltage wiring and high voltage equipment... 1050 volts In making high potential tests, the follow- {ng precautions should be taken: 1, All high potentia! teste must be made by plaoing electrodes on the olroult under tast before cloaing awitch, and ‘opening switch before removing elec trodes, Dangorous over-voltage aur~ (gee may reault from making or broak- ing the high voltage circult with the cloctrodes. 2, It te of the utmost importance that a reliable high potential tester be ‘used, to ineure that an adequate test 4a made and also unnecessary over~ stressing of Insulation does not take place. In regard to the features which should be incorporated inahighpotea~ fal tester, the following points are pertinent: a, Wave form », Surges cc Voltage regulation 3. In maktng high potential tests, ex- treme care should be taken to 900 that every person is in the clear Ddofore applying the voltages. 4, When tosting Electro-Motive arma- ‘tures individually, strap around the commutator with bare wire, before applying high potential testa. SHIPPING GENERATOR-ALTERNATOR It te absolutely necessary that the arma ture be blocked under 2 stub abaft fixture placed in the alternator rotor spider to -25- ete sa laces iefibre pieoss should be inserted in the air ap of the gonerator to prevent damage durisig shipment. Each generator ahtpped from Electro-Motive has a skid and sup- porting jack, Generators shipped back to Electro-Motive should be returned onthis, skid and Jack, The compressor coupling guard, if applicable, should be removed ‘from the outgoing generator and reassem- bled on the incoming generator, as goner~ tor 1s shipped complete lees coupling guard assembly, Drawing 8107436 maybe obtained on request as an aid in shipping of generator, INSTALLATION OF MAIN GENERATOR- ALTERNATOR IN LOCOMOTIVE UNIT ‘Tho installation of main generator and alternator is similar to removal, with exception that it requires more time, ‘are and skill, Before a main generator is installed, ‘check and clean the mounting plates, Be ‘sure these plates are smooth, free of burrs and high spats, Before lifting the generator into the unit, check and clean the mounting pads on the Locomotive bed frame, Be sure these pads are clean and free of burrs. ‘Check the surface on the engine and generator coupling disos, both must be smooth and cloan, Add a little ofl or ‘whito lead to the fitting suxfaces. Check ‘that bolt holes in couplings are clean and ‘smooth. ‘Apply 2 2-8/8" socket wrench to the engine to generator coupling bolt nuts to make sure they are tightened to 1600 fi-tbs, Any generators using the old style 2-2/16" mits must be torqued to 11200 ft-Ibe, Inspect and clean shims. Shims must be ‘smooth, free from burrs and kinks, Shims should have been tagged after xemoval a woueimer ov wey uiey vy aman a ‘thelr original position at this time, ‘Lift generator and guide slowly and care- fully into engine room, Set generator on ‘mounting pada as close to engine coupling diso as possible, Line up hole patterns in the engine and generator coupling disos by harring oF Jacking engine over. Push generator to- ‘ward engino until sts coupling fita into the bevelled groove in tho engine coupling disc. ‘Check all coupling bolts to eve that they are smooth and clean, Place a itil oll ‘with white lead on 8/4" coupling bolts and {install all bolts through generator coupling igo and engine coupling dise from the engine side. Check to be sure the gen~ erator disc 1s not cocked and is properly mated to the engine coupling disc. Once the generator fe attached to the engine, do not bar or Jack engine over ‘until all fish paper or fibre strips are removed fram between armature andfield coils. There should be no fish paper ‘under the alternator fleld cotis, Line up dowel holes and snatall base bolts. Do not insert dowels or base bolts until ‘generator ts aligned with engine, ALIGNING GENERATOR WITH ENGINE ‘The alignment of generator with engine 4s divided into tareo operations: 1, Thrust — Finding the longitudinal po- sition of armature with respect to the frame oF aligning generator batrng {tn housing. Operations No. 2 and No, 8 are carried ‘out simultaneously. 2, Angular — Neutralizing the angularity ‘of generator to engine coupling, Radial — Balancing and setting tho atx fp between the generator armature and the field poles. 26 - @‘After generator Is coupled to engine, it is vory {mportan: to locate the generator frame so as to have the single bearing ‘at the commutatar end located axtally in auch a way a8 to avold a thrust load in lther direction. The gonorator has a Doaring float of ebout 5/16" between the bearing cap and cover tn bearing housing. ‘This bearing float (end play) 1s stamped ‘on bearing cover at lubricating tube. The bearing in the generator housing must be spaced a6 shown in Fig, 28. 1, Remove one ail pan handhole cover and take out all the crankshaft thrust by prying aginst a crankshaft web and crankeage. Move all crankshaft ‘thrust toward generator end of engine. 2, Next, locate measurement mumber stamped with 1/2" numbers on top of right horizontal rib of end bell. NOTE: Meaturemeet™X" should be uted for aligning ing er explained i fox Notless than 13/64" grt 3764-1766 rng Cap Clompeerser Coupling Dia! Indicator Sopp generator-compressor coupling, this stamped number 1s the meus~ turement in Inches from top right spot-faced surface of the bearing cover to outer end surface of the ‘mule compressor coupling goer ‘mounted on generator shaft. This ‘measurement "X" Fig, 28, is about 9” when armature bearing in gen- erator housing is flush with inside of the bearing cap. 1b. On locomotives having a Falk type gonorator-compressor coupl ‘this measurement "X" is takenfrom top right spot-faced surface of tho outer bearing cover to outer ond surface of comprossor-coupling ‘adapter mounted on the generator shaft and is about 7-16/82", ¢. Tho measurement "X" on gener- ators not having coupling gear or Indleatortor checking ‘ouplingclgnment 1/4" na topee pipe treed Pig. 28 — Generator Rearing To Housing Alignment -2-to oumpressor when installed in locomotive) is taken from top right ppot-faced surface of outer bearing ‘cover to outer ond surface of al- ternaior slip xing hub and is about 519/22", NOTE: The measurement stamped on end bell is determined during final ‘generator assembly with the arma- ture purposely positioned so that its end play ia all taken up in the ‘direction of the engine coupling, 8, Dopendirg won the application in the {ndividusl locomotive, make a meas- ‘urement as Listed under a, b, or © of Item 2. More generator frame in celther direction away from or toward the engine to obtain a measurement Which will be 1/18" +3/64" ~1/64" greater than the figure stamped on generator ond bell, Alignment Procedure ‘The proper operation of the power plant requires thit the generator armature shaft and generator frame be in Line ‘with engine crankshaft, and that the alr gap bo equally spaced. I is equally im- portant that eccentricity at the coupling bbe held to a minimum ae thie directly affects balarce, brush and bearing wear, ‘The air gap of the gonerator must be uniform wittin plus or minus .010" from average under each main pole, as well as ‘under each commutating pole and also from the front to rear of each pole to obtain the p:oper electrical characteris- ‘es of the generator. Since the generator has only one roller bearing, the rocommended method for Aligning the «tr gap and coupling is at the engine end of the generator. ‘The aligning procedure 1s divided into two operations, both of which are carried angular misalignment of the generator to ‘engine coupling, (t) balancing and setting ns of two dial indicators mounted on a support rod 8122000, Which 18 sorewed into a tapped 1/4" pipe thread hole in the D14 alternator field spider, a measurement of the coupling misalignment and generator ‘air gap varlation is determined, Both indloators revolve with the armature shaft, ‘The plunger of one indicator rides on the outside machined dlameter of the alternator aluminum housing at the Joint where the stator winding guard connects to the housing, ee Fig. 28, 2, With the engine turning ack assembly, the flywhoel should be turned so that the indicator rod {a in a vertical post- tion, This will place both indicators ‘oar the top of the alternator housing. 8, After clamping the indicators on the rod, the plunger buttons of the indi- ators are brought to bear upon the surfaces as shown In Fig. 28, In jetting the indicator, depress tho plunger until the pointer makes one ‘complete revolution or .100", There being 200" total revolving travel to ‘the indicator potnter, there still is 100" plus left to work with, and the plunger can back out to show minus Tending for total of .10 With the indicator set, tun the fly- wheel, with engine Jack, one-half revolution in a clockwise direction, ‘when facing commutator of generator ‘then rotate the flywheel three-quar- tora of @ revolution in a counter clockwise direction. (‘The reason for the counterclockwise rotation instead ‘of continued clockwise rotation 1s to prevent the indicators from strlldng = 28 -I the alternator terminal boara), rom the three-quarter counter-clockwise position, Tetum the indicators to the starting point and check registration on indicators, The pointer must return to toro, if not, Teset indicstors and make another check or replace indi= ‘ators, if defective, 5, From this fixed point, revolve the fywneel a nait revolution (180") ln a clockwise direction (when facing the ‘commutator end of the generator) and record the readings at the 90° and 180° pointe whea rotating in this direction, 6, From the 180° point tn Step § revolve the flywheel three-quarters of a rev- olution in a counter-clookwise direc- ‘lon and record the indicator reading at this point, Returnthe dla! indicators back to the original starting or fixed point, Indicators must then register ‘The generator 4e considered to be aligned when readings are obtained as shown in Fig. 29, Torque engine to generator 3/4"-16 bolts to 295 ft-lbs, Since sny movement of the generator frame affects both the coupling and air ‘gp, readings must be ropented for both ater each setting. Experience will indi cite the proper shim thickness to bring the readings within the limits specified. Pull length ahims should he used when ote 2.000 O16 #.000 ote gr os 2.0 te E10 ote 2020 Indicator On Dee Indicetor On Fig, 29 — Generator To Engine Coupling Alignment powwiuis, singe ope oun anny ow necessary to conform to the limits spect~ ted for the alr gap and coupling. ‘After installation of a new generator and ‘upon completion of line-up withthe engine, trun the power plant for a short time be= fore the locomotive is moved, This will fallow the gonorator to settle so that when ‘the dowels are installed there will be no further run-in nooossary. Install generator to undoxtrame dowels. ‘Torque generator hold down bolts to 1200 ft-lbs and secure bolts with lock plates, ‘Air Compressor Drive Alignment With Gear Type Main Generator Coupling ‘To align air compressor coupling flange to main generator gear drive proceed as follows: 4, Disconnect coupling by Temovingbolts attaching compressor ring gear to compressor flange, see Fig, 20, 2, Side compressor ring gear toward generator to clear front face of oom- ‘pressor gear assembly teeth, 8, In order to avold overcompression of felt washers, the compressor must first bo located to give a clearance Almension of 7/32""1/32" between ‘the pilot face of compressor flange fand front face of the generator-to- compressor coupling gear assembly, End play in the compressor shaft rnsed not be taken into cousideration ‘when locating compressor to eblain ” ‘the 7/32" clearance, asnorméliy there ig. but .010" end play with the com~ pressor cold. ‘A dial indioatot support rat Pig, 80, for holding the 4s fastened to ono of th standard threaded holes of pressor coupling gear onthe shaft, and extends horizontally thai ‘one of the three 2" diemeter holeadin {he compressor flange. r Sti pee5. [Attach two dial indicators to the tool post, ‘The button of one indicator rides the outer rim of the compressor flange to check radial alignment; the button of the other indicator rides the face of the compressor flange, toward the compressor, to check the angular alignment, Rotate generator shaft and compressor shatt together, either by rotating each the same amount, or hy tying the two ‘units together 1a such a way that com pressor allgament will not be sffec= ted, The two unite oan betled together by a loose fitting bolt through the 1/2" holes in the compressor flange andthe ‘compressor ring gear. Radial runout should not exceed .005" total indicator reading. Total runout between generator gear face andoom= pressor flange face should not exceed 010". Before resssembling, the surfuce of ‘the coupling gear teeth should be coated generously with = N.LG.L (National Lubricating Grease Institute) grease of #3 consistency containing 18 to 16% eodium base soup. Further Iubrication should not be necessary until unit 6 disassembled for over~ ‘haul. This coupling is normally noisy due to built-in gear lash. The t= troduction of lubricant under high pressure 1s not approved, as there 1s ‘danger of rupturing the felt seals, thus allowing lubricant to flow over alter- nator slip rings and brushes. MAINTENANCE DATA ‘SPECIFICATIONS Weights Generator (eomplete-without sheet fron housing) . « DC Armature « ‘AC Rotor Generator field assembly ‘AC Stator (complete). + ‘Nominal Air Gap (under) Main pol ‘Commutating pales = « ‘Brush Holder Number of brush arms Clearance betwoen brush holder and commutator . ~~ 17,710 tbs. 6,246 Is. 1,400 Iba. 17.130 Ibe. ‘980 Ibe. We" + 1/16" 0"Number of brushes per arm... ++ 5 sots (split) ‘ize of brush | ‘Adjustable pressure brush holder . . « 5/8" 1-8/16"x 2-9/16" (long side) (5/8" made up of two brushes) se 29/980" 1-6/16" x 29/16" (Long ste) (21/32" made up of two brushes) Wear Limit Adjustable pressure brush holder .....++.+ 19/16" (long side) Constant pressure brush holder (8381071). - Constant pressure brush holder + +++++++++ 1-1/8" (long ste) Grade ceces essen sce eeeee rece tenes severe DEB Type sees fees Spring tension ‘Adjustable pressure brush holder... (ow limit with worn brush) «++... Constant pressure brush holder (8831071) «es eeeee eee 3.28 Ibs, Commutator Minimum diameter . . see" Neck wicth (minimum) ya Mica grove depth . « 3/64" to 5/68" 1020" Mice greove width Resistance at 75°C, 142 Gensrator ‘Armature ‘Armature (1-10) = « Main Ciroutt A-D . + + 00260 to 00270 ohms 00174 to :00191 ohms 100445 to .00463 ohms 00222 to .00230 ohms Intorpole AB. - BE vieseecee ‘00221 to .00231 okms Differential Field C-D ..« [00136 to .00142 ohms DF oe 00137 to .00142 obms Compensating Field EF {00848 to .00862 obms Bc. [00350 to .00886 ohms Starting Fiold . 100872 to .00896 ohms Shun Field. 91,78 to 96.48 ohms Battery Field teens 1.16 to 1.22 ohms ‘D2 And D12 Generators Armature ee eeeeee eee 00306 to ,00318 ohms 100204 to 00212 ohms 100480 to ,00498 ohms 00220 to .00228 okms ‘00222 to .00231 okms 100140 to ,00148 ohms ‘Armature (1-10) + Main Clroult AD... Interpole A-B. AE. Differential Field BC FD. [00240 to 00148 ohms Compensating Field E-P [00398 to .00408 ohms 100306 to 00412 ohms 100860 to .00583 ohms 91.2 to 95.8 ohms 1.45 401.22 ae cD Starting Pleld Shurt Pield . ses. Battery Field14 Alternator Alternator Rotor (Glip ring to alip ving) . « cesses 2,18 b0.2.29 obms [Alternator Stator ‘(Dhase to phase) = Leeteeereee 00965 to .01045 obma Maximum allowable variation otwoon any 2 phases ve ee eeseeeree +0001 ohms Roller Bearing Outer dtametes sions * OO * z = 001s" 000" Bearing bore sane"’ “oyn a + 000" Width vee e eee eared Intornal clearance (before assembly) 0036" to ,005" Internal cleszance (after assembly) - 002" min, ‘Bearing Housing Bore Diameter ‘End Play Clearance (After assembly in generator housing) EQUIPMENT LIST GREASE CHART 2052924 Additive bearing* 8068027 gossess ‘Bearing « 8122000 Cap. Grinder ~ Commutator Scale ~ Brush tension testing Saw - Undercutting (.030") + Rod = Dial indicator support eo 18 on $1/4 08 Lien Eon Vieni vaen ‘Rod = Dial indicator support . @139046 Cover. « [Abrasive ~ Flexible ‘leaning stone « 8149435 Sealed bearing** stad Armature bearing ellen . et a/a"'x 18" long (two) - 8169226 Bearing... +++ +++ 14 on. 1/4 on TLITT we on £14 on. TLT1 18 02.2 1/4 08. Guide - Armature bearing cap alignment «+. + -. 9159227 Cover aller - Manual ~ Main generator benting «+++ 6168577 *Lubrico ME «... «868104 (25 ipa) (Export only) vee eeee eee + 821962 {8102808 (120 Ibs.) ‘Adapter - Commutator . « 195928 **Texaco Regal Stone ~ Finish grinding Starfax #2. a x2" 8") e20179L **Cyprina RA stine - Brash eoaiing osc, + 8204987 Grade 3 +s. +0y + 6240810 ( 36 Ibe.) Blower - Vaouum eleanor... €210140 18249820 (120 Ibs.) Bar - Allgament (for 8052924 (9079816 ( 38 tbe) = eno14s sat0142 - sama 32