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85 Reference _ Specification: S-3713 Fleet: B-IV System: Traction Motors Latest Revision Date: SEPTA TECHNICAL SPECIFICATION 1.0 SPECIFICATION TITLE TRACTION MOTOR (5GE1264B1I ARMATURE OVERHAUL 2.0 PRE-RELEASE REVIEW NAME INITIAL & DATE HANK TYLER 3.0 APPROVAL FOR RELEASE Signature Scu:hXX:KcCkkcu Sachit K. Kakkar 4.0 SPECIFICATION RELEASE DATE 06/06/2006 Technical Services Contract 64

86 Reference Specification:. Fleet: System: Latest Revision Date: B-IV Traction Motors AGENDA and REVISIONS SEPTA TECHNICAL SPECIFICATION Change No Release Date Reason for Issue Release Approval Technical Services Contract 65

87 Reference _ Specification: S-3773 Fleet: B-IV System Traction Motors Latest Revision Date: 5.0 SCOPE AND PURPOSE OF SPECIFICATION This specification outlines and provides criteria for service ofequipment for a SEPTA system rail vehicle; enabling an experienced, competent bidder to proceed to furnish an acceptable end item. The service performed by the bidder and the resulting end item, shall comply with all applicable specifications, standards, codes, regulations, and procedures for the type of equipment and its application specified. The service and resulting end item shall comply with the O.E.M.'s latest specifications and following criteria, as minimum requisites. Supplementary relative information and criteria will be furnished on an "as required" and "as determined" basis, and shall become part of this specification. The Authority requires that, as a prerequisite, the Contractor posseses operable equipment capable of compliance to all paragraphs of this Specification. All work functions processes, tests, and inspections shall be performed at and within the Contractor's facilities. Any subcontracting ofwork to comply with the Specifications shall be limited to a maximum often percent (10%) ofthe dollar value ofthe total work contracted and shall be performed by a subcontractor approved by SEPTA Rail Equipment Engineering. 6.0 SPECIFIC CRITERIA 6.1 Tvpe ofequipment The armature for the 5GE1264B1 which is a four pole, commutating pole, series wound, 300/600 volt direct current, self ventilated traction motor. 6.2 Reference Specifications and Drawings Specification Drawing Title S-1426 A-1763 Taper Ring Gauge for Armature Shaft S-2646 N/A Armature Rewind Kit S-2646 D-3019 Armature Main Winding Assembly S-2646 A-3020 Molded Mica Equalizer Insulator Quadrant S-2549 C-2884 Shaft S-2850 B-3571 Armature Assembly S-2852 B-3831 Armature Core Assembly W/0 Commutator S-2853 C-3573 Commutator Assembly S-2854 B-3574 Commutator End Spacer S-2855 B-3575 Lamination End Plate Technical Services Contract 66

88 Reference _ Specification: S-3773 Fleet: B-IV System: Traction Motors Soecification Drawing Title S-2856 B-3576 Stepped Lamination S-2857 B-3577 Armature Lamination S-2858 B-3578 Rear Coil Support S-2868 B-3572 Core Assembly S-2893 A-40I8 Commutator Nut Latest Revision Date: 6.3 Data MODEL NUMBER MAXIMUM PERMISSIBLE SPEED 5GE1264B RPM COMMUTATOR DIAMETER--NEW 7-1/2 Inch DIAMETER ~ MINIMUM PERMISSIBLE (WITHOUT ARMATURE REWIND).. 7-1/8 Inch DIAMETER - MINIMUM PERMISSIBLE (WITH ARMATURE REWIND) 7-1/4 Inch SIDE MICA - THICKNESS _ Inch UNDERCUTTING: SLOT WIDTH Inch SLOT DEPTH FINISH.. DUST GROOVE DIMENSIONS: 3/64 to 5/64 Inch 32 RMS WIDTH Inch DEPTH RUNOUT (MAXIMUM AFTER RESURFACING) to Inch T.l.R Inch VARIATION OF INDICATOR BETWEEN ANY TWO ADJACENT BARS Inch RISER WIDTH - MINIMUM 3/8 Inch RESISTANCE AT 25 C (WITHOUT CABLES): ARMATURE* Min., Max. *NOTE: Armature resistance to be measured between a 42 bar span starting with any bar and proceeding around commutator. WEIGHT: ARMATURE ONLY 294 Pounds Technical Services Contract 67

89 Reference _ Specification: S-3773 Fleet:^ B-IV System: Traction Motors Latest Revision Date: 7.0 WORK REQUIREMENTS 7.1 Basic Overhaul The basic overhaul, by definition, shall consist ofthe following operations: Armatures shall be appropriately cleaned, inspected, and tested for all mechanical, and electrical defects (static and dynamic). This includes core loss testing per Para and all measurmentsandtestparametersofpara. 6.3,7.1, and 7.3. Record all data. All armatures shall be blown out, degreased, cleaned, and baked dry prior to detailed inspection and test. Bake temperature shall in no instance exceed 320 F. All coils shall be serviced and reinsulated with vacuum pressure impregnation using a Class H' or better insulating material. All VP! procedures shall be per the armature VPI procedure ofparagraph herein. Pressure shall be provided by either dry nitrogen or a SEPTA R.E.D. approved dry air system The following components shall be repaired, serviced, or refurbished: Commutator: Commutators are to be visually inspected for obvious defects. Diameter and riser widths are to be measured. The condemning diameter of a commutator whose armature does not require rewind is inches. The condemning diameter of a commutator whose armature requires rewind is inches. The condemning width ofa commutator riser is 3/8 inch. Commutators shall be: A. Resurfaced, undercutto a depth of 3/64 to 5/64 inch, raked, and light polished for a 32 R.M.S. finish or better. This shall be accomplished with the armature it its own bearings. B. Total indicator runout is inch maximum. NOTE: This requirement is also part offinal acceptance testing with the armature in its own bearing. Refer to Paragraph C. Technical Services Contract 68

90 Reference_ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: C. Variations of indicator reading between any two (2) adjacent bars is inch maximum. D. A 0.23 to 0.26 inch wide dust groove or "gutter" is to be machined in the commutator. Dust groove is to be ±.005 inch deep Armature: A. Bands and wedges. B. Each armature shall be dynamically balanced. Static balance is not acceptable. Run the armature on its own journals. Maximum permissible unbalance at each end shall not exceed two (2) grams. Balancing shall be accomplished by utilizing the balancing grooves when provided..corrections for unbalance may be made by the addition of metal by welding, bolting, or riveting. The use of balancing putty shall only be used for fine tuning and shall be placed on an underside surface that will not be adversely affected by extremely high 'G' forces (centrifical force). Under no condition shall balancing material obstruct cooling ventilation channels or the air gap between pole pieces and the armature core surface. NOTE: Keyway must be filled with half key during balancing operations. C. Shaft. No metalizing permitted. If a shaft indicates prior metalizing, it shall be replaced. All shaft dimensions shall be measured for proper bearing fit. Condemning limits shall be as follows: Pinion End min., max. Commutator End min., max. Check taper using ring gauge ofsepta Specification S-1426, latest revision. D. The armature coils as an assembly shall be reinsulated with VPl. Appropriate masking material shall be used to preclude insulation from areas other than intended Final test per Paragraph 7.3 including commutator runout of inch, maximum, after assembly in frame. 7.2 Additional Overhaul (as required basis) Technical Services Contract 69

91 Reference _ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: Additional overhaul items shall include a "price schedule" that includes all cost of replacement parts (material) and labor Subcontractor shall, upon receipt ofunits, initiate a complete and thorough inspection and test. Conditions found as a result shall be formally transmitted to SEPTA for approval prior to initiating work other than basic overhaul The following components shall be replaced as required with new parts and/or material: Armature Coils Rewind shall be performed using the armature rewind kit as specified by SEPTA Specification S~, latest revision. VPI shall be performed twice after installation, with a complete cure/bake cycle after each VPI operation L2 TIG welding only shall be permitted Rewinding shall be as follows: A. Preparation ofrewinding Armature coils shall be removed by machine tool cutting the TIG welding at commutator risers. An absolute minimum amount of commutator riser metal shall be removed. Use a 1/8 inch machine cut off tool for groove cutting coils in back ofrisers and at front and rear coil end plate punchings. The groove cut shall be 1/8 to 3/8 inches outboard of components. Coils and wedges in core slots may be removed by flame burning or high pressure water spray. 1. When flame burning method is used, the commutator shall be protected by a hood and armature continually rotated at low RPM (10 to 12 RPM). Commutator surface temperature shall not exceed 155 C (312 F). Core lamination surface temperature shall not exceed 360 C (684 F). NOTE:These temperatures are important to protect sodium silicate insulation coating finish on Technical Services Contract 70

92 Reference _ Specification: S~3773 I Fleet: System: Latest Revision Date: B-IV "II Traction Motors each core lamination and commutator mica. This damage will increase electrical losses and heating, causing core hot spots. 2. A controlled burnout oven may be used ifdesigned for armatures. This equipment and procedure must be approved by SEPTA. 3.. The stripped armature can be cleaned by glass bead air blast, or it may be steam cleaned with a mild detergent. NOTE:Do Not Use Water Soluble Cleaners Such As Sodium or Potassium Hydroxide. Thoroughly rinse with live steam and hot water to remove all traces ofcleaning compound and oven bake in an air circulated oven for six (6) hours at 300 F ±10 F. Carefully remove slot fillers, coils and cross connection pieces. Protect mica and copper at rear ofcommutator risers. Do not bend slot riser segment when removing coil pieces. Bending will result in cracked mica and cracked segments. Carefully remove all potting and varnish compound from slots. Commutator must be replaced if slot riser segments are broken or cracked. B. Armature Inspection and Test 1. After armature clean~up, the armature shaft, commutator, coil supports, and core lamination shall be mechanically inspected and core loss tested. Core loss testing shall be performed per Paragraph C. Armature Rewind Procedure Technical Services Contract 71

93 Reference _ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: 1. Ground test commutator by wrapping commutator surface with bare copper wire. For used commutators, apply 4000 VAC. New or refilled commutators shall be ground tested at 5000 VAC for 15 seconds. 2. Inspect core, coil support and slots carefully to assure burr free assembly. Be sure end punchings line up properly. 3. Clean assembly ofall debris with compressed air. Inspect for and remove any copper chips from behind risers. 4. Check centerline of commutator bar slot (.010+ maximum tolerance) to insure line up with centerline ofpunching slot. 5. Insulate front coil support and assembly cross connectors with material per S 1439, latest revision. 6. Wind armature using industry standards methods to insure integrity ofthe windings. NOTE: In many cases, it will be necessary to "persuade" the coil intothe slot and seat it. Micarta or equal and/or hard fiber drifts six inches wide and approximate coil thickness can be used. The edges ofthese drifts that contact the coil should be smooth. The force of the mallet blow to press and seat coil in the slot must be absorbed over full length ofdrift. 7. After coils are installed, ground test armature commutator and windings at 2500 AC (RMS) to shaft for 1 minute. Technical Services Contract 72

94 Reference _ Specifioation; S Fleet: B-IV System: Traction Motors Latest Revision Date: 8. Temporary banding is required to pull armature coils up tight to final position for machining off coil extensions and before TIG welding. Preheat armature in air circulated oven at ]50 C (302 F) for three hours. Apply temporary band within one hour after removal from oven. 9. Mylar tape or equal application ~ apply two layers of Mylar tape or equal over both end coil extensions to prevent banding tape from adhering to coil insulation. Apply temporary band at 250 ±10 lbs. tension and 3/4" tape. Do not relax banding tension at any time during application of both core bands and coil extension bands. Apply temporary banding to commutator coil extension. Wedge armature using proven industry standards. NOTE:Do not remove glass banding around core until armature is at ambient temperature. 10. Machining Set armature in engine lathe centers. Machine off overhanging leads at riser face. Do not use air hammer and chisel or saw to cut off extension length. 11. Surge Testing Before TIG Welding Inspect and clean commutator surface. Surface where brushes run must be clean for good contact. Turned over machine edges ofcopper bar end must be removed. Use sand paper wire brush and/or hack saw blade as required. Place in Surge Tester, center brush radial with commutator surface in center of any bar. The included bars between the center brush and each out side brush should be approximately 6 bars. The armature is now ready to test. Briefly, a high voltage is applied to each half of the armature Technical Services Contract 73

95 Reference_ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: winding with the center brush a common point and a pattern of each half compared on a cathode ray tube screen. Test voltage should be 500 volts peak bar~to--bar (for 6 bar spread, use 3000 volts). Observe pattern on the scope screen. There are actually two patterns (one for each half of the winding). The two patterns should be superimposed and appear as one. The armature should be turned one revolution. If each bar pattern appears as one, the armature is free of electrical faults. Conversely, if traces do not coincide, there must be a fault, and the annature fails Surge Testing. Necessary repairs will be required on an armature that fails Surge Test. 12. TIG Welding TIG welding of conductors to risers is required. The following requirements for TIG welding shall be adhered to: a. The coils must be cleaned. b. The leads should be flush with the front ofthe commutator riser. c. The TIG welding shall be accomplished with the commutator risers in a horizontal position. d. The welding shall be performed in a series of small "spots" or "puddles" so that the entire lead is welded to a commutator box. Technical Services Contract 74

96 Reference _ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: NOTE:A continuous weld will not be permitted. TIG welding procedures must be submitted to SEPTA for approval by the Contractor. e. All spot welds must be done with the highest current and shortest time possible. This method will result in the lowest heat input and maximum annealing of riser and coil leads. The maximum temperature permissible during the welding operation is 315 C (600 F) measured 3/8" from riser face on the coil lead. A slight discoloration to a light brown will be noticed. f. The 5/32 inch spots or puddles shall be 5/32 inch apart on each riser and shall not weld adjacent bars together during the process. g. Glass bead blasting or wire brush to remove light welding smut from the vertical risers. 13. Surge Test After TIG Welding Surge test after TIG welding, follow procedure as outlined in "Surge Testing Before TIG Welding", Para C.11. If armature passes Surge Test, remove all temporary banding. 14. Hot Permanent Banding Front. Rear Coils and Commutator End Wrap with impregnated glass tape (approximately 400 feet x 3/4 inch wide x.015 or equal). Heat rotor at 135 C (275 F) for six hours or at 140 C (284 F) for four hours in air circulated oven. If oven is without mechanical air circulation, double the time. Other types of heating may be used if approved by SEPTA. Place armature in banding lathe. Application of permanent bands must be Technical Services Contract 75

97 Reference _ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: within one quarter hour after removal from oven. At no time during banding should core temperature fall below 98 C (200 F). Fill all cavities between adjacent top leads behind the risers and commutator slots with Sterling 415E phenolic putty, or SEPTA Engineering approved equivalent. Fill voids flush with top ofriser. Smooth putty. Use beaded edge tape to restrain side motion of glass tape during banding. Use polyester impregnated glass tape having glass twine diameter equal to final thickness ofband. Length should be such that ends are closely butting as possible. The glass twine should be at least one half inch from core iron to assure impregnation can penetrate to coils and insulation, and to facilitate drainage. Apply front glass band. Edge restraint and banding will be applied over riser 1/4" to ensure sealing ofthis area. CAUTION: Do not allow tape to contact the commutator riser area without beaded restraint tape being in position. The sharp commutator copper will cause the tape to break when under pressure. Begin wrapping first layer of tape at low tension directly on area ofcoils to be banded. Continue to wrap tape upon itself, gradually building up tension until full tension of 250 ± 10 lbs. for 3/4 inch tape. Full band tension should be built up within the fourth turn. After full tension has been attained, wrap tape uniformly across full width of band. Keep height level at 9.80 inch diameter maximum. If surface of coils does not present an even surface start banding in low area and level surface as tape is being applied. This will prevent overloading and breaking outside strands of tape. Wrap tape at moderate, even speed at 28 to 40 feet per minute. Both bands are to be below outside Technical Services Contract 76

98 Reference _ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: diameter ofarmature core. Tape shall not show signs offraying or splitting while being wound on armature. To terminate banding, tack down the last layer of banding tape with a soldering or sealing iron. This will prevent relaxation of tension, thus assuring maximum retained tension throughout the entire band. Before tying off or tacking down the finished glass band, the application tension should be dropped to zero over 2 to 3 turns to provide the stress reliefso the band does not snap back when cut. Cover band with nonadhesive strip. Hold strip tight to glass band with a few turns of masking tape. The purpose is to smooth out excessive resin during curing. 15. Commutator End Band Use a file to smooth the sharp edges of Mica "V" ring. Remove any loose mica flakes from the surface of "V" ring. Apply 1 layer GE or equal banding tape over mica, tucking it into space between commutator bar end "V" ring. Apply 2 layers 1/2 lap Mylar shrink tape. Cure now or during subsequent operations as follows. A final epoxy silicone resin gel coat shall be applied after undercutting and rotational seasoning. 16. Curing Armature Place armature in curing oven within 15 minutes after completion ofbanding. Cure time: 150 C(302 F) 135 C(275 F) 4 hours 6 hours While rotor is in lathe for final commutator turning and undercutting, slightly bevel edge of O.D. of sting band with a file to remove any sharp edges produced by resin during curing cycle. Do not machine O.D. of bands. High bands are to be Technical Services Contract 77

99 Reference _ Specification: S-3773 FIeet:_ B-IV System: Traction Motors Latest Revision Date: replaced. They should be at or below the O.D. of the core iron O.D. 17. Surge Test After Final Banding and Cure Repeat Surge Test Procedure as outlined in "Surge Test Before TIG Welding", Para C Armature Vacuum Pressure Impregnation fvpi) NOTE: It cannot be stressed too strongly that the temperature of the armature and the temperature ofthe impregnated material are the principle factors that determine the quality ofthe finished armature. The factors must be controlled. A suitable impregnant shall be used in the presence of a dry surcharge to be applied. Masking compound to all machined surfaces and area not to be impregnated. The application of impregnant shall take place promptly after banding curing cycle. The armature should be at 43 C-54 C (110 F-130 F), i.e. warm but not hot, to ensure good penetration and not cause thickening of the impregnant from overheating. Impregnant shall be applied by "VPl" method as follows: a. Lower armature into processing tank. b. Attach the recording thermocoupler to the armature. c. Close vacuum pressure vessel. Begin to evacuate a dry vacuum of 5 millimeters of mercury for not less than 90 minutes. After dry vacuum, check aitnature temperature, it Technical Services Contract 78

100 Reference_ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: should be at least 38 C--40 C (100 F-120 F). Ifheat loss is less than 38 C (100 F), preheat to a higher temperature. This temperature range is necessary to have sufficient heat in armature to lower the viscosity of the impregnant so that sufficient wetting and fill is attainable. d. While still under vacuum, the resin shall be introduced. Observe rise of resin in impregnation tank through sight glass in tank cover. When resin has risen above.25 inches ofcommutator risers, stop the resin flow. e. Hold wet vacuum for one hour. f. Close valve to vacuum source. Open pressure surcharge. When pressure has stabilized between 70 and 80 lbs. per square inch, hold for one hour with pressure on resin for "WET" pressure cycle. g. Release Pressure. Return resin to storage tank. Allow armature to drain free of resin for ten to twenty minutes. Remove armature from tank. h. Remove resin from shaft extension, balancing grooves and vertical risers. i. Place armature horizontally in a rotating armature fixture. Place rotating fixture in oven. Rotational speed to be 20 to 25 RPM. Bake time shall be eight hours at 145 C ±5 C. 19. Repeat VPI procedure, Paragraph C Commutator (complete). Commutator shall be completely seasoned and spin cycled in accordance with the latest specifications and practices of original equipment manufacturer. In addition, all commutators shall be Technical Services Contract 79

101 Reference _ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: spin seasoned on the armature after initial installation, commutator nut retightening, rewinding, and/or welding. (The stability of the commutator becomes questionable after retightening, rewind, and TIG welding.) Spin seasoning shall be performed after balancing per Para. 7.I.4.8.B. Spin seasoning shall consist of the following cycle repeated three (3) times, with the armature in a spin seasoning stand and performed in its own bearings. Heat the commutator to +165 C ± 10 C (311 to 347 F) using gas fired heat directly on the commutator surface. The temperature controller shall be capable ofholding the temperature within plus or minus 5 degrees C. Attain a rotational speed of 6400 ± 50 RPM. Maintain temperature and speed for 30 minutes. Cool to + 50 C (+122 F) maximum while maintaining 6400 RPM. Repeat the cycle for a total ofthree (3) cycles. Profile the commutator next to the riser and on brush tracks. certain that the TIR does not exceed inch and bar to bar deflection is less than inch. Ifthese limits are exceeded, true tl^e commutator by diamond turningor grinding then repeatthe entire spin seasoning process. All new or refilled commutators shall be procured from the following sources only: Kirkwood Commutator Corp., The Electric Materials Co., Calumet Armature & Electric Co., or SEPTA Rail Equipment Engineering approved equivalent. NOTE: The option of substituting a refilled commutator for a new shall be SEPTA R.E.D.'s and the following criteria shall be met. The commutator shell bore specification is ± inches. Be Technical Services Contract 80

102 Reference _ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: The TIR shall remain within this tolerance. No metalizing or sleeving of any kind is permitted. If the shell fails to meet these requirements and/or OEM dimensions and tolerances, the shell shall be replaced with new and the old shell returned to SEPTA, Only shells that meet the dimensional requirements ofa 1264B1 commutator shall be refilled. The copper segment material shall have a composition of25 to 50 Troy ounces silver per ton copper. Rockwell hardness to be E86 E Commutator Nut Tightening Original, new, and refilled commutators must have the commutator "V" ring nut checked for tightness. Procedure a. Place armature in oven and heat long enough to reach 150 C (302 F). Measure temperature on commutator with surface pyrometer. b. Place armature vertically on level press platform. Vertical position is important to obtain equal pressure on "V" ring and commutator segments. c. Place tightening tools on commutator "V" ring. d. Apply 26 ton hydraulic force to "V" ring. Press at 5.25 inch diameter. e. Tighten commutator nut to 300 ft--lbs (±10 ft--lbs). f. Check movement of nut using scribe index. If nut moves more than.625 inches circumferentially, place armature back in oven and reheat unit until it reaches 150 C (302 F). NOTE: Ifnut does not move, loosen nut to ensure it is not frozen (locked) in place. Technical Services Contract 81

103 Reference _ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: g. Remove armature from oven and repeat, tightening until nut moves less than inches circumferentially. h. After hot press, allow armature to cool until it reaches room temperature. (Check nut for tightness at 300 ft.-lbs. (±10 ft,-lbs.). i. Weld nut to cap at spots 180 apart at dynamic balancing and after spin seasoning, when required using a bronze welding rod Commutator Turning. Resurfacing, and Undercutting On new or refilled commutators installed on lathe centers, make a light machine cut to 7.56, ,.040 inch diameter having a finish of32 RMS. Make chamfer cut on end of commutator bars having.03, ±.003 inch x 45". The total maximum indicated runout of the commutator shall be.0005 inches TIR. Worn or damaged commutators shall be resurfaced by removing the minimum amount ofcopper for a smooth, parallel surface of32 RMS finish and within.0005 inches TIR maximum and bar to bar variations of inch maximum. Commutator minimum diameter shall be per Section 2.0 of this specification. Clear cuttings away from armature, taking care that no cuttings enter annature windings. An approved undercutting machine is required. Record armature serial number, diameter ofcommutator, and undercut width. An wide square undercutter cutter, set to depth of.062 inch shall be used. Do not chamfer bars. Bar edges may be dragged to provide a slight radius having no burrs or sharp edges. No side mica is allowed. Do not remove more than.002 inch from copper bar sides. Record armature serial number, diameter ofcommutator and undercut width Commutator Gel Coat End Band Final Finish Application of epoxy gel finish coat procedure for new or refilled commutators and commutators not replaced. A Technical Services Contract 82

104 Reference _ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: smooth final epoxy gel coat shall be applied according to the following procedure: Rotate armature slowly, approximately 10 to 15 RPM and apply coat of epoxy silicone resin, NEC ~440-07, Sterling U958/C12, or equal. Pour and spread with a wood paddle over glass tape. Add epoxy as required to cover glass band and seal edges ofcommutator bars at and slightly below mica bar level. Do not use excess to fill up ends of commutator bar slots (excessive epoxy in bar slot must be removed when cured). Epoxy seal edge ofmica "V" cup to steel "V" ring approximately 1/16 inch below I.D. edge of mica on O.D. ofsteel "V" ring. Continue to rotate armature slowly until epoxy gel coat is cured to a smooth and shiny surface at ambient temperature without air bubbles Armature Laminations (Punchings'l Core shall be examined for lamination damage. Fused laminations shall be separated either by grinding or filing. Bent laminations shall be realigned Main NOTE: All cores must be core loss tested. Test results shall be submitted to SEPTA for approval prior to replacement or acceptance. Core loss testing shall be performed as follows: a. Check core laminations for hot spots. Solidly bolt one (1) electrode on each end of core. Apply the proper current as calculated for the area ofthe core back iron, volts per turn, and ampere turns. Hold for one-quarter hour. Check lamination surface for hot spots. Hot spot temperature should not be more than 10 C(18 F) above Technical Services Contract 83

105 Reference_ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: average lamination temperature in 1/2 hour. Ifhot spots cannot be cleaned, by tapping lamination end with a rubber or leather mallet, core shall be restacked with new laminations. New laminations shall be per AISl Ml9 with a C5 core plating (insulation). b. With the proper current applied, measure and compute the cores power factor (pq [pf= watts/volts x amperes] which shall be 0.2 to 0.7. Measure and compute the cores watts per pound which shall be 10 maximum. Ifthe above requirements cannot be met, the core shall be restacked with new laminations. The Lexseco, Inc. Mode 1081 core loss tester is an approved type of core loss test equipment. Core loss test equipment of different design can be used if approved by SEPTA Engineering Ends if irreparable, replace Coil Supports Armature Head (coupling end) replace if irreparable Pressure Ring (commutator end) - replace if irreparable Shaft Replace if conditions of Paragraph C cannot be met. All replacement shaft dimensions shall be within O.E.M. tolerances and suitable for proper bearing fit per Paragraph C. 7.3 Final Test -- Record all data Electrical Criteria and Tests Technical Services Contract 84

106 Reference _ Specification: S-3773 Fleet: B-IV System: Traction Motors Latest Revision Date: Test for insulation resistance, 500 megohms minimum, with 1000 VDC on the following: a. Armature to ground HiPot test with Hz. for one (1) minute on Items a. No breakdown shall occur. NOTE: HiPot shall be performed ONLY on new materials Perform open circuit, short circuit, and polarity tests after motor assembly and prior to run up Electrical Criteria Resistance measure resistance at 25 C (77 F). Armature min., max. *NOTE: Armature resistance to be measured between a 42 bar span starting with any bar and proceeding around the commutator Test as required to assure compliance to all paragraphs of this specification and. functional operation Record all test data and send one (1) copy with the armature and one (1) copy to SEPTA Rail Equipment Engineering. 8.0 INSTRUCTIONS TO BIDDER The bidder shall review these specifications and immediately, clearly, and fully communicate to SEPTA all exceptions, significant deviations, conflict of information, and questions; and may submit alternates, in writing, for consideration prior to submitting a bid. Unless amended in writing by SEPTA these specifications shall remain in full force for the duration of the contract. In order to obtain a qualified and qualitative response from bidders, it is strongly requested that bidders reply categorically to the specifications. Brochures will not be accepted as a substitute for a completed response to the specifications. (Brochures may be submitted only as supplementary reference bid material.) 9.0 PROPOSAL SUBMISSION Technical Services Contract 85

107 Reference _ Specification: S-3773 Fleet: B-IV System:_ Traction Motors Latest Revision Date: A proposal shall be furnished which will demonstrate to the satisfaction of SEPTA that the bidder is capable of meeting the intent of this Specification. This proposal shall provide detailed manufacturing process instructions that relate to each ofthe operations outlined in this Specification WORKMANSHIP Refer to contract documents REPAIR PARTS AND SERVICE - Not applicable WARRANTY Refer to contract documents GENERAL 13.1 Painting Not applicable Safetv The bidder furnished equipment shall present no hazard or detrimental effect to SEPTA personnel, equipment, or property; or to bystanders equipment or property lest liability claims be invoked consistent with the Contract Documents Documentation The bidder shall maintain complete and current records, data, inspection, quality control, test reports, and drawings. These shall be available to SEPTA upon request. Data/Inspection Sheets shall be approved by SEPTA Rail Equipment Engineering prior to start ofwork. Successful bidders Quality Assurance Program shall be submitted for approval Parts and Package Identification - Not Applicable Materials and Processes -- All materials used for the overhaul and repair of each item of apparatus shall be O.E.M. or as permitted under this Specification INSPECTION 14.1 Equipment Inspection - SEPTA will inspect prior to shipment and, as required, monitor workmanship, quality control, inspection, and testing at the subcontractors location. Inspection and testing shall demonstrate compliance of the equipment under these specifications. SEPTA may elect to waive preshipment inspection and inspect at receiving. Any rework necessitated by unsatisfactory results shall be the sole responsibility of the subcontractor. The subcontractor shall be responsible for his suppliers and their products as well as his in house services. Technical Services Contract 86

108 Reference _ Sped fication: S-3773 Fleet; B-IV System: Traction Motors Latest Revision Date: SEPTA inspection shall not necessarily constitute acceptance nor shall it in any way replace subcontractor inspection or otherwise relieve the subcontractor of his responsibility to furnish an acceptable end item Facilities Inspection The Authority shall havethe right to inspect Contractor's facilities prior to award of contract to insure that all equipment necessary to comply with specifications is available and operable. The Authority shall have the right to inspect repair facilities at any time, and without prior notice, during Contractor's normal business hours, for the duration ofthe contract Replaced Material/Parts ~ All replaced material and/or parts including scrap metal shall be returned to SEPTA with identification of unit (including type and serial number) that is was removed from OPTIONS Not applicable DELIVERY ~ Refer to contract document SHIPPING Refer to contract document TRAINING - Not applicable PARTS AND INSTRUCTION BOOKS - Not applicable. Technical Services Contract 87

PATCO SPECIFICATION GE 1255A3 TRACTION MOTOR REPAIR PAGE 1 of 5 PAGES Rev. 1, December 24, 2012

PATCO SPECIFICATION GE 1255A3 TRACTION MOTOR REPAIR PAGE 1 of 5 PAGES Rev. 1, December 24, 2012 PAGE 1 of 5 PAGES ATTACHMENTS A. Inspection Maintenance and Basic Overhaul, Traction Motor Type GE 1255 A3 (GE Document GEK63200) B. PATCO 1255 Motor Planning Sheet (latest Revision) GENERAL Overview This