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 document provides guidance for the Basic Repair and Rewinding of PATCO s GE 1255 A3 traction motors. Reference A contains repair specifications for the motors as manufactured by GE. The repair procedures specified in Reference A are to be followed except where noted herein, or where a change has been specified by the Original Equipment Manufacturer (OEM). The OEM for the GE 1255 A3 motor is Swiger Coil Systems Dicvision of WABTEC, corporate successor to General Electric Transportation Systems Business Division. Warranty The motor shall be unconditionally guaranteed against defects in materials and workmanship supplied by the vendor for a period of 1 year (12 months) after the motor is placed in service. Parts All parts used in the repair of PATCO s motors shall be supplied by the OEM. Lubricants, resins, cleaning agents and processes specified in Reference A may no longer be available or be best practice. If the Contractor wishes to make a substitution, a description of the proposed substitution and reason for the request shall be submitted to PATCO for review and approval. Receipt Inspection & Documentation Traction motors will be sent to vendors along with a Will Advise Purchase Order (PO). Upon receipt at the vendor s facility, the motor shall be inspected using the guidelines of Ref. A (Planning sheet). The work proposed by the vendor shall be entered on the planning sheet with contract pricing. The completed Planning sheet shall be faxed or e-mailed to PATCO s Director of Equipment, who will review the proposed work, accept it or request a revision and advise PATCO s Purchasing Department to issue a revised PO in the amount shown on the final
PAGE 2 of 5 PAGES Planning Sheet. Receipt of the revised PO will be the vendor s notice to proceed. Repair work may be performed on the motor prior to approval of the planning sheet by PATCO at the vendor s risk. PATCO does not require documentation of work performed, e.g., test records, to be furnished, but this documentation must be compiled and retained by the vendor for a period of five years or until the motor is again overhauled, whichever is longer. These records shall be made available for review by PATCO representatives at PATCO s request. The reviews may occur either at the vendor s facility or at PATCO s Lindenwold Maintenance Shop. Shipping When repair work has been completed, a metal identification tag shall be riveted to the motor frame adjacent to the original manufacturer s plate, if still present. Nameplates affixed by previous repair vendors, if present, shall be removed. The information shall include the Motor Model Number, Motor Serial Number, Vendor Purchase Order/Work Order Number, Repair Completion Date and Vendor Name/Address. Motors shall be shipped one per skid, properly strapped to insure no damage occurs to the leads, with a suitable covering to protect the motor from rain or snow. Vendors must construct skids, similar to the photo below, for shipping motors.
PAGE 3 of 5 PAGES BASIC OVERHAUL Below is a list of the tasks to be performed; it contains several tasks in addition to those included in reference A. Reference A specifies how to do the tasks. All items listed are to be included in the cost of the Basic Overhaul, except where noted. Inspection Disassemble Clean, armature and field, bake dry Dimensional check of all parts to be reused, including gaging of all threaded holes. (Motor Head mounting holes, side cable bracket mounting holes, top cable bracket mounting holes), verify that commutator has at least one half service life remaining Replace any filter mounting buttons worn more than one half through Electrical tests consisting of: DC Resistance to ground for both field and armature Bar to bar resistance test armature Surge comparison test armature Core loss test armature Surge comparison test fields Basic repairs Tighten and spin season commutator Reinsulation Armature- VPI, bake, dip, bake frame - dip and bake (Do not apply any other brush or spray-on varnish or paint to any part of the armature or to any part of the field coils, other than at the lead connections inside the motor frame.) Turn, undercut and de burr commutator Inspect brushholders, rebuild or replace ( replace at PATCO expense). Exception brushholders in motors with less than two years service and no damage may be reused. Brushholder rebuild, where required, shall include: Gage brush holders in accordance with GE Dwg P6746256 New springs New shunts New insulators Inspect Teflon creepage band (All seamed Teflon, epoxy, polyester/glass or burned creepage bands are to be replaced, at PATCO s expense) Replace bearings, grease with Shell Alvania Grease #2 Replace bearing lubrication hose; ensure that lube passage into bearing housing is clean. Install new brushes supplied by PATCO (PATCO stock # 44C0115) Motor lugs are to be replaced, except in the case of motors with less than two years servicepatco shall receive credit for lugs not replaced.;replacement lugs shall be of the solder type and be manufactured by AMP. Replace all motor leads using cross-linked polyolefin insulated cable, AWG 3/0, Surprenant specification DAA1068A, 2000V,.065 wall thickness. Use new watertight feedthru bushings. Motors with less than two years service, as indicated by nameplate
Final Test PATCO SPECIFICATION PAGE 4 of 5 PAGES shall have leads and connectors reused if they have no physical damage. PATCO shall receive credit for leads not replaced. Balance armature Seat brushes, air cure commutator (Ref A, p 34, except the NOTE should read Air curing at a maximum speed of 4050 rpm, approximately 160 field amps, 440 armature volts.) Thoroughly blow out motor with compressed air. Additional work as determined by the receipt inspection shall be listed on Ref. B, which is to be forwarded to PATCO for approval. Upon approval, a revised Purchase Order will be issued; this will constitute your notice to proceed with the work. Substitute the following for: No Load Saturation, p. 34 Ref. A, High voltage run, Bearing and heating-up run, Overspeed test, Vibration test and Bearing noise, p. 35, Ref. A: Final test shall use a test unit that supplies the armature and field circuits independently, to allow rated field current and rated armature voltage to be supplied concurrently. Load testing is not required. The motor is to be run ½ hour in each direction during the final test. Bearing temperature shall be measured at the outside of the bearing caps. Test Procedure (The procedure given below is one way to do this, vendor may propose an alternate for PATCO approval) Measure commutator profile Instrumentation tachometer, (2)temperature probes for bearing housings, vibration probes, one horizontal, one vertical and one axial Apply 300 amps to exciting field. Raise armature voltage until motor runs at about 4050 rpm, hold for ½ hour, stop motor, reverse armature leads, repeat Raise armature voltage until motor runs at 5520 rpm, hold for 2 minutes Bearing temperatures must rise no more than 50 C Stop Measure commutator profile Limits: Bearing temperature - 50C rise above room temperature Vibration.002 Commutator runout TIR.001, rate of change.0001 between adjacent bars,.0004 in a group of 20 bars. There shall be no change in this measurement between start and end of test.
ARMATURE REWINDING PATCO SPECIFICATION PAGE 5 of 5 PAGES Per reference (C), with the addition of all new armature laminations on all rewound motors. PATCO may, from time to time, require additional work. This will be indicated on the Purchase Order. FIELD COIL REPLACEMENT Reinsulation of Coils If original copper is in satisfactory condition, field windings may be re-insulated using original copper with new ends brazed on as needed to restore length. The OEM insulation system shall be used and the finished coil shall meet OEM specifications for a new coil.