GEK-91696D

H86488
26 OCT 2009

AC ELECTRIC DRIVE
DRILLING MOTORS
FOR

DRILLMEC
ROTARY TABLES

GEB22
HORIZONTAL DRILLING MOTOR

Customer Order No.

GE Requisition No.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or
maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user’s purposes, the matter should be referred to
the General Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this
manual. GE has no obligation to keep the material up to date after the original publication.

THERE ARE NO WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.

Verify numbers for parts, tools or material by using the Renewal Parts or Tool Catalogs or contact your General Electric
representative for assistance.
Do not order from this publication.
GE
Transportation

1150 HP AC Drilling Motor,

Model 5GEB22 a
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Document No. GEK-91696, Rev. D

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GE
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

© {2009} General Electric Company. All rights reserved. The information contained in this publication is the property of
General Electric Company and is disclosed in confidence. This publication is intended for use by GE customers solely
for purposes of operating and performing routine maintenance of purchased or licensed GE products, and it shall not
be reproduced, redistributed, retransmitted, translated, abridged, adapted, condensed, revised or otherwise modified, in
any form, in whole or in part, or used for any other purpose, or disclosed to third parties, without the express written
consent of GE.
GE and Customer agree that the information contained herein does not purport to cover all details or variations in GE
products or to provide for every possible contingency with installation, operation or maintenance. Should further infor-
mation be desired or should particular problems arise that are not covered sufficiently for the user’s purposes, the matter
should be referred to General Electric Company. Any applicable Federal, State or local regulations or company safety or
operating rules must take precedence over any information or instructions given in the Technical Documentation. GE
has no obligation to keep the material up to date after the original publication.

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GENERAL ELECTRIC COMPANY EXPLICITLY DISCLAIMS ALL WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR
ANY PURPOSE IN CONNECTION WITH THIS PUBLICATION AND USE THEREOF.
a
m
If you are not an authorized recipient of this publication, you are hereby notified that anyrperusal, use, distribution, copy-
n fo immediately return to GE at the
ing or disclosure is strictly prohibited. If you have received this publication in error, please
following address: GE Transportation, Technical Publications Department, Building l I14, 2901 East Lake Rd., Erie, PA 16531.
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GE

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 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

CONTENTS

Page
1. GENERAL INFORMATION.......................................................................................................................................................................................... 4
1.1. INTRODUCTION ........................................................................................................................................................................................................... 4
1.2. SAFETY INFORMATION.............................................................................................................................................................................................. 4
1.3. ATEX CERTIFICATION.................................................................................................................................................................................................. 4
1.4. INSTALLATION AND OPERATIONAL INSTRUCTIONS..................................................................................................................................... 5
1.5. MODEL DIFFERENCES............................................................................................................................................................................................... 13
2. CONTROLS AND INDICATORS................................................................................................................................................................................ 13
3. FUNCTIONAL DESCRIPTION ................................................................................................................................................................................... 13
4. SCHEDULED MAINTENANCE.................................................................................................................................................................................. 13
4.1. MONTHLY SCHEDULED MAINTENANCE PROCEDURE................................................................................................................................. 14

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4.2. CLEANING THE MOTOR............................................................................................................................................................................................ 16
5. REMOVAL AND REPLACEMENT PROCEDURES ............................................................................................................................................... 16
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5.1. MOTOR PREPARATION FOR SHIPMENT.............................................................................................................................................................. 16
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5.2. DISASSEMBLY PROCEDURES.................................................................................................................................................................................. 19
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5.3. INSPECTION AND REPAIR PROCEDURES .......................................................................................................................................................... 25

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5.4. STEAM CLEANING....................................................................................................................................................................................................... 28
5.5. STATIC ELECTRICAL TESTING.................................................................................................................................................................................. 29
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5.6. ROTOR SUBASSEMBLY PROCEDURES................................................................................................................................................................ 30
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5.7. ROTOR INSTALLATION INTO THE STATOR FRAME ......................................................................................................................................... 35

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5.8. MOTOR BEARING CHECKS AFTER ASSEMBLY................................................................................................................................................. 37
5.9. FINAL ASSEMBLY OF ROTOR DRIVE END (DE) COMPONENTS ................................................................................................................ 39
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5.10. FINAL ASSEMBLY OF ROTOR CONNECTION END (CE) COMPONENTS.................................................................................................. 39
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5.11. ELECTRICAL RUNNING TESTS................................................................................................................................................................................ 39
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5.12. HUB INSTALLATION.................................................................................................................................................................................................... 40
6. SUMMARY DATA........................................................................................................................................................................................................... 44
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6.1. DRILL MOTOR DATA.................................................................................................................................................................................................... 44
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6.2. DRILL MOTOR COMPONENT IDENTIFICATION................................................................................................................................................ 46
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6.3. INSPECTION DATA....................................................................................................................................................................................................... 47
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6.4. SPECIAL TOOLS AND MATERIALS......................................................................................................................................................................... 47

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GE

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GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

1. GENERAL INFORMATION
1.1. INTRODUCTION
This publication provides basic instructions for inspection, maintenance, and overhaul procedures the drilling
motor model 5GEB22. Figure 1 represents the 5GEB22 motor with cooling blower and connection box. Figure
2 depicts the 5GEB22 grounding block and rotor lock for shipment. Also included in this publication are special
tools and materials required to perform the procedures.
For general drilling motor information, refer to Table 9 in section 6.1.2. Drill Motor General Data in this publication.
For drilling motor application data, refer to Table 8 in section 6.1.1. Drill Motor Application Data in this publication.
This publication has significant changes since the last release. Due to major changes, there are no revision bars.

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a
y Motor with Blower and Connection Box.
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Figure 1. 5GEB22 Drilling
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1.2. SAFETY INFORMATION ie t
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r othemustpotential
Safety precautions, which be observed when working on this equipment, appear throughout this publica-
P
tion. WARNINGS indicate for personal injury, and CAUTIONS indicate the potential for equipment
GE
damage.
1.3. ATEX CERTIFICATION
ATEX certification applies only to those motors with the increased safety nameplate shown in Figure 3 .
NOTE: In order to maintain ATEX approval, only GE Transportation original parts shall be used as replace-
ment parts.

Due to format changes, revision bars are not used.

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 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

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PFigure 2. 5GEB22 Drilling Motor Without Cooling Blower or Connection Box.
1.4. GEAND OPERATIONAL INSTRUCTIONS
INSTALLATION
WARNING: Installation shall be in accordance with the instruction as defined in EN 60079–14:2008 “Electrical
apparatus for explosive gas atmospheres, Part14. Electrical installation in hazardous areas (other than mines)".
Guard for couplings, belts, or chains should be installed as needed to protect against accidental contact with
moving parts. Machines accessible to the public should be further guarded by screens, guard rails, etc., to
prevent the public from coming in contact with the equipment. Failure to observe these precautions may result
in injury or death.
1. This machine is suitable for operation in typical oil well drilling industry rig environments including offshore
platforms and mobile drilling units. Use the motor in the correct ATEX category only as indicated in Figure
3 . For other types of applications and environments, please contact your GE representative to determine
suitability.

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GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

DRILLING MOTOR MODEL NO. – 5GEB22

SERIAL NO.
COOLING–3000 SCFM AIR SUPPLIED
BY BLOWER UNIT
CLOSED COOLING SYSTEM, IP56, TO MAINTAIN MAX.
INTERNAL AIR TEMPERATURE OF 45 C

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RATINGS S9 CONTINUOUS

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AMBIENT AIR MAX 45 C 45 C / 55 C
PHASE 3
AC VOLTS (L-L) 587
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AMPS AC 1380 1120 / 1048
RATER RPM 800

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SHAFT HP 1400 1150 / 1075

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MAX. FREQUENCY HERTZ 153

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MAX OPERATING RPM 3000

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CONSTANT HP 800–1800 RPM (600 VOLT L–LINE SUPPLY)

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WITH 600 VOLTS MAINTAINED ABOVE 820 RPM

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CONSTANT HP 800–2400 RPM (690 VOLT L–LINE SUPPLY)

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WITH 690 VOLTS MAINTAINED ABOVE 940 RPM
INSULATING CLASS

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CONNECTION WYE

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INGRESS PROTECTION IP44 / 6424 LBS (2914 Kg)

ar IP56 / 7124 LBS (3238 Kg)

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GE Figure 3. Safe Electrical Parameters for the 5GEB22 Motor.
E-50984

2. It is the end user’s responsibility to ensure that the motor with steel components including shaft, stator
frame, stator core, and rotor core, along with the blower and variable speed drive are installed in the correct
designated area and will not be subjected to existing (or foreseeable) aggressive destructive substances.
3. Periodic lubrication is not required on model 5GEB22 drilling motor between scheduled overhaul intervals
because the bearings are grease packed and permanently sealed. Motor bearings MUST be replaced after
25,000 hours of operation, which is 90% of calculated bearing life. All maintenance must be carried out in
accordance with:
a. EN 60079–17:2003— Electrical apparatus for explosive gas atmospheres, Part 17. Inspection and
maintenance of electrical installations in hazardous areas (other than mines).

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 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

b. IEC 60079–19:2006 — Electrical apparatus for explosive gas atmospheres, Part 19. Repair and over-
haul for apparatus used in explosive atmospheres (other than mines or explosive industry).
4. Safe electrical parameters are defined in Figure 3 and Figure 4 defines the safe environmental parameters
for the drilling motor model 5GEB22. The drilling motor may be operated in the presence of typical vibration
levels encountered on land and offshore rigs.

CERTIFIED Ex e II T3 (TAMB –40 C to +55 C)

IEC 60034–1

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SIRA 09ATEX3077X
Year of Construction

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1180

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Motor Model Number: 5GEB22

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Maximum Current: 1800 AMPS (RMS)

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Ratio Max./Nom. (IA / IN) Current: 1.36

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Safe Stall Time: 37 Seconds

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Temperature Protection Devices Must Be

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Set At 190 C (maximum)

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DO NOT OPEN WHEN ENERGIZED

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Figure 4. Safe Environmental Parameters for the 5GEB22 Motor.
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1.4.1. Drilling Motor Model 5GEB22 Operational Requirements

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The drilling motor requires:
1. G
The cableEfitted to the equipment must be capable of withstanding maximum temperatures of 230°F (110°C)
at the cable entry point. No PVC type insulation is permitted.
2. The equipment must be supplied continuously with at least 3000 Standard Cubic Feet per Minute (SCFM)
(84930 SLPM) of cooling air. The cooling arrangements must be suitable for the area in which it is installed.
When fitted to the equipment, the cooling arrangements must ensure that the equipment satisfies a degree
of protection of at least IP44.
3. RTDs supplied with the motor are to be connected to intrinsically safe circuits to meet compliance of the Ex
certification for operation in a hazardous environment. The protective device must be suitably certified as
compliant with the European Directive 94/9/EC as a Safety Related Device. These circuits are to be manually
reset only and will trip (stop) the motor at 190 °C (374 °F).

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GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

1.4.2. 5GEB22 Motor Equipped with Closed Loop Cooling System

When the motor is equipped with a closed loop cooling system, the cooling arrangement must ensure that the
equipment satisfies a degree of protection of at least IP56. The motor must be used in accordance with the
duties defined in this certificate, with the water cooler supplied with coolant in accordance with Table 2 .
TABLE 2. 5GEB22 CLOSED LOOP COOLING OPTIONS
Duty Minimum Water Flow Rate Max. Coolant Temp. (at cooler inlet)
S1 (continuous) 100 US gal/min (378.5 liters/min) 33.0 °C (91.4 °F)
S1 (continuous) 50 US gal/min (189.2 liters/min) 25.0 ºC (77 ºF)
S9 (Duty A) 100 US gal/min (378.5 liters/min) 33.0 °C (91.4 °F)
S9 (Duty A) 50 US gal/min (189.2 liters/min) 25.0 ºC (77 ºF)
S9 (Duty B) 100 US gal/min (378.5 liters/min)
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37.7 °C (99.86 °F)
S9 (Duty B) 88 US gal/min (333.1 liters/min) a
36.0º C (96.8 ºF)
S9 (Duty B) 50 US gal/min (189.2 liters/min) rm
28.0 ºC (82.4 ºF)
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TABLE 3. 5GEB22 DUTY CYCLES
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Duty Reference Specification
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120 seconds on at 800 rpm, 1400 HP, 9200 lb/ft torque, followed by 90 seconds on at 80
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rpm, no load. (S9 duty)
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B
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144 seconds on at 669 rpm, 1150 HP, 9025 lb/ft torque, followed by 116 seconds on at 80
rpm, no load. (S9 duty) d
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32 seconds on at 800 rpm, 1400 HP, 9200 ft/lb torque, followed by 30 seconds on at 800
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rpm, no load. (S9 duty)
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1.4.3.
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Drive Systems Used with the i5GEB22
The 5GEB22 motor shallo bepused with one of the drives indicated in Table 4 or as listed in the ATEX certification.
P
The drive outputs shallrbe limited to 1800 amps maximum.
GE

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 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

TABLE 4. DRIVE SYSTEM LIST.

MANUFACTURE MODEL
GE AC2000AW Variable Speed Drive
Cegelec Bauteil GD3000E AC Drive System
Unico Inc Type 2400 Series (Part #109341) with or without a smoothing inductor
Ross Hill Model 6000
National Oilwell Varco
Ross Hill Model ABB ACS800 manufactured by NOV
ABB ACS600 manufactured by ABB
ABB
ABB ACS800 manufactured by ABB
Compact AC Drive P1030 with or without a smoothing filter
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Compact AC Drive P1180 with or without a smoothingatfilter
Offshore & Marine ASA
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Compact AC Drive P1300 with or without a smoothing
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Compact AC Drive P1500 with or withoutI a smoothing filter
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M&I Type AC1350
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Type OIDM G5M-5C00 id
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Omron
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Type OIDM G5M-5900
Type 875TCX d
Stadt Automasjon
a n6G2N0-AFE (limited to 586 Amps)
Stadt/ABB
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Converter
t a Converter
Alstom e
ri 6SE7241-IFQ20-3AB0-Z PWM Inverter
MV3000

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GE
Siemens Sinamics S120 Bluedrive
6SE704 1-**** (see Figure 5 below)

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GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

SIEMENS DRIVE IDENTIFICATION 6SE7041 - * * * *

RATED CURRENT INDICATOR:

0 = 1000A (M CHASSIS)
2 = 1200A (L OR M CHASSIS)
5 = 1500A (M CHASSIS)

DC LINK VOLTAGE INDICATOR:

V = 930V (690V LINE-LINE)
U = 780V (600V LINE-LINE)

CHASSIS INDICATOR: it on
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DIGIT 2 OR 6
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Figure 5. Siemens Drive Nomenclature.
1.4.4. Grounding Instructions C o
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Grounding motor frames is required to safeguard personnel from electric shock in the event of an insulation
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failure in the machine.
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WARNING: Failure to properly groundeelectrical equipment may expose personnel to a potentially hazardous
condition in which serious or fatalrinjury from electrical shock is possible.
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Grounding conductorsP rmust be provided between the machine frame and the supporting structure to avoid
G
may be standing
E
hazardous potential voltage
while
difference between the machine frame and the adjacent surface on which a person
touching the machine
NOTE: This type of ground connection is referred to in electrical standards as “equipment ground" or “en-
closure ground" which is not to be confused with “system" or “circuit" grounding. Drilling drive systems
normally do not have an intentional circuit ground connections, except through high impedance detectors.
Grounding conductors must be provided on drilling units on which the construction on the unit and/or instal-
lation of the machines does not inherently ensure positive grounding of the equipment. Examples are those
portable (modular) platform rigs and land rigs which do not already have ground cables to all machinery struc-
tures. Offshore rigs with equipment fastened to the decks by bolting or welding should not require additional
grounding. Reference ABS Rules for Building and Classing Steel Vessels, section 4−8−4/23.3 and IEEE Standard
45−2002, Recommended Practice for Electrical Installations on Shipboard, section 21.4.

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 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

1.4.5. Grounding Procedures

The 5GEB22 has a ground block attached to the frame as shown in Figure 2 . The mounting stud is 3/8–16 thread.
To attach a ground cable to the ground block:
1. Obtain a 3/8–16 nut and a lockwasher. Also required is a cable lug to fit the ground cable and terminal hole
clearance for the 0.375 diameter stud.
2. Prepare a ground conductor (use appropriate size cable per National Electrical Code) long enough to run
from the motor frame to an existing ground conductor system or to a suitable equipment ground point as
defined by the National Electrical Code Article 250 or other applicable regulation. Check that the system
ground detector is also connected to the Common ground point for the rig and make connection if neces-
sary.
3. Install terminal lugs on cable. Remove paint, rust and oil from all surfaces to which the cables are to be

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attached and bolt the lugs securely to these surfaces. Torque the nut to 25 lb-ft (34 Nm).
t by applying a rust
4. After installation, protect the ground stud, nut, and cable lug connection fromacorrosion
inhibitor on the exposed components.
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1.4.6. Motor Coupling and Alignment
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excessive vibration and damaging forces on shaft and bearings. nti
CAUTION: Be sure to align, or check alignment carefully on either motors a MG sets. Misalignment can cause
or

Time taken to assure good alignment will be returned finid

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reduced downtime.
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1.4.6.1. Coupled Drives
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On coupled drives, when a motor and a driven
be used to facilitate alignment. Three−bearing
together have four or more bearings, flexible couplings should
requires a rigid coupling.
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r when using either solid (rigid) or flexible couplings, is essential to
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t or shaft failures.
CAUTION: Careful alignment of machines,
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prevent excessive vibration, hot ibearings,
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p
used between motorP roshaft and
Couplings must be properly sized to be capable of driving maximum machine torque. Interference fits should be
coupling.
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1.4.6.2. V-Belt Drives
On V−belt drives, the driving and driven shafts should be located so that they are parallel and the sheaves aligned.
If properly aligned, there is minimum wear on the belts and no excessive thrust on the machine bearings. The
sheave should be mounted as close as possible to the motor bearings. The following recommendations should
be followed concerning the minimum sheave pitch diameter which can be used for the particular motor. The
belt manufacturer should be consulted for the maximum speed ratio and belt for the particular application.
The following formula and data can be used to select the MINIMUM allowable sheave diameter from the stand-
point of bearing life and shaft stress. A larger sheave will further reduce the shaft stress and bearing loading.
This data is based upon the belts being tightened to a maximum total pull of 1.5 times the required transmission
load used in the sheave diameter calculation. Belts should never be tightened more than necessary to transmit
this torque.
D = HP/RPM X 189000/W

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GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

Where D = Minimum sheave pitch diameter in inches for V-belt application.

HP/RPM = Maximum ratio of horsepower, including overloads, to the speed which that power occurs.
W = Maximum allowable radial load.
Belt−driven machines may be equipped with sliding rails. Proper and constant belt tension is easily maintained
and the replacement of belts is simplified. This reduces the operating cost and increases the efficiency. Sliding
rails are to be used for floor mounting only.
Belt idlers reduce the life of the belts and should not be used if any other method is available. The belts should
never be forced over the sheaves. When the drive is started and operating at full speed and full load, the take−up
should be adjusted until only a slight bow appears in the slack side. If slippage occurs after the belt tension has
been correctly adjusted, the belts and pulleys have not been chosen properly for the job.

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CAUTION: Over−tightening to avoid this slippage may result in early failures of belts, shafts, and bearings.

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Belt tension should be checked and adjusted following the belt manufacturer’s recommendations.
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There is normally a drop in tension during the first 24 to 48 hours of operation.orDuring this "run in" period, the
nfBelt tension should be rechecked
belts seat themselves in the sheave grooves and initial stretch is removed.
after a day or two of operation. l I
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t life results if the belts and sheaves are kept
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Matched belts run smoother, look better, and last longer. Longer belt
e guards or other obstructions.
clean and the belts are prevented from rubbing against the belt
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1.4.6.3. Grouting
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On concrete foundations, a minimum of one inch (25 C mm) should be allowed for grouting.
A rich, non−shrink grout should be used. a n grade grout mixtures are available commercially. If the grout
High−
r y ratio of 1:2 is recommended. Just enough water should be used
is to be prepared at the site, a cement−sand
a surface of the foundation should be wet and the grout rammed or
to give a stiff mixture. The clean, tbut rough
puddled under the base.
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1.4.6.4. Flexible Coupling Alignment
P supports before setting the base in position. Before grouting the base, the alignment
Level all mountingEbase
G as follows:
should be checked
1. Remove all coupling bolts and slide the shells back so the hub faces are exposed.
2. Check the coupling hub spacing is in accordance with the outline dimensions with the units in the mechan-
ical center of their end play.
3. Start with the coupling next to the largest unit (usually the motor) or near the middle of multiple units. Check
the radial alignment by using a straightedge across the two hubs at vertical and horizontal. Or, clamp a dial
indicator to one hub and use the outside diameter of the other member to give indication of the misalign-
ment. Be sure the dial indicator supports do not bend or sag, since this will give inaccurate readings. The
maximum variation should not exceed 0.002 inches (0.05 mm).
4. Insert a feeler gage or use the dial indicator at hub faces. Measure the gap between hub faces at 0, 90, 180
and 270 degrees and record. Rotate both shafts together 90 degrees and repeat the gap readings. Continue
rotation in 90 degree increments until five sets of readings are taken. The fifth set of readings is a check on

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 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

the first set of readings to assure that data is reliable. The readings should not vary by more than 0.002
inches (0.05 mm) between the four readings taken at each coupling position.
5. Correct the horizontal alignment by shifting frames on the base and the vertical alignment by shimming
between the machines and the base.
6. Repeat Steps 2, 3 and 4 on each coupling, working away from the motor or center unit.
7. Recheck the couplings on long sets after completing the above checks, because shimming when checking
subsequent units may affect those already checked. After the set has been aligned within the specified
limits, the coupling shells may be bolted together.
1.5. MODEL DIFFERENCES
TABLE 5. 5GEB22 MODEL DIFFERENCE INFORMATION

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5GEB22A1 Original design 5GEB22.
5GEB22A2
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Same as 5GEB22A1 except new rotor shaft material.
5GEB22A3 Same as 5GEB22A2 except new CE bearing.
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5GEB22A4
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Same as 5GEB22A2 except stator terminal alignment.
5GEB22A5 lI
Same as 5GEB22A3 except stator terminal alignment.
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5GEB22C1 t
Same as 5GEB22A2 except shaft lengthened and CE insulated bearing.
5GEB22D1
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Same as 5GEB22A3 except rotor shaft diameter increase.
5GEB22D2
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Same as 5GEB22D1 except without ABS shaft certification.
5GEB22D3
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Same as 5GEB22D1 except stator terminal alignment.
5GEB22D4
nd
Same as 5GEB22D2 except stator terminal alignment.

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2. CONTROLS AND INDICATORS r
a 5GEB22. Refer to drive system instruction publications for controls and indi-
t
Not Applicable to drill motoremodel
cators.
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3.
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FUNCTIONAL DESCRIPTION
The Model G E drilling motor is a force–ventilated, three–phase alternating–current induction motor de-
5GEB22
signed for use in the oil and gas industry to power offshore and land based drilling rigs. The normal function of
the horizontally mounted 5GEB22A motor is to provide power for the mud pumps and drawworks. The 5GEB22D
motor has an oversized shaft and is designed for belted horizontal applications such as mud pumps.
Motor speed is controlled by varying the frequency of the alternating current in the motor stator windings. The
direction of rotation of the motor rotor is changed by reversing the phase rotation in the motor stator.
The motor is force ventilated by a blower assembly, meeting IP44. It can also be provided with a closed loop
cooling system meeting IP56.
4. SCHEDULED MAINTENANCE
Periodic maintenance should be performed to ensure successful motor operation. The following procedures de-
tail the procedures for Scheduled Maintenance. The motor bearings do not require lubrication between overhaul
intervals due to packed grease and permanently sealed bearings.

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GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

NOTE: In order to maintain ATEX approval, only GE Transportation original parts shall be used as replace-
ment parts.
4.1. MONTHLY SCHEDULED MAINTENANCE PROCEDURE
4.1.1. Covers, Seals, and Latches
WARNING: Hazardous voltages are present in this equipment. Follow shutdown procedures to ensure power
is not applied to the machine before performing any maintenance procedures. Failure to do so may result in
injury or death.
1. Remove all power from the machine before attempting maintenance procedures.
2. Clean the outside of the machine and remove the inspection covers.

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WARNING: When using compressed air for cleaning purposes, flying debris and particles may present a hazard
to personnel in the immediate area. Personnel should be provided with, and trained in the use of, protective
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equipment as specified by applicable federal or state safety regulations. Failure to do so may result in injury or
death. rm
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3. Use clean, dry compressed air and blow the dirt and dust from the interior of the machine.

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4. Check exterior covers to ensure the felt seals are intact. Replace seals if missing, broken, deformed or hard-
en
ened.

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5. Install the covers into position on the machine. Torque the cover bolts to 58 ±2 lb.–ft. (79 ±2,7 Nm).
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4.1.2. Power Cable Inspection
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Inspect the power cables for: a n
During inspection of the power cables and associated hardware, replace any components that are damaged.

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1. Inspect the cable terminals for discoloration from heat, arc damage, cracks or fractures. Replace terminals
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and/or cable if damage is found.
2.
r op are tight and arcing is not present.
Ensure terminal connections
3. P for cracked, worn, cut, bubbled or burnt insulation. Replace the cable if damage is
Inspect cableEinsulation
found. G
4. Check cable connection bushings and mounting hardware (such as cable cleats). Replace damaged or miss-
ing hardware.
5. Check the ground cable connection to the motor frame. Ensure the connection is tight on the ground stud.
4.1.3. Megohmmeter Test
The insulation condition of the motor and cables can be determined by a megohmmeter test. When the high
voltage of the megohmmeter test instrument is applied to the power components of the motor circuit, a high
ohm reading indicates good insulation quality. Low ohm readings indicate insulation breakdown, moisture/de-
bris contamination, or carbon tracking. To test the power circuit insulation with a megohmmeter:
1. Ensure all the components in the power circuit are not affected by a megohmmeter test. Check the drive
system for megohmmeter test procedures or disconnect power cables from the drive system. If cables are

14
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

disconnected for the megohmmeter, make sure the cables are insulated from touching any surrounding
surfaces.
2. Connect a lead from the megohmmeter instrument to the motor TA lead.
3. Connect the second lead of the megohmmeter to a cleaned ground connection.
4. Apply a 500 volt megohmmeter test to the power circuit.
5. If the reading is above 2 megohms, the power circuit insulation is satisfactory and proceed to Step 7.
6. If the reading is below 2 megohms, the power circuit insulation is degraded or bad. Perform the following
procedures to attempt to raise the ohm reading:
a. Check the power cables for cracks, scuffed or open insulation. Repair or replace the cables if dam-
age is found.
it on
b. Water or dirt/debris contamination may be adversely affecting the ohm reading. Disconnect the
a
power cables from the motor and retest just the stator leads. If the reading is still below 2 megohms,
rm
the motor will have to be removed for cleaning or repair. Refer to 4.2. CLEANING THE MOTOR in this
publication for cleaning instructions.
nfo
7. Connect one lead of the megohmmeter to the motor lead TA.
ia lI
t
en
8. Connect the second lead of the megohmmeter to one of the RTD leads (red, white, or white).
9. Apply a 500V megohmmeter test to the circuit. f id
o n
d C
10. If the reading is greater than 2 megohms, proceed to Step 11. If the reading is less than 2 megohms, check
the RTD cable for cracked, scuffed, or open insulation. Repair or replace the cable if damage is found. If no
n
cable damage is found, then the RTD is defective and should not be used.
a
r y
11. Move the first lead of the megohmmeter from the motor TA lead to a cleaned motor frame ground while
t a
leaving the second lead of the megohmmeter connected to one of the RTD leads (red, white, or white).
r ie
op
12. Apply a 500V megohmmeter test to the circuit.

Pr
13. If the reading is greater than 2 megohms, proceed to Step 14. If the reading is less than 2 megohms, check
GE
the RTD cable for cracked, scuffed, or open insulation. Repair or replace the cable if damage is found. If no
cable damage is found, then the RTD is defective and should not be used.
14. Repeat Steps 7 through 13 until all the RTD cables have been checked against the stator motor leads and
the motor frame.
15. Remove the megohmmeter leads and return all components to operating condition.
4.1.4. Motor Mounting Hardware
Check the motor mounting bolts, nuts, and associated hardware. Ensure the hardware is not missing or loose.
Replace missing hardware and tighten loose bolts.

15
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

4.2. CLEANING THE MOTOR

Cleaning the motor is essential to long–term motor life. When the drilling motor is removed from its machinery,
accumulated dirt and oil buildup can be removed. The external motor surfaces can be cleaned by steam clean-
ing. The internal motor components should not be sprayed with a steam cleaner. To clean the motor:
1. Clean the motor only when the drilling motor is removed from its machinery and power is removed from the
motor.
WARNING: Personnel performing cleaning procedures must wear protective clothing, gloves and eye protec-
tion. Follow local practices and procedures for cleaning. Failure to do so may result in injury or death.

CAUTION: Alkali and chlorinated hydrocarbon cleaning solutions are not recommended for cleaning drill motors
due to the adverse affects on motor insulation. Use of these solutions may cause motor failure or reduced motor
life.
io n
CAUTION: Do not spray the internal components of the motor with a steam cleaner. Moisture
at contamination
may cause motor failure or reduced motor life.
r m
f ointerior motor components are
protected from spray during cleaning
l I n
2. Cover the motor air inlet and outlet with heavy plastic and tape. Ensure the

3. Steam clean the external surfaces of the motor. Do not directtthe ia spray at motor openings or the plastic
covers. Recommended cleaning solutions are: CHEMICAL e n INC., 809 or GE BETZ KLEEN SBC120.
METHODS,
f idfrom the motor.
n
4. When steam cleaning is complete, let excess fluid drain
o
5. Remove the plastic covers or protective coversCand tape from the motor.
n d
WARNING: When using compressed air for cleaning
y ashould
purposes, flying debris and particles may present a hazard
a r
to personnel in the immediate area. Personnel be provided with, and trained in the use of, protective
t
equipment as specified by applicable federal or state regulators. Failure to do so may result in injury or death.
6. Using compressed air, p rieout the interior of the motor to remove all dirt, dust and moisture. If necessary,
blow
romotor thoroughly.
apply heat to dry the
P
5. REMOVAL ANDEREPLACEMENT PROCEDURES
G
The following procedures outline the overhaul process. All procedures may not be required even though all are
described. Inspection of the components will determine the procedures necessary to return the motor to oper-
ation.
Do not order replacement parts from this publication. Refer to the PARTS CATALOG for the motor for the correct
replacement part number.
5.1. MOTOR PREPARATION FOR SHIPMENT
The drill motor must be prepared for shipment to prevent damage to components during shipping. The following
sections detail rotor locking procedures and packaging for shipment.

16
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

5.1.1. Rotor Locking for Shipment

The rotor must be locked in position prior to shipment to prevent damage to bearings and other components of
the motor. Figure 2 depicts the 5GEB22 rotor locking arrangement. To lock the rotor for shipment:
1. Remove two diametrically opposite bearing cap bolts and washers (Item 31, Figure 15 ). Place the removed
bearing cap bolts and washers into a bag that will be attached to the locking bolt.
2. Thread 0.625–11 x 4.54 in. lock bolts (with jam nuts threaded onto the bolts) into the bearing cap holes as
shown in Figure 6 . The lock bolt heads are painted yellow to distinguish the bolts as rotor locking bolts.
3. Torque the rotor locking bolts to 30 lb.–ft. (40,7 Nm). To secure the locking bolts into place, run the jam nuts
down to the bearing cap and tighten.
4. Secure the bag containing the two removed bearing cap bolts and washers to the rotor locking bolts as
shown in Figure 2 .
io n
5.
at going into service. To
After motor shipment, the rotor locking bolts must be removed prior to the motor
remove the rotor locking bolts:
r m
a. Back the jam nuts away from the bearing cap.
nfo
l I
b. Remove the bearing cap bolts from the attached bag
t ia the rotor locking bolts.
on
c. Thread the bearing cap bolts and washers intoethe n bearing cap holes.
f id
o
d. Torque the bearing cap bolts to 115 ±15 nlb.–ft. (156 ±20,3 Nm).
e. Place the removed rotor lockingd C
bolts and jam nuts into the bag and store for future motor ship-
ment.
a n
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t a
ri e
p
P ro
GE

Figure 6. Rotor Lock Bolts.

17
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

5.1.2. Motor Packaging for Shipment

After locking the rotor for shipment, the motor should be securely packaged to avoid damage during shipment.
To package the motor for shipment:
1. Prepare wood stock of sufficient length to skid the motor as shown in Figure 7 . The yellow pine wood stock
must be able to support the approximate 5700 lbs. (2585 kg) weight of the motor (not including the blower
and connection box).
2. Drill 1.62 in. (41,2 mm) clearance holes in the wood stock to fit the holes in the motor mounting feet (four
holes).
WARNING: The drill motor weighs approximately 5689 lbs. (2580 kg). Use appropriate lifting devices when lifting
the motor. Failure to do so may result in injury or death.

it on
3. To avoid damage to the motor during handling:
a. Do not lift the motor by the rotor shaft. a
rm
b. Do not allow the motor to impact another object when lifted.
n fo
I
c. Do not wrap the rotor with straps or banding for shipment.l Any securing straps or banding should
be wrapped around the motor frame. t ia
4. Lift the motor onto the wood frame and align the motordfoot e nholes with the wood frame holes.
n fi mounting feet and wood stock frame. Tighten the
bolt into position. C o
5. Install four 1.5–6 in. bolts and washers through the motor
d
6. Slush the machined surfaces with a rustninhibitor before enclosing the motor for shipment.
y a
5.1.3. Motor Storage
a r
The motor should be preparedie
t
p r for storage to prevent damage.
1. When preparing the
P romotor for storage:
GEin thisa platform
a. Construct
ment
to secure the motor as described in section 5.1.2. Motor Packaging for Ship-
publication.
b. Slush the exposed machined surfaces with a rust inhibitor.
c. Install wire leads to the anti−condensation heater that allow the heater leads to be connected to
an external power source.
d. Install cover and side panel to crate the motor.
e. Apply power to the anti−condensation heater while motor is stored.

18
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

ALLOW CONTAINER
CLEARANCE FROM
MOTOR ON BOTH ENDS

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a
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1.5-6 BOLTS, NUTS, AND

n
WASHERS, 4 PLACES

Co
APPROXIMATE WEIGHT OF MOTOR 5689 LBS (2580 KG)
E-50540

d
Figure 7. Shipment Preparation for the 5GEB22 Motor.
n
2.
y a
When removing the motor from storage:
a r
a. Disconnect powert from the anti−condensation heater.
r ie
opcrating material from the motor.
b. Remove the
r
E P the rust inhibitor from the machined surfaces.
c. Remove
G
d. Visually inspect the motor for excessive rust or other defects.
e. Megger the stator leads as described in section 4.1.3. Megohmmeter Test in this publication.
f. If the motor has been in extended storage, the grease in the bearing should be replaced. Follow the
overhaul instructions in the following sections to disassemble the motor for bearing access.
5.2. DISASSEMBLY PROCEDURES
5.2.1. Hub Removal
When removing a hub, use a suitable puller, similar to Part 41B535703G1, Figure 32 . This is a simple, efficient
hydraulic puller employing the float method of removal. A complete unit consists of a pump kit, a backing plate,
an adapter, a felt ring and a bolt.

19
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

NOTE: Do not heat the hub before pulling it, and do not use steel wedges between the hub and bearing cap.
1. Remove the set−screw plug from the tapped hole in the end of the shaft.
2. Screw the backing plate, with felt ring in place, to the end of the shaft as tight as possible by hand. Back off
the backing plate to line up the slot with the tapped hole in the end of the shaft. This is to provide sufficient
clearance for the hub to pop off.
3. Screw the pressure−fitting adapter into the hole in the shaft until it seats at the bottom.
4. Attach the pump by screwing the connector on one end of the pressure tube into the adapter, and the other
end into the pump.
5. Close the hand relief valve and work the pump handle to force oil into the groove in the armature shaft under
the hub. When sufficient pressure has been built up, the hub will pop off the shaft and be stopped by the
felt washer and backing plate.
io n
NOTE: Capacity of the pump is 40,000 psi (275800 kPa). It holds sufficient oil to remove
at oil.eight to ten hubs;
m
check at each use. Periodically, remove the filling plug and refill with SAE−10 lubricating
r
6. Open the relief valve, disconnect the pump from adapter, remove the adapter
nfo and backing plate from the
l I
shaft, and lift off the hub. Reinsert the plug to prevent clogging the hole.
5.2.2. Rotor Removal t ia
e n
To remove the rotor from the motor assembly:
f id
CAUTION: Special precautions should be taken to avoid o n to the rotor, bearings, or bearing fits when
damage
C to a horizontal position.
lifting the rotor in the vertical position or turning the rotor
d
NOTE: Numbers in parenthesis () refer toaitem n numbers in Figure 15 located in section 6.2. DRILL MOTOR
y
COMPONENT IDENTIFICATION of thisrpublication, unless otherwise noted.
t aposition.
rie
1. Place the motor in a horizontal
2. Remove the eight boltspand flat washers (31) securing the connection−end bearing housing to the connec-
P
tion−end frame head. ro Remove the connection−end bearing cap
3. Screw twoGlong E guide studs (.625–11 X 10) through the frame head and into the connection−end bearing
inner cap (35) in opposite holes of the six just emptied. These studs will help to guide the rotor out of the
motor frame.
4. Place the motor on a heavy−duty stand with the drive−end up. Level the motor so that the rotor can be lifted
vertically with a hoist without damaging the bearing or bus rings.
5. Remove the eight bolts (10) and flat washers holding the drive−end frame head to the motor frame.
6. Screw a 1 in.−8 steel lifting eyebolt into the threaded hole in the drive−end of the rotor shaft (5).
7. Align the hoist cable with the center line of the rotor and attach the hoist hook to the lifting eye.
NOTE: The connection−end bearing and housing and the drive−end frame head, bearing and housing are
removed with the rotor as an assembly.

20
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

CAUTION: Use extreme care when turning the rotor to the horizontal position to avoid damage to the core and
the bearing and frame head fits. Use two hoists when positioning the rotor horizontally.
8. Carefully lift the rotor assembly out of the motor stator and place the rotor in a horizontal position on a
wooden cradle supporting the core assembly.
9. With the rotor in the horizontal position, remove the two long guide studs (.625–11 X 10) from the connec-
tion−end bearing housing.
10. Remove and service the rotor bearings according to instruction in section 5.2.3. Connection End (CE) Bearing
Assembly Removal of this publication.
5.2.3. Connection End (CE) Bearing Assembly Removal
There are two Connection End (CE) bearing assemblies used for the 5GEB22 models. Models of the 5GEB22 man-
ufactured prior to October, 2001 use the original design CE bearing assembly as shown in Figure 8 . 5GEB22
it on
models manufactured after September, 2001 ( Figure 9 ) use an enhanced performance CE bearing assembly.
Refer to section 6.2. DRILL MOTOR COMPONENT IDENTIFICATION in this publication for details of differences in
a
the CE bearing designs. The following sections describe the CE bearing removal for both designs of CE bearings.
rm
Select the removal procedure appropriate for the bearing design on the drill motor.
nfo
lI
5.2.3.1. Connection End Bearing Assembly Removal Procedure for 5GEB22 Models Manufactured Prior to October,
2001
t ia
October, 2001. To remove the CE bearing assembly:
id en
The following procedure details the removal procedure for 5GEB22 drill motor models manufactured prior to
f
n in Figure 15 located in section 6.2. DRILL MOTOR
COMPONENT IDENTIFICATION of this publication,C o
NOTE: Numbers in parenthesis () refer to item numbers
unless otherwise noted.
n drotor bearing nut (33). Attach the spanner wrench (GE Tool 9945228)
a blow hammer, tap the wrench handle in a counter clockwise (CCW)
1. Remove the two set screws (40) from the
to the rotor bearing nut. Usingya dead
a r the spanner wrench, and remove the bearing nut from the rotor.
direction to loosen the nut. Remove
iet (GE Tool 41D736059G3), and use the hydraulic jack to pull the connection–end
2. Assemble the bearingrpuller
opand bearing (34) from the rotor shaft.
bearing housing (35)
r
P housing – with the bearing down – on a flat surface. Reassemble the bearing puller (to
3. Position the bearing
E
G
GE Tool 41D736059G4), and use the hydraulic jack to push the bearing from the bearing housing.

21
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

± ±

± ±

it on
a
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iden
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C o
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y a
ar
Figure 8. Connection End (CE) Bearing Assembly for Models Manufactured Prior to September 2001.
ie t
r
r op
P
GE

22
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

± ±

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±

n
±

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id en
n f
C o
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ar
Figure 9. Connection End (CE) Bearing Assembly for Models Manufactured After September 2001.
ie t
r
5.2.3.2. Connection End Bearing Assembly Removal Procedure for 5GEB22 Models Manufactured After September,
2001
r op
P
The following procedure details the removal procedure for 5GEB22 drill motor models manufactured after to
GE
September, 2001. To remove the CE bearing assembly:
NOTE: Numbers in parenthesis () refer to item numbers in Figure 15 located in section 6.2. DRILL MOTOR
COMPONENT IDENTIFICATION of this publication, unless otherwise noted.
1. Remove the four bearing clamp (41) retaining bolts and hardened washers (42).
2. Thread two bolts into the bearing clamp (41) jack out holes. Tighten the bolts alternately until the bearing
clamp (41) is free of the rotor shaft fit. Remove the bearing clamp and remove the jack out bolts from the
bearing clamp.
3. Assemble the bearing puller (GE Tool 41D736059G3), and use the hydraulic jack to pull the connection–end
bearing housing (35) and bearing (34) from the rotor shaft.
4. Position the bearing housing – with the bearing down – on a flat surface. Reassemble the bearing puller (to
GE Tool 41D736059G4), and use the hydraulic jack to push the bearing from the bearing housing.

23
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

5.2.4. Drive End Bearing Assembly Removal

The following procedures details the drive end (DE) bearing assembly ( Figure 10 ) removal. To remove the DE
bearing assembly:
NOTE: Numbers in parenthesis () refer to item numbers in Figure 15 located in section 6.2. DRILL MOTOR
COMPONENT IDENTIFICATION of this publication, unless otherwise noted.
1. Remove the eight bolts and the flat washers (8) from the outer bearing cap (7).
2. Support the weight of the DE frame head (11) with a hoist, taking care not to lift the rotor off its support.
Assemble the bearing puller and use the hydraulic jack to pull the frame head (11), roller bearing (3), and
inner bearing cap (12) from the rotor.
3. Use an arbor press and fixtures to separate the bearing assembly (3) from the DE frame head (11).

it on
4. Remove the inner shaft collar (1) only if damaged, if outside of inspection limits, or if the shaft must be re-
moved from the rotor. If necessary, use a puller to remove the sleeve.
a
5.2.5. Connection End Frame Head Removal rm
nfo
lI
Removal of the connection end frame head may be required to gain access to the bus rings and stator coil
ia
connections. To remove the CE frame head:
t
iden
NOTE: Numbers in parenthesis () refer to item numbers in Figure 15 located in section 6.2. DRILL MOTOR
COMPONENT IDENTIFICATION of this publication, unless otherwise noted.
f
nthe frame head (27) to the stator frame (21).
o
1. Remove the eight bolts and flat washers (28) holding
C holes of the CE frame head (27). Evenly tighten the jack
d
2. Thread three 1–8x3 jack out bolts into the threaded
n stator frame (21) fit.
a
out bolts until the frame head is free of the
y 220 lbs. (100 kg). Use appropriate lifting devices for this
r
a or death.
WARNING: The CE frame head weighs approximately
e t
ri
weith. Failure to do so may result in injury
3. Lift the frame head (27)pfrom the stator frame (21).
P ro
GE

24
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

±
±

it on
a
rm
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ia lI
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iden
n f
C o
n d
y a
ar
ie t
r
op
r Figure 10. 5GEB22 Drive End (DE) Bearing Assembly.
P
E REPAIR PROCEDURES
5.3. GAND
INSPECTION
5.3.1. Rotor Shaft Inspection
Check dimensions as shown in Figure 16 located in section 6.3.1. Rotor Shaft Inspection Data in this publication.
5.3.2. Stator Coils and Bus Rings Connection Inspection
Inspect the stator coils and bus rings as follows:
1. Examine the bus rings for damaged or loose connections.
2. Observe the condition of the coil insulation and varnish. Evidence of burned or charred insulation or varnish
may indicate an overheating condition from a defective connection or defective coils.

25
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

5.3.2.1. Repairing Stator Coils to Bus Ring Connection, Cleaning and Breaking the Connection
The connection of the stator coils to the bus ring can be repaired when the connection shows signs of overheat-
ing. The connections are exposed by cutting and stripping the insulation around the connection requiring the
use of a hammer, knife, chisel, screwdriver, pry bar, and slip joint pliers. To expose the connections for repair:
NOTE: Read this entire procedure first to become familiar with these steps.
1. Position the stator frame to obtain the best working position for the connections to be cleaned.
2. Remove any mounting hardware (bolts, nuts, insulating blocks, etc.) from the area of the brazed connection.
3. Use the knife, chisel, and hammer to cut the insulation. Cut the insulation down to the copper the full length
of the connection.

it on
4. After cutting the insulation the full length, pry the insulation away from the connection using the slip joint
pliers, pry bar, screwdriver, or knife.
a
5. Brazing tool heat can be used to soften the insulation for final cleaning. Alternately heat the insulation, and
scrape off all material until reaching bare copper. rm
nfo
lI
NOTE: Use the resistance brazing machine (GE Tool 41D780746–1 or equivalent) and tongs (GE Tool
ia
41D780746–11 or equivalent) to produce the heat necessary to separate the connection. Passing current
t
through the brazing tongs carbons and the metal to be separated produces heat.
nfree of dirt, oil and insulating material such as
6. The area of the joint to be disconnected must be clean d e
fi
and
varnish and tape.
n
o when using compressed air. Failure to do so
C
WARNING: Observe all government and shop safety regulations
d
may result in injury.
n
a that is to be opened. Keep an air supply nozzle on hand to cool
y
Ther air supply also is used to cool the surrounding area by dissipating heat
7. Position the brazing tong on the connection
parts after separation occurs. a
ir et
from the area being heated.
o pin pulses ONLY. This enables the heat to spread out gradually, providing a more
r
CAUTION: Power is to be applied
P area, and eliminating any intense hot spots that may damage the ring or coil
even heating of the connection
material.
G E
8. Apply power to the brazing tongs in pulses ONLY until the heat melts the brazing material in the joint, then
shut off the power.
9. Quickly remove the brazing tongs, and using the screwdriver or pry bar, spread the connection joints before
the solder cools and resolidifies.
10. When the bus ring and stator coil connections are separated, repair or replace damaged bus rings, straps,
or stator coil leads prior to brazing the connection together.
11. Before brazing together, ensure the material is clean, parts being brazed are flat against each other to pre-
vent voids.
5.3.2.2. Repairing Stator Coils to Bus Ring Connection, Brazing and Insulating
To braze and insulate the connection after repairs have been made:

26
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

NOTE: The brazing median can be used in strip form (GE Part 41A231281P46) or rod form (GE Part
41A330300P2). It is recommended that strips 0.010 in (0.25 mm) thick cut into squares or rectangles 0.06 in.
(1.6 mm) larger than the conductors, be used for the initial connection. Use the brazing rod to fill voids after
the initial connection. Use of this material eliminates the need for flux.
1. The connection area of the material to be brazed must be clean and free of dirt, oil, and insulating materials.
2. If necessary, bend the soft copper connecting straps to align the connection.
NOTE: When using brazing material in strip form, the strip should be sandwiched between the two pieces
being brazed, which must be flat along the entire length of the joint.
3. Insert a brazing strip between the two connecting straps being brazed.
4. Position the brazing tongs on the area to be brazed, and clamp in place.

it on
WARNING: Observe all government and shop safety regulations when using compressed air. Failure to do so
may result in injury. a
CAUTION: Power is to be applied in pulses ONLY. This enables the heat to spreado
m
outr gradually, providing a more
f
even heating of the connection area, and eliminating any intense hot spotsnthat may damage the ring or coil
material. l I
t iathe brazing solder flows freely. Using an air
5. Apply power to the brazing tongs in pulses ONLY, and heat n until
nozzle, blow air on the surrounding area while heatingeto dissipate heat from the area being brazed.
f id
NOTE: When brazing, silver solder in rod form will n
out or to fill voids. C o be required to fill areas where the strip may have dripped

d
n NOTairrelease
6. Remove power from the tongs, but do
y a
hold the connection. Blowing compressed
the tongs until the silver solder has cooled enough to
on the brazed area will speed the cooling.
r
ausing Micamat (part number 41A239176P215) and half lap insulating tape (part
7. Insulate the connection area
e t
i other appropriate insulation material specific to the connection area.
number 41A239176P15)
r or

r
8. Varnish applicationopover the new insulation is required either by P5D-EP25 VPI process or hand application.
P
5.3.3. Stator / RotorEReconditioning
G
The stator and rotor must be reconditioned during the overhaul procedures before being returned to service.
These process help ensure long operating life for the components.
The stator assembly should be treated by Vacuum Pressure Impregnation (VPI) with an approved varnish. VPI
will seal and secure the stator coils. VPI only after cleaning, inspection and testing of the stator assembly. The
VPI process is GE Process P5D–EP25.
The rotor assembly should be treated by a powder coating process. Powder coat the rotor after cleaning and
inspecting. The powder coat treating is GE Process P6C–EP45.
Due to changing technology, contact your local GE representative or Drill Product Service Center for current
instruction processes at time of overhaul. Drill product Service Center contact information as follows:

27
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

GE Transportation
Attention Drill Product Service
2901 East Lake Road
Erie, PA 16531
www.GEtransportation.com
5.4. STEAM CLEANING
5.4.1. Steam Cleaning Introduction
WARNING: Cleaning agents may be toxic and/or flammable. Cleaning agents can cause serous or fatal injury
if used without proper precautions. For safety; do not inhale fumes, use only in adequately ventilated areas,
it on
avoid contact of cleaning agents with the skin, do not expose cleaning agent to flame or sparks, and observe
cautions and warnings issued by the manufacture of the cleaning agent.
a
m
Care must be taken in the selection and strength of cleaning agents or detergents rused in conjunction with steam
cleaning. Typical cleaning agents pH (alkalinity) are alkaline and not chemically oneutral. Check the pH level with
facceptable
l n
a pH monitor or pH test paper strips to ensure of the cleaning solution is inIan range. If pH test paper
ia level.
is used, Table 6 depicts the pH test paper color and corresponding alkalinity
t
TABLE 6. CLEANING AGENT PH DATA. e n
f id Base−Alkaline
Acid Neutral
o n
5—6 7 8
d C 9 10 11
Orange Yellow Greenn Ivy—Green Blue Purple
a
y greasy mechanical equipment is cleaned should not be used to clean
r
a make up and high concentrations of cleaning agents in solution, utilizing
Cleaning processes in which heavy, dirty,
e t
electrical equipment. Due to chemical
ri processes on electrical equipment can have a significant impact on the life
the mechanical equipment cleaning
of the electrical insulation p
r o systems used in motors
P
E agent is available at Chem Methods, Inc., 12703 Trisket Road, Cleveland, OH 44111. Chem
A suggested cleaning agent for use in steam cleaning processes for electrical equipment is CM−809−S (or equiv-
G
alent). This cleaning
Methods, Inc. telephone number is (216) 476−8400. This cleaning agent is Potassium Phosphate based and does
not contain caustic materials or silicate.
The mixed steam cleaning solution should be heated to 158 °F to 194 °F (70 °C to 90 °C) and have a pH of 10.5
to 11.0. Approximately a 10% solution of the cleaning agent and heated water should achieve the pH level. The
10% solution should be used on the rotor and stator of the motor. If needed, a 50% solution of the cleaning
agent and heated water can be used on the motor frame externally. Do not allow the stronger solution to leak
internally to the motor.
To control the cleaning agent in solution, a steam cleaner with an adjustable soap (cleaning agent) valve should
be used.

28
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

To clean the motor:

1. Using the 50% solution, spray the external motor frame with the cleaning solution. Let the cleaning solution
soak the motor frame five to twenty minutes (depending on the contaminant) to penetrate the accumulated
contaminants.
2. If deposits of contaminants are too heavy to be steam cleaned off, manually scrap the debris off and steam
clean.
3. Rinse the cleaning solution off motor with steam and hot water.
4. Blow the motor frame dry with clean, dry compressed air.
5. After motor disassembly during the overhaul process, clean the internal motor components using a 10%
cleaning solution.
6. Rinse of the cleaning solution off with hot water heated to a minimum 194ºF (90ºC).
it on
a
rm
NOTE: The internal motor components must be thoroughly rinsed. Cleaning solutions may form a crystalline
compound if left on the motor components. The motor insulation systems may be affected by the crystalline
deposits which may shorten the insulation life.
nfo
ia lI
WARNING: When using compressed air, loosened debris may make the surrounding area dangerous for per-
t
en
sonnel. Ensure all personnel are clear and wear appropriate safety equipment. Follow all local regulations and
procedures for compressed air use. Failure to do may result in injury or death.
f id
o n
7. Using clean, dry compressed air, blow excess water off internal motor components.

d C
8. Bake the motor electrical parts in a ventilated oven at 257ºF to 320ºF (125ºC to 160ºC) for 8 to 12 hours.
a n
9. Allow parts to cool to room temperature and visually inspect for defects.
r y
t a
10. Perform the Megohmmeter and High−Potential tests described in section 5.5.1. Static Electrical Testing In-
ie
troduction of this publication.
r
o p does not meet specifications in tests, bake an additional two hours in the oven and
retest. P r
11. If the stator assembly

5.5. E
G TESTING
STATIC ELECTRICAL
5.5.1. Static Electrical Testing Introduction
Static electrical tests include a Megohmmeter test and High−Potential (Hi−Pot) test. Both tests check motor insu-
lation systems. Always perform the Megohmmeter test prior to the Hi−Pot test. High voltage used in the Hi−Pot
test may be destructive to insulation if water or debris is present. If the Megohmmeter test indicates moisture or
debris is present, clean the stator as described in section 5.4.1. Steam Cleaning Introduction of this publication.
Once the Megohmmeter test specification is met, proceed to the Hi−Pot test.
5.5.1.1. Megohmmeter Test
Perform the Megohmmeter test as described in section 4.1.3. Megohmmeter Test in this publication.

29
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

5.5.1.2. High–Potential (Hi–Pot) Test

WARNING: High−Potential (Hi−Pot) testing is performed with high voltage electrical power. Follow safety regu-
lations and local practices for high voltage testing. Failure to do so may result in injury or death.
Hi−Pot tests evaluate the insulation dielectric strength (ability to insulate) of the motor insulation systems. High
voltage is applied to each motor phase to test insulation to ground during the test. To perform the Hi−Pot test:
CAUTION: Always perform the Megohmmeter test before Hi−Pot test. Damage may occur to insulation during
Hi−Pot testing if moisture or debris is present in the coils of the stator. Failure to do so may result in permanent
damage to the stator windings requiring replacement of the stator.
1. Ground one lead of the RTD temperature sensor for sensor protection. Do not Hi−Pot the RTD during testing.

it on
2. Apply the specified high voltage at 60 Hz to each motor lead for one minute with the other lead of the Hi−Pot
connected to ground. There should not be any significant current (amperage) leakage to ground during
testing. The voltage applied should be:
a
rm
fo
a. New or recoiled stator − apply 3500 VAC rms.
b. Reconditioned stator − apply 2500 VAC rms.
lI n
t ia
en
c. In−service or used stator − apply 2250 VAC rms.

f id
3. If the stator windings show significant current leakage to ground, clean the stator as described in section
n
5.4.1. Steam Cleaning Introduction in this publication. After cleaning, retest the stator windings.
o
5.6. ROTOR SUBASSEMBLY PROCEDURES
d C
5.6.1. Rotor Balancing a n
r y
t a
Dynamic balance of the rotor assembly is required for smooth operation and low vibration. If not corrected, an
ie
out−of−balance rotor will lead to complete motor failure.
r
opto within 50 gram−in. at both ends of the rotor.
The rotor must be balanced
r
E P only to the location and method of attaching the balance weights. The set−up, fixtures
These instructions pertain
G in the balance machine, and the procedures required to obtain a balance within specified
to hold components
limits is dependent on the type of balance machine. Therefore, follow the operating procedures for the balance
machine used.
CAUTION: Use ONLY the specified welding rod. Use of other types may result in poor welds leading to motor
failure.
NOTE: Keep weld splatter out of the rotor core vent holes when welding balance weights to the end plate.
Attach the balance weights as needed by welding to the rotor end plates at a diameter of 13.75 in. (276,9 mm).
Use welding rod GE Spec. G50E37, BRONZE (AWS−E−Cu−Sn−C). Weld the balance weights using GE weld process
P8B−EP35.

30
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

5.6.2. Connection–End (CE) Frame Head Installation

NOTE: Numbers in parenthesis () refer to item numbers in Figure 15 located in section 6.2. DRILL MOTOR
COMPONENT IDENTIFICATION of this publication, unless otherwise noted.
WARNING: The CE frame head weighs approximately 220 lbs. (100 kg). Use appropriate lifting devices for this
weith. Failure to do so may result in injury or death.
To assemble the connection–end frame head (27), align the frame head on the motor frame. Install and
hand–tighten the eight bolts and hardened flat washers (28) holding the frame head (27) to the motor frame
(21). Then torque the bolts evenly in a diametrically opposite sequence to 468 ±28 lb–ft (634 ±38 Nm).
5.6.3. Connection−End (CE) Bearing Assembly
To assemble the CE bearing onto the 5GEB22 rotor:
it on
NOTE: Numbers in parenthesis () refer to item numbers in Figure 15 located in section 6.2. DRILL MOTOR
COMPONENT IDENTIFICATION of this publication, unless otherwise noted. a
m
r area dangerous for per-
WARNING: When using compressed air, loosened debris may make the surrounding
f o
sonnel. Ensure all personnel are clear and wear appropriate safety equipment.
procedures for compressed air use. Failure to do may result in injury orldeath. In Follow all local regulations and
t ia
e
1. Using clean, dry, compressed air, blow debris from CE bearing n mounting area on the rotor shaft (5).
f id parts are clean and free of damage or burrs.
2. Inspect all CE bearing assembly components to ensure
o n
3. The rotor assembly must be in the horizontal
the assembly procedure. d C position and blocked to prevent rotation or movement during
n
4. If removed, install the rotor lockingacollar (36). To install the collar:
r y
t a collar (36) to 212°F (100°C) in an oven.
e
a. Heat the rotor locking
ri
WARNING: Components heatpin ovens may be hot enough to cause injury. Use appropriate safety equipment
P rofor handling heated components. Failure to do so may result in injury.
and follow shop procedures
E
b. GRemove the locking collar (36) from the oven and place onto the rotor shaft. Press the collar into
position against the shoulder of the rotor shaft (5).
c. Secure the collar into position until it cools.
5. Fill the cavity of the CE inner bearing cap (35) with 2.2 oz. (62.4 g) of GE specification D6A2C10 grease.
6. Pack the CE bearing (34) with 5 oz. (142 g) of GE specification D6A2C10 grease.
7. Evenly heat the CE inner bearing cap (35) to 212°F (100°C) in an oven to expand the cap’s bearing fit for the
CE bearing (34). Remove the inner bearing cap (35) from the oven and place onto a flat surface. Press the
CE bearing (34) (rotor side of the bearing as shown in Figure 15 ) into the inner bearing cap (35) bearing fit.
8. Cover or coat the CE rotor shaft (5) running surfaces with 0.25 oz. (7 g) of GE specification D6A2C10 grease.

31
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

9. Heat the CE inner bearing cap, with the CE bearing, to 212°F (100°C) in an oven. Remove the heated assembly
from the oven and immediately slide the assembly onto the CE end of the rotor shaft. Press the assembly
tightly against the shaft shoulder. Secure the assembly in position until cool.
10. Securing the CE bearing assembly on the rotor shaft (5) depends on the 5GEB22 model. Select the appro-
priate process for the 5GEB22 model.
a. For 5GEB22 models manufactured prior to September, 2001, the CE bearing assembly is secured
on the rotor shaft with a bearing retaining nut (33). Refer to Figure 8 for grease application during
assembly process. To secure the bearing assembly on the rotor shaft, thread the nut into the tapped
end of the rotor shaft until hand tight. Insert a spanner wrench (tool number 9945228) into the
holes on the outside flat of the bearing nut. Using a brass sledgehammer, strike two or three sharp
blows, driving the nut clockwise, approximately one quarter turn from hand tightened. Thread the
two locking set screws (40) into the bearing retaining nut (33) and torque the set screws to 40 ±2

it on
lb—ft (54 ±3 Nm). Using a heavy center punch, stake or peen each set screw in two places to prevent
loosing.
a
rm
b. For 5GEB22 models manufactured after September, 2001, the CE bearing assembly is secured on
fo
the rotor shaft with a bearing clamp (41). Refer to Figure 9 for grease applications during assembly

lI n
process. To secure the bearing assembly on the rotor shaft, Inspect the rotor shaft bore (5) and
clamp (41) to ensure the components are free of damage and burrs. Lightly coat the rotor shaft
t ia
bore with GE specification D6A2C10 grease to facilitate assembly. Insert the bearing clamp into the
en
rotor shaft bore. Thread the clamp bolts (42) through the clamp into the tapped holes of the rotor

f id
shaft. Tighten the clamp bolts alternately to evenly to draw the clamp into the rotor shaft bore.
When the clamp is fully seated in the rotor shaft, torque the clamp bolts to 58 ±2 lb—ft (78 ±3 Nm).
o n
d C
11. Apply the gasket and assemble the dummy CE bearing cap 41C689896 ( Figure 36 ) with four bearing cap
bolts and hardened washers (31). Thread the bolts through the dummy bearing cap into the inner bearing
a
cap (35) to secure the bearing assembly. n
r y
5.6.4. Drive End (DE) Bearing Assembly
t a
r ie
NOTE: Numbers in parenthesis () refer to item numbers in Figure 15 located in section 6.2. DRILL MOTOR
op
COMPONENT IDENTIFICATION of this publication, unless otherwise noted.
r
P
To assemble the DE bearing:
GEcompressed air, loosened debris may make the surrounding area dangerous for per-
WARNING: When using
sonnel. Ensure all personnel are clear and wear appropriate safety equipment. Follow all local regulations and
procedures for compressed air use. Failure to do may result in injury or death.
1. Using clean, dry compressed air, blow any loose debris clear of the DE rotor shaft (5).
2. Inspect the DE bearing assembly and rotor shaft to ensure parts are free of damage and burrs.
3. The rotor should be in the horizontal position and blocked to prevent movement and rotation.
WARNING: Components heated in ovens may be hot enough to cause injury. Use appropriate safety equipment
and follow shop procedures for handling heated components. Failure to do so may result in injury.
4. If removed, install the inboard DE shaft collar (1) onto the rotor shaft (5). to install the rotor shaft:

32
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

a. Heat the shaft collar (1) to 212°F (100°C) in an oven.

b. With the rotor in a horizontal position, remove the collar from the oven and press onto the rotor
shaft (5) drive end until seated against the rotor shaft shoulder. Secure the collar in place until cool.
c. After the collar has cooled, coat the rotor shaft collar’s running surfaces with GE specification
D6A2C10 grease as shown in Figure 10 .
d. Pack approximately 8 oz. (227 g) with GE specification D6A2C10 grease into the DE inner bearing
cap (12) as shown in Figure 10 . Coat the inner bearing cap running surfaces with the same grease.
5. Place the inner bearing cap in position over the DE shaft collar (1).
6. Install the flinger (2) onto the rotor shaft drive end. To install the flinger:
a. Heat the flinger to 212°F (100°C) in an oven.
io n
b. Ensure the inner bearing cap (12) is in position on the rotor shaft driveaend.t
c. With the rotor in a horizontal position, remove the flinger fromothe rmoven and press onto the rotor
f (1). Secure the flinger in position
shaft drive end until the flinger is seated against the shaftncollar
until cool. l I
i a
t specification D6A2C10 grease.
d. When the flinger has cooled, coat the flinger withnGE
7. ide(5) drive end. To install the bearing inner race:
Install the DE bearing (3) inner race onto the rotor fshaft
o n
a. Heat the inner race to 212°F (100°C) C in an oven.
d remove the inner race from the oven and press onto the rotor
a
b. With the rotor in a horizontal nposition,
shaft drive end until theyinner race is seated against the flinger (2). Secure the inner race in position
a r
until cool.
ie t
p
c. When the innerr race has cooled, coat the race with GE specification D6A2C10 grease.
8. P ro(rollers and outer race) with 16 oz. (454 g) with GE specification D6A2C10 grease as shown
Fill the DE bearing
in Figure E10 .
G
9. Assemble the DE frame head (11), the DE inner bearing cap (12), and DE bearing (3) (outer race and rollers)
together. To assembly these components:
a. Cold press the DE bearing (3) (outer race and rollers) into the DE frame head (11). Refer to Figure 10
for approximate position of the bearing in the frame head.
b. Install the DE bearing pilot tool (8849499P7), Figure 37 , on the rotor shaft as shown in Figure 11 .
NOTE: Without the use of a rotor drive–end bearing pilot, the upper–most rollers will drop toward the center,
making the assembly of rollers over the inner race difficult. Refer section 6.4. SPECIAL TOOLS AND MATERI-
ALS in this publication for the bearing pilot, guide stud and dummy bearing cap part numbers.
c. Thread a guide stud (.625–11 X 10) in the inner bear cap (12) as shown in Figure 11 .

33
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

d. Align the inner bearing cap gasket (9) over the guide stud onto the inner bearing cap (12) as shown
in Figure 10 .
WARNING: The DE frame head weighs approximately 75 lbs. (34 kg). use appropriate lifting devices for this
weight. Failure to do so may result in injury.

e. Lift the DE frame head (11) with a hoist, align on the guide stud, and install onto the rotor shaft over
the DE bearing as shown in Figure 12 . The DE frame head should remain supported by the hoist
until the inner bearing cap (12), the DE frame head (11), and the outer dummy bearing cap (7) are
bolted together.
f. Remove the DE bearing pilot tool (8849499P7) from the rotor shaft.
g. Install and align the outer gasket (9) over the guide stud onto the DE frame head.

it on
h. Align the dummy bear cap, Figure 38 , (6796493P3, used for assembly purposes) on the guide stud
and position against the DE frame head (11).
a
m
r the lastcapbearing
f o
i. Thread four bearing cap bolts with washers (8) through the dummy bearing and DE frame head
position. Tighten the bolts to secure the assembly together. In
(11) into the inner bearing cap (12). Remove the guide stud and thread cap bolt into

it al until the rotor is installed in the

stator frame. e n
NOTE: Do not assemble the remaining DE bearing assembly components

f id
o n
d C
a n
r y
GUIDE STUD FOR
t a
ASSEMBLING FRAMEHEAD

ri
BOLTS IN INNER BEARING CAPe
p
P ro
GE
BEARING PILOT USED
TO GUIDE FRAMEHEAD
(WITH OUTER RACE AND
ROLLERS) OVER THE INNER RACE.
E-50559

Figure 11. DE Bearing pilot and Guide Studs Installed.

34
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

BEARING PLOT

GUIDE STUD

it on
a
rm
nfo
lI
E-50560

ia
Figure 12. DE Frame Head Installed Over DE Bearing on Rotor Shaft.
t
5.7. ROTOR INSTALLATION INTO THE STATOR FRAME
id en
n f
NOTE: Numbers in parenthesis () refer to item numbers in Figure 15 located in section 6.2. DRILL MOTOR
o
COMPONENT IDENTIFICATION of this publication, unless otherwise noted.
C
The rotor assembly is installed by lowering dthe rotor into the vertical stator frame. The rotor assembly consists
n
of the CE bearing with inner bearing capa(35), the rotor shaft (5) and core (23), the DE frame head (11), and the DE
r
bearing assembly (3) with the DE dummy y bearing cap. To install the rotor assembly into the stator frame:
t abe mounted on the stator frame (21) prior to rotor installation. If the CE frame
1. The CE frame head (27) must
e
i the CE frame head as follows:
head is not installed, rinstall
p
o stator frame (21) CE frame head fit is free of damage and burrs.
a. Ensurerthe
E P
b. GEnsure the CE frame head (27) stator frame fit is free of damage and burrs.
c. Align the CE frame head (27) on the stator frame (21) so that the largest gap on the CE frame head
bearing cap mounting holes is toward the stator frame feet as shown in Figure 13 .
d. Thread the CE frame head eight mounting bolts and hardened flat washers (28) through the CE
frame head into the tapped holes of the stator frame (21).
e. Tighten the bolts to draw the CE frame head into the stator frame fit evenly.
f. When the CE frame head is fully seated against the stator frame, torque the mounting bolts to 468
±27 lb—ft (634 ±36 Nm).

35
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

it on
a
rm
nfo
ia lI
t
iden
n f
C o
n d
y a
ar
t
LARGEST BEARING CAP

ie
BOLT SPACE TO BE AT

r 6 O’CLOCK POSITION

op
WHEN FRAME HEAD (27)

r
IS ASSEMBLED TO FRAME (21)

P
GE Figure 13. CE Frame Head and CE Bearing Cap Alignment.
E-50831

2. Mount the stator frame in a heavy–duty stand with the Drive End (DE) up. Level the stator frame so that
the rotor can be lowered vertically into the frame with a hoist without damaging the bearings or bus rings.
Allow enough clearance for the guide studs on the rotor assembly to extend approximately 8 inches (203
mm) beyond the CE frame head (27)
3. Ensure the DE of the stator frame (21) is free of damage and burrs in the frame head fit.
4. Ensure the DE frame head (11), mounted on the rotor shaft, is free of damage and burrs.
5. Remove the CE outer dummy bearing cap from the end of the rotor shaft. The inboard CE gasket must
remain aligned on the inner bearing cap (35).

36
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

6. Thread two long guide studs (.625–11 X 10) into opposite holes of the inner bearing cap (35). Do not thread
the guide studs into the rotor locking ring (36). The studs must move freely to align with the CE frame head
(27) mounted on the stator frame (21).
7. Screw a 1 in.– 8 X 2.62 steel lifting eyebolt (GE Tool N672P39) into the threaded hole in the Drive End (DE) of
the rotor shaft.
WARNING: The partial rotor assembly weighs approximately 1887 lbs. (856 kg). Use appropriate lifting devices
for this weight. Failure to do so may result in injury or death.

CAUTION: Exercise extreme care when turning the rotor from the horizontal position to avoid damage to the
core and the bearing and frame head fits. A suitable turning fixture or two hoists should be used to position
the rotor vertically.

it on
8. Carefully lift the rotor assembly from the horizontal position, attaching a hoist hook to the lifting eye. Align
the hoist cable with the center line of the stator frame (21), and slowly lower the rotor into the motor frame,
a
guiding the long studs through the appropriate connection–end frame head (31) holes.
m
9. Install and hand–tighten the eight bolts and hardened flat washers (10) rholding the DE frame head (11) to
o fit then tighten the bolts evenly
the stator frame (21). If the DE frame head (11) does not seat into the fframe
l
in a diametrically opposite sequence until the DE frame head is mated n
I to the stator frame. Following the
same diametrically opposite sequence, torque the bolts to the
t ia of 472 ±24 lb—ft (640 ±32 Nm).
value
10. Rotate the motor to the rotor shaft horizontal position.en
f id head using the two guide studs protruding through
11. Align the dummy bearing cap, Figure 36 , on the CEn frame
the CE frame head. Thread two bearing capobolts and hardened washers (31) into the open holes of the
dummy bearing cap. Remove the two guideCstuds and thread two bearing cap bolts and hardened washers
n
(31) into the open holes. Torque the bolts d to 115 ±5 lb—ft (155 ±7 Nm).
5.8. MOTOR BEARING CHECKS AFTERrASSEMBLY ya
t a() refer to item numbers in Figure 15 located in section 6.2. DRILL MOTOR
e
ri of this publication, unless otherwise noted.
NOTE: Numbers in parenthesis
p
COMPONENT IDENTIFICATION
5.8.1. Connection End P roBearing Runout Check
(CE)
To check theGCEE bearing (34) runout:
1. Raise the CE end of the motor 4 to 6 in. (102 to 152 mm), and force the rotor toward the Drive End (DE).
2. Clamp a dial indicator on the face of the Connection End (CE) of the rotor shaft (5).
3. Zero the dial indicator reading on the face of the CE rotor bearing (34) outer race.
4. Rotate the rotor to determine the bearing runout.
a. If runout is within allowable limits for runout as shown in section 6.1.2. Drill Motor General Data in
this publication, proceed to the next bearing check procedure.
b. If runout is outside allowable limits, retighten the CE bearing cap bolts (31) and CE frame head bolts
(28). Repeat the runout check.

37
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

c. If runout remains excessive, disassemble the motor to check the CE frame head (27) bearing fit, and
the CE bearing housing (35) bearing fit, and inspect all parts for burrs, debris, or component wear
to determine cause of excessive bearing runout. Reassemble the motor and repeat runout check.
5.8.2. Drive End (DE) Bearing Runout Check
To check the DE bearing (3) runout:
1. Raise the DE end of the motor 4 to 6 in. (102 to 152 mm), and force the rotor toward the Connection End (CE).
2. Clamp a dial indicator on the face of the Drive End (DE) of the rotor shaft (5).
3. Zero the dial indicator reading on the face of the DE rotor bearing (3) outer race.
4. Rotate the rotor to determine the bearing runout.

it on
a. If runout is within allowable limits for runout as shown in section 6.1.2. Drill Motor General Data in
this publication, proceed to the next bearing check procedure.
a
rm
b. If runout is outside allowable limits, retighten the DE bearing cap bolts (8) and DE frame head bolts
(10). Repeat the runout check.
n fo
c. If runout remains excessive, disassemble the motor to checkl the I DE frame head (11) bearing fit, and
a for burrs, debris, or component wear
the DE inner bearing cap (12) bearing fit, and inspect alltiparts
e n
to determine cause of excessive bearing runout. Replace any worn components. Reassemble the
motor and repeat runout check.
f id
5.8.3. Drive End (DE) Bearing Radial Clearance Check on
To check the DE bearing (3) radial clearance: d
C
a n4 to 6 in. (102 to 152 mm), force the rotor toward the Connection
y
1. With Drive End (DE) of the motor raised
r
End (CE).
t a
r
2. Select a feeler gage thicknesse
i for the drive–end
equal to the minimum radial clearance given in section 6.1.2. Drill Motor Gen-
o p
eral Data of this publication rotor bearing.
P
3. Place the feeler gage r flat against the rolling surface of the inner race of the DE rotor bearing (3), just in front
E bearing roller. Hand–turn the rotor shaft just enough to roll the top bearing roller over the
minimum G
of the uppermost
radial clearance feeler gage.
4. Repeat the minimum clearance check for each bearing roller in the drive–end rotor bearing. Reject the bear-
ing if one or more bearing rollers will not roll over the minimum radial clearance feeler gage.
5. Select a feeler gage thickness equal to the maximum radial clearance given in section 6.1.2. Drill Motor
General Data of this publication for the drive–end rotor bearing. Place the feeler gage flat against the rolling
surface of the inner race of the drive–end rotor bearing. Hand–turn the rotor shaft to check that none of
the bearing rollers will roll over the maximum radial clearance feeler gage. Reject the bearing if one or more
bearing rollers will roll over the maximum radial clearance feeler gage.
5.8.4. Rotor Shaft End–Play Check
To check rotor shaft (5) end—play:
1. With the motor horizontal, force the rotor to seat at the Drive End (DE).

38
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

2. Clamp a dial indicator to the motor frame at the Connection End (CE) of the motor or the dummy CE bear-
ing cap. Zero the indicator ball on the face of the rotor bearing nut (33) for models manufactured prior to
September 2001 or the rotor bearing clamp (41) for models manufactured after September 2001.
3. Force the rotor back to seat at the Connection End (CE). The amount of rotor shaft end–play indicated must
not exceed the end–play given in section 6.1.2. Drill Motor General Data of this publication.
5.9. FINAL ASSEMBLY OF ROTOR DRIVE END (DE) COMPONENTS
If the rotor bearings pass the bearing runout and radial clearance checks, install the remaining DE component
parts as follows:
NOTE: Numbers in parenthesis () refer to item numbers in Figure 15 located in section 6.2. DRILL MOTOR
COMPONENT IDENTIFICATION of this publication, unless otherwise noted.
1. Remove the dummy DE bearing cap.
io n
2. Pack the DE outer bearing cap (7) with 8.0 oz. (227 g) of GE Specification D6A2C10tgrease. Ensure the gasket
a
(9) is in place between the bearing cap and frame head.
r m
3. Assemble the bearing cap (7) insert to the DE frame head (11) and innerfo bearing cap (12) with eight bolts and
hardened flat washers (8), and torque the bolts to 115 ±5 lb–ft (155In±7 Nm).
it athel sleeve:
4. Install the DE outer sleeve (4) onto the rotor shaft (5). To install
e n
f
a. Heat the DE outer sleeve (4) to 110°C (230°F)id oven.
in an
n
b. Remove the sleeve from the oven andopress it onto the DE rotor shaft until seated against the inner
race of the DE bearing (3).
d C
n
c. Secure the sleeve in placeauntil cool.
r y
5.10. t
FINAL ASSEMBLY OF ROTOR CONNECTIONa END (CE) COMPONENTS
r ie parts as follows:
p
Install the remaining CE component
o
NOTE: Numbers P r
in parenthesis () refer to item numbers in Figure 15 located in section 6.2. DRILL MOTOR
COMPONENTEIDENTIFICATION of this publication, unless otherwise noted.
G
1. Remove the dummy CE bearing cap.
2. Apply 2.8 oz. (79.4 g) of GE Specification D6A2C10 grease to the CE bearing cap (32).
3. Align the CE bearing cap (32) with the largest gap between holes toward the mounting feet as shown in
Figure 13 . Assemble the bearing cap (32) to the CE frame head (27) and inner bearing housing (35) with
eight bolts and hardened flat washers (31), and torque the bolts to 115 ±5 lb–ft (155 ±7 Nm).
5.11. ELECTRICAL RUNNING TESTS
After the motor has been reconditioned and reassembled, perform the following tests to ensure that the motor
will operate satisfactorily:
WARNING: Electrical tests are performed at high voltage. Electrical shock can cause serious or fatal injury.
Proper precautions should be taken and observed by personnel performing testing to avoid injury

39
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

NOTE: Numbers in parenthesis () refer to item numbers in Figure 15 located in section 6.2. DRILL MOTOR
COMPONENT IDENTIFICATION of this publication, unless otherwise noted.
1. Using stiff putty, secure thermometers to the Drive End (DE) (7) and Connection End (CE) (32) bearing caps.
The thermometers should be in physical contact with the bearing cap for a valid test.
2. Run the motor unloaded in the following sequence. Applied waveforms should be sinusoidal. The measured
temperature should not exceed 100°F (55°C) rise above room temperature during or at the end of the tests.
a. Run the motor for two minutes on 41 Hz 572 volts rms line−to−line. The average amperage of the
three phases should be between 368 and 453 rms amperes. Motor rpm should be approximately
820 during the test.
b. Run the motor for two minutes on 82 Hz 572 volts rms line−to−line. The average amperage of the

it on
three phases should be between 130 and 150 rms amperes. Motor rpm should be approximately
1640 during the test.
a
rm
c. Run the motor for forty minutes on 61 Hz 572 volts rms line−to−line. The average amperage of the
fo
three phases should be between 145 and 183 rms amperes. Motor rpm should be approximately
1220 during the test.
lI n
ia
3. Run motor overspeed test. Run the motor for two minutes on 155 Hz 540 volts rms line−to−line. Motor rpm
t
en
should be between 3080 and 3090. Observe for any unusual noise or vibration.

f id
4. Run motor vibration test. Run the motor on 150 Hz until the motor rpm is 3000. Measure vibration at the CE
n
and DE bearings. Vibration should not exceed 0.44 peak in/sec (11,2 peak mm/sec). If vibration is excessive,
o
C
rebalance the rotor or consult the GE Transportation Representative.
d
a n
5. Check for bearing noise. Run the motor on 60 Hz 572 volts rms line−to−line. Motor rpm should be approxi-
mately 1200. Check the DE bearing with a demodulation meter. The demodulation meter should not register
in excess of 1.49g. r y
a
tthe motor on 70 Hz 572 volts rms line−to−line. Motor rpm should be approxi-
6. ie
Check for bearing noise. Run
r bearing with a demodulation meter. The demodulation meter should not register
in excess of 1.49g. op
mately 1400. Check the CE

P r
7. E Test. Hi−Pot any stator terminal to ground at 3500 VAC rms 60 Hz for one minute. Ground
Perform Dielectric
one lead ofGthe RTD during the test.
5.12. HUB INSTALLATION
5.12.1. Hub Fitting
To prevent a hub from slipping, it should have at least 75 percent fit on the shaft; i.e., at least 75 percent of the
tapered bore of the hub should be in contact with the tapered fit on the shaft. Before mounting a hub, check
and correct the fit as follows:
1. Lightly cover the bore of the hub with a blueing compound such as Prussian Blue.
2. Snap the cold hub forcefully onto the shaft.
3. Mark the relative angular position of hub with respect to the shaft.

40
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

4. Remove the hub from the shaft. A convenient method of removal is by the use of two finely tapered steel
wedges (hardened and ground), which are carefully driven between the hub and the bearing outer sleeve
on the shaft.
5. IMPORTANT! Inspect the taper fit of the shaft; blueing of the hub bore should now show on the shaft. If at
least 75 percent of shaft surface shows traces of blueing, the fit is satisfactory. If, however, only a few spots
of blueing show on the shaft, the fit is not satisfactory.
6. Dress down the blue spots on the shaft very lightly with a fine emery cloth such as No. 400A Triemite.
7. Blue the hub bore again (refer to Step 1) and repeat Steps 2, 4, 5 and 6. Be sure to place the hub onto the
shaft in the same position as marked.
8. Generally, the fit will be improved, but the foregoing procedure may have to be repeated several times to
obtain a 75 percent fit.

it on
9. Under no circumstances use a lapping compound since lapping will produce a shoulder at the large end of
a
the tapered fit. A shoulder will prevent a perfect fit when the hub is mounted hot; i.e., when it is mounted in
the advanced position.
rm
nfo
10. After a good fit has been obtained, thoroughly clean the shaft and the hub bore to remove all blueing, oil or
grease. Then mount the hub.
ia lI
t
en
5.12.2. Hub Mounting

f id
1. Thoroughly clean the hub fit on the shaft and bore of the hub (refer to the procedure in section 4.2. CLEANING
n
THE MOTOR in this publication). Remove any scoring on the shaft or hub bore.
o
C
2. Spot the cold hub on the shaft by hand and check for at least 75 percent fit. Refer to section 5.12.1. Hub
d
n
Fitting in this publication. If necessary, dress the shaft to obtain this fit.
a
3.
r y shaft.
Trial mount the cold hub onto the Measure and record the position of the hub with respect to the end
t a
of the shaft. Take measurements with a micrometer advance gauge (similar to that shown in Figure 14 ).
Zero the gauge. Refer toeFigure 39 in section 6.4.3.6. Hub Installation Advance Gage in this publication for
p ri
advance gage information.

P ro
GE

41
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

ADVANCE GAGE

ROTOR HUB
SHAFT

it on
a
rm
nfo
ia lI
t
id en E-50962

n f
Figure 14. Using Advance Gage for Hub Installation.
C o
4. Mark points of measurement, and mark across the end of shaft and hub face so that the hub, when heated,
n d
can be mounted in exactly the same angular position, and so the advance measurement can be made from
the same point.
y a
ar
t
CAUTION: Zero settings of advance gauge must not be disturbed until all readings on the hub are completed.
ie
r
op
5. Mount the hub hot onto the shaft so as to secure an advance from the cold position to the hot position along

Pr
the axis of the shaft as indicated in this section. The ESTIMATED difference between shaft temperature and
hub temperature (temperature rise) that will provide this advance is also given. The temperature difference
GE
is only an estimate and should be adjusted (if necessary) to provide the advance within prescribed limits.
Refer to Table 7 .
CAUTION: The temperature of the hub must not exceed 250°C (482°F); otherwise the hub may become annealed.
NOTE: For rise or change in temperature from ambient (room or part), only compare the ratio of change
between Celsius and Fahrenheit. Every 5 degrees of change in Celsius, Fahrenheit change will be 9 degrees.
The opposite would be true for Fahrenheit to Celsius change comparison; every 9°F change represents 5°C
change. Do not add or subtract the offset (32 degrees).

42
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

TABLE 7. HUB RISE TEMPERATURE IN DEGREES ABOVE SHAFT TEMPERATURE

PART NUMBER OF HUB ADVANCE, INCH (MM) TEMPERATURE RISE
493A471 .120 — .130 (3.048 — 3.302) 387°F (215°C)
41A237799 .120 — .130 (3.048 — 3.302) 387°F (215°C)
84B519250P1 .110 — .120 (2.794 — 3.048) 387°F (215°C)

6. Heat the hub in an oven until it has reached a uniform temperature (the desired number of degrees above
shaft temperature). For example, if the shaft temperature is 77°F (25°C), the hub is heated to (ambient) 77°F
(25°C) + (heat rise) 387°F (215°C) = 464°F (240°C) hub temperature, which is maximum allowable hub tem-
perature.
7. Measure the temperature of the shaft and the hub with the same instrument. An accurate method must
be provided for measuring hub and shaft temperatures quickly before mounting the hub. This can best be
it on
done with a hand pyrometer. In using the pyrometer, place point of the gauge inside the bore of the hub to
obtain the fit temperature.
a
rm
8. Insure that the hub bore and the shaft taper are clean prior to assembling the heated hub to the rotor shaft.
fo
Then, using adequate hand protection, quickly mount the hot hub on the shaft in the same angular position
n
lI
as when cold. When the hub is nearly in engagement with the taper fit (not in actual contact), snap it forcibly
ia
into place with a quick push. It is important that the hot hub be instantly snapped into position before it has
t
cooled; otherwise, it will freeze to the shaft and cannot be adjusted further.
n The advance from cold to hot position along the
e
9. Check the hot or shrunk−on position of the hub on thedshaft.
i Check the actual advance with an indicator gauge,
n f
axis of the shaft must be held within the limits indicated.
located in the same relative position as used o to measure the cold position in Step 3 (as shown in Figure 14 ).
C
d remove the hub and repeat the assembly procedure.
10. If the advance is not within specified limits,
a n
r y
a
ir et
r op
E P
G

43
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

6. SUMMARY DATA
6.1. DRILL MOTOR DATA
6.1.1. Drill Motor Application Data
TABLE 8. 5GEB22 APPLICATION DATA
SPEED (RPM) TORQUE, LB-FT (NM) HORSE- VENTILATION IPH AMPS TIME
POWER (SCFM)
0 10600 (14372) 0 3000 1470 15 seconds
669 9025 (12236) 1150 3000 1270 144 seconds load,
116 seconds no load
800 7550 (10236) 1150 3000 1120 Continuous
800 9200 (12474) 1400 3000 1380 it on
120 seconds load,
a 90 seconds no load
800 9200 (12474) 1400 3000 rm
1380 32 seconds load,
nfo 30 seconds no load
1600 3773 (5116) 1150 3000
ia l I 1095 Continuous
1800 3351 (4543) 1150 3000t 1125 Continuous

id en
6.1.2. Drill Motor General Data
n f
C o
TABLE 9. 5GEB22 GENERAL DATA

n d
Weight, complete motor (less connection box and blower), lbs. (kg) 5693 (2582)
Weight, rotor only, lbs. (kg) y a 1623 (736)
ar
Maximum permissible speed, RPM
ie t 3000
r
Maximum permissible vibration, peak in/sec (mm/sec) 0.44 (0.01118)

r op
Stator field resistance each pair of terminals at 25 °C (77 °F), ohms 0.0088 — 0.0108
P
Stator field megger value (any terminal to ground) ≥ 2 Megohms
RTDs, ohms/material GE 100/platinum
Drive end (DE) bearing diametrical clearance range, assembled, in. (mm) 0.005 (0.127) — 0.009 (0.229)
Connection end (CE) bearing diametrical clearance range, assembled, in. (mm) 0.0005 (0.0127) — 0.0035 (0.089)
Rotor balance, each end, gram—inches 50
Runout measured from shaft to outer race, each end, in. (mm) 0.001 (0.0254)
Rotor drive end bearing grease lubrication capacity, ounce (gram) 32.5 (921.37)
Rotor connection end bearing grease lubrication capacity, ounce (gram) 10.25 (29.06)
Bearing lubricant (for additional information, refer to section 6.1.3. Drill Motor GE Spec D6A2C10
Lubricant D6A2C10 Data in this publication)

44
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

6.1.3. Drill Motor Lubricant D6A2C10 Data

D6A2C10 grease is a lithium soap base grease with added antioxidant. It contains an oil of heavy viscosity and
is especially suitable for high speed, high temperature open or shielded bearings in drilling motors. D6A2C10
grease specifications are listed in Table 10 .
TABLE 10. 5GEB22 LUBRICANT DATA
Worked Consistency, 77 °F (25 °C), MM/10 220 — 240
Dropping Point, Minimum Degrees °F (°C) 380 (193.14)
Mineral Oil Viscosity at 100 °F (,37.74 °C), SSU 475 — 525
Free Alkali, Percent (Max) 0.50
Free Acid, Percent (Max) 0.000
Color Amber
it on
Base (with Antioxidant) a
Lithium
Oxidation Resistance Time to Reach 20 psi Drop at 210 °F, Hr. (Min) rm
1000
Corrosion
nfo Must pass
Approved Vender
ia lI Shell Oil
t
en
Brand Name Cyprina RA

f id
o n
d C
a n
r y
t a
r ie
r op
P
GE

45
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

6.2. DRILL MOTOR COMPONENT IDENTIFICATION

19 17 24 25 26
27
13 14
15 21 23
12 16 17 18 19
20 22
28
11
10

9 29

30
8

ion
39
6

at
31

m
5 6

o r
f
32

l I n 33

t ia 35

en
4 3 2 1 18 38 36 34 40
37

id
5 42

n f
41

C o
d
VIEW OF PRODUCTION

a n
AFTER SEPTEMBER 2001
NOTE: ALL PARTS SAME EXCEPT THOSE SHOWN

REF. DESCRIPTION
ry REF. DESCRIPTION
1 D.E. SHAFT COLLAR
t a 22 STATOR CORE
2 FLINGER

r ie 23 ROTOR CORE

op
3 ROLLER BEARING 24 BUS RING SUPPORT
4 SLEEVE 25 TAP BLOCK
5
6
ROTOR SHAFT
PIPE PLUG
Pr 26
27
BUS RINGS
C. E. FRAME HEAD

GE
7 BEARING CAP (OUTER) 28 BOLT AND HARD WASHER
8 BOLT AND HARD WASHER 29 BUS RING CLAMPS
9 GASKET 30 BOLT AND INSULATING SLEEVE
10 BOLT AND HARD WASHER 31 BOLT AND HARD WASHER
11 D.E. FRAME HEAD 32 C. E. BEARING CAP
12 BEARING CAP (INNER) 33 BEARING RETAINING NUT
13 STATOR AIR BAFFLE 34 ROLLER BEARING
14 FELT (AIR DAM) 35 C. E. BEARING HOUSING
15 TIE RING 36 COLLAR (ROTOR LOCKING)
16 STATOR COIL 37 SHAFT NUT
17 ROTOR END RING 38 SHAFT WASHER
18 BALANCE WEIGHT 39 GASKET
19 ROTOR BAR 40 SET SCREW
20 ROTOR CAGE STOP RING 41 BEARING CLAMP
21 STATOR FRAME 42 BOLT AND HARD WASHER
E-50557

Figure 15. 5GEB22 Drill Motor Component Identification.

46
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

6.3. INSPECTION DATA

6.3.1. Rotor Shaft Inspection Data

it on
a
rm
nfo
ia lI
t
id en
f
Figure 16. Rotor Shaft Dimensional Checks.
n
6.4. SPECIAL TOOLS AND MATERIALS
C o
nd
The following section detail special tools and materials recommended for 5GEB22 overhaul.
y a
6.4.1. Standard Removal Tool Assemblies
a r
e t
ri 11 . The tool assemblies consists of various individual components that are detailed
The following tool assemblies listed in Table 11 are used to aid disassembling the 5GEB22. Tool assemblies de-
p
scriptive figures follow Table
o this.
r
in the section following
P
G E TABLE 11. TOOL ASSEMBLIES
TOOL ASSEMBLY DESCRIPTION FIGURE REFERENCE
6751547G1 CE BEARING INNER RACE REMOVAL TOOL Figure 17
6751547G4 DE OUTER SLEEVE REMOVAL TOOL ASSEMBLY Figure 18
6751547G5 DE BEARING INNER RACE REMOVAL TOOL ASSEMBLY Figure 19
6751547G6 DE INNER BEARING CAP REMOVAL TOOL ASSEMBLY Figure 20
6751547G7 DE INNER SLEEVE REMOVAL TOOL ASSEMBLY Figure 21
6751547GX CE INBOARD ROTOR LOCK SLEEVE REMOVAL TOOL ASSEMBLY Figure 22

47
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

it on
a
rm
nfo
ia lI
t
id en
n f
C o
n d
a
Figure 17. CE Bearing Inner Race Removal Tool 6751547G1.
y
ar
ie t
r
r op
P
GE

48
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

it on
a
rm
nfo
ia lI
t
iden
n f
C o
n d
a
y Sleeve Removal Tool Assembly 6751547G4.
Figure 18. DE Outer
ar
e t
p ri
Pro
GE

49
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

it on
a
rm
nfo
ia lI
t
iden
n f
C o
d
Figure 19. DE Bearing Inner Race Removal Tool Assembly 6751547G5.
n
y a
ar
ie t
r
r op
P
GE

50
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

it on
a
rm
nfo
ia lI
t
iden
n f
C o
Figure 20. DE Inner Bearing Cap Removal Tool Assembly 6751547G6.

n d
y a
ar
ie t
r
r op
P
GE

51
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

it on
a
rm
nfo
ia lI
t
id en
n f
C o
Figure 21. DE Inner Sleeve Removal Tool Assembly 6751547G7.
n d
y a
ar
ie t
r
r op
P
GE

Figure 22. CE Inboard Rotor Lock Sleeve Removal Tool Assembly 6751547GX.

52
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

6.4.2. Individual Components of Tool Assemblies

The following list of components in Table 12 are used to create the tool assemblies listed in the previous section.
Detail figures for significant individual components follow Table 12 in this section. Item numbers within the fig-
ures of tool assemblies identify individual components in Table 12 .
TABLE 12. TOOL ASSEMBLIES INDIVIDUAL COMPONENT LISTING.
ITEM PART NUMBER DESCRIPTION QUANTITY FIGURE REFERENCE
1 6733347G1 CLAMP PLATE 1 Figure 23
2 8806566P1 BOLT, 2-8X6.25 (SPECIAL) 1 Figure 24
3 8806567P1 PRESS CAP 1 Figure 25
4 6734764P2 CLAMP 2 Figure 26
5 6727124G1 RING 1
it on Figure 27
6 41A235078P1 STUD, .625-11X4.75 (GRADE 8) 4 a —
7 N203P33 NUT, .625-11 (GRADE 5) 4 rm —
8 6734765P2 CLAMP
nfo2 Figure 28
9 6727110G1 RING
ia lI 1 Figure 29
t
en
10 6733346P6 CLAMP 2 Figure 30
11 6717242P1
id
STUD, .4375-14X11 (GRADE 5)
f
4 —
12 8806337P1 n
STUD, .625-11X12.5 (GRADE 5)
o
4 —
13 6717243P1 C
STUD, .625-11X16.75 (GRADE 5)
d
4 —
14 N203P27B13
n
NUT, .4375-14 (GRADE 5)
a
4 —
15 UNASSIGNED
y
CLAMP PLATE
r
1 Figure 31
16 UNASSIGNED
t a
STUD, .5-13X8.75 (GRADE 5) 3 —
17 UNASSIGNED
r ie NUT, .5-13 (GRADE 5) 3 —

r op
P
GE

53
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

°
° °

°
°

it on
a

°
°

rm
nfo
ia lI
t
id en
°
n f
o
° ° °

d C
a n
r y
t a
r ie
op
°

Pr
GE °

Figure 23. Clamp Plate 6733347G1 (Item 1, Table 12).

54
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

°
°

it on
Figure 24. Bolt 8806566P1 (Item 2, Table 12).

a
rm
nfo
ia lI
t
id en
n f °

C o
n d
y a
ar
t
ie 25. Press Cap 8806567P1 (Item 3, Table 12).
r
rop Figure
P
GE

55
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

it on
a
rm
nfo
ia lI
t
°

id en
n f
C o
n d
y a
ar
ie t
r
r op
P
GE
°

Figure 26. Clamp 6734764P2 (Item 4, Table 12).

56
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

it on
a
rm
nfo
ia lI
t
id en
n f
C o
Figure 27. Ringd6727124G1 (Item 5, Table 12).
a n
r y
t a
rie
o p
Pr
GE

57
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

° °

it on
a
rm
nfo
ia lI
t
id en
n f
C o
n d
y a
ar
ie t
r
r op °

P
GE

Figure 28. Clamp 6734765P2 (Item 8, Table 12).

58
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

it on
a
rm
nfo
ia lI
t
id en
n f
C o
n d
Figure 29. Ring 6727110G1 (Item 9, Table 12).
y a
ar
iet
r
rop
P
GE

59
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

° °

it on
a
rm
nfo
ia lI
t
iden
n f
C o
d
an
°

r y
ie ta
r
r op
P Figure 30. Clamp 6733346P6 (Item 10, Table 12).
GE

60
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

it on
a
rm
nfo
ia lI
t
en
Figure 31. Clamp Plate (Item 15, Table 12).
6.4.3. Other Special Tools and Materials
f id
o n
6.4.3.1. DE Hub Removal Tool Assembly
d C
a n
The Table 13 describes the components that make up the 41B535703G1 Hub Removal Tool Assembly. The fig-
ures in this section depict the assembly and significant components.
r y
t a
TABLE 13. HUB REMOVAL TOOL 41B535703G1.
r ie
ITEM PART NUMBER p DESCRIPTION
o MANUAL HYDRAULIC PUMP (10000 PSI)
QUANTITY FIGURE REFERENCE
1 8843947P20
Pr 1 —

GE
2 8864170P1 HYDRAULIC FITTING ADAPTER 1 Figure 34
3 41B535119G1 BACKING PLATE 1 Figure 33
4 41A230939P14 FELT RING, 0.125 (THICK) X 3.9 (ID) X 5.5 (OD) 1 —
5 N22P39040 BOLT, 1-8 X 2.5 1 —

61
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

3 4
2
HUB

it on
5 ROTOR
SHAFT

a
rm
nfo
ia lI
t
id en
n f
o
41B535703G1 HUB REMOVAL TOOL ASSEMBLY

ITEM PART NUMBER

d C
DESCRIPTION QNTY

an
1 8843947P20 MANUAL HYDRAULIC PUMP 1
2 8864170P1 HYDRAULIC FITTING ADAPTER 1
3 41B535119G1
r y BACKING PLATE 1

ta
4 41A230939P14 FELT 1

ie
5 N22P39040 BOLT, 1-8X2.5 1

r
p 32. 41B535703G1 Hub Removal Tool Assembly.
E-50541

r oFigure
P
GE

62
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

1.00
(25.4)
1.0625 (26.9875) DIA THRU .40 (10.16)

1.75 (44.45)

3.85 (97.79) DIA

3.85 (97.79) DIA

it on
a
rm

1.60 (40.64)
nfo
ia lI
t
id en
n f
Co
CEMENT FELT RING HERE
WITH 497A806P12
.4375 (11.1125) DRILL
n d
a
THRU 2 HOLES

MAKE FROM B4C1B

r y
ie ta
250 FINSH ALL SURFACES
MEASUREMENT IN INCHES (MILLIMETERS IN PARENTHESES)

r
r op
P
GE Figure 33. Hub Removal Tool Backing Plate 41B535119G1.
E-50832

63
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

3.125
(79.375)

0.5625 0.875
0.625
(14.287) (22.225)
(15.875)
0.50 0.5625-18 UNF-2B
(12.7) 0.25 RAD 0.4375 BOTTOM TAP
(6.35) (11.1125)

30°

0.750
30° (19.05)
0.180 +/- 0.005 DIA

0.0625 CHAM

it on
0.375-24
(4.572 +/- 0.127)

UNF-2A (1.5875)
0.125 DRILL

0.2187 DIA
0.375 DIA

a
0.900 +/- 0.005 DIA
0.285 +/- 0.002 DIA

(31.75)

(9.525)

(5.555)
(22.86 +/- 0.127)
(7.239 +/- 0.0508)

rm
nfo
ia lI
t
MAKE FROM B5F4M STEEL

en
ALTERNATE MATERIAL B4C1A
125 FINISH ALL SURFACES

id
MEASUREMENTS IN INCHES (MILLIMETERS IN PARENTHESES)

n f
o
E-50542

C
Figure 34. 8864170P1 Hydraulic Fitting Adapter.
d
6.4.3.2. Bearing Nut Spanner Wrench
a n
r y
a
Bearing nut spanner wrench 9945258 ( Figure 35 )is used to remove and tighten the CE bearing nut.
t
r ie
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P
GE

64
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

1.105 + .005
0
(28.067 + .127) 45 PART 1 HANDLE
NITRIDE HARDEN
4.000 + .007 DIA RC 52-54
(101.600 + .1778) 3
0

BOLT CIRCLE 1 (25.4)

RAD

1.105 + .005
(28.067 + .127)
1.105 + .005
(28.067 + .127)

0
3
+ 1.5 (38.1) RAD

BLANCHARD GRIND
it on
1.105 + .005
(28.067 + .127)
17.0 (431.8)
20.75 (527.05)
a

.75 (19.05)
rm
PART 4 DRILL FOR .625 (15.875) REAMER, PART 1 & 2,
2 OPPOSITE HOLES, REAM ASSEMBLED

fo
BOLT
.53125 (13.4938) DRILL THRU, .8125 (20.6375), 2 OPPOSITE

lI n
HOLES, C’BORE HANDLE .8125 (20.6375), .1875 (4.7625) DEEP

.5-13 TAP THRU

t ia
en
2 OPPOSITE HOLES
PART 3 PIN

id
DRILL .5625 (14.287)
.8125 (20.6375) C’BORE,
1.0 (25.4)
BLANCHARD
GRIND

f
C’BORE .8125 (20.638) .5625 DEEP
.125 (3.175) DEEP, C’SINK

n
2 OPPOSITE HOLES
.031 (794), 2 OPP. HOLES

o
.75 (19.05) DIA
5.5 (139.7) DIA

d C .6255 +.000/-.001 DIA

(15.8877 +.0000/-.0254)

n
3.125 (79.375) DIA
.03125 RAD

a
BOLT CIRCLE
2.3125 (58.7375) DIA (.79375)

r y
THRU, PARTS 1 & 2 .6255 +.000/-.001 DIA
.1094
(2.7788)

a
(15.887 +.0000/-.0254)

ie t .0625 RAD

r
(1.5875)

op
.0312 (.7925) RAD

r
1.4375 (36.5125)
2.25 (57.15)

.625 (15.875)

PART 2 PLATE .46875 (11.90.63) DIA

P
NITRIDE HARDEN
RC 52-54

GE
PART 3 PIN
9945228 SPANNER WRENCH ROCKWELL ‘C’ 45-50
PIN ENLARGED FOR DETAIL
PART DESCRIPTION
1 HANDLE (4140)
2 PLATE (4140)
3 PIN (T.S)
4 SOCKET HEAD SCREW (.5-13X1.25)

MEASUREMENTS IN INCHES (MILLIMETERS IN PARENTHESES)

E-50833

Figure 35. Bearing Nut Spanner Wrench 9945228

65
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

6.4.3.3. CE Dummy Bearing Cap

1.125 (28.575)
.50 (12.70)
.180 +.000/-.010 .5625 (14.287) DRILL THRU
(4.572 +.000/-.254) 4 HOLES ON 9.5 (241.3) BC

it on
a
(200.4060 +.0254/-.0000)

(215.011 +.1016/-.0000)
7.890 +.001/-.000 DIA

8.465 +.004/-.000 DIA

rm
10.5 (266.7) DIA

nfo
ialI
t
iden
n f
C o
27
0

nd
y a
r
250 FINISH ALL SURFACES
MEASUREMENT IN INCHES (MILLIMETERS IN PARENTHESES)
t a
r ie
r op
P
GE E-50834

Figure 36. CE Dummy Bearing Cap 41C689896.

66
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

6.4.3.4. DE Bearing Guide

2.75
(69.85) 1.0 FLAT
(25.4)

.25 .375

it on
(6.35) (9.525)
.75

a
(19.05)

(146.2530 +.0254/-.0000)

(189.8400 +.0000/-.0254)
7.474 +.000/-.001 DIA
5.758 +.001/-.000 DIA
rm
fo
5.781 DIA
(158.750)

(146.837)

(152.400)
6.25 DIA

6.00 DIA
.5 RAD
lI n
ia
(12.70)

t
id en
n f
C o
n d
a 6 0

y
250 FINISH ALL SURFACES

r
BREAK ALL SHARP CORNERS WITH .062 (1.575) RAD

a
ie t
CARBURIZE, HARDEN, AND GRIND (G) SURFACES AS SHOWN
MEASUREMENT IN INCHES (MILLIMETERS IN PARENTHESES)

r
r op
P
GE E-50835

Figure 37. DE Bearing Guide.

67
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

6.4.3.5. DE Dummy Bearing Cap

3.0
(76.20)

.0625 (1.5875) RELIEF

.625-11 NUT
WELD

it on

12.5625 (319.0880) DIA

3.0 (76.20)
a

11.50 (292.10) DIA

14.75 (374.65) DIA
rm
nfo
ia lI
t
id en
n f
C o
n d .031 (.7874) CHAMFER
.140 (3.556)
.6875 (17.4625) DRILL THRU

y a 1.125 (28.575)

r
4 HOLES ON 13.5 (342.9) BC

t a
250 FINISH ALL SURFACES
r ie
op
MEASUREMENT IN INCHES (MILLIMETER IN PARENTHESES)

Pr
GE E-50836

Figure 38. DE Dummy Bearing Cap 6796493P3.

68
 GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

6.4.3.6. Hub Installation Advance Gage

it on
a
rm
nfo
ia lI
t
id en
n f
C o
nd
y a
ar
ie t
r
r op
P
GE E-50961

Figure 39. Hub Installation Advance Gage, GE 41D790941G1.

69
GEK-91696D
1150 HP AC Drilling Motor, Model 5GEB22

it on
a
rm
nfo
ialI
t
iden
n f
C o
nd
y a
ar
ie t
r
r op
P
GE

NEW 06–98, GAS

REV 09–98, MGC/DGK
REV 12–01, GMD
REV 10–02, GMD
REV 03–09, PAB

70
 PB-31107-008

GE Renewal Parts
--------------------------------------------------------------------------------------------------------------------------------
Use original equipment parts for reliability
PARTS BULLETIN

UNCONTROLLED COPY See On-Line Master for Current Revision

--------------------------------------------------------------------------------------------------------------------------------

AC MOTOR
MODEL 5GEB22A3

09-APR-2008

--------------------------------------------------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------------------------------------------------
© 2006 General Electric Company. All rights reserved. The information contained in this
publication is the property of General Electric Company and is disclosed in confidence. This
publication is intended for use by GE customers solely for purposes of operating and conducting
normal running maintenance of purchased or licensed GE products, and it shall not be reproduced,
redistributed, retransmitted, translated, abridged, adapted, condensed, revised or otherwise
modified, in any form, in whole or in part, or used for any other purpose, without the express written
consent of GE. However, if a GE customer (“Customer”) requires additional copies of this document
or portions thereof for internal use, GE hereby grants to Customer a limited right to reproduce this
publication, in whole or in part, and Customer agrees to use such authorized copies (“Copies”) solely
for its intended purposes. Any Copies made under this limited reproduction right shall contain this
notice and any other legal notices appearing in this publication. The Customer shall be responsible
for complying with U.S. export control laws with respect to distribution of all Copies.

GE and Customer agree that the information contained herein does not purport to cover all details
or variations in GE products or to provide for every possible contingency with installation, operation
or maintenance. Should further information be desired or should particular problems arise that are
not covered sufficiently for the user’s purposes, the matter should be referred to General Electric
Company. Any applicable Federal, State or local regulations or company safety or operating rules
must take precedence over any information or instructions given in the Technical Documentation.
GE has no obligation to keep the material up to date after the original publication.

GENERAL ELECTRIC COMPANY EXPLICITLY DISCLAIMS ALL WARRANTIES OF

ACCURACY, MERCHANTABILITY OR FITNESS FOR ANY PURPOSE IN CONNECTION
WITH THE TECHNICAL DOCUMENTATION AND USE THEREOF.
--------------------------------------------------------------------------------------------------------------------------------
 PB–31107–008
GE Proprietary and Confidential Information

2 34
4 9

42
43

15 22
14 6 7
8
17 3 10
18 13 12 23 30
19
21 11 38 24 31
36 32
16 37 33
38
39 35 20 41
29
40
27
28

25 26

Ref. 1
(Representative Illustration)
FIG. 1

-1-
 PB–31107–008
GE Proprietary and Confidential Information

47

47

TOP VIEW

47

44
45 46
SIDE VIEW

(Representative Illustration)
FIG. 2

-2-
 GE Proprietary and Confidential Information
UNCONTROLLED COPY PB-31107-008
AC MOTOR MODEL 5GEB22A3
See On-Line Master for Current Revision

--------------------------------------------------------------------------------------------------------------------------------
FIG. REF.
NO. NO. PART NO. QTY DESCRIPTION
--------------------------------------------------------------------------------------------------------------------------------
1 1 5GEB22A3 1 AC MOTOR (SEE PB-31107-008)
1 2 41E903972G4 1 STATOR ASSEMBLY
1 3 41E903972G5 1 STATOR ASSEMBLY REWIND KIT
1 4 84B512931P1 6 BUS RING SUPPORT POST, 8 1/2 IN LONG
1 6 84A205426P1 6 CLAMP BAR, 3/4 IN WIDE, 2 1/4 IN LONG
1 7 N22P21072B13 12 BOLT, HEX HD, 1/4 IN-20, 4 1/2 IN LONG
1 8 N405P41B13 12 LOCKWASHER, 1/4 IN
1 9 84A205424P1 6 TAP BLOCK, 3/4 IN WIDE, 2 1/4 IN LONG
1 10 497A806P83 AR CEMENT
1 11 6744700P2 1 BEARING CAP, INNER
1 12 4713640P1 1 FLINGER, 8 1/4 IN OD
1 13 8864951P167 1 ROLLER BEARING
1 14 4732906P1 2 GASKET, 0.021 IN THICK, 15 IN OD
1 15 41C637314P1 1 FRAME HEAD
1 16 84B512960P1 1 BEARING CAP
1 17 41B537660P9 8 WASHER, FLAT, 0.725 IN ID, 1 IN OD
1 18 N22P33060 8 BOLT, HEX HD, 5/8 IN-11, 3 3/4 IN LONG
1 19 N5700P21 2 PIPE PLUG, SQ HD, SOLID, 1/8 IN
1 20 4732351P1 1 SLEEVE, 9 7/32 IN OD
1 21 3X8717 AR ADHESIVE PUTTY, 8 0Z CAN W/BRUSH APPLICATOR
1 22 84D713322P1 1 FRAME HEAD
1 23 4732368P1 2 GASKET, 0.021 IN THK
1 24 334B761P1 1 BEARING CAP
1 25 8864951P301 1 ROLLER BEARING
1 26 84B515283P1 1 BEARING CLAMP
1 27 41B537660P6 4 WASHER, FLAT, 0.562 IN ID, 0.938 IN OD
1 28 N22P29020B13 4 BOLT, HEX HD, 1/2 IN-13, 1 1/4 IN LONG
1 29 84B515189P1 1 BEARING CAP
1 30 41B537660P9 8 WASHER, FLAT, 0.725 IN ID, 1 IN OD
1 31 N22P33048B13 8 BOLT, HEX HD, 5/8 IN-11, 3 IN LONG
1 32 N5700P21 2 PIPE PLUG, SQ HD, SOLID, 1/8 IN
1 33 3X8717 AR ADHESIVE PUTTY, 8 0Z CAN W/BRUSH APPLICATOR
1 34 84C620926G4 1 ROTOR ASSEMBLY
1 35 84D730122P2 1 SHAFT
1 36 8864959P130 1 LOCKWASHER, 150 MM
1 37 8864959P30 1 NUT, 150 MM
1 38 2766829ADP14 AR BALANCE WEIGHT, 5/8 IN WIDE
1 39 84A204808P1 1 SET SCREW, HEX SOC HD, 3/8 IN-24, SELF-LOCK
1 40 41A232821P1 1 SLEEVE
1 41 84B512988P1 1 COLLAR
1 42 N22P39032 12 BOLT, HEX HD, 1 IN-8, 2 IN LONG
1 43 41B537660P21 12 WASHER, FLAT, 1.063 IN ID, 2 IN OD
2 44 41A235078P57 2 STUD, 3/8 IN-16, 1 3/4 IN LONG
2 45 497A806P78 AR THREADLOCKER 271, HIGH STRENGTH
2 46 N5700P31 2 PIPE PLUG, SQ HD, 1/4 IN
2 47 N5700P51 2 PIPE PLUG, SQ HD, 1/2 IN
0 48A 493A471P1 1 HUB, 9.120 IN OD, POWER TAKE-OFF

--------------------------------------------------------------------------------------------------------------------------------------------
09-APR-2008
08/21/01 RENEWAL PARTS LIST PAGE 1

RPL 4303
COVER ASSEMBLY
UPPER UNUSED CONN BOX PORT
SPEC 4303

HUNT PART
ITEM QTY COMPONENT NUMBER

1.00 1 COVER PLATE 4303.01B

2.00 1 GASKET 4218.06B

3.00 1 NAMEPLATE - WARNING 41A 237902 P001

4.00 4 PIN N 532 P1106

5.00 12 BOLT L 661

6.00 12 LOCKWASHER L 532

F:\WKSHEETS\EVERYONE\RPL\RPLFORM.WK4
07/11/01 RENEWAL PARTS LIST PAGE 1

RPL 4302
COVER ASSEMBLY
LOWER UNUSED HEATER PORT
SPEC 4302

HUNT PART
ITEM QTY COMPONENT NUMBER

1.00 1 COVER PLATE 4248.01B

2.00 1 GASKET 4239.01B

3.00 1 NAMEPLATE - WARNING 41A 237902 P001

4.00 4 PIN N 532 P1106

5.00 6 BOLT L 661

6.00 6 LOCKWASHER L 532

F:\WKSHEETS\EVERYONE\RPL\RPLFORM.WK4
 RENEWAL PARTS LIST PAGE 1

FILE: RPL4722G1/4 JUNCTION BOX ASSEMBLY

SPEC 4722 group1 thru 4
SEE ILLUSTRATION DWG 4722RPLG1/4

HUNT PART
ITEM QTY COMPONENT NUMBER

1.00 1 JUNCTION BOX ASSEMBLY 4749B

2.00 1 LID 4722.05

3.00 1 PLATE ASSEMBLY 4723

4.00 1 BUS BAR SUPPORT ASSEMBLY 4722.13B

5.00 2 BUS BAR PHS A & C 4722.09B

6.00 1 GASKET, LID 4722.10B

7.00 1 PARTITION 4722.11

8.00 1 MCT ASSEMBLY 4757

9.00 4 INNER GLASTIC INSULATION BUS BAR 4218.12B

10.00 4 OUTER GLASTIC INSULATION BUS BAR 4218.13B

11.00 2 BACKSIDE GASKET 4218.06B

12.00 1 RUBBER GROMMET 3373A

14.00 2 GASKET, TOP & BOTTOM COVER 4218.05B

22.00 1 JUMPER-BUSS BAR 4722.14B

23.00 1 JUMPER-BUSS BAR 4722.15B

24.00 1 JUMPER-BUSS BAR 4722.16B

25.00 2 GROUND STUD ASSEMBLY 4245A

28.00 1 DIN RAIL TERMINAL BOARD ASSEMBLY 4308B

29.00 17.5 RACEWAY-HORIZONTAL 4218.17B

30.00 1 COPPER BUS BAR 4218.19B

33.00 2 COVER, JUNCTION BOX TOP OR BOTTOM 4218.04B

34.00 2 STRAP INSULATOR 4722.17B

 SERIES 1950
INTEGRAL EXPOSION-PROOF PRESSURE SWITCHES
INSTALLATION AND OPERATING INSTRUCTIONS

1950 SWITCH OUTLINE DRAWING

INSTALLATION:
1. Select a location that is free from excessive vibration, corrosive
atmosphere and where the ambient temperature is between –40 degrees
and +140 degrees F. Switch may be installed outdoors or in areas where
the hazard of explosion exists. (See page 1 for specific types of hazardous
service).
2. Mount standard switches with the diaphragm in a vertical plane and with
switch lettering and Dwyer nameplate in an upright position. Some
switches are position sensitive and may not reset properly unless they are
mounted with the diaphragm vertical. (Special units can be furnished for
other than vertical mounting arrangements if required.)
3. Connect switch to source of pressure, vacuum or differential pressure.
Metal tubing with ¼ inch O.D. is recommended, but any tubing which will
not restrict the air flow can be used. Connect to the two 1/8 inch NPT
female pressure ports as noted below:
A. Differential pressures – connect pipes or tubes from source of
greater pressure to high pressure port marked HIGH PRESS. and
from source of lower pressure to low pressure port marked LOW
PRESS.

Page 1 of 4 File: 1158.UB

 B. Pressure only (above atmospheric) – connect tube from source of
pressure to high pressure port. The low pressure port is left open to
atmosphere.
C. Vacuum only (below atmospheric pressure) – connect tube from
source of vacuum to low pressure port. The high pressure port is
left open to atmosphere.
4. To make electrical connection, remove the three hex head screws from
the cover and, after loosening the fourth captive screw, swing the cover
aside. Electrical connections to the standard single pole, double throw
snap switch are provided by means of screw terminals marked “common”,
“norm open”, and “norm closed”. The normally open contacts close and
the normally closed contacts open when pressure increases beyond the
set point. Switch loads for standard models should not exceed the
maximum specified current rating of 15 amps resistive. Remember that
switch capabilities decrease with an increase in ambient temperature, load
inductance, or cycling rate. Whenever an application involves one or more
of these factors, the user may find it desirable to limit the switched current
to 10 amps or less in the interest of prolonging switch life.

ADJUSTMENT
To change the set point:
A. Remove the plastic cap and turn the slotted. Adjustment Screw at the top
of the housing clockwise to raise the set point pressure and counter-
clockwise to lower the set point. After calibration, replace the plastic cap.
B. The recommended procedure for calibrating or checking calibration is to
use a “T” assembly with three rubber tubing leads, all as short as possible
and the entire assembly offering minimum flow restriction. Run one lead to
the pressure switch, another to a manometer of known accuracy and
appropriate range, and apply pressure through the third tube. Make final
approach to the set point very slowly. Note that manometer and pressure
switch will have different response times due to different internal volumes,
lengths of tubing, fluid drainage, etc. Be certain the switch is checked in
the position it will assume in use, i.e. with diaphragm in a vertical plane
and switch lettering and Dwyer nameplate in an upright position.
C. For highly critical applications it is a good idea to check the set point
adjustment and reset it as necessary once or twice in the first few months
of operation. This will compensate for any change in initial tension which
may occur in the spring and diaphragm. For most applications this change
will not be significant and no resetting will be required.

Page 2 of 4 File: 1158.UB

MAINTENANCE
The moving parts of these switches need no maintenance or lubrication. The only
adjustment is that of the set point. Care should be taken to keep the switch
reasonably clean. Periodically the vent drain plug should be rotated one turn
clockwise then returned to its original position. This will dislodge deposits which
could accumulate in applications where there is excessive condensation within
the switch.

The New Model 1950 Explosion-Proof switch combines the best features of the
popular Dwyer Series 1900 Pressure Switch with a compact explosion-proof
housing.

The unit is U.L. and CSA listed, FM approved for use in Class I, Groups C & D,
Class II, Groups E, F, & G and Class III atmospheres. It is also totally rain-tight
for outdoor installations. Twelve models allow set-points from .03 to 20 inches
W.C. and from .5 to 50 PSI.

Easy access to the SPDT switch for electrical hook-up is provided by removing
the top plate of the three-part aluminum housing. Adjustment to the set point of
the switch can be made without disassembly of the housing. The unit is very
compact, about half the weight and bulk of equivalent conventional explosion-
proof switches.

CAUTION: Use of the Model 1950 switch with explosive media connected to the
low pressure port (including differential pressure applications in such media) is
not recommended. Switch contact arcing can cause an explosion inside the
switch housing which, while contained, may render the switch inoperative. If
switch is being used to sense a single positive pressure relative to atmosphere,
run a line from the low pressure port to a non-hazardous area free of combustible
gases.

Page 3 of 4 File: 1158.UB

PHYSICAL DATA
Temperature limits: -40°F to 140°F.0°F to 140°F for 1950P-8, 15, 25, and 50.
Rated Pressure: 1950 - 45IN. W.C., 1950P - 35 PSI, 1950P - 50 only – 70 PSI.
Maximum surge pressure: 1950 – 10 PSI, 1950P - 50 PSI, 1950P – 50 only –90
PSI.
Pressure Connections: 1/8” NPT.
Electrical Rating: 15 amps, 125, 250, 480 volts, 60Hz. A.C. Resistive 1/8 H.P. @
125 volts, ¼ H.P. @ 250 volts, 60 Hz. A.C.
Wiring connections: 3 screw type; common, norm. open and norm. closed.
Conduit connections: ½ “ NPT.
Set point adjustment: Screw type on top of housing. Field adjustable.
Housing: Anodized cast aluminum.
Diaphragm: Molded fluorosilicone rubber. 04 model, silicone on nylon.
Calibration Spring: Stainless Steel.
Installation: Mount with diaphragm in vertical position.
Weight: 3 ¼ lbs. 04 model, 4 lbs, 7 oz.

Response Time: Because of restrictive effect of flame arrestors, switch response

time may be as much as 10 – 15 seconds where applied pressures are near set
point.

NOTE: The last number-letter combination in the 1950 model number identifies
the switch electrical rating (number) and diaphragm material (letter). The 2f
combination is standard as described in the physical data above. In the case of
special models, a number 1 rating is the same as 2; a number 3 or 4 rating is
10A 125, 250, 480 VAC – 1/8 HP 125 VAC, ¼ HP 250 VAC; and a number 5 or 6
rating is 1A 125 VAC. A letter B indicates a Buna-N diaphragm, N; Neoprene, S;
Silicone, and V; Viton.

Hunt Engine, Inc.

14805 South Main St.
Houston, Texas 77035
Phone: 713-721-9400
Fax #1: 713-721-7346
Fax #2: 713-721-0343
sales@huntengine.com
www.huntengine.com

For spares order Hunt part numbers:

Filter differential pressure switch: 3227A
Blower differential pressure switch: 2606A

Page 4 of 4 File: 1158.UB

05/05/2004 RENEWAL PARTS LIST PAGE 1

RPL 4239G2
SPACE HEATER APPLICATION
100 WATT - 110/240 VOLT ATEX
SPEC 4239G2

HUNT PART
ITEM QTY COMPONENT NUMBER

1.00 1 SPACE HEATER 3781AP07

2.00 1 COVER ASSEMBLY 4248B

2.01 1 COVER PLATE 4248.01B

2.02 2 BRACKET 4248.02B

3.00 1 CONNECTION BOX 3775A

4.00 1 CABLE GLAND 4320AP02

5.00 LINE ITEM NOT USED

6.00 LINE ITEM NOT USED

7.00 2 BOLT L600

8.00 2 LOCKWASHER LA528

9.00 1 GASKET - COVER 4239.01B

10.00 1 NAMEPLATE - WARNING 41A237902P1

11.00 4 SCREW L3615-1206

12.00 1 GASKET - CONN BOX TO COVER PLATE 4239.02B

F:\WKSHEETS\EVERYONE\RPL\RPLFORM.WK4
STB Range
Small Sheet steel enclosures

18
STB Range
Small Sheet steel enclosures

Enclosures from the STB range are Features:

typically used as distribution boards and • 8 sizes with in two material designs
throughout building automation.
We recommend the stainless steel ver- • Lid with 4 hexagonal M 6
sions from this range for the chemical and slotted-head screws
food industries, due to high demands • Earth studs
placed in these fields.
• Fixing lugs

Our assembly service can supply

these enclosures preassembled with
terminals and cable glands according
to customer requirements.

STB Range
Technical data
Material Sheet steel 1.5 mm
Stainless steel 1.4404 1.5 mm
Finish Painted Light grey, semi gloss textured, similar to RAL7032
Stainless steel Polished, chemically dipped
Gasket Sizes 1-4: chloroprene
Sizes 5-6: silicon HT800
Lid fixing 4 captive hexagonal head, slotted M 6 screws
Earthing M 6 earth studs made of brass
Enclosure mounting External brackets with 8 mm drillings
Equipment mounting TAS 20 rail welded to enclosure base
Protection class IP 66
Impact resistance 7J
Temperature range -20°C to + 85°C

Special versions
Finish Special colours according to customer requirements
Equipment Assembled according to customer requirements with terminals and cable glands
Openings without threads according to customer requirements
Sizes Special sizes according to customer requirements

Approvals
ATEX KEMA00ATEX8500 X

Ordering information
Type Length x Width x Depth Interior height RAL 7032 Stainless steel Weight (Stainl. steel)
mm mm Cat. No. Cat. No. g
STB 1 120 x 120 x 80 76 3873100000 3873300000 1,400
STB 1.1 150 x 120 x 80 76 9524770000 9524780000 1,550
STB 2 150 x 150 x 90 86 3873500000 3873700000 1,900
STB 2.1 190 x 150 x 90 86 9524790000 9524800000 1,960
STB 3 190 x 190 x 100 96 9513870000 9513890000 3,000
STB 4 250 x 250 x 120 116 9513900000 9513920000 3,700
STB 5 160 x 380 x 120 116 9505260000 9505300000 3,700
STB 6 250 x 400 x 130 126 9505270000 9505310000 5,400

Accessories
Lock nuts
Type Cat. No.
Sliding fixing nut M5 with screw for TS 32 and TS 35 SFNS 5 0433500000
Sliding fixing nut M5 with screw for for TS 15 SFNS 4 0500000000
Sliding fixing nut M3 with screw for terminal strips SFNS 3 3875100000
M 6 earthing rod nut, brass M6 9502700000
See appendix, page 78

19
Renewal Parts List
Drawing Number: 4827G04

Drawing Title: SPEED SENSOR APPLICATION KIT

Drawing Description: GEB22A1 & 2 APPLICATIONS

1024PPR / 5-24VDC

Part Number Component Quantity

4828BP02 SPEED SENSOR - AVTRON - HOLLOW SHAFT 1

TYPE

4827.04A MACHINE DETAIL TO INSTALL SHAFT IN GEB 1

28 BEARING RETAINER CLAMP

4827.01A 1" DIAMETER SHAFT 1

4827.02A SHAFT SEAL - 1.00X1.503X.25 1

4732368P1 GASKET - BEARING CAP 1

L616 SCR - 5/16-18UNC-2BX.75 LG 1

LA529 LOCK WASHER, SLT - .3125 NOM 1

Wednesday, September 26, 2007 Page 1 of 1

 Pulse Generator
Instructions
8 9 0 1 E . P L E A S A N T VA L L E Y R O A D
M6-4, M6-5, M6-6,
INDEPENDENCE, OHIO 44131-5508 M6-7
T E L E P H O N E : ( 1 ) 2 1 6 - 6 4 2 - 4 2 3 4 • FA X : ( 1 ) 2 1 6 - 6 4 2 - 9 7 4 3 EXPLOSION PROTECTED
E - M A I L : t a c h s @ a v t r o n . c o m • W E B : w w w. a v t r o n . c o m / t a c h s . h t m HOLLOW SHAFT

DESCRIPTION AVAILABLE RESOLUTIONS

The Avtron Model M6-4, M6-5, M6-6 and M6-7, are Zero-Speed -48 OPTION -51 OPTION -60 OPTION
Hollow Shaft Rotary Incremental Pulse Generators. They are a LOW 240 256 300
similar to the model M4 Heavy Mill Duty rotary hollow shaft MEDIUM 480 512 600
incremental pulse generators but utilize flameproof and increased
safety construction. The M6 has been tested in accordance with HIGH 960 1024 1200
European Standards EN50014-2 Edition December 1997
(A1,A2), EN50018-2 Edition 2000, EN 50019-2 Edition 2000, EU rotor: 1/2 the base PPR, the base PPR, or double the base PPR
Directive 94/9/EC and is certified by Epsilon and UL International (see table). With two outputs the same pulse generator can provide
DEMKO A/S (Certificate of Conformity No. 02 ATEX 131477) for two different PPRs from a given rotor at the same time. Only one
use in CAT 2 (Zone 1) Gas Group IIC potentially explosive rotor per pulse generator is possible.
atmospheres when marked with the code EEx de IIC T4 - II 2 G Example: an M6 could use a 1024 PPR sensor output on one side
(Tamb -20°C to +80°C). for feedback to a drive system, and simultaneously use a 256 PPR
When mounted to a motor or machine, the M6 output is directly sensor on the other side for a process computer.
proportional to shaft position (pulse count) or speed (pulse rate). The NOTE: All resolutions are generated from real transduced signals.
M6 can be used for both control and instrumentation applications.
The hollow shaft version of the model M6 eliminates shaft couplings, INSTALLATION CONSIDERATIONS
adapter flanges, or accessory mounting faces. The unit employs a
hollow shaft and clamping collar to lock the pulse generator to the The M6 standard flexible anti-rotation bracket will tolerate ± 0.1" of
shaft. An anti-rotation bracket prevents rotation of the pulse shaft end float. Consideration should be taken when positioning
generator while allowing for shaft end float. the pulse generator.

The enclosures on all Model M6s are rated IP 66 to protect the CAUTION
internal components from the entry of dust and water. Additionally,
Be careful not to damage clamping fingers during
the M6 uses magnetoresistive sensing technology, making the M6
ideal for demanding industrial environments. handling. Do not tighten clamping collar before
installation onto motor shaft. Damaging clamping
All M6s can be equipped with one or two outputs. Each output is fingers can affect the quality of installation.
electrically independent and totally isolated. For many applications
this feature provides a running spare output by simply Unlike the hollow shaft M6, a solid shaft pulse generator
interchanging the output connectors. installation uses a flexible coupling to compensate for shaft end
float and runout. In a solid shaft configuration this misalignment
These outputs are available as single phase; two-phase (A,B) 90° and runout can reduce the life of the mechanical parts like the
––
apart for direction sensing; with complements (A,B) and with marker coupling and bearings. While the hollow shaft M6 eliminates the
–
pulse (Z,Z). Output resolution is partly determined by the rotor’s potential for bearing and coupling failures from misalignment,
base PPR (pulses per revolution). Additionally, the sensor module excessive housing movement (wobble) may cause undesirable
can provide any one of three different resolutions from the same vibrations. The higher the RPM the more severe the vibration will
be from housing movement. In a typical installation a housing
M6 PART NUMBERS and AVAILABLE OPTIONS: movement of 0.007" TIR or less (as measured at the outside
diameter of the main pulse generator body) will not have an
M6 – 1 S 1 H H 48 Z T 000
adverse effect. If excessive housing movement is detected in the
Special Modifications installation:
Connector T – Conduit Box with Terminal Block, 1/2” NPT
W – Conduit Box, Terminal Block & Wire Gland 1. Check the shaft the M6 is mounted on for excessive shaft
Marker Z – Marker runout. NEMA MG1 calls for 0.002" TIR or less.
– None 48-480 2. Verify that the M6 engagement with the motor shaft
Base PPR 51-512
conforms to the engagement rules on page 4. In general,
60-600
X – None maximizing engagement will minimize housing movement.
Right
Output L – Low Range (Base PPR x 1/2) 3. Verify that the mounting shaft diameters conform to the
Range M –Medium Range (Base PPR x 1) rules on page 4. Excessive housing movement occurs
Left
H – High Range (Base PPR x 2) 1 – 5 to 24 VDC when the clearance between the motor shaft and pulse
Line Driver 2 – 5 to 18 VDC generator shaft allows the two center lines to miss match.
Shaft Style S – Standard Stub Shaft 3 – 18 to 24 VDC 4. Loosen the clamping collar and rotate the motor shaft 180°
within the M6 hollow shaft sleeve.
0 – Non-Standard Shaft 4 – 1'' Hollow Shaft 5. Make sure the clamping collar is tightened equally on both
Shaft Size 1 – 5/8 x 2'' Solid Shaft 5 – 1 1/8'' Hollow Shaft sides.
2 – 5/8 x 2.64'' Solid Shaft 6 – 2'' Hollow Shaft 6. Move the split in the clamping collar over a solid portion of
7 – 2 3/8'' Hollow Shaft the M6 shaft.
If excessive housing movement still exists after the above steps, spheres to which the M6 may be subject. It is however the
it may be necessary to physically bias the attitude of the pulse responsibility of the end user to ensure that the M6 is selected
generator on the motor shaft while the clamping collar is being correctly for the potentially explosive atmosphere in which the
tightened. Either by eye or using dial indicators, note the position equipment is to be put into service.
around the outside diameter of the pulse generator that is most
out of position from true while turning the motor shaft slowly. With Clean machine shaft of any dirt and check for any burrs or
the motor shaft no longer turning, loosen the clamping collar. damage.
While applying moderate force by hand against the outside
The hollow shaft M6 is intended to be installed with a torsionally
diameter of the pulse generator on the side opposite where the out
rigid flexible anti-rotation arm. See specifications for maximum
of true position was observed, retighten the clamping collar.
shaft and bearing load ratings. The pulse generator should not be
Several iterations may be necessary if the first attempt under or
rigidly mounted in a fashion that exceeds these ratings.
over compensates. This method may be used to help compensate
for undersized shafts, shaft runout, bent clamping fingers, and Instructions for Installation of the Standard Flexible Anti-
other problems. Rotation Bracket:
INSTALLATION Install the anti-rotation bracket to the motor side of the M6 using
two 3/8-16 screws and thread locker.
Refer to page 4 for outline and mounting dimensions.
Remove screws from clamping collar, apply anti-seize compound
The M6 does not produce flammable gasses or dusts in normal supplied to the inside of the collar and thread locker supplied to the
operating modes. The M6 does not cause injury or harm when threads and reinstall. Place clamping collar loosely on the inboard
used in conjunction with the installation guide. The M6 does not end of the shaft. Carefully slide M6 onto the shaft. DO NOT FORCE.
produce ignition capable electrical sparks or arcs and has been Pulse generator should slide on easily. After verifying M6 fit onto
designed not to produce potential ignition sources from shaft, remove M6, apply anti seize compound (supplied) to shaft and
electromagnetic, acoustic, optical or other energy sources. The re-install M6 (see shaft engagement). Tighten screws on clamping
M6 is not considered as a safety device and is not suitable for collar evenly until snug, then firmly tighten.
connection into a safety system.
Secure free end anti-rotation bracket to frame. Use supplied
The installer should refer to the latest edition of the following insulating hardware if necessary as shown. Adapter kits are
standards before installing or operating in a Hazardous Area: available for NEMA 56C and 8 1/2" mounting faces.
EN 1127-1 Explosive Atmospheres - Explosion prevention and Optional torque arm kits are available (supplied with instructions).
protection, basic concepts, and methodology.
Equipment needed for installation
EN 60079-14 Electrical apparatus for explosive gas atmo- Supplied:
spheres - Part 14: Electrical installations in hazardous areas 1. M6 7. Nut, 1/4-20
(other than mines). 2. Clamping Collar 8. Washer, Flat 1/4 (2)
3. Anti-rotation Bracket 9. Washer, Lock, 1/4
The M6 housing and shaft materials are listed in the spe- 4. Thread Locker 10. Washer, Shoulder,
cifications. These materials are not considered as able to trigger 5. Screw, Button Hd., Insulating
3/8-16 x .50 11. Washer, Flat, Insulating (2)
an explosion in normal operating modes and various fault modes 6. Screw, Socket cap 12. Anti Seize
in accordance with the requirements for Cat 2 equipment. These 1/4-20 x .62
materials are not known to react with any explosive atmo-
SPECIFICATIONS
ELECTRICAL ENVIRONMENTAL
A. Operating Power (Vin) (See Line Driver Options) A. Enclosure Rating: IP66
1. Volts ............................5-24 VDC B. Operating Temperature: -20 to 80°C
2. Current ........................120mA, no load C. Hazardous Locations: EEx de IIC T4 (Tamb -20°C to +80°C)
B. Output Format
– –
1. 2O/ & Comp (A,A, B,B)
– OUTPUT TERMINATIONS
2. Marker ........................1/Rev (Z,Z)
C. Signal Type......................Incremental, Square Wave, 50 ±10% Duty Cycle
D. Direction Sensing ............O / A leads O
/ B for CW rotation as viewed Terminal Block: EEx e II compression type. Accepts AWG 14 to AWG 20 stranded
....................................from the back of the tach looking at the wire. Housing available with 3/4 NPT or optional armored cable gland available
....................................non-drive end of the motor. (maximum ambient temperature with gland +60°C allowing for 20°C rise in
E. Transition Sep. ................15% minimum housing.)
F. Frequency Range ............0 to 150,000 Hz.
G. PPR ................................240, 256, 300, 480, 512, 600, 960, 1024, 1200 LINE DRIVER SPECS
H. Line Driver Specs: ..........See table

MECHANICAL Line Driver Options

A. Shaft Inertia ....................0.8 to .23 oz. In. sec.

2 1 2 3
B. Acceleration ....................5,000 RPM/Sec. Maximum Voltage Input (Vin) 5 - 24 VDC 5 - 18 VDC 18 - 24 VDC
C. Starting Torque ................1.5 to 20 Oz. In.
D. Speed ................................5,000 RPM Max. except -7 (2 3/8”, 3600 RPM Max.) Output High (volts) (Vin) -2 (typ) (Vin) -1 (typ) 330 ohm pull up
E. Weight..............................18 lbs. Maximum Output High 80 (max) 80 (Avg), 330 ohm pull up
F. Shaft Diameter (milliamps) 1500 Peak
Tolerance ....................See drawing on page 4.
G. Shaft Engagement ..........See drawing on page 4. Output Low (volts) .5 (typ) .5 (typ) 1 (max)

H. Bearing Protection: Shaft seal & double bearing seal. Output Low 80 (max) 80 (Avg), 50 (Avg)
I. Bearing Life with No Additional Loading: 6.1 x 109 Revolutions (milliamps) 1500 Peak
J. Maximum Additional Bearing Load: Protection Reverse Voltage, Reverse Voltage, Reverse Voltage,
1. -1 (5/8”): 5 pounds axial or 20 pounds radial Transient, Transient, Transient,
2. -4 & -5 (1” & 1 1/8”): 10 pounds axial or 30 pounds radial Short Circuit Short Circuit Short Circuit
3. -6 (2”): 25 pounds axial or 75 pounds radial (high and low) (none) (low)
4. -7 (2 3/8”): 30 pounds axial or 90 pounds radial
Maximum Cable 1000 ft @ 5 volts 2000 ft 1000 ft
K. Shaft Material: Black Oxide treated steel.
Drive (feet) 500 ft @ 12 volts
L. Housing Material: Cast aluminum with Polane S Plus polyurethane 200 ft @ 24 volts
enamel finish.
Not Supplied: Physical properties of cable such as abrasion, tensile strength,
7/32" Allen wrench solvents, marine applications, etc., are dictated by the specific
3/16" Allen wrench (M6-4, & M6-5 only) application. Requirements for hazardous locations are dictated by
1/4" Allen wrench (M6-6 & M6-7 only) the relevant codes. General electrical requirements are: stranded
copper, 20 AWG thru 14 AWG each wire pair individually shielded
Shaft Engagement For end of Shaft Mounting
with braid or foil with drain wire, 0.05 uF maximum total mutual or
Applications:
direct capacitance, outer sheath insulator, 2,000 ft. max. (see line
(See outline drawing) driver specifications.) Temperature ratings of wire and wire glands
should be 20°C over the maximum expected ambient or motor
For shaft lengths greater than the maximum engagement allowed, temperature to allow for temperature rise in the pulse generator
end of shaft mounting may still be employed by locating the pulse itself.
generator away from the motor using a spacer between the motor
and anti-rotation bracket. MAINTENANCE
WIRING INSTRUCTIONS There are no field replaceable parts in an M6. The unit should be
returned to the factory for all repairs.
The M6 can be wired for single phase, two-phase, with or without
complements, with or without markers. See wiring diagrams on the Build up of large amounts of contamination are to be avoided, therefore
following page. periodic cleaning is recommended.
For bidirectional operation of the 2-phase Tach, proper phasing of the The condition of the bearings is important to the safety of the explosion-
two output channels is important. Phase A channel leads phase B proof housing. The bearing manufacturer’s rated life (see specifications) can
channel for clockwise shaft rotation as viewed from the anti-drive or be adversely affected by application specific conditions. If the unit shows
accessory end of the motor (M6 mounting end). signs of bearing wear indicated by noise or degradation of the electrical
signal output, it should be returned to the factory for repair.
Refer to the system drawing for specific cable requirements
where applicable.
WIRING DIAGRAMS
M6-4, M6-5, M6-6, M6-7 PULSE GENERATORS
FOR DIFFERENTIAL APPLICATIONS

SIGNAL CODE

OPTION REF
"T" & "W" SIGNAL

BLACK
M6 1 COM
RED 2 +V +5 TO +24 VOLTS*
GREEN 3 ØA
YELLOW –
4 ØA
BLUE 5 ØB
GRAY –
6 ØB
ORANGE 7 Z = MARKER
WHITE –
8 Z

*(SEE LINE DRIVER OPTIONS)

FOR SINGLE ENDED SINGLE PHASE APPLICATIONS FOR SINGLE ENDED TWO PHASE APPLICATIONS
OUTPUT OUTPUT
BOX BOX

M6
BLACK M6
RED 2 *
+5 TO +24 VOLTS
1 COMMON BLUE 5 ØB
RED 2 *
+5 TO +24 VOLTS

GREEN GROUND
3 SIGNAL
GREEN
3 ØA
BLACK
1 COMMON
GROUND

*(SEE LINE DRIVER OPTIONS) *(SEE LINE DRIVER OPTIONS)

NOTE: Avtron standard warranty applies. Copies available upon request. TYPICAL WIRE:
Specifications subject to change without notice. 18 AWG, multiple pair, individually shielded.
Title
1/4-20 x 0.62 [15.87] SOCKET HD CAP SCREW 6.44 [163.63] 4.40 [111.76]
WITH INSULATING WASHERS SUPPLIED

3.77 [95.88] 0.56 [14.23]

OPTIONAL

Company Name
2nd OUTPUT

INTERNAL ANTI-ROTATION
GROUNDING LUG BRACKET 4.45 4.00
[113.03] [101.60]
SHAFT COLLAR

suitable for our application.

7.19
[182.63]
DIA

Authorized Company Representative

AA DIA SHAFT 5.32
EXTERNAL [135.13]
GROUNDING LUG
OPTION "T"
TERMINAL BLOCK
CC
STUB SHAFT
3/4" NPT ENGAGEMENT
5.44 [138.23]
BB
OPTION "W"
0.100 (2.54) MIN

Date
2.75 CLEARANCE REQUIRED TERMINAL BLOCK
WITH ARMOURED CABLE GLAND
B28393 NOTE: CABLE GLAND Tamb (-60°C to 80°C)
MUST BE DERATED FOR
VTRON MANUFACTURING, INC.
CLEVELAND, OHIO TEMPERATURE RISE IN ENCODER.
Ex CLEVELAND, OHIO USA
Ex PULSE GENERATOR
PULSE GENERATOR 0539 INSULATING WASHER

These instructions have been reviewed and the product evaluated as

M6 DETAIL
M6 INSULATING
Type Option Code Rev Ser.No. Date Mfg
Type Option Code Rev Ser.No. Date Mfg SHOULDER WASHER
PPR VDC INSULATING
PPR VDC FLAT WASHER STEEL FLAT WASHER
* DIMENSION
Imax= 160mA, Pmax= 4.48W Ea Output
2.81 Imax= 160Ma, Pmax= 4.48W Ea Output
EEx de IIC T4 (Tamb -20°C to +80°C)
SHAFT AA BB CC MIN/MAX
EEx de IIC T4 (Tamb -20°C to +80°C) OPTION MOTOR SHAFT OD LENGTH ENGAGEMENT
CE 0539 Ex II 2 G 4 1.0000/0.9995 [25.4000/25.3873] 4.30 [109.22] 2.000/2.620 [50.800/66.548]
Cert No.
Cert No. DEMKO ATEX 02 131477
DEMKO 02E.131806 IP66 5 1.1250/1.1245 [28.5750/28.5623] 4.30 [109.22] 2.000/2.620 [50.800/66.548]
IP66 LOCK WASHER
WARNING: DO NOT OPEN IN A FLAMMABLE
6 2.0000/1.9990 [50.8000/50.7746] 4.48 [113.79] 2.250/2.750 [57.150/69.850]
WARNING: DO NOT OPEN IN A FLAMMABLE
ATMOSPHERE OR WHEN ENERGIZED STEEL INSULATING FLAT WASHER 7 2.3750/2.3740 [60.3250/60.2996] 4.58 [116.33] 2.500/3.000 [63.500/76.200]
ATMOSPHERE OR WHEN ENERGIZED FLAT WASHER ANTI-ROTATION
BRACKET

EU DECLARATION OF CONFORMITY
The Model M6 Pulse Generator has been assessed and type tested against the following Harmonized European Standards:
EN 50081-1:1992, EN 50082-1:1998. The Model M6 has been found to be compliant with the requirements of EU Directive
89/336/EEC provided that the following conditions are met: The electrical supply to the M6 must be within specified limits.
The electrical supply must offer suitable protection from voltage surges unless the application does not require such
protection. On behalf of Avtron Manufacturing: Stephen L D’Henin, Certification Manager, Epsilon Certification Service.
4 - IDENTIFICATION LABEL: SEE ABOVE
3 – DIMENSIONS IN PARENTHESIS
3 – ARE MILLIMETERS
2 – ALL DIMENSIONS ARE APPROX.
1 – WEIGHT: 18 LBS. MAX. REV: 04-16-04x
NOTES:

* “VDC” to be “5-18” or “5-24” or “18-24” 8901 E. PLEASANT VALLEY RD., INDEPENDENCE, OH 44131, U.S.A. • (1) 216-642-4234 • FAX (1) 216-642-9743 • www.avtron.com/tachs.htm
 File: Airiomi
Revision: “B”
Page 1 of 5

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

HUNT AIRDYNE BLOWER MOTOR ASSEMBLY

Introduction:

The purpose of this manual is to aid in the proper installation and operation of Hunt Airdyne
Blower Motor assemblies manufactured by Hunt Engine, Inc. These instructions are intended to
supplement good general practices and are not intended to cover detailed instruction procedures,
because of the many varieties of airdynes manufactured by Hunt Engine, Inc.

It is the responsibility of the purchaser to assure that the installation and maintenance of this
equipment are handled by qualified personnel experienced in such work and equipment. Field
service personnel are available from Hunt Engine, Inc. to supervise installation or to assure
proper operation at startup.

Storage:

If airdynes are stored for any length of time, they should be stored in a clean, dry location to
prevent rust and corrosion. Outdoor storage is not recommended. When outdoor storage is
necessary, they should be protected from the elements as best possible. Cover the airdyne inlet
and outlet, and keep motors dry and clean.

Extended Storage:

Airdynes are to be stored in their original containers or equivalent protection and should be kept
in a clean, dry, protected warehouse where exercised control over temperature, dust, dew point,
shock and vibration is reasonable maintained.

A) Temperature: Between 50 degrees F and 120 degrees F

B) Maximum relative humidity of 60%

C) Shock or vibration: 2 mils maximum to prevent bearings from

brinelling. Exceeding this limit will require
vibration dampening material under the units.

Manually rotate blower once a month. All motors with space heaters are to have the heaters
connected if storage conditions exceed 60% relative humidity and/or if temperatures are below 50
degrees F.

Motor windings should be meggered at the time the equipment is put in storage. At the time of
removal from storage, the resistance reading must not have dropped more than 50% from the
initial reading. Contact Hunt Engine, Inc., if motor resistance is less than 50% of the initial
reading.

It is recommended that upon airdyne installation, the vibration levels be checked to assure that
the levels do not exceed the levels set forth in this manual. (See Table 1)

Storage records complying with the above requirements should be maintained.

 File: Airiomi
Revision: “B”
Page 2 of 5
Installation – Drilling Motor Mounted:

Installation of the Hunt Airdyne blower motor assembly onto a DC drilling motor is relatively
straight forward. Lock out the power source to the DC drilling motor as well as the power source
for the AC blower motor. Clean the mounting surface areas of both the DC drilling motor and the
Hunt Airdyne. Using the gasket and fasteners supplied in the installation kit, install the Hunt
Airdyne on the DC drilling motor. The Hunt Airdyne should be oriented on the DC drilling motor
so that when viewing the DC drilling motor from the commutator end (end opposite the drive hub),
you will be viewing the Hunt Airdyne from the rainhood end. The bolts should be torqued to 35 ft.
lbs. (425 in. lbs.)

The AC blower motor should be wired to its power source by a qualified electrician in a manner
that meets all applicable electrical codes. IMPORTANT! The AC blower motor must be wired to
rotate in the proper direction. The proper direction is indicated by an “arrow" nameplate affixed to
the blower housing. If the name plate is missing, look at the airdyne from the blower motor end.
If the blower outlet is offset to the left, the motor should rotate counterclockwise. If it is offset to
the right, it should rotate clockwise.

Start and run the airdyne long enough to confirm that it is operating properly. See following
trouble shooting chart. If any problem cannot be remedied, contact Hunt Engine, Inc.

Installation – Remote Mounted:

Remote installations of Hunt airdyne blower motor assemblies require advance engineering to
assure that the DC drilling motor is supplied with a sufficient amount of cooling air. Sizing of the
airdyne is determined by calculating the total pressure drop through the system, including
ductwork and drilling motor accessories. Installation procedures for each remote system are
therefore unique and it would not be practical to attempt to cover all possibilities herein. In
general, the basic concept is the same as for drilling motor mounted units. After installing the
system in accordance with the engineered design, check the system to confirm that it is operating
properly. Consult the trouble shooting guide if there is a problem. If the problem cannot be
remedied, contact Hunt Engine, Inc.

Maintenance - Blower:

Periodic inspection of all the airdyne parts is the key to good maintenance and trouble-free fan
operation. Frequency of inspection must be determined by the user and is dependent upon the
severity of the application. Prepare a maintenance schedule and make sure it is strictly adhered
to.

Never service or adjust rotating equipment while it is in operation. Lock out the power source
before performing maintenance.

Regular fan maintenance should include the following:

1) Check the airdyne impeller for any buildup of foreign material or wear
from abrasion. Both can cause excessive vibration, which will lead to
damage of the impeller and other fan components. Replace the impeller
if excessive wear is noticed. Carefully clean the impeller of any foreign
material.

2) Consult the trouble shooting guide for excessive vibration or noise,

insufficient performance, or when the airdyne does not operate. (See
Table 2.)
 File: Airiomi
Revision: “B”
Page 3 of 5
Maintenance – Blower Motor:

The fundamental principle of electrical maintenance is keep the motor clean and dry. This
requires periodic inspection of the motor, the frequency of which depends upon the type of motor
and the service.

Periodic checks of voltage, frequency, and current of a motor while in operating are
recommended. Such checks assure the correctness of frequency and voltage applied to the
motor, and yield an indication of the airdyne load. Comparison of these data with previous data
will give an indication of the airdyne performance. Any serious deviations should be investigated
and corrected.

Vibration:

Excessive airdyne vibration can be caused by many things. All possible sources of the excessive
vibration must be checked out and corrective action taken immediately to correct the problem.
See the airdyne trouble-shooting chart (Table 2) for possible causes of excessive airdyne
vibration.

A vibration analyzer will be of great assistance in determining the amount of vibration. The
following values give an indication of the airdyne vibration condition. Vibration readings should
be taken on the motor or on the airdyne housing. Horizontal, vertical, and axial readings should
be taken.

Table 1

Vibration Displacement in Mils, “Double Amplitude”

Fan RPM Good Fair Slightly Rough Rough

3000 0.02/0.45 0.45/1.00 1.00/2.00 2.00/4.00

3600 0.20/0.40 0.40/0.85 0.85/1.75 1.75/3.25

Interpolate for airdyne speeds other than shown above. The airdyne should not be operated
unless the maximum vibration reading is in at least the “Fair” range.

TABLE 2

Airdyne Trouble-Shooting Chart

Problem Possible Causes

_ Accumulation of material on impeller

Excessive _ Worn or corroded impeller
Vibration _ Bent shaft
_ Impeller loose shaft
_ Impeller out of balance
_ Motor out of balance
_ Loose or worn bearings
_ Loose bearing bolt
_ Loose impeller mounting bolts
_ Weak or resonant foundation
 File: Airiomi
Revision: “B”
Page 4 of 5

_ Foundation not flat and level

_ Structures not crossbraced

Horsepower _ Air density higher than design

to high _ Impeller rotating in the wrong direction

_ Impeller rotating in the wrong direction

Airflow
to low _ Actual system is more restrictive (more resistance to flow) than expected
_ Leaks or obstructions in duct work
_ Filters are dirty and clogged
_ Inlet our outlet screens are clogged
_ Restricted fan inlet or outlet
_ No straight duct at fan outlet
_ Sharp elbows near fan inlet or outlet
_ Improperly designed turning vanes

Airflow _ Actual systems is less restrictive (less resistance to flow) than expected
too much _ Filters not in place

Airdyne does _ Blown fuses

not operate _ Electricity turned off or not wired properly
_ Wrong voltage
_ Overload protector has broken circuit

Excessive _ Accumulation of material on impeller

noise _ Worn or corroded impeller
_ Bent shaft
_ Impeller loose shaft
_ Impeller hitting housing
_ Impeller out of balance
_ Loose or worn bearing
_ Defective or bad bearings
_ Loose airdyne mounting bolt
_ System pulsation or surge
_ Noise from high velocity system
_ Duct work to small
_ Fan in stall condition (danger)
_ Rattle of components in high velocity air stream
_ Leaks in duct work
_ Vibrating duct work
_ Vibrating parts not insolated from structure

Spare Parts:

Spare parts are not normally required for first year of operation. If spare parts are desired, it is
suggested that a spare blower motor and impeller be ordered.
 File: Airiomi
Revision: “B”
Page 5 of 5

Replacement Parts:

See replacement parts list for your particular airdyne blower motor assembly, identified by a Hunt
spec number and/or serial number.

For additional information concerning this product, please contact:

Hunt Engine, Inc. Phone: 713-721-9400 (24 Hours)

14805 South Main Fax #1: 713-721-7346 (24 Hours)
Houston, Texas 77035 Fax #2: www.huntengine.com
RPL 4965G06 HUNT AIRDYNE BLOWER MOTOR ASM
MODEL 22A1-17.4CW-36440
SPEC 4965G06

HUNT PART
ITEM QTY COMPONENT NUMBER

1.00 1 ELECTRIC MOTOR - U.S. ELEC 4435A

2.00 1 SUPPORT ASM-MOTOR 4967

3.00 1 WHEEL ASM - CW 3780G01

4.00 1 HOUSING ASM 4968

5.00 1 SEAL, MOTOR FACE 4223.01B

6.00 2 GASKET - HOUSING SIDE 2525.02B

7.00 1 GASKET - HOUSING DISCHARGE 4968.04C

8.00 1 LOUVER BOX 4340R1

9.00 1 LOUVER 4323AP01

10.00 4 RETAINER CLIP 220189-005

11.00 1 NAMEPLATE - ROTATION - CW 2968A

12.00 1 NAMEPLATE - MODEL, S/N ETC 2709A

 R

MANUFACTURER U S MOTOR
MANUFACTURER'S ID NO. AB37
B.H.P. 15.0
R.P.M. - SYNCHRONOUS 3600
R.P.M. - FULL LOAD 3545
PHASE - Hz. 3 - 60
VOLTS - FULL LOAD 230 460
AMPS. - FULL LOAD 35.0 17.7
FRAME SIZE 254T
AMBIENT - DEG. C AT 1.15 SF N/A
AMBIENT - DEG. C AT 1.00 SF 55
ENCLOSURE X-P
INSULATION CLASS F
TEMPERATURE CODE LATER
NEMA DESIGN B
EFF. % - FULL LOAD 90.2
LOCKED ROTOR CODE H
U.L. FILE NO. - MOTOR LATER
U.L. FILE NO. - CONN BOX N/A
C.S.A. FILE NO. LATER

HUNT ENGINE, INC.

HARVEY, LA. HOUSTON, TEXAS

REV ONE - GEA - 19 JULY 2000: UPDATED TECH DATA FOR IMPROVED
EFFICIENCY MOTORS.

TITLE MOTOR DATA SHEET

DRAWN WKA PROJ.ENGR. S/O

APPD. CHKD. DWG.

NO. 4435MDS
DATE Dec 17, 1998 APPD

SCALE DATE
REVISION NO. 1
 U.S. Electrical Motors
Installation and Maintenance Manual
SAFETY FIRST NOTE: Motors operating under rated load and allowable ambient conditions may feel
High voltage and rotating parts can cause serious or fatal injury. Safe installation, hot when touched; this is normal and should not be cause for concern. When in
operation, and maintenance must be performed by qualified personnel. Familiariza- doubt, measure frame surface temperature and confer with nearest office. Enclosed
tion with and adherence to NEMA MG2, the National Electrical Code (NEC) and local motors normally have condensation drain openings. Insure that drain openings are
codes is required. It is important to observe safety precautions to protect personnel properly located and open (plugs removed) for the motor mounting position. Drain
from possible injury. Personnel should be instructed to: openings should be at the lowest point of end brackets, frame housing and terminal
housing when the motor is installed. This may require modification of motor to
1. Be familiar with the equipment and read all instructions thoroughly before accomplish. If unit appears wet, and/or has been stored in a damp location, dry out
installing or working on equipment. thoroughly and check for adequate insulation resistance to ground before operating.
2. Avoid contact with energized circuits or rotating parts.
3. Disconnect all power sources before initiating any maintenance or repair. WARNING: Guards should be provided for all exposed rotating parts to prevent
4. Act with care in accordance with prescribed procedures in handling and possible personal injury. Keep fingers and foreign objects away from ventilation and
lifting this equipment. other openings. Applications involving high inertia loads may damage equipment due
5. Be sure unit is electrically grounded in accordance with code requirements. to motor overspeed during coast shutdown. Such applications should be referred to
6. Be sure equipment is properly enclosed or protected to prevent access by U.S. Electrical Motors.
children or other unauthorized personnel in order to prevent possible accidents.
7. Be sure shaft key is fully captive before unit is energized. CAUTION: Do not force drive coupling or other equipment onto shaft, as bearing
8. Avoid contact with capacitors until safe discharge procedures have been damage may result
completed.
9. Provide proper guarding for personnel against rotating parts and applications POWER SUPPLY AND CONNECTIONS
involving high inertia loads which can cause overspeed. The power supply must agree with values on nameplate. Terminal voltage should not
10. Avoid extended exposure to equipment with high noise levels. vary more than ±10% of nameplate voltage at rated frequency. Unbalanced line
voltage, greater than one percent, can cause overheating. Do not exceed the
INSPECTION AND HANDLING continuous rated load amperes on the nameplate. Starting controls and overload
Inspect unit to make sure no damage has occurred during shipment. Check protection should be properly sized in accordance with the NEC and the control
nameplate for correct speed, horsepower, voltage, Hertz, and phase for conformance manufacturer’s recommendations.
with power supply and equipment. WARNING: Units should be lifted using all
eyebolts or lugs if provided. These eyebolts or lugs are provided for lifting this unit Motor connections should be made by following instructions on connection diagram.
only and must not be used to lift any additional weight. Lifting angle, from shank of Determine direction of rotation before connecting driven equipment. If direction of
eyebolt, must not exceed 30° for machines with single and 45° for machines with rotation label is supplied, operate only in specified direction. Rotation may be
multiple lifting means. Replacement eyebolts must be per ASTM A489 or equivalent. reversed on three phase motors by interchanging any two line connections. On single
All eyebolts must be securely tightened. Be careful not to touch overhead power phase motors, interchange leads per connection diagram on motor. Wiring of units,
lines with lifting equipment. Failure to observe this warning may result in serious controls and grounding shall be in accordance with local and NEC requirements.
personal injury. WARNING: Failure to properly ground unit may cause serious injury to personnel.
Where unexpected starting could be hazardous to personnel, do not use automatic
STORAGE reset starting devices.
Units should be stored indoors, in a clean, dry location & winding should be protected
from excessive moisture absorption. NOTE: If motors are to be stored for more than USE OF VARIABLE FREQUENCY DRIVES
one year, refer to U.S. Electrical Motors. If gear and belt transmission units are to be Electric motors can be detrimentally affected when applied with variable frequency
stored for more than six months, refer to U.S. Electrical Motors. drives (VFD’s). The non-sinusoidal waveforms of VFD’s have harmonic content which
causes additional motor heating; and high voltage peaks and short rise times, which
LOCATION result in increased insulation stress, especially when long power cable lengths are
WARNING: Use only UL Listed Hazardous Location Motors for service in Hazardous used. Other effects of VFD’s on motor performance include reduced efficiency,
Locations as defined in Article 500 of the NEC. Units should be located in a clean, increased load current, vibration and noise. Standard motors utilized with VFD’s
well-ventilated area. WARNING: Units should be located in a suitable enclosure to must be limited to those application considerations defined in NEMA MG-1 Part 30.
prevent access by children or other unauthorized personnel to prevent possible
accidents. NEMA MG-1 Part 31 defines performance and application considerations for Definite
Purpose Inverter fed motors. To insure satisfactory performance and reliability, U.S.
INSTALLATION / MOUNTING Electrical Motors offers and recommends nameplated inverter duty motor products
Mount units on a firm, flat surface sufficiently rigid to prevent vibration. Drive belts which meet the requirements of NEMA MG-1 Part 31. The use of non-inverter duty
and chains should be tensioned in accordance with supplier recommendations. motors may result in unsatisfactory performance or premature failure, which may not
Couplings should be properly aligned and balanced. For belt, chain and gear drive be warrantable under the Terms and Conditions of Sale. Contact your U.S. Electrical
selection refer to the drive or equipment manufacturer. For application of drive Motors Field Sales Engineer for technical assistance for motor selection, applications
equipment refer to applicable information in NEMA MG1. and warranty details.
10 Pin Bendix Wiring 9 Pin Sub-D Wiring
Vector Blower / Encoder Connection Pin # Function Pin # Function
Motors have been dynamically balanced using a half key the same length as the full
D +VDC 1 +VDC
key shipped with the motor. If pulley keyway length is less than this length, rework
F COM 2 A
long key by removing one-half of excess length between pulley and end of key to
A A 3 A'
maintain balance.
B B 4 B
C Z 5 B'
Do not restrict motor ventilation. Unless otherwise specified on nameplate, motor is 6 Z
H A'
designed for operation in accordance with NEMA MG1 “Usual Service Conditions” J B' 7 Z'
which states an ambient temperature range of -15°C to 40°C (5°F to 104°F). Stan- K Z' 8 N/C
dard grease lubricated units are suitable for operation within this temperature range, E N/C 9 COM
special lubricants may be required for ambient temperatures outside of the range.
 U.S. Electrical Motors
Installation and Maintenance Manual
OIL LUBRICATION
Most oil lubricated units are shipped without oil. Refer to instruction manual with unit for specific type and grade of oil to be used, change interval and level. If lubrication
instructions specify synthetic oil, do not substitute. WARNING: For applications in the food and drug industry (including animal food), consult the petroleum supplier for lubricants
that are acceptable to the Food & Drug Administration and other governing bodies.

MAINTENANCE
Inspect units at regular intervals. Keep units clean and ventilation openings clear of dust, dirt or other debris. Lubricate units per this operating instruction sheet and instruction
plate on unit. Excessive lubrication may damage the unit. Do not over-grease. WARNING: Disconnect all power sources to the unit and discharge all parts which may retain
an electrical charge before attempting any maintenance or repair. Screen and covers must be maintained in place when unit is in operation. Failure to observe this warning may
result in personal injury.

U.L. Listed Motors For Use in Hazardous Locations: Repair of these motors must be made by the manufacturer or manufacturer’s authorized service station approved to repair
U.L. Listed motors. The U.L. listing applies to the electric motor only and not to the belt or gear transmissions or other devices that may be connected to the motor.

GREASE LUBRICATION INSTRUCTIONS

Units are prelubricated at the factory and do not require initial lubrication. Relubricating interval depends upon speed, type of bearing and service. Refer to Table 1 for
suggested regreasing intervals. Operating conditions may dictate more frequent lubrications. Motor must be at rest and electrical controls should be locked open to prevent
energizing while motor is being serviced. (refer to section on Safety). If motor is removed from storage, refer to storage procedures.

To relubricate bearings, remove the drain plug. Inspect grease drain and remove any blockage with a mechanical probe taking care not to damage bearing. CAUTION: Under
no circumstances should a mechanical probe be used while the motor is in operation. Add new grease at the grease inlet, refer to Table 1 for replenishment quantities. New
grease must be compatible with grease in the motor (See Caution Note). Run the motor for 15 to 30 minutes with the drain plug removed to allow purging of any excess grease.
Shut off unit and replace the drain plug. Return motor to service. CAUTION: Overgreasing can cause excessive bearing temperatures, premature lubricant breakdown
and bearing failure. Care should be exercised against overgreasing.

TABLE 1
Recommended Grease Replenishment Quantities & Intervals
(For Lubrication of Units in Service)
Bearing Number - Common Bearing Number - AFBMAX Grease Lubrication Interval
62XX 63XX XXBC02 XXBC03 Fl. Oz. 3600 RPM 1800 RPM 1200 RPM
6203 - 6207 6303 - 6306 17 - 35 17 - 30 0.2 2 years 3 years 3 years
6208 - 6212 6307 - 6309 40 - 60 35 - 45 0.4 1 year 2 years 2 years
6213 - 6215 6310 - 6311 65 - 75 50 - 55 0.6 1 year 2 years 2 years
6216 - 6220 6312 - 6315 80 - 100 60 - 75 1.0 6 months 1 year 2 years
6221 - 6228 6316 - 6320 105 - 140 80 - 100 1.8 6 months 1 year 1 year
For motors mounted vertically or in hostile environments, reduce intervals shown by 50 percent.

Refer to motor nameplate for bearings provided on a specific motor. For bearings not listed in the table above, the amount of grease required may be calculated by the formula:
G = 0.11 x D x B
where: G = Qty of grease in fluid ounces; D = Outside diameter of bearing (inches); B = Width of bearing (inches)

TABLE 2
Recommended Greases
THE FOLLOWING GREASES ARE INTERCHANGEABLE WITH THE GREASE AS PROVIDED IN UNITS SUPPLIED FROM FACTORY (unless stated otherwise on a
lubrication nameplate provided on motor).

Manufacturer Grease (NLGI No. 2)

Exxon Mobil Polyrex EM
Chevron USA Inc. SRI No. 2

CAUTION: Greases of different bases (lithium, polyurea, clay, etc.) may not be compatible when mixed. Mixing such greases can result in reduced lubricant life and premature
bearing failure. When necessary, prevent such intermixing by disassembling the motor, removing all old grease from bearings and housings (including all grease fill and drain
holes). Inspect and replace damaged bearings. Fill bearing housings and bearings approximately 30% full of new grease. Remove any excess grease extending beyond the
edges of the bearing races and retainers. Refer to Table 2 for recommended greases.

RENEWAL PARTS & WARRANTY SERVICE

When inquiring for renewal parts, call the U.S. Electrical Motors Parts Department (Memphis, Tennessee) or a Parts Stocking Distributor. For warranty service call the nearest
U.S. Motors Authorized Service Station. Give them complete nameplate data including ID number, etc. Request installation & maintenance manuals by product name.

REGIONAL OFFICES PHONE FAX REGIONAL OFFICES PHONE FAX

DOMESTIC U.S. SALES (888) 637-7333 (314) 553-1101 MONTERREY, MEXICO (52) 8-389-1312 (52) 8-389-1310
INTERNATIONAL SALES (314) 553-3185 (314) 553-2135 CARACAS, VENEZUELA (58) 02-2377522 (58) 02-2329727
MONTREAL, QUEBEC/CANADA (800) 361-5509 (514) 332-5912 BOGOTA, COLOMBIA (57)1- 439-5420 (57)1- 439-5417
TORONTO, ONTARIO/CANADA (905) 475-4670 (905) 475-4672

IN109-34K 11/00 ©2000 U.S. Electrical Motors - Prices, specifications and ratings subject to change without notice. Printed in the U.S.A
Quality Control Work Instruction (QCW) UNCONTROLLED COPY
See on-line master for current revision
HUNT ENGINE INC. - HOUSTON OPERATIONS
DEDICATED TO CUSTOMER SATISFACTION

SUBJECT: DOCUMENT I.D. REVISION NO.

Production Testing - Hunt Airdyne Blower Motor Assemblies QCW 4-10-01E 1

PURPOSE:

To Establish procedure for Production Testing of Hunt Airdyne Blower Motor Assemblies.

SCOPE:

Applicable to Production Department.

PROCEDURE:

1.Prepare Test Report Form QCD129 for each unit, completing all pre-test entries.

2.As indicated on Form QCD 129, affix unit (with Aircure, if applicable) to either the customer's DC drill-
ing rig motor, our test DC motor, our balometer or our adjustable static pressure fixture.

3.Connect AC power leads from our test control/monitoring panel to the AC blower motor. Power up
unit. Confirm that frequency meter reads 60 Hz. (or 50) +/- 1.0 Hz. Confirm that blower wheel is turning
in proper direction.

4.Observe and record the data called for on Form QCD 129R3.

5.The Test Technician signs off on Form QCD 129R3 and secures approval from Engineering.

6.Upon approval, the Test Technician checks, signs and dates Form 3121A (minilla tag) and wires it to
the Airdyne.

7.The completed test reports are then given to the Production Coordinator for insertion into the applica-
ble production order.

DEFINITIONS:

FORMS:

QCD 129R3 - Test Report (supercedes TR-104)

ORIGINATED/REVISED BY: APPROVED BY: ISSUE DATE: PAGE

.Frank B. Doonan Frank B. Doonan 19 Feb 04 1
 Corporate Headquarters
Quality Control Work Instruction (QCW) UNCONTROLLED COPY
See on-line master for current revision
HUNT ENGINE INC. - HOUSTON OPERATIONS
DEDICATED TO CUSTOMER SATISFACTION

SUBJECT: DOCUMENT I.D. REVISION NO.

Production
Produc Testing - Hunt Airdyne Blower Motor Assemblies QCW 4-10-01E 1
0

This QCW replaced TP-104

REVISION SUMMARY:

None - Oringinal Issue

DISTRIBUTION (Uncontrolled Copies):

All Departmental Managers

I – Indicates revised area(s) from previous issue

Form No. QCD103 Revision 0 (1 Jul 96)

ORIGINATED/REVISED BY: APPROVED BY: ISSUE DATE: PAGE

Frank B. Doonan Frank B. Doonan 19 Feb 04 2
 Hunt Engine, Inc.
14805 South Main
Houston, Texas 77035
Tel: 713-721-9400
Fax #1: 713-721-7346
Fax #2: 713-721-0343
www.huntengine.com

14 Feb 2003

WARRANTY POLICY

HUNT ENGINE, INC. MANUFACTURED PRODUCTS

Hunt Engine, Inc. warrants the equipment to be free from defects in material and workmanship that may develop
under normal use and service within one year following delivery of the equipment. Hunt Engine agrees to
correct such defects, which examination shall disclose to Hunt Engine’s satisfaction to be defective, by
repair or replacement F.O.B. Houston, Texas and such correction shall constitute fulfillment of obligation
with respect to such defect under this warranty.

This warranty shall be Hunt Engine’s sole obligation hereunder and is in lieu of all other warranties, express or
implied, including warranties of merchantability and fitness for a particular purpose, and all other obligation or
liabilities, including consequential damages or contingent liabilities arising out of failure of any part or item or
remanufacture to operate properly, and no person is authorized to give any other warranty or to assume any
additional obligation on Hunt Engine’s behalf unless made in writing and signed by an officer of Hunt Engine, Inc.

WARRANTY EXCLUSIONS

No warranty made by Hunt Engine, Inc. under this warranty policy shall be applicable unless Hunt Engine is given
prompt notice of the defect as soon as discovered.

Likewise, no warranty made by Hunt Engine, Inc. under this warranty policy shall extend to defects which result or
arise from (I) Willful or negligent operation or handling of the equipment or component parts by the customer or
user, (II) Alteration, modification or repair of the equipment or component parts by or at the direction of the
customer or user unless authorized in writing by Hunt Engine or (III) Adoption of such equipment to uses not
recommended by Hunt Engine, Inc.

INTELLIGENT CREATIVE SOLUTIONS – DRILLING MOTOR ACCESSORIES

 6.30 3.03
2.00
7.00
NOTE:
1. ALL DIMENSIONS ARE IN INCHES
UNLESS NOTED OTHERWISE. GENERAL ARRANGEMENT
LOCKOUT SWITCH APPL.
FOR DRILLMEC MOTORS
- BK 5338 0