PPL Manual R3 - Hull 2023 - Chain

Operating and Maintenance Manual
For
Triplex & Quintuplex Pumps
Customer Name:___PPL Shipyard___P2023____

Model #:_____E-2200_______
Serial #:_22002509, 22002609, & 22002709
339 Magnolia Business Park Dr.· Magnolia, TX 77354

Ph: 281-252-7867 · Fax 281-766-1982
info: mrw@eweco.com
Operation and Maintenance Manual Page 1

2
Ellis Williams Engineering Operating And Maintenance Manual
For Triplex & Quintuplex Pumps
PREFACE
This manual is provided for guidance of those who wish to install,

repair, maintain, or adjust the EWECO pumps. The information is
intended for operators and service personnel who are familiar with
drilling equipment. It will not cover every situation that may be
encountered. Always use good, sound mechanical practices and safety
precautions.
Each pump is a combination of a basic design and optional features.

This manual provides information on all the optional features. Because
of this, some of the features described in this manual may not be
present on a specific pump. Always use good, sound mechanical practices
and safety precautions.
Specifications are in accordance with engineering design and should be

followed in all repairs. Operation and maintenance information on
equipment other than EWECO products is taken, in part, from the various
manufacturers’ service manuals. In the event of conflict between this
manual and component manufacturer’s information, the manufacturer’s
information will take preference over this manual unless specifically
stated otherwise.
The material used in the construction of the pump is satisfactory for

use in sour gas (Hydrogen Sulfide) environment if the drilling fluid
condition is maintained as specified in NACE Standard MR0175. This NACE
standard specifies:
1. Maintenance of pH 10 or higher to neutralize H2S in the drilling

formation, or
2. Use chemical sulfide scavengers, or
3. Use of a drilling fluid in which oil is the continuous phase.
Failure to control the drilling fluid as specified can result in
sulfide stress cracking for certain components and result in serious
personal injuries.
EWECO reserves the right to change, discontinue or

modify pump models at any time without notice and
without incurring any obligation.

3
! WARNING !
-BEFORE SERVICING PUMPS
1.Read manufacturers manual prior to operation or

servicing the pump.
2.Shut down or disengage the pump power source.

Failure to shut down power before servicing can
result in serious personal injury and property
damage.
3.Shut down all pump accessory equipment.
4.Relieve or “bleed off” all pressure from the pump

fluid module(s). Failure to relieve pressure before
servicing can result in serious personal injury
5.Do not use a high-pressure air or nitrogen source

for charging the suction dampener. Use only a hand
operated air pump. Over-pressure can cause
component damage resulting in personal injury.
6.Do not pipe the relief valve by-pass line into

the pump suction system piping. High-pressure
surges could cause damage to components, resulting
in personal injury.
7.Always use the rig hoist, lifting appliance, or

jib crane to lift items over 40 lbs. Failure to use
such devices could cause personal injury.
8. Always wash the inside of a pump fluid end if

the pump is to be idle for an extended period.
Microbiological action in certain drilling muds can
produce harmful quantities of sulfides if the mud
is stagnant and confined.

4
Table of Contents
Section 1 - General
INSTALLATION_______________________________________________________ 9
PREPARATION________________________________________________________ 9
FOUNDATION ________________________________________________________ 9
SUCTION PIPING ____________________________________________________ 9
DISCHARGE PIPING _________________________________________________ 10
OPERATION ________________________________________________________ 12
PRIOR TO START-UP ________________________________________________ 12
LUBRICATION_______________________________________________________ 13
OIL CAPACITIES____________________________________________________ 14
AFTER START-UP____________________________________________________ 16
MAINTENANCE ______________________________________________________ 17
DAILY ____________________________________________________________ 17
INITIAL OPERATION ________________________________________________ 18
SEMI MONTHLY _____________________________________________________ 18
MONTHLY___________________________________________________________ 19
SEMI ANNUALLY_____________________________________________________ 19
ANNUALLY__________________________________________________________ 19
STORAGE __________________________________________________________ 20
START-UP AFTER STORAGE ___________________________________________ 21
DISASSEMBLY (FLUID END)___________________________________________ 22
FLUID END MODULES ________________________________________________ 22
PISTONS AND LINERS _______________________________________________ 23
VALVES AND SEATS _________________________________________________ 23
ASSEMBLY (FLUID END) _____________________________________________ 24
FLUID END MODULES ________________________________________________ 24
PISTONS AND LINERS _______________________________________________ 25
VALVES AND SEATS _________________________________________________ 28
SUCTION LINE DAMPENER ____________________________________________ 28
DISASSEMBLY (POWER END) __________________________________________ 29
PONY RODS ________________________________________________________ 29
WRIST PINS _______________________________________________________ 29
CROSSHEADS _______________________________________________________ 30
CROSSHEAD GUIDE___________________________________________________ 30
MAIN BEARINGS_____________________________________________________ 31
CRANKSHAFT-GEAR-CONNECTING ROD____________________________________ 31
CONNECTING ROD AND BEARINGS ______________________________________ 32
CRANKSHAFT AND GEAR ______________________________________________ 32
PINION AND BEARINGS ______________________________________________ 32
ASSEMBLY (POWER END) _____________________________________________ 34
PINION AND BEARINGS ______________________________________________ 34
CRANKSHAFT AND GEAR ______________________________________________ 34
CONNECTING ROD AND BEARINGS ______________________________________ 35
MAIN BEARINGS_____________________________________________________ 36
CRANKSHAFT ASSY INSTALLATION______________________________________ 36
CROSSHEAD GUIDES _________________________________________________ 37
CROSSHEAD_________________________________________________________ 37
PONY RODS ________________________________________________________ 38

5
Table of Contents (cont’d)
STEEL FASTENER TORQUE SPECIFICATIONS (LUBED)______________________ 39

TROUBLE SYMPTOMS _________________________________________________ 39
KNOCKING-FLUID END CAUSES_________________________________________ 40
KNOCKING-POWER END CAUSES ________________________________________ 40
VIBRATION_________________________________________________________ 40
RAPID PISTON AND LINER WEAR ______________________________________ 41
LINER DIFFICULT TO INSTALL IN LINER BUSHING_______________________ 41
Section 2 – Model Specific

Performance Chart_________________________________________________ 43
Lifting Procedure_________________________________________________ 44
General Assembly Drawing__________________________________________ 45
Crankshaft Assembly_______________________________________________ 46
Crossshead Assembly_______________________________________________ 47
Pinion Assembly___________________________________________________ 48
Fluid End Assembly________________________________________________ 49
Recommended Spare Parts___________________________________________ 50
Motor Connection Arrangement______________________________________ 51
Nordlock©_________________________________________________________ 52
Lube Pump Motor (Rotary Gear)_____________________________________ 64
Section 3 – Serial Number Specific

**Documents in this section are only present if applicable
Stroke Counter____________________________________________________ 79
Junction Boxes____________________________________________________ 107
Motor Spec Sheets_________________________________________________ 109
FAT Test Reports__________________________________________________ 389

6
GLOSSARY
NOTE: Refer to figures 1 and 2 on the following page for the position
of the components in the following description.
1. Discharge Manifold – Provides connections for pulsation dampener,

pressure relief valve, and discharge pressure gauge and mud discharge
2. Chain Drive – Multiple strand roller chain running on sprockets,

providing power transmission plus speed reduction from the drive motors
or engine to the pump power end. The chain and sprockets are enclosed
with an oil tight guard with lube oil sump. A cover plate at the pump
pinion shaft provides access to a manual pump rotating device.
3. Discharge Dampener – A pulsation dampener mounted in the discharge

piping and charged to approximately 1/3 the discharge pressure for
smoothing the pulsations in the discharge piping.
4. Discharge Strainer Cross – A strainer screen installed in a flanged

cross, connected to the discharge manifold, that removes large pieces
of debris from the pump discharge. The screen should be removed
regularly, cleaned and replaced.
5. Electric Drive Motors – DC traction type motors or AC variable

frequency motors.
6. External Lube Oil Pump – Electric powered pump providing lubrication

pressure to the pump crankcase.
7. Fluid End – Mud pumping system containing modules (fluid cylinders),

suction and discharge valves, suction and discharge manifolds, liners
and pistons.
8. Crank Case Cover – Cover for the crankcase of the pump allowing
access to the crankshaft and pinion shaft.
9. Inspection Cover – Crosshead compartment – An opening for access to

the crossheads, crosshead guides, wrist pins and crosshead bearings.
10. Inspection Cover – Crank Case Cover – An opening for inspection of

the pinion and gear tooth contact.
11. Liner Wash Pump – An electric powered centrifugal pump circulating

liner wash and cooling fluid from the liner wash tank to the liner
spray nozzles.
12. Liner Wash Tank – Storage for the liner wash fluid. It is divided
into two sections, a settling section and a reservoir section. The tank
should be cleaned and filled regularly.

7
GLOSSARY (cont’d)
13. Lube Oil Filter – An external filter to clean the lube oil.
14. Oil Level Dip Stick – An oil level check on both sides of the pump.
The oil level is checked when the pump is idle.
15. Power End – Mechanical conversion of rotary input motion to

reciprocating output for powering the pistons.
16. Reset Relief Valve – A relief valve that must be reset manually.
This valve is installed in the discharge piping as near the pump
discharge manifold as possible with the valve discharge connected to
the mud tank. Set the valve relief pressure approximately 10% above the
maximum operating pressure for the liner size in use.
17. Rotation Fitting – A 2” hex bar attached to both ends of the pinion
shaft for rotating the pump manually during service.
18. Service Crane – A light duty crane mounted on the pump for handling
heavy equipment, liners, etc. when servicing the pump.
19. Suction Dampener – A pulsation dampener usually charged with low

pressure air to smooth the flow of fluid into the fluid end modules.
20. Suction Manifold – A distribution pipe bolted to the inlet openings

of the fluid end modules to supply drilling fluid to the fluid end.
This manifold may contain the suction dampener.
21. V-belt Drive – Multiple, high capacity, 8V size belts arranged in

banded sets and running on v-belt sheaves; providing power transmission
plus speed reduction from the drive motors or engine to the pump power
end. The belts and sheaves are enclosed with a ventilated safety guard.
An opening at the pump pinion shaft provides access to a manual pump
rotating device.
22. V-belt Motor Mount – A mounting frame over or behind the pump
supporting the electric drive motors or engine with provisions for
moving the motors or engine to tighten the v-belts.

8

9
INSTALLATION
PREPARATION
Planning Ahead
Proper pump installation requires thought and planning before the rig-
up is made. It is difficult and expensive to correct errors in piping,
pulsation dampener mounting, and equipment tie down after they have
been fabricated and welded in place. The following outline is intended
as a guide when planning installation and can help avoid unnecessary
and expensive corrections.
FOUNDATION
Setting Pump
Set the pump level. This is necessary for proper distribution of the
lubricating oil in the power end when the pump is running.
Temporary Support
Plank or beam foundation matting should support the pump evenly
throughout its length.
Fixed Support
Fixed or permanent installations must be leveled when the pump is set.
The foundation should support the pump evenly throughout its length.
Follow the mounting locations shown on the assembly drawing. Shim the
support points as necessary. Do Not lock the pump down unevenly as this
places the frame in an unnecessary strain.
SUCTION PIPING
Dampener Location
The EWECO flanged suction pulsation dampener must always be installed
directly inside the pump suction manifold.
NOTE:
When necessary to use a “welded in” suction line dampener it must be
mounted as close to the pump suction manifold flange as possible. To
insure satisfactory performance, never place valves or turns between
the suction line dampener and the pump suction manifold inlet.
Dampener Pressure
Precharge the suction dampener to 15 psi. Adjust the dampener charge pressure upward
or downward as necessary to obtain the smoothest operation for the specific suction
conditions of the pump. See Suction Piping Arrangement.

10
INSTALLATION
SUCTION PIPING ARRANGEMENT
EWECO triplex mud pumps need to be equipped with a properly installed
charging pump The optimum suction manifold pressure is:•50-70 psi for
maximum volumetric efficiency and expendable parts life.
COMMON SUCTION MANIFOLD

Two or more pumps may have their suction connections made to a common
manifold providing the manifold has a cross-sectional area greater than
the sum of the individual pump inlet areas. Never use a manifold with a
smaller area, as this will decrease the pump efficiency.
SUCTION LINE VALVES

Always use full opening valves such as a gate or butterfly valves.
Never use a restricting valve such as a plug valve as this type will
restrict the flow and reduce the pump efficiency.
PRESSURE RELIEF VALVE

Provide a relief valve for the piping between the pump suction inlet and the charging
pump discharge. This valve should be set at approximately 50 psi and should be mounted
in the top of the line near the suction dampener. The relief valve provides protection for
the charging pump and suction dampener in the event of a high pressure surge occurring
in the suction line.
DISCHARGE PIPING

11
INSTALLATION
Discharge Cross
The discharge piping can be simplified by using the forged discharge

cross (1) available from EWECO as optional equipment. This forged cross
provides two outlets for mud lines (2) and a mounting for the discharge
pulsation dampener on top of the cross. The cross also incorporates a
side connector for mounting a pressure gage. The complete assembly may
be flanged directly to either side (1 or 4) of the pump and is provided
with an integral support from the cross to the pump frame. See page 39
for bolt torque
Cross Strainer
The optional EWECO discharge strainer cross (3) adds an easy access
for strainer to the discharge cross described above. The strainer
should be checked and cleaned at least once a month.
Pressure Relief Valve

The pump discharge manifold end opposite the discharge cross may be
used for connecting a high pressure relief line and a by-pass line.
Always provide a full opening “manual reset” type of pressure relief
valve to protect the system against damage from over pressure. DO NOT
put any type of shut-off valve between the relief valve and the
discharge manifold. The relief valve discharge line should be the same
size as the valve discharge opening. The piping should be short,
straight, securely anchored and provide escape for the fluid back to
the mud tank. The discharge line must slope downward at least ¼” per
foot to prevent solids from settling in the line. The following are
recommendations for setting the actuation pressure of a Retsco relief
valve.
Retsco Valve
The Retsco valve has a variance of ±3%, regardless of the actuation
pressure. The last mark on the indicator’s scale represents 8000psi.
The actuation pressure should be set to 1.03 times the maximum pressure
rating of the liner being used. If the operating pressure is 7500psi,
then the actuation pressure should be set to 7725psi.
All adjustments should be made with the valve at normal operating

temperature.
! WARNING !
The relief valve must not be connected to the discharge cross for
several reasons:
1. A plugged strainer could prevent the relief valve from sensing and
relieving excessive pump discharge pressures.
2. The relief valve and its by-pass line could interfere with and
inconvenience removal of the strainer clean-out flange for periodic
cleaning of the strainer.

12
Operation
Pulsation Dampener
Always use a discharge pulsation dampener in the discharge line of each
pump to prevent harmonic vibration from damaging the discharge piping.
Mount the dampener on a discharge cross flanged directly to the
discharge manifold.
See page 39 for bolt torque.
PRIOR TO START-UP
Power End Lubrication

Remove the drain plugs from the crankcase (18) and drain any moisture
or contamination that has accumulated.
Fill the pump power end with Extreme Pressure Gear Oil. Refer to the
table below and select an oil meeting the recommended AGMA number
specification for the ambient conditions. When starting a new pump for
the first time or making a start-up after storage, open the inspection
covers and pour oil into the crosshead oil reservoir. This fills the
internal oil reservoirs and assures immediate lubrication. For those
pumps with an external lube pump (electric), make sure the pump is
operational and pumping oil through all the internal lube lines.
* Moly-lube or oil containing Molybdenum should not be used

in any roller bearing pumps *

13
LUBRICATION
POWER END
It is important that the proper crankcase oil level be maintained. The oil
level may be checked with the pump idle by following the prescribed
procedures. Allow the pump to remain idle for a five minute period before
checking the idle oil level. This will allow the oil to equalize and give a
“Full” reading at the top mark of the dipstick.
The oil should be routinely changed after six months or 2,000 hours of
operation, or if the oil has become overly contaminated. Replace the oil
with approved lubricant. At each oil change, remove the breather cap and
clean. Remove the crosshead cover and clean the setting chamber beneath
the crosshead of all sludge and debris.
PISTON AND RODS
The piston and liners are cooled and lubricated by an electrical pump
system. The system directs clean water onto the piston and liners in a
regulated flow. Water running off accumulates in the compartmentalized
sump, located below the piston rod, where it is recirculated by the lube
system. This sump collects effluent and solid waste which might not
otherwise be recirculated through the lubrication system. The sump should
be flushed at each oil change. Clean water should always be used.

14
Operation
Pump Oil Capacities
Note that the oil level is measured (17) with the pump at rest. The oil
level should be at the centerline of the lowest eccentric bearing
roller with a connecting rod throw at its lowest point during rotation.
Light Weight Triplex Pumps Oil Capacity

(Max HP Rating) (US Gallons)
EH-750 55 gal
EH-1000 75 gal
EH-2200 185 gal
EWECO Triplex Pumps Oil Capacity

E-447 40 gal
E-600/E-800 55 gal
E-1000/E-1100 110 gal
E-1300/E-1600 185 gal
E-2200 210 gal
Quintuplex Pumps Oil Capacity

EQ-750 45 gal
EQ-1000/EQ-1300 75 gal
EQ-2200 230 gal
Chain Drive Lubrication
Fill the chain case on chain driven pumps with a non detergent motor
oil. Use the following table as a guide in selecting the proper
viscosity of oil for the ambient air temperature at the pump.
SAE
Ambient Temperature
Viscosity
+20°F to +60°F No. 20W
+40°F to +120°F No. 30W
+60°F to +140°F No. 40W

15
Operation
Drive alignment
Assure that the input drives to the pump are properly aligned. There
are numerous methods available to make sure the sheaves are aligned.
EWECO recommends using a laser alignment tool. The laser line should
contact both edges of both sheaves or sprocket in the drive.
Liner Spray Lubrication

Fill the liner piston spray system with clean water and a good
synthetic fluid, such as Castrol Syntilo 9951 or equivalent or water-
soluble oil.A synthetic fluid (Castrol Syntilo 9951 or equivalent) is
most desirable when mixed with clean water. A water-soluble oil can
also be used for this purpose depending on the corrosiveness of the
water and/or drilling mud. A mixture ranging from 10-20% synthetic
fluid or soluble oil is suggested with clean water depending on the
size of the liner spray wash volume tank. If “plain” water is used
without a mixture of oil to combat heat corrosion, the operator must
exercise greater than normal care and maintenance to prevent heat and
corrosion damage to the parts in and adjacent to the liner piston
chamber. Coating the clamps and all exposed surfaces with a thread
compound will minimize the effects of corrosion. If liner spray
manifold system is used make sure the spray nozzles are properly
positioned for the size of the liner being used. The liner piston spray
system must be arranged to start before or at the same time as the mud
pump to prevent damage to the piston and liner.
Note:
Effective cooling of the piston and liner can only be accomplished when
the temperature of the coolant is below that of the drilling mud. In
some circumstances it may be necessary to provide external means for
removing the heat from the coolant fluid.
Liner Spray Pump

An electrically driven or a v-belt driven centrifugal pump is used on
all triplex mud pumps for supplying coolant to the liners and pistons.
Note:
The seal on the centrifugal pump will be damaged if the pump is allowed
to run dry; or cavitate. Maintain a flooded suction to the centrifugal
pump at all times.
Keep the oil reservoir of the centrifugal pumps utilizing oil

lubricated bearings filled to the proper level with SAE 20 motor oil.
Fluid End Check

Check to be sure the liners and pistons have been properly installed
and that the rod and liner clamps have been tightened. Make sure the
valves have been installed and that the valve covers have been
tightened.
Line Valves and Charging Pump

Open all valves in the suction and discharge lines and check to be sure
the suction charging pump is arranged to start up at the same time, or
before the start of the triplex mud pump. Never start the mud pump
ahead of the charging pump as this will result in cavitation,
incomplete filling, and damage to the
fluid end parts.
16
Operation
AFTER START-UP
Pump Speed
Bring the pump up to speed gradually. This allows the flow velocity of
the fluid in the suction line to match the requirements to the pump
without cavitation.
Suction Dampener Charge and Adjustment

The suction line pulsation dampeners are charged only with a hand-
operated air pump.
!! ATTENTION !!
USE OF HIGH PRESSURE AIR SOURCE OR NITROGEN
BOTTLE TO CHARGE THE SUCTION DAMPENER
CAN RESULT IN EQUIPMENT DAMAGE AND SERIOUS
INJURY TO PERSONNEL.
Charge the dampener to approximately 15 psi before initial start-up to
provide a cushion for the diaphragm when the charging pump is started.
However, this is only a precaution to prevent accidental damage to the
diaphragm and the proper charge and final adjustment must be determined
with the pump operating. The dampener charge level will be different
for “charged” suction operation and for
“natural” suction operation. This is readily adjusted using an ordinary
tire pump.
Lubrication
Note:
Do not operate the pump without the external lube system, if this
system is installed.
V-belt Drive
Listen to the operation of the drive under load. Squealing or increased
noise above normal condition indicates that the belts need adjustment.
The adjustment of new belts should be checked after several hours of
operation as new belts tend to “seat” in the drive and loose tension.
Check the sheave alignment during the belt tension check. A laser
alignment tool or string across the sheave edges should touch each
sheave at both the near and the far edges.

17
Maintenance
DAILY
Routine
Daily inspection and maintenance of the pump drive, power end and fluid
end will result in considerable savings by detecting minor problems
before they escalate into major repairs. Inspect pump to ensure that
all threads that are exposed to the atmosphere are coated with rust
inhibitor.
Power End
Check the pressure gages on the external lube oil filter. Clean the
strainer and the strainer magnets if the pressure differential between
the gages is greater than 15 psi when the pump is at operating
temperature.
Check the oil level in the pump end daily. Do this with pump at rest.
Chain Case
Check the oil level in the chain case of a chain driven pump daily. Do
this with the pump operating.
Belt Drives
Observe the belt drives of a belt driven pump daily. Tighten the belts
if slipping or squealing is noticed. Do this with the pump stopped and
in a safe condition. See page 34. Always check sheave alignment when
tension is adjusted.
Auxiliary Pumps
Lubricate the shaft and packing as instructed by the manufacturer.
Pistons and Liners

Observe the condition of the liners and pistons. A small amount of the
drilling fluid is washed from the liner on each stroke. This does not
necessarily indicate worn out pistons or liners. Smooth wear on the
liners normally means smooth wear on the pistons. This combination
should run until such time as the drilling fluid “by-pass” is visible
on each stroke or becomes excessive.
Cleaning Liner Chambers

Check the liner-piston coolant daily. Add as required and replace if
dirty.(Change Liner Wash fluid weekly or at the point of piston/liner
washout. Which ever occurs first) Flush the sump with fresh water
before adding clean coolant.
!! ATTENTION !!
DIRTY COOLANT WILL INCREASE WEAR OF THE

LINERS AND PISTONS AND WILL SHORTEN THE
LIFE OF THE COOLANT PUMP.
Spray Manifold
Check the spray nozzles on the liner spray manifold daily. Clean as
necessary to insure an adequate coolant-lubricant supply for the liner
and piston.
18
Maintenance
Rod and Liner Clamps
Recheck the liner and rod clamps for proper tightness after the first
few hours of operation following assembly. This allows the taper
locking assembly to become seated. Proper tightening will insure
minimum movement of the rod components.
Valve Covers
Pumps equipped with “Fast Change” style valve covers should be checked
for tightness after the first few hours of operation.
Suction Dampener
Check the pressure. It must be proper for the operating condition,
approximately 15 psi.
INITIAL OPERATION
During the first 500 hours of new pump operation, some maintenance and
inspection in addition to the daily inspection is required.
Magnets
Clean the magnets in the external oil strainer every 50 hours or until
no particles are noticed on the magnets at two inspection intervals.
Lubricating Oil
The lubricating oil should be changed at 250 hours or 3 months
operation. Which ever occurs first during the initial operating period.
Pinion and Gear

Some corrective pitting of the gear is expected during the initial
operation period. These pits should be small, round or oval and
dispersed along the pitch line of the gear teeth. They should not
expand and form single larger pits. Pitting activity should slow to a
halt during the initial operation period.
SEMI MONTHLY
Valve Cover Threads
Remove all valve covers every two weeks. Carefully clean all mud and
debris from the threads on the cover screw and in the bolt ring.
Completely grease the cleaned threads with a drill collar thread
compound. It is important that an anti-seize compound be used to
provide the necessary protection against corrosion, galling and
seizing. Do not use an ordinary tool joint “thread dope” as these
materials lack the ability to effectively protect the joint.
Valve Cover Plug and Packing

Clean and coat the top of the valve plug with the same compound used on
the valve cover threads. Inspect the valve cover packing and carefully
clean and coat the shoulder in the cylinder above the packing before
installing the plug. This is necessary to prevent cocking of the plug
and allows a full metal-to-metal lock up of the cover.
19
Maintenance
SEMI MONTHLY (cont’d)
Valve Guide Bushing
Inspect the bushing in the valve stem guide and replace if visibly
worn. A worn bushing will cause increased valve wear.
Valve and Seats

Check the valves and seats for wear. Replace cut or worn inserts
Piston Hub Seal

This is a compression seal fitting against the flange and radius on the
piston rod. The seal must not be altered or damaged. The seal must be
correctly placed in the piston hub groove.
Piston Rod Lock Nut

Replace the piston rod lock nut if it has been damaged or corroded, or
if the locking nylon has lost its ability to effectively grip the
threads. Any nut that has been used three (3) times should be replaced.
MONTHLY
Cross Strainer
The optional discharge strainer cross incorporates a strainer sleeve
that should be checked and cleaned at least once a month.
Studs and Nuts

Check all of the fluid cylinder studs and nuts for tightness, including
the valve cover bolt on rings, cylinder to frame studs, liner pilot
bushing studs, and discharge to suction studs.
Gaskets and Seals

Inspect the power end for badly leaking gaskets or loose capscrews;
replace as required.
Semi-Annually
Power End Lubrication

Drain and clean the power end oil sump and the settling area under the
crossheads every six months. Refill with proper grade of EP gear oil.
See page 5 for Grade.
Lubrication System Magnets

Clean the magnet in the oil pump strainer area.
Lubrication Lines
All lines should be in place, continuous and free of obstructions.
Annually
Crosshead Guides
Grooved crosshead guides indicate improper lubrication. Check the
lubrication system and the condition of the crosshead extension rod
seals. Replace if severely worn or scarred.
20
Maintenance
Annually (cont’d)
Clearances
Check the clearance in all bearings, the crossheads and the main gears.
Record this data for future reference. If the bearing clearance exceeds
two times the maximum installed clearances, repairs should be made. If
the clearance has increased abnormally, a more thorough inspection is
indicated to locate the source of the wear. For install clearances, see
parts catalogue.
Bolting
Check tightness of the main frame mounting bolts, and crosshead pin
retainer bolts. Check all bolting safety wires. If wires are broken,
determine the cause and correct. Tighten loosened bolts. Replace broken
safety wires.
Check the tightness of the main bearing cap bolts. For pumps with
“Super Bolts” the torque for the tightening bolts is stamped on the top
of the nut. For others, refer to the bolt toque data on page 33.
Main and Pinion Gears

Inspect the condition of the main gear and pinion gear teeth. Some
minor pitting may be noted during the “Break-in” period of the pump.
This is considered “initial pitting” or “corrective pitting”. It should
be light and limited to an area near the pitch line of the gear teeth.
It should extend across the length of the teeth. Scoring, significant
pitting or continued increase of pitting should be thoroughly inspected
and the source of the problem removed. Replace parts that are worn
beyond the recommended clearance.
STORAGE
Power End
If the pump is to be idle for longer than one week, it should be
prepared for storage. Remove the power end covers. Drain and clean the
main sump and settling tank. Coat all bearings, finished surfaces, and
the entire inside surface of the power end with a rust inhibiting oil.
Replace the covers. Raise the fluid end of the pump and block it up so
that the pump slopes downward toward the power end. Replace the main
sump drain plug with a 90° elbow. Point the elbow down and cover the
opening with a wire mesh screen. This will permit air circulation and
prevent condensation build-up.
Fluid End
Remove the fluid end valves, piston rods and liners. Clean the inside
of the fluid ends and all parts. Coat the entire fluid end, valves and
parts, with a rust inhibiting oil. Clean the liner spray system and
settling tank. Put clean oil into the liner spray pump to prevent
rusting. Coat the tank and inner spray parts with a rust inhibiting
oil.
Periodic Inspection
Inspect the pump and rotate the gears once a month. Re-coat with a rust
inhibiting oil.

21
Maintenance
START-UP AFTER STORAGE

!! ATTENTION !!
ANY PUMP THAT HAS BEEN IN STORAGE, EITHER AFTER FIELD

USE OR AS SHIPPED FROM THE PLANT WILL NEED AN INSPECTION
TO MAKE SURE IT HAS NOT BEEN DAMAGED IN ANY WAY, AND
THAT ALL PARTS ARE PROPERLY IN PLACE. FAILURE TO OBSERVE
THE FOLLOWING POINTS CAN RESULT IN SERIOUS DAMAGE.
Power End
Remove all of the covers on both the power end and the fluid end. Clean
and inspect all of the parts and the finished surfaces. Check all of
the bearings to make certain they are clean and in good condition. Fill
the power end to the proper level. Use a clean EP gear oil of the
proper viscosity. See page 5. Make sure oil is poured into the
crosshead reservoir and is worked into all of the bearings
Note:
Before Filling Crankcase with Oil
Re-Install Drain Plug.
Fluid End
The valves, pistons, liners, and all fluid end parts must be properly
installed and in good condition. Carefully tighten all of the bolts,
nuts, studs, working connections and covers. Fill the liner spray
system with a clean coolant.

22
Disassembly (Fluid End)
*refer to Section 2 for Fluid End descriptions and quantities
Suction Module/Discharge Module

The suction module portion of the two-piece fluid modules may be
removed without disturbing the discharge module. Remove the capscrews
connecting the module to the suction manifold and the nuts from the
studs holding it to the discharge module. The discharge module portion
of the two-piece fluid end may also be removed without disturbing the
adjacent modules. First, remove the suction module, the liner, piston,
liner pilot bushing, and the discharge manifold. Remove the nuts
holding the discharge module to the frame and slide it out over the
suction manifold.
Suction Manifold
It is not necessary to remove the suction manifold except for
replacement of the manifold. Remove sufficient suction piping to allow
removal of the manifold. Remove the capscrews connecting the manifold
to the suction modules and replace with the new manifold. It is good
practice to also replace the gaskets and seals connecting the manifold
to the suction modules and the suction piping.
23
Disassembly (Fluid End)

PISTONS AND LINERS
Relieve Pressure
Close the shut-off valves in the suction and discharge lines and open
the by-pass line to the mud tanks before attempting any work on the
fluid end modules, liners, pistons or valves. This relieves the
pressure in the modules and eliminates the danger of opening a valve
cover, or removing a liner clamp while the part is still under load.
Rod Clamps
The rod clamps are identical and may be removed with ordinary wrenches.
Piston Removal With Liner In Place

The two-piece piston rod permits removal of a piston without disturbing
the liner. Remove the rod clamps and rotate the pump to position the
pony rod in the rear stroke position. Remove the sub-rod. Remove the
piston rod and piston from the liner.
Piston and Liner Removal As A Unit

Remove the rod clamps and the liner lock ring. Rotate the pump to place
the pony rod in the rear position. Remove the sub-rod. Move the liner
out of the liner pilot bushing with a pry bar between the collar on the
liner and the end of the pilot bushing. Lift the piston and liner as an
assembly, up and out of the liner chamber.
Piston Cups
It is possible to change the piston cup without removing the hub from
the rod. Remove the snap ring in the front of the hub and the end plate
to permit removal of the piston cup.
Pistons/Pistons Hub Seal

The complete piston is changed by removing the piston rod nut and
sliding the straight bore piston hub off the rod. A pressure actuated
seal fits in a counterbore in the hub and seals against the radius and
shoulder on the rod. Do not alter or damage this seal.
Liner Sealing Wear Plate

In pumps with wear plates, the wear plate is retained by the liner
bushing. Remove the liner bushing and pry the wear plate from the fluid
end to replace the wear plate. A wear plate seal is located under the
wear plate. Always replace this seal.
VALVES AND SEATS

Cover Plug Packing/Valve Stem Guide
After removing valve cover screw, remove the valve cover plug. Remove
the valve cover seal from the fluid end bore. The upper valve stem
guide is attached to the valve cover plug. Remove and replace the upper
valve stem guide or the bushing as necessary.
Valves and Seats

Lift out the valve spring and valve. The valve seat can now be removed.
Always use the hydraulic valve seat puller furnished with the pump when
pulling a valve seat. This avoids the possibility of damaging the fluid
end modules with a torch.

24
Assembly (Fluid End)
*refer to Section 2 for Fluid End descriptions and quantities
Preparation
Parts should be clean and free of burrs, nicks and raised metal on the
mounting and sealing faces and bores. All parts used in an assembly
should be available and ready to install before the assembly process is
begun.
FLUID END MODULES
Liner Sealing Wear Plate
For those modules which use wear plates, install the wear plate seal in
its counterbore and follow with the wear plate.
Liner Retainer to Discharge Module

Attach the liner retainer to the discharge module and tighten the
fasteners to the proper torque. (See Torque Chart page 33).

25
Assembly (Fluid End)cont’d

FLUID END MODULES (Continued…)
Discharge Module To Frame Face

Install the discharge module to the frame and tighten the nuts finger
tight. Do not tighten securely at this time.
Suction Module To Discharge Module

Install the suction module to discharge module seal in its counterbore.
Slide the suction module over the studs and tighten the nuts to the
proper value (See Torque Chart page 33).
Liner Bushing
For those modules that use a liner bushing , place the liner bushing
over the liner studs and tighten against the wear plate. Torque the
nuts to proper value. (See Torque Chart page 33)
Tightening Suction Modules To the Suction Manifold

Always use new seals between the suction manifold and the suction
modules. Tighten the bolts evenly to the proper torque value.
(See Torque Chart page 33).
Tighten Discharge Modules To Frame Face

Tighten the nuts holding the discharge modules to the frame.
(See Torque Chart page 33). Use a rotating X pattern of tightening.
Note:
The suction module to the suction manifold connection must be tightened
before the discharge modules are tightened against the frame.
Discharge Manifold
Always use new seals between the discharge manifold and the discharge
modules. Tighten the bolts evenly to the proper torque value.
(See Torque Chart page 33)
PISTONS AND LINERS

Pistons and Piston Rods
Install the pistons on the piston rods. These pistons have a straight
cylindrical bore and are made to shoulder on the rod. A seal is used to
seal the piston hub against the shoulder on the rod.
Make sure the seal is positioned in the hub as the assembly is made up
against the shoulder on the rod.

26

PISTONS AND LINERS (cont’d)
Piston Rod Lock Nut
Inspect the piston rod lock nut and replace if the nut shows signs of
corrosion, thread damage, or the crushing effects of tightening with an
improper wrench. All piston rod lock nuts require replacement after
being made up approximately three times. The locking nylon in the end
of the nut looses its ability to grip the threads and prevent back-off.
Failure to regularly replace the piston rod nuts can lead to damaged
pistons, rods, cylinders, etc. Tighten the piston rod nut to the proper
value. (See Torque Chart page 33).
Piston and Liner Assembly

Grease the inside of the liner and the outside of the piston. Install
the piston in the liner so that the piston rod nut and the end of the
liner having the counterbore for the liner seal are on the same end.
Grease the outside of the liner.
Note:
Grease is recommended for the inside of the liner and the outside of
the piston. Do not use tool joint compounds on the piston.
Piston and Liner Installation As a Unit

Clean and dry the face of the wear plate or module. Install the liner
seal in the end of the liner. Coat the inside of the liner retainer
with a thin coat of corrosion resistant grease. Turn the pump so that
the pony rod and sub-rod are in the rear position. Then slide the liner
and piston assembly in the liner retainer and against the module or
wear plate.
Liner Nut
Grease the liner retainer and liner nut threads. Slide the liner nut in
place over the end of the liner and tighten by using a brass rod and
sledgehammer to strike the hammer lugs, until tight.
Piston Rod and Piston Installations With Liner In Place

Rotate the pump so the pony rod is in the rear position with the sub-
rod removed. Grease the piston and the liner bore. Install the piston
in the liner. Pry bar stops are located in the bottom of the frame to
facilitate this assembly.
Sub-Rod Installation
Check the faces of the piston rod, sub-rod and pony rod for upsets,
burrs, etc. Remove any raised metal on the contacting faces. Position
the sub-rod between the pony rod and piston rod and rotate the pump to
bring the connections together.

27

Piston Rod Clamps
ROD CLAMP INSTALLATION
Following is EWECO’s recommendations on how to install the Rod Clamp and what is
important to check:
Before installation, inspect both clamps and rod ends to make sure they
are free from any cracks, burrs, dings or foreign material. Any burrs
or dings can be cleaned up with a flapper wheel or fine grain grinder.
Any rod ends or clamps showing cracks must be discarded and replaced
immediately. With rod ends clean and inspected, coat the clamps with
Kopr-Kote to resist corrosion. Install the rod clamps at pony rod-sub
rod connection and sub rod-piston rod connection. Make sure the rod
clamps are facing the proper direction (arrows pointing towards the
fluid end). Once the clamps are fitted over the connection, tighten the
bolts evenly, alternating back and forth from one bolt to the other, to
the specified torque value in table 1. WARNING: Do not torque one side
to full torque value and then torque the other side to full torque
value. While tightening the bolts, repeatedly tap both halves of the
clamp lightly with a small (3lb) hammer to ensure proper seating. Make
sure the ends of the clamps are not being deformed when compared to the
center of the clamp. See figure 1 for the correct and incorrect clamp
orientation.
With new clamps, the average nominal gap between the clamps is ½”. This
dimension is for reference only and by no means is used to determine if
a part will or will not work correctly. The most important factors are
that there must be a gap between the 2 clamp halves and that the
surfaces must run parallel to each other. After repeated use and wear,
the top and bottom clamps will start coming closer together. When the
clamp halves start to touch, the clamps should be taken out of service
and replaced with new clamps.
28

Liner Spray Manifold (For Pumps Equipped)
Drop the liner spray manifold over the piston rod and slide it over the
end of the liner. Connect the hose to the outlet at the bottom of the
liner chamber. The hose may be connected to either side.
VALVES AND SEATS

Valve and Valve Insert
The valve insert is removable and is held in place with a valve lock.
Make sure the insert is securely held to the valve as a loose insert
will rapidly wear and wash the valve. Replace the valve if a new insert
extends more than 1/16” beyond the valve or if the valve is cut (washed).
Valve Seat
The taper in the module and the outside of the seat must be clean, dry
and free of nicks and burrs at assembly. Use a valve seat driver to
drive the valve seat to obtain an initial seal. Do not strike the valve
seat directly.
Valve Spring
Install the valve in the seat and center the valve spring on the valve.
Valve Stem Guide

Install a new valve stem guide bushing when the old one is worn enough
to permit 1/8” clearance between the valve stem and guide
Valve Cover Seal

Clean the seal seat in the module. Lightly grease the valve cover seal
and place it in the counterbore in the module. Replace the seal if it
is cut or broken down at the outer edges.
Valve Cover Plug

Coat the bottom seating surface and outside of the valve cover plug
with grease. Make sure the valve spring is centered on the plug.
Thoroughly coat the top surface of the plug with grease.
Threaded Ring
Coat the threads with tool joint compound. If a new threaded bolt-on
ring is being installed, tighten the nuts fastening it to the module
with the proper torque value. (See Torque Chart page 33). Use a
rotating X pattern of tightening.
“Fast Change” valve covers

Use a 2 ft. bar through the valve cover and tighten with 4 blows of a
16 lb. sledgehammer.
SUCTION LINE DAMPENER

Charge the suction line dampener to 15 psi. This dampener is precharged
using air. Adjust the dampener charge pressure upward or downward as
necessary to obtain the smoothest operation for the specifi c suction
conditions of the pump. See Suction Piping Arrangement page viii.

29
Disassembly (Power End)
*refer to Section 2 for Crosshead descriptions and quantities
PONY RODS
Pony Rod Stuffing Box
Remove the bolts mounting the pony rod stuffing box to the diaphragm
plate. Slide the stuffing box off the pony rod.
Crosshead Diaphragm Plate
Remove plate only if Stub rod flange OD is larger than the Plate ID
Unbolt and remove the diaphragm plate and the gasket. This opening is
large enough to permit the crosshead to be taken through the opening
and removed out through the liner chamber.
Pony Rod
Remove the pony rod bolts and remove the pony rod.
WRIST PINS
Crosshead Pin
The wrist pin retainer plates are faced to the outside on the right and
left crossheads. Remove the outer wrist pin retainer bolts that thread
into the crosshead. Leave the bolts in place that thread into the wrist
pin. Utilize the drilled and tapped holes in the retainer plates to
“jack” the wrist pin from the crosshead. Remove one of the outer
crossheads for access to the center wrist pin and retainer.

30

CROSSHEADS
Crossheads
The crossheads (1) can be removed through the diaphragm plate opening
and the liner chamber; after removing the Stuffing box, diaphragm
plates, and stub rods. Place a wooden board on the crosshead guide
under the connecting rod once the crosshead has been removed to prevent
scoring the guide.
CROSSHEAD GUIDES
Crosshead Guides
The crosshead guides are bolted to the main frame. Remove the crosshead
and remove the four bolts and clamp bars holding the crosshead guide.
Shims, if present, should be left in place if the guide is to be
reinstalled. If a new guide or crosshead is installed, a new shim
package and realignment is necessary.

31

MAIN BEARINGS
*refer to Section 2 for Crankshaft descriptions and quantities

Main Bearing
The main bearing can be removed without removing the crankshaft from
the floating carrier only. Use the following procedure. This same
procedure is used to removes the main bearing from the crankshaft that
has been removed from the frame. Disconnect the lube lines. Remove the
two main bearing cap nuts and the cap. Support the crankshaft assembly
to remove the downward load on the main bearings. Loosen the main
bearing retainer bolts 2 or 3 turns. Grooves are provided under the
inner bearing race with connections on the end of the crankshaft, to
permit oil pressurization, for ease of bearing removal. When the
bearing is loose on the shaft remove the retainer, shims and bearing
from the crankshaft.
CRANKSHAFT – GEAR – CONNECTING ROD
Crankshaft Assembly
The gear-crankshaft-connection rod assembly can be removed with careful
handling. Remove the wrist pins and slide the crossheads away from the
crankshaft assembly. Support the connecting rods with come-a-longs.
Disconnect the lube lines. Remove the main bearing caps. Lift the
crankshaft assembly. See the pump general assembly for clearance
dimensions and approximate weight.
32

CONNECTING ROD AND BEARINGS
Connecting Rod and Bearing
Do not remove the connecting rod or bearings unless they are to be
replaced or it is required for further disassembly. If necessary, the
connecting rods can be taken off by removing the outer bearing
retainers, removing the roller retainer ring and separating the
bearing. This separates the bearing in the connecting rod and leaves
part on the crankshaft. Remove the inner retainers and use a hammer and
brass rod to tap the bearing parts from crankshaft and connecting rod.
Wrist Pin Bearing
The outer race and roller assembly of the wrist pin bearing may be
pulled or pushed from the connecting rod using an adapter plate
slightly smaller than the O.D. of the bearing. Do not drive the bearing
from the rod with a hammer as this may damage the bearing. The inner
race of the wrist pin bearing is shrunk on the wrist pin. (Reference
the crosshead assembly shown on page 20). If the race is to be replaced
it may be heated quickly with a torch and slipped off the wrist pin.
CRANKSHAFT AND GEAR
Gear Removal and/or Turning
It is necessary to remove a connecting rod by separating the bearing to
remove the main gear. The main gear should not be removed unless it is
being replaced. The main gear is bolted to the crankshaft. The gear may
have a slight shrink fit to the crankshaft. If the gear is turned to
use the unworn side of the teeth, do not remove the main gear from the
crankshaft. It is necessary to turn the gear and crankshaft together as
a unit. The main gear is not centered in the pump therefore the pinion
shaft and pinion shaft bearing carriers must also be turned when the
main gear and crankshaft are turned.
PINION AND BEARINGS
*refer to Section 2 for Pinion descriptions and quantities

Pinion Shaft
The pinion shaft bearings are carrier mounted. This permits the pinion
and bearings to be moved out of the frame to the left or right. Remove
the oil lines and bearing carrier bolts. Jackscrew holes are provided
to push the carrier from the pump frame. Support the shaft and remove
the bearing carriers. Slide the shaft out of the pump frame. The pinion
bearing inner race and the oil seal race remain on the shaft while the
bearing outer race and rollers remain in the carrier; therefore the
carrier should remain on its original end of the shaft.
33
PINION AND BEARINGS (CONTINUED...)

Removal of Pinion with Crankshaft and Gear In Place
It is not necessary to remove the crankshaft and gear in order to
remove the pinion shaft. Removal of the bearing carriers and bearings
permits the pinion shaft to be disengaged from the gear and removed
from the pump.
Removal of Pinion Bearing Without Removing Pinion Shaft

A pinion bearing can be replaced without pulling the pinion shaft by
removing the oil lube lines and bearing carriers. Support the shaft to
prevent it from moving. Use the jackscrew holes in the bearing carriers
to jack the bearing carrier out of the frame. The inner bearing race
and seal race can be removed with a puller.
Pinion Bearings
The inner bearing race and seal race can be removed from the shaft with
a puller. The outer race and rollers can be pulled from the bearing
carrier.

34
Assembly (Power End)

General
Nuts, bolts and studs are installed with torque in accordance with page
33 unless specifically noted otherwise Nut and bolt connections located
inside the pump use lock nuts. Bolts in tapped holes inside the pump
are fitted with Nordlock© security washers (see Nordlock© info in
Section 2).
PINION AND BEARINGS
Pinion Shaft and Bearing
It is possible to install the pinion assembly with or without the
crankshaft and gear in place. Install the pinion bearing inner races
and seal races on the pinion shaft by heating to 300°F. Use an electric
oven or oil bath to heat the parts. Never apply direct flame to a
bearing. Install the pinion bearing rollers and outer race into the
bearing carrier. This is a slip fit. Install the bearing retainers and
bolts Safety washer the retainer bolts.. Place the pinion shaft into
the pump frame before installing the bearing carrier assemblies. Slide
the bearing carrier assembly and gasket over the pinion shaft and into
the pump frame. Use caution as the bearing carrier assembly meets the
inner race on the pinion shaft. Make sure the oil line holes in the
carrier are oriented to allow the oil lines to be re-installed. Press
the pinion bearing oil seal into the carrier. Use care to prevent
damage to the lip of the pinion shaft oil seal. Install the seal
retainer with the gasket and tighten in place. Cover the keyway in the
shaft to protect the seal during installation.
CRANKSHAFT AND GEAR
*refer to Section 2 for Crankshaft descriptions and quantities

35

CRANKSHAFT AND GEAR (CONT’D)
Gear Mounting
The gear pilot diameter may be a light shrink fit on the crankshaft.
The gear is held in place with bolts and locknuts. Position the
crankshaft vertically with the single eccentric side up. Support it
underneath the gear-mounting flange. If necessary uniformly heat the
gear until it slides over the pilot on the crank. Use new bolts.
Install and tighten. (See page 39 for bolt torque) Normal installation
positions the gear and pinion to the right of center, viewed while
standing at the power end looking toward the fluid end. Make sure the
gear is installed so that the gear teeth will be mesh correctly with
the pinion.
CONNECTING ROD AND BEARINGS
General
The connecting rod bearings are a shrink fit on the crankshaft. Heat
the bearings in an electric oven or oil bath to 300°F. Do not overheat.
Each bearing consists of 3 parts, outer race and rollers, inner race
and retainer ring. Keep the parts of each bearing together as sets.
Always place the bearing on the shaft so that the roller assembly may
be removed by removing the retainer ring. Always place the bearing
races against a stop. The stop may be a shoulder or a set of bolt-on
retainers.
Connecting Rods
Warm the connecting rod to 200°F. If heating with a torch, Do not apply
flame directly to the rod. Keep torch moving to apply uniform heat.
Slide the connecting rod bearing down into the rod. Hold the bearing
tight against the shoulder until the rod cools. Install the segmented
retainers to lock the bearing in place. Tighten the retainer bolts.
(See Torque Chart page 33) Nordlock© the retaining bolts.
Center or Inner Connecting Rod Bearings
The bearing must install against a stop on the crankshaft. Warm the
bearing to 200°F. Slide the bearing on the crankshaft with the loose
ring leading. The bearings are identical in size requiring the center
bearing to be slipped over the end-bearing journal. Hold the bearing
against the stop until it is cool. Install segmented retainers to lock
the bearing in place. Tighten the retainer bolts (See Torque Chart
page 33) Nordlock© the retaining bolts.
Outer Connecting Rod Bearings
All center connecting rods and bearings must be completely installed
before the outer bearing is placed on the crankshaft. Bolt-on retainers
are used to form the stop for the outer bearing. Slide the bearing on
the crankshaft with the loose ring of the outer race leading. Hold the
bearing against the stop until it is cool. Install the segmented
retainers to lock the bearing in place and tighten the retainer bolts.
(See page 39 for bolt torque)
Wrist Pin Bearing Outer Race and Roller Assembly
Warm the connecting rod to 200°F. If heating with a torch, Do Not apply
directly to the rod. Keep torch moving to apply uniform heat. Slide the
wrist pin bearing into the rod. Insure that the ends of the bearing are
flush with the sides of the connecting rod. Hold until cool. There are
no bearing retainers.
Note:
Both the connecting rod bearing and wrist pin bearing may be installed
at the same time, if necessary or desirable.
36

MAIN BEARINGS
Installation
These bearings are double row, spherical roller bearings with a tapered
bore. Match the tapers and install bearing until straight and snug. Use
the bearing retainer and bolts to draw the inner bearing race up onto
the taper until the internal clearance between the outer race and the
rollers is .005” to .008”. Use a feeler gauge to check this clearance.
Measure the shim gap between the retainer and the end of the
crankshaft. Remove the retainer and reinstall with this amount of
shims. Tighten the retainer bolts to the proper torque valve.
(See page 39 for bolt torque) Recheck the internal bearing clearance.
CRANKSHAFT ASSEMBLY INSTALLATION
Crankshaft Assembly
Place pieces of wood on the lower crosshead guides to protect the
guides from being damaged by the connecting rods during crankshaft
assembly installation. For crankshaft assembly installation use the
same lifting procedure as used for the crankshaft assembly removal.

37

CROSSHEAD GUIDES
*refer to Section 2 for Crosshead descriptions and quantities
Crosshead Guides
The crosshead guides are bolted into the main frame with clamp bars and
bolts. Install the guides in the frame without shims, and tighten
securely. Check the clearance over an installed crosshead using a
feeler gage between the top of the crosshead and the top guide at front
and rear of each guide. The measurements should be uniform. Operating
clearance should be no less than .014” and a maximum of .030”.
Final Clearance Check

Always check the crosshead clearance after the Wrist pin retainer is
tightened. Use a long feeler gauge and check the clearance in several
places.
CROSSHEAD
Pack the wrist pin bearing rollers with grease to insure the rollers
stay against the outer bearing race during wrist pin installation.
Place the end of the connecting rod inside the crosshead and align the
bearing with the crosshead hole. Insert the small end of the wrist pin
and push the wrist pin through the crosshead and wrist pin bearing
Do not force or drive the wrist pin. The pin is a close fit in the
bearing; however, it must not bind in the bearing.
Wrist Pin Retainer Plate
Align the lubrication holes in the retainer plate and the wrist pin.
Bolt the retainer plate to the installed wrist pin and torque the
bolts. Rotate the wrist pin-retainer plate assembly to align the holes
in the retainer plate and the crosshead. Tighten the retainer plate to
crosshead bolts (10) to 125-ft-lbs.

38

PONY RODS
Pony Rod Installation
Unbolt and remove the diaphragm plate from the crosshead compartment.
These plates are line bored with the pump frame and must not be
interchanged. The diaphragm plates are marked 1, 2, 3. Bolt the pony
rod to the crosshead and torque the grade 8 bolts to their proper
value. (See page 39 for bolt torque) Make sure all the mating surfaces
are free of nicks and/or burrs. Slide the diaphragm plate and gasket
over the pony rod and bolt the diaphragm plate to the pump frame.

39
STEEL FASTENER TORQUE SPECIFICATIONS (LUBED)1

SAE GRADE 5 SAE GRADE 8 ASTM A193 GRADE B7
FASTENER THREAD FASTENERS FASTENERS FASTENERS (STUDS)2
SIZE SERIES USA METRIC USA METRIC USA METRIC
fractional UNITS UNITS UNITS UNITS UNITS UNITS
(decimal) (ft-lb) (N-m) (ft-lb) (N-m) (ft-lb) (N-m)
1/4 20 UNC 6 9 9 12
(0.250) 28 UNF 7 10 10 14
5/16 18 UNC 13 18 18 25
(0.313) 24 UNF 14 20 20 28
3/8 16 UNC 23 31 33 44
(0.375) 24 UNF 26 36 37 50
7/16 14 UNC 37 50 52 71
(0.438) 20 UNF 41 56 58 79
1/2 13 UNC 57 77 80 108
(0.500) 20 UNF 64 86 90 122
9/16 12 UNC 82 111 115 156
(0.563) 18 UNF 91 123 128 174
5/8 11 UNC 113 153 159 215 128 174
(0.625) 18 UNF 128 173 180 244 145 197
3/4 10 UNC 200 271 282 382 227 308
(0.750) 16 UNF 223 302 315 427 254 344
7/8 9 UNC 322 437 455 617 366 497
(0.875) 14 UNF 355 481 501 679 404 547
1 8 UNC 483 655 682 924 549 745
(1.000) 14 UNS 541 734 764 1036 615 834
1-1/8 7 UNC 595 807 966 1309 778 1055
(1.125) 8 UN 618 839 1003 1360 808 1095
12 UNF 668 906 1083 1469 873 1183
1-1/4 7 UNC 840 1139 1363 1848 1098 1488
(1.250) 8 UN 869 1178 1409 1910 1135 1539
12 UNF 930 1262 1509 2046 1216 1648
1-3/8 6 UNC 1102 1494 1787 2423 1439 1952
(1.375) 8 UN 1178 1598 1911 2591 1539 2087
12 UNF 1254 1701 2034 2758 1639 2222
1-1/2 6 UNC 1462 1983 2371 3215 1910 2590
(1.500) 8 UN 1555 2108 2521 3418 2031 2754
12 UNF 1645 2231 2668 3618 2149 2914
1-3/4
8 UN 3305 4482
(1.750)
2
8 UN 5025 6814
(2.000)
BOLT AND
CAPSCREW
B7 Studs
MARKINGS ON HEAD
NOTES:
1
ALL TORQUE VALUES GIVEN ARE FOR LUBRICATED FASTENERS.
2
ALL STUDS USED ON EWECO PUMPS ARE GRADE B7. NUTS ON STUDS SHOULD BE
TORQUED TO GRADE B7 SPEC EVEN IF THE NUT ITSELF IS GRADE 8.
40
TROUBLE SYMPTOMS
KNOCKING – FLUID END CAUSES
o Improper pre-charge or operation of discharge or suction pulsation
dampeners: Keep discharge dampener pre-charged with nitrogen to 400 to
650 psi.
o Loose valve seats, washed out valves or seats, valves cocked in
seats: Check for loose seats
by pulling up sharply on bottom of seat with a jerk hammer. Examine
valves for uneven wear, fluid cuts, and loose valve inserts.
o Loose piston hubs: Check piston nut for proper tightness.
o Charging pumps output too low: Charge pressure in the suction
manifold should be between 50 and 70 psi with the mud pump operating.
o Charging pump packing loose or worn out permitting air to be drawn
into suction: While running the charge and mud pumps, hose water over
the packing area. If knocking stops adjust or replace packing.
o Restriction in suction line or plugged suction line strainer (if one
is used).
o Air or gas in mud: Examine mud pits for excessive bubbles. Check that
mud return lines terminate below mud level. Check degassing equipment.
o Loose or worn piston rod clamps. The two clamp faces must never meet
metal-to-metal. There should be no relative movement between rod and
clamp.
o Discharge cross strainer plugged with trash preventing proper
discharge dampening.
o Swollen valve stem guide inserts causing valves to stick.
Note:
Most pump knocking problems are fluid end related. All
checks upon the fluid end of the pump should be performed
before investigating the power end.
KNOCKING – POWER END CAUSES
o Loosen wrist pin: Remove outer screws in retainer plate and bump pin
lightly. If pin moves easily in crosshead, re-torque and re-shim.
o Upset on crosshead liner.
o Excessive clearance (over .018”) in crosshead or connecting rod
bearing.
VIBRATION
o Unbalanced drive sprockets or sheaves.
o Slack drive chains or belts.
o Inadequate pump support.
o Drive chains composed of both new and old sections.
o Motors not synchronized on a dual shunt wound, D.C. Motor Drive: To
check – isolate one motor by disconnecting one drive chain or belt and
operating pump with one motor.

41
TROUBLE SYMPTOMS
RAPID PISTON AND LINER WEAR
o Insufficient coolant sprayed into liner causing overheating: Check
spray manifold nozzles or holes in drilled rods for plugging.
o Coolant too hot (over 100°F): Use a larger coolant sump or heat
exchanger or switch to a non-recirculating clean water system.
o Coolant contaminated with trash and mud.
o Mud has high concentration of sand or solids: Generally results in
streaked liner bores. Check de-sanders and clean mud tanks.
o Oil base muds can deteriorate piston cups and valve disc if aniline
point of oil is less than 150°F. Check with suppliers and use special
pistons and valve discs.
o Corrosive mud attacks liners. The mud pH should be above 8.5. See
page ii. Use premium liners with corrosive muds.
o Hydrogen sulfide attacks piston cups.
LINER DIFFICULT TO INSTALL IN LINER BUSHING
o Paint on the two pilot diameters of the liner: Remove paint with
emery cloth.
o Liner bushing “egg-shaped”. Replace liner bushing.
o Burr on piloting diameters inside liner bushing. Remove burr.
o Trash on wear plate. Wear plate and liner end must be clean and dry.
Note:
Always coat the liner piloting diameters with drill collar compound
before installation.

Section 2
Model Specific Information

EWECO
E-2200 HIGH PERFORMANCE TRIPLEX
CONTINUOUS DUTY PUMP PERFORMANCE CHART
Strokes
E-2200 Per Min.
110 100 90 80 70 60
High Performance
15” Stroke Triplex Input HP** 2200 2000 1800 1600 1400 1200
Discharge
Plunger/Piston Output
Size
Pressure
Gal/Rev
OUTPUT - Gallons Per Minute*
Rating
9” 2,628 12.393 1363 1239 1115 991 868 744
8 ½” 2,946 11.054 1216 1105 995 884 774 663
8” 3,326 9.792 1077 979 881 783 685 588
7 ½” 3,784 8.606 947 861 775 689 602 516
7” 4,344 7.497 825 750 675 600 525 450
6 ½” 5,038 6.464 711 646 582 517 452 388
6” 5,912 5.508 606 551 496 441 386 330
5 ½” 7,036 4.628 509 463 417 370 324 278
5” 7500* 3.825 421 382 344 306 268 230
*BASED ON 100% VOLUMETRIC EFFICIENCY; ** BASED ON 95% MECHANICAL EFFICIENCY
ELLIS WILLIAMS ENGINEERING ALL ROLLER BEARING PUMP DESIGN HAS PROVEN TO BE GREATER THEN 98% MECHANICALLY EFFICIENT AT SPEED
Features
MINIMUM WEIGHT/MAXIMUM PERFORMANCE WITH CONTINUOUS DUTY LIFE EXPECTANCY
HIGH PERFORMANCE STEEL FABRICATED POWER END WITH STEEL HERRINGBONE GEARS
ANTI-FRICTION ROLLER BEARINGS THROUGHOUT
FORGED STEEL ECCENTRIC CRANKSHAFT
DOUBLE (REDUNDANT) FAILSAFE INTERNAL LUBE SYSTEM
METAL TO METAL LINER LOCK
HIGH CAPACITY LINER WASH SYSTEM
Classification General Duty

INPUT HORSEPOWER RATING………………….…….……………………….. 2200
PUMP SPEED………………………………………….…….…………………….. 110
STROKE LENGTH…………………………………………….…………………... 15”
MAXIMUM PISTON SIZE………………………………………………………... 9”
FLUID END WORKING PRESSURE RATING….………………………………. 7500 PSI
DISCHARGE CONNECTION SIZE………………………………………………. 5” FLANGE
SUCTION CONNECTION SIZE………………..……..………………………….. 12” FLANGE
VALVE SIZE………………………………………………………………………. API 7
LINER STYLE………….…………………………………………………….......... EWECO
CRANKCASE OIL CAPACITY…………………………………………………... 210 GALLONS
LINERWASH CAPACITY………………………………………………………… 290 GALLONS
PUMP WEIGHT COMPLETE, LESS SKID……..……………………………….. 82,490 LBS
WEIGHT WITH PACKAGE………………………………………………………. 121,000LBS
INTERNAL GEAR RATIO…..………………………….……………………….... 4.85 : 1
DRIVE SHAFT DIA……………………...………………………………………... 9 ¾”
Ellis Williams Engineering Co., Inc.
P.O. Box 1309, Tomball, TX 77377-1309
327 Magnolia Business Park Dr., Magnolia TX 77354
Tel: (281) 290-9637 Fax: (281) 290-6157

Recommended Spares
ITEM P/N DESC QTY.
1 1231112 ROD-PONY 2
2 1231119 PACKING-PONY ROD 9
3 1231179 BAFFLE DISC 2
4 1231207 ROD-PISTON 2
5 1231208 CLAMP-PISTON ROD 4
6 1244330 LINER-7.0" 12
7 215528-06 LINER-6.5" 12
8 215528-07 LINER-6.0" 12
9 215528-08 LINER-5.5" 12
10 1244331 LINER-5.0" 12
12 1250208 PISTON ASSEMBLY-7.0" URETHANE 12
18 1165638 VALVE-API 7 48
19 781613 SEAT, API 7 48
20 781573 SPRING API 7 48
21 1231222 FLUID END QUANTUM-STUDDED 1
22 1231223 GASKET-DISCHARGE MANIFOLD 6
23 1231224 RING-VALVE COVER 1
24 1231225 LOCK-VALVE COVER 1
25 1231226 COVER-VALVE 1
26 1231228 VALVE GUIDE-DISCHARGE 6
27 1231229 GASKET-VALVE COVER 36
28 1231230 BACKUP RING-VALVE 2
29 1234480 SUCTION POT-E2200 1
30 1234481 FLANGE-SUCTION, E2200 1
31 1231232 GUIDE-SUCTION VALVE, E2200 6
32 1231233 BUSHING-SUCTION VALVE GUIDE 12
33 1231234 GASKET-SUCTION VALVE 24
34 1231235 BACKUP RING-SUCTION E2200 2
35 1234482 COUPLING-6 VITAULIC 2
36 1231236 GASKET-VICTAULIC SUCTION ELBOW 12
37 1231237 ELBOW-90 DEG. 6 VITAULIC, 1
38 1231238 ADAPTOR-SUCTION 1
39 1231239 GASKET-SUCTION FLANGE, 24
40 1240985 PUMP-LINERWASH 1
41 1236173 REPLACEMENT FILTER FOR Y15-149-5-M 4
42 1236243 VALVE-RESET RELIEF RX 7500 PSI 1
43 1240987 PUMP-EXTRNL LUBE # 2,W/ MOTOR CW ROTATION 1
44 1236580 GAUGE, 0-10K MODEL 8 2-1/16 API 10K 1
45 776447 BLADDER-L20, HYDROGENATED 4
46 PA299 VALVE-CHARGING L20 DAMPENER 1
47 1254323 HOSE-CHARGING L20 7500 PSI 1
48 1248659 NUT-LOCK 1-1/2-8 12
49 1231181 GASKET-WEAR PLATE 18
50 1244282 GASKET-LINER 5.0 / 5.5 48
51 1244283 GASKET-LINER 7.0/7.5 48

US ENGLISH • UNC
Technical information

A closer look
NORD-LOCK’s proven wedge-locking method meeting DIN 25201 utilizes

tension instead of friction to secure a bolted joint, making it superior to
traditional methods.
The NORD-LOCK bolt securing system

incorporates a pair of washers that have α>β
cam faces on one side with the cam angle α
“a“ greater than the thread pitch "b”.

In addition, there are radial teeth on the
opposite sides. The pre-assembled washers β
are installed in pairs, cam face to cam face.
When the bolt and/or nut is tightened the teeth of the NORD-LOCK washers
grip and lock the mating surfaces, allowing movement only across the cam faces.
Any rotation of the bolt/nut is blocked by the wedge effect of the cams.

The talent behind
the curves
Working together with us can optimize your applications. Put your bolted
joints to the test simulating a worst-case scenario. At our in-house laboratory
we run vibration tests and measure torque-load ratios.
The Junker vibration test meeting DIN 65151 is an excellent method for testing and comparing the security
of bolted joints. In a Junker test the bolted joint is subjected to transverse movements while the tension is
being continuously measured by a load cell.
The diagram displays NORD-LOCK´s superior performance. Most of the commonly used locking devices show
limited holding performance when exposed to vibration. Whereas, bolted joints secured with NORD-LOCK
washers only lose some of the initial preload due to normal settlements between the contact surfaces.
NORD-LOCK’s unique wedge-locking function is proved by the clear increase in clamp load during untightening.
Vibration test Untightening

bolt M8, grade 8.8, with clamp length 25 mm
Clamp load [kN]
Regular nut M8 on bolt with Nord-Lock

at 70% of yield point
Regular nut M8 on bolt, clamp length
50 mm
Nylon-inserted nut
Split ring
Regular nut M8 on bolt
Load cycles
The unique wedge-locking action of the NORD-LOCK washers can easily be verified. Tighten a bolted joint with NORD-LOCK,
then untighten. During untightening, sliding must always occur between the cam faces of the washers. Upon overriding
of the cams a “click effect” should be felt when the nut/bolt comes loose. Visual inspection of the mating surfaces should
show clear impression marks made by the radial teeth of the washers. When these criteria are met, NORD-LOCK washers
will safely lock bolted joints exposed to severe vibration and dynamic loads.

High quality material
NORD-LOCK washers are available in a variety of materials, which
all comply with European directives on ELV & RoHS.
Our standard steel washers are coated with the zinc flake coating
Delta Protekt®. The process includes a base and top coat.
Zinc flake coated NORD-LOCK washers endure a minimum of 600

hours of salt spray testing in accordance with ISO 9227. The image
to the right shows a sample of zinc flake coated NL24 washers after
1000 hours of salt spray testing.
NORD-LOCK steel washers are made of EN 1.7182 or equivalent alloy. All steel washers are
through hardened.
NORD-LOCK stainless steel washers (A4) are made of EN 1.4404 (US standard AISI 316L) or
equivalent alloy. All stainless steel washers are surface hardened.
Other steel alloys available on request

254SMO - for highly corrosive environment - made of EN 1.4547 or equivalent alloy
INCONEL® 718 - for high temperature environment - made of EN 2.4668 or equivalent alloy
INCONEL®/HASTELLOY® C-276 - for acid environment - made of EN 2.4819 or equivalent alloy
Hardness table
Zinc flake coated
Washer type Range Non-coated
(flZnnc - 600)
Steel (through hardenend) NL3 – NL130 > 465 HV1
Stainless steel A4 (surface hardened) NL3 ss – NL80 ss > 520 HV0.05
Please note: In order to assure the unique mechanical locking function of the NORD-LOCK washers, the hardness
of the mating surfaces must be lower than the hardness of the NORD-LOCK washers (see table above).

Counter-bores & slots
NORD-LOCK’s outer diameters are suitable for counter-bores. In
addition, washers with enlarged outer diameter (sp) are available
for use on large/slotted holes, painted surfaces or soft materials,
e.g. aluminium. For optimum results use NORD-LOCK sp washers
together with flanged nuts/bolts. Flanged nut with NL sp
(enlarged outer diameter)
Vibration test slotted holes

Clamp load [kN]
Flanged nut with Nord-Lock sp (enlarged outer diameter)

Regular nut with Nord-Lock sp (enlarged outer diameter)
Regular nut with Nord-Lock standard (standard outer diameter) Regular nut with NL sp
(enlarged outer diameter)
Load cycles
Example for Junker vibration of M12 bolt (8.8) Regular nut with NL
(standard outer diameter)
Painted surfaces
NORD-LOCK washers safely secure bolted

Painted surface after use of joints on painted surfaces provided the
Nord-Lock with enlarged
outer diameter
washers’ teeth properly impress into the
painted mating surface. Upon untighten-
ing sliding will occur between the cam
faces of the washers assuring the unique
wedge-locking effect while avoiding any
Painted surface after use of
Nord-Lock with standard abrading of the painted surface.
diameter

Minimize torsional
stress
During tightening, bolts are subjected to both tensile and torsional stress.
The desired tensile stress (clamp load) is achieved when the bolt is axially
elongated. Unwanted torsional stress (twisting) in bolts arises during
tightening due to friction between the contact surfaces in the threads.
High thread friction increases twisting of the bolts and causes yielding at
lower clamp load levels than normal.
Applying an adhesive significantly increases thread

Yield points:
friction during tightening. The graph to the right
Clamp load [kN]
lubricated thread
shows that when tightening bolts with adhesives
on the threads, only half as much clamp load was
dry thread
obtained before reaching the yield points compared
to when tightening similar bolts lubricated. Since adhesive on thread
NORD-LOCK’s unique wedge-locking technique is
not affected by lubrication, the thread friction, and
thereby also the torsional stress, can be minimized.
In addition, the diagram shows that at any given

torque value the clamp load deviation for lubricated
bolts is very low. Using NORD-LOCK washers to-
gether with lubrication, bolted joints will be safely Torque [Nm]
locked at the highest possible preload level.
Example of a torque-load diagram for M12 bolt (8.8)

NORD-LOCK washers can be used
with standard and high grade bolts.
NORD-LOCK for
tapped holes.
NORD-LOCK washers are

sized for counter-bores.
Through holes require two

pairs of NORD-LOCK.
For stud bolts NORD-LOCK

washers lock the nut, and
eliminate the need for
adhesives.
Use a flanged nut/bolt

together with NORD-LOCK
“sp” washers for slotted
holes or on soft material.
NORD-LOCK washers must

not be used on washers that
are not captivated in place.

NORD-LOCK washer dimensions UNC - preassembled pairs
STEEL, ZINC FLAKE COATED (DELTA PROTEKT ®) - ELV & RoHS compliant
Washer Bolt size øi øo Thickness T Min. package Approx. weight

size UNC Metric [inch] [inch] [inch] [pairs] lbs / 100 pairs
NL3 #5 M3 0.13 0.28 0.07 200 0.09
NL3.5 #6 M3.5 0.15 0.30 0.07 200 0.07
NL3.5sp #6 M3.5 0.15 0.35 0.07 200 0.13
NL4 #8 M4 0.17 0.30 0.07 200 0.09 Øi
NL4sp #8 M4 0.17 0.35 0.07 200 0.13
NL5 #10 M5 0.21 0.35 0.07 200 0.11
NL5sp #10 M5 0.21 0.43 0.07 200 0.24
NL6 M6 0.26 0.43 0.07 200 0.15
NL6sp M6 0.26 0.53 0.10 200 0.44
NL3 – NL8
NL1/4” 1/4” 0.28 0.45 0.07 200 0.18
NL1/4”sp 1/4” 0.28 0.53 0.10 200 0.40 Ø i ±0.004 inch
NL8 5/16” M8 0.34 0.53 0.10 200 0.33 NL10 – NL42
NL8sp 5/16” M8 0.34 0.65 0.10 200 0.64 Ø i ±0.008 inch
NL3/8” 3/8” 0.41 0.65 0.10 200 0.51
NL3/8”sp 3/8” 0.41 0.83 0.10 200 1.01 NL45 – NL130
NL10 M10 0.42 0.65 0.10 200 0.51 Ø i +0.02/-0 inch
NL10sp M10 0.42 0.83 0.10 200 0.97
NL11 7/16” M11 0.45 0.73 0.10 200 0.64
NL12 M12 0.51 0.77 0.10 200 0.64
NL12sp M12 0.51 1.00 0.13 100 2.01
NL1/2” 1/2” 0.53 0.77 0.10 200 0.60
NL1/2”sp 1/2” 0.53 1.00 0.13 100 2.05
NL14 9/16” M14 0.60 0.91 0.13 100 1.39
Øo
NL14sp 9/16” M14 0.60 1.21 0.13 100 3.22
NL16 5/8” M16 0.67 1.00 0.13 100 1.52
NL16sp 5/8” M16 0.67 1.21 0.13 100 2.84
NL18 M18 0.77 1.14 0.13 100 1.87
NL18sp M18 0.77 1.36 0.13 100 3.48
NL3 – NL24
NL3/4” 3/4” 0.79 1.21 0.13 100 2.31
NL3/4”sp 3/4” 0.79 1.54 0.13 100 4.85
Øo ± 0.008 inch
NL20 M20 0.84 1.21 0.13 100 2.09 NL27 – NL42
NL20sp M20 0.84 1.54 0.13 100 4.48 Øo ±0.012 inch
NL22 7/8” M22 0.92 1.36 0.13 100 2.84
NL22sp 7/8” M22 0.92 1.65 0.18 50 7.30 NL45 – NL130
NL24 M24 1.00 1.54 0.13 100 3.70 Øo +0/-0.08 inch
NL24sp M24 1.00 1.91 0.18 50 9.94
NL1” 1” 1.10 1.54 0.13 100 3.37
NL1”sp 1” 1.10 1.91 0.18 50 9.26
NL27 M27 1.12 1.65 0.26 50 7.25 T
NL27sp M27 1.12 1.91 0.26 25 11.88
NL30 1 1/8” M30 1.24 1.85 0.26 50 9.26 NL3 – NL24
NL30sp 1 1/8” M30 1.24 2.30 0.26 25 19.75 T ± 0.01 inch
NL33 1 1/4” M33 1.35 1.91 0.26 25 8.75
NL27 – NL42
NL33sp 1 1/4” M33 1.35 2.30 0.26 25 18.32
T +0/-0.02 inch
NL36 1 3/8” M36 1.47 2.17 0.26 25 12.32
NL36sp 1 3/8” M36 1.47 2.48 0.26 25 20.17 NL45 – NL130
NL39 1 1/2” M39 1.59 2.30 0.26 25 13.85 T ± 0.03 inch
NL42 M42 1.70 2.48 0.26 25 16.46
NL45 1 3/4” M45 1.82 2.76 0.28 25 * 22.49
NL48 M48 1.95 2.95 0.28 25 * 26.46
* NL45–NL130
NL52 2” M52 2.11 3.15 0.28 25 * 28.66
NL56 2 1/4” M56 2.33 3.35 0.28 10 * 29.76 upon inquiry
NL60 M60 2.48 3.54 0.28 10 * 33.51
NL64 2 1/2” M64 2.64 3.74 0.28 10 * 36.82 Materials and dimensions are
NL68 M68 2.80 3.94 0.37 1* 62.15 subject to change without
NL72 M72 2.96 4.13 0.37 1* 67.68 prior notice.
NL76 3” M76 3.11 4.33 0.37 1* 73.43 Please consult our website
NL80 M80 3.27 4.53 0.37 1* 79.41 for current dimensions:
NL85 M85 3.47 4.72 0.37 1* 83.42 www.nord-lock.com
NL90 M90 3.64 5.12 0.37 1* 105.09
NL95 M95 3.83 5.31 0.37 1* 109.81
NL100 M100 4.07 5.71 0.37 1* 129.87
NL105 M105 4.27 5.91 0.37 1* 135.10
NL110 M110 4.46 6.10 0.37 1* 140.32
NL115 M115 4.66 6.50 0.37 1* 165.96
NL120 M120 4.86 6.69 0.37 1* 171.83
NL125 M125 5.06 6.81 0.37 1* 168.94
NL130 M130 5.25 7.01 0.37 1* 174.54

Torque guidelines [ftlb]
Nord-Lock zinc flake coated (Delta Protekt®) washers

with electro zinc plated bolt (grade 5)
Oil, GF=0,75 GTP600, GF=0,75 Dry, GF=0,62
µg = 0,10, µw = 0,16 µg = 0,08, µw = 0,15 µg = 0,15, µw = 0,18
Washer Bolt Pitch Torque Clamp load Torque Clamp load Torque Clamp load
size size [TPI] [ftlb] [lb] [ftlb] [lb] [ftlb] [lb]
NL3 #5 40 1.1 550 1.0 550 1.1 450

NL3.5 #6 32 1.4 630 1.3 630 1.5 520
NL4 #8 32 2.7 970 2.4 970 2.6 800
NL5 #10 24 3.9 1,200 3.5 1,200 4.0 1,000 Torque guidelines for other bolt
NL1/4” 1/4 20 9.1 2,200 8.3 2,200 9.0 1,800
grades are available on request
NL8 5/16 18 18 3,600 16 3,600 18 3,000
NL3/8” 3/8 16 30 5,400 28 5,400 31 4,400 through your local NORD-LOCK
NL11 7/16 14 47 7,300 42 7,300 47 6,100 representative.
NL1/2” 1/2 13 73 9,800 66 9,800 74 8,100
NL14 9/16 12 104 12,600 94 12,600 104 10,400
NL16 5/8 11 145 15,600 131 15,600 146 12,900
NL3/4” 3/4 10 254 23,100 230 23,100 257 19,100
NL22 7/8 9 408 31,900 369 31,900 413 26,400
NL1” 1 8 617 41,800 557 41,800 624 34,600
GTP600 = graphite lubricant
NL30 1 1/8 7 771 46,400 697 46,400 780 38,400
GF = ratio of yield point
NL33 1 1/4 7 1075 58,900 969 58,900 1090 48,700
µg = thread friction
NL36 1 3/8 6 1410 70,200 1270 70,200 1430 58,100
NL39 1 1/2 6 1860 85,500 1670 85,500 1880 70,600 µw = washer friction
Nord-Lock Delta Protekt® with non-plated bolt (grade 8) Nord-Lock Delta Protekt® with ASTM A574 bolt, (high-grade)
Oil, GF=0,71 GTP600, GF=0,75 Oil, GF=0,71 GTP600, GF=0,75

µg = 0,13, µw = 0,14 µg = 0,08, µw = 0,13 µg = 0,13, µw = 0,12 µg = 0,08, µw = 0,11
Washer Bolt Pitch Torque Clamp load Torque Clamp load Washer Bolt Pitch Torque Clamp load Torque Clamp load
size size [TPI] [ftlb] [lb] [ftlb] [lb] size size [TPI] [ftlb] [lb] [ftlb] [lb]
NL3 #5 40 1.5 740 1.3 780 NL3 #5 40 1.7 870 1.6 910
NL3.5 #6 32 1.9 840 1.7 890 NL3.5 #6 32 2.2 990 2.0 1,050
NL4 #8 32 3.5 1,300 3.1 1,400 NL4 #8 32 3.8 1,500 3.7 1,600
NL5 #10 24 5.1 1,600 4.6 1,700 NL5 #10 24 5.8 1,900 5.5 2,000
NL1/4” 1/4 20 12 2,900 11 3,100 NL1/4” 1/4 20 13 3,400 12 3,700
NL8 5/16 18 24 4,900 21 5,100 NL8 5/16 18 26 5,700 23 6,000
NL3/8” 3/8 16 41 7,200 36 7,600 NL3/8” 3/8 16 45 8,400 39 8,900
NL11 7/16 14 64 9,800 56 10,400 NL11 7/16 14 70 11,500 60 12,200
NL1/2” 1/2 13 99 13,100 86 13,900 NL1/2” 1/2 13 109 15,400 93 16,300
NL14 9/16 12 138 16,800 122 17,800 NL14 9/16 12 148 19,800 141 20,900
NL16 5/8 11 197 20,900 171 22,100 NL16 5/8 11 216 24,600 184 26,000
NL3/4” 3/4 10 346 30,900 299 32,700 NL3/4” 3/4 10 378 36,400 321 38,400
NL22 7/8 9 556 42,700 479 45,100 NL22 7/8 9 607 50,200 514 53,000
NL1” 1 8 840 56,000 724 59,200 NL1” 1 8 916 65,900 776 69,600
NL30 1 1/8 7 1190 70,600 1030 74,500 NL30 1 1/8 7 1300 83,000 1100 87,700
NL33 1 1/4 7 1660 89,600 1430 94,600 NL33 1 1/4 7 1810 105,000 1530 111,000
NL36 1 3/8 6 2180 107,000 1880 113,000 NL36 1 3/8 6 2380 126,000 2020 133,000
NL39 1 1/2 6 2870 130,000 2470 137,000 NL39 1 1/2 6 3140 153,000 2640 161,000

NORD-LOCK washer dimensions UNC - preassembled pairs
STAINLESS STEEL A4 (according to EN 1.4404, AISI 316L)
Washer Bolt size øi øo Thickness T Min. package Approx. weight

size UNC Metric [inch] [inch] [inch] [pairs] lbs / 100 pairs
NL3ss #5 M3 0.13 0.28 0.09 200 0.09
NL3.5ss #6 M3.5 0.15 0.30 0.09 200 0.09
NL3.5spss #6 M3.5 0.15 0.35 0.09 200 0.15
NL4ss #8 M4 0.17 0.30 0.09 200 0.09 Øi
NL4spss #8 M4 0.17 0.35 0.09 200 0.15
NL5ss #10 M5 0.21 0.35 0.09 200 0.13
NL5spss #10 M5 0.21 0.43 0.09 200 0.24
NL6ss M6 0.26 0.43 0.09 200 0.20
NL6spss M6 0.26 0.53 0.09 200 0.35 NL3ss– NL8ss
NL1/4”ss 1/4” 0.28 0.45 0.09 200 0.20 Ø i ±0.004 inch
NL1/4”spss 1/4” 0.28 0.53 0.09 200 0.33
NL10ss– NL42ss
NL8ss 5/16” M8 0.34 0.53 0.09 200 0.26
Ø i ±0.008 inch
NL8spss 5/16” M8 0.34 0.65 0.09 200 0.53
NL3/8”ss 3/8” 0.41 0.65 0.09 200 0.37 NL45ss–NL80ss
NL3/8”spss 3/8” 0.41 0.83 0.09 200 0.84 Ø i +0.02/-0 inch
NL10ss M10 0.42 0.65 0.09 200 0.35
NL10spss M10 0.42 0.83 0.09 200 0.82
NL11ss 7/16” M11 0.45 0.73 0.09 200 0.57
NL12ss M12 0.51 0.77 0.09 200 0.55
NL12spss M12 0.51 1.00 0.13 100 1.79
NL1/2”ss 1/2” 0.53 0.77 0.09 200 0.53
NL1/2”spss 1/2” 0.53 1.00 0.13 100 1.76 Øo
NL14ss 9/16” M14 0.60 0.91 0.13 100 1.21
NL14spss 9/16” M14 0.60 1.21 0.13 100 2.89
NL16ss 5/8” M16 0.67 1.00 0.13 100 1.34
NL16spss 5/8” M16 0.67 1.21 0.13 100 2.84
NL18ss M18 0.77 1.14 0.13 100 1.76 NL3ss – NL24ss
NL18spss M18 0.77 1.36 0.13 100 3.44 Øo ±0.008 inch
NL3/4”ss 3/4” 0.79 1.21 0.13 100 2.12
NL27ss – NL42ss
NL3/4”spss 3/4” 0.79 1.54 0.13 100 4.63
Øo ± 0.012 inch
NL20ss M20 0.84 1.21 0.13 100 1.96
NL20spss M20 0.84 1.54 0.13 100 4.54 NL45 ss– NL80ss
NL22ss 7/8” M22 0.92 1.36 0.13 100 2.71 Øo +0/-0.08 inch
NL22spss 7/8” M22 0.92 1.65 0.13 50 4.92
NL24ss M24 1.00 1.54 0.13 100 3.35
NL24spss M24 1.00 1.91 0.13 50 7.72
NL1”ss 1” 1.10 1.54 0.13 100 3.13 T
NL1”spss 1” 1.10 1.91 0.13 50 7.10
NL27ss M27 1.12 1.65 0.27 50 7.61 NL3ss– NL24ss
NL27spss M27 1.12 1.91 0.27 25 12.89 T ± 0.01 inch
NL30ss 1 1/8” M30 1.24 1.85 0.27 50 9.76 NL27ss– NL42ss
NL30spss 1 1/8” M30 1.24 2.30 0.27 25 21.01 T +0/-0.02 inch
NL33ss 1 1/4” M33 1.35 1.91 0.27 25 9.37
NL45ss – NL80ss
NL36ss 1 3/8” M36 1.47 2.17 0.27 25 13.13
NL39ss 1 1/2” M39 1.59 2.30 0.27 25 14.85
T ± 0.03 inch
NL42ss M42 1.70 2.48 0.27 25 17.54
NL45ss 1 3/4” M45 1.82 2.76 0.27 25 * 22.49
NL48ss M48 1.95 2.95 0.27 25 * 26.46 * NL45ss–NL80ss
NL52ss 2” M52 2.11 3.15 0.35 1* 44.31 upon inquiry
NL56ss 2 1/4” M56 2.33 3.35 0.35 1* 46.96
NL60ss M60 2.48 3.54 0.35 1* 51.81 Materials and dimensions are
NL64ss 2 1/2” M64 2.64 3.74 0.35 1* 56.88 subject to change without
NL68ss M68 2.80 3.94 0.35 1* 62.17 prior notice.
NL72ss M72 2.96 4.13 0.35 1* 67.68 Please consult our website
NL76ss 3” M76 3.11 4.33 0.35 1* 73.41 for current dimensions:
NL80ss M80 3.27 4.53 0.35 1* 79.37 www.nord-lock.com
NL3 to NL20 available upon request in other steel alloys, e.g. 254SMO,
Inconel® 718 and Inconel®/Hastelloy® C-276.
10
Torque guidelines [ftlb]
Nord-Lock stainless steel (A4) washers with

ASTM F593 bolt (stainless steel) lubricated with GTP600
316, 316L, GF=0,65 303, 304, 305, GF=0,65

µg = 0,14, µw = 0,15 µg = 0,14, µw = 0,15
Washer Bolt Pitch Torque Clamp load Torque Clamp load

size size [TPI] [ftlb] [lb] [ftlb] [lb]
NL3 #5 40 - - - -
NL3.5 #6 32 - - - -
NL4 #8 32 - - - -
NL5 #10 24 - - - -
NL1/4” 1/4 20 5.2 1,300 5.2 1,300
NL8 5/16 18 10.3 2,200 10.3 2,200
NL3/8” 3/8 16 18 3,300 18 3,300
NL11 7/16 14 28 4,500 28 4,500
NL1/2” 1/2 13 43 6,000 43 6,000
NL14 9/16 12 61 7,700 61 7,700
NL16 5/8 11 85 9,500 85 9,500
NL3/4” 3/4 10 104 9,800 104 9,800
NL22 7/8 9 166 13,500 166 13,500
NL1” 1 8 251 17,700 251 17,700
NL30 1 1/8 7 356 22,300 356 22,300
NL33 1 1/4 7 497 28,300 497 28,300
NL36 1 3/8 6 653 33,800 653 33,800
NL39 1 1/2 6 859 41,100 859 41,100
GTP600 = graphite lubricant Temperatures

GF = ratio of yield point
NORD-LOCK washers have similar temperature
µg = thread friction
characteristics as bolts/nuts of corresponding
µw = washer friction
material. The hardness of NORD-LOCK steel
1ft = 0,3048 m washers decreases at temperatures above 200°C.
1lb = 0,4536kg = 4,450 N Stainless steel (A4) washers start to degrade at
1ftlb = 0,3048 x 0,4536 x 9,81 = 1,356 Nm temperatures above 500°C. For applications up to
700°C we recommend our Inconel® 718 washers.
Lubrication
Calculation of load area
NORD-LOCK recommends the use of a good lubri-
The load area [mm2] under the washer must be
cant (e.g. GTP600 or Molykote® 1000) in order to
larger than the clamp load [N] divided by the yield
reduce friction, minimize preload deviation and
point [N/mm2] of the material.
protect against corrosion.
Clamp load [N]
Load area [mm2] >
Yield point [N/mm2]
Reuse
Design
NORD-LOCK washers can normally be reused. How-
2D & 3D models of all NORD-LOCK products can be
ever, for high temperature applications, reuse is not
found through www.nord-lock.com
recommended. Always lubricate fasteners before
reusing!
11
US ENGLISH • Printed in Sweden 102007 • M-1556US
Authorized Distributor
www.nord-lock.com

SIEMENS ENERGY & AUTOMATION, INC.
LITTLE ROCK, ARKANSAS
ELECTRICAL MOTOR DATA
CUSTOMER : National Oilwell Varco

SALES ORDER NUMBER :
CUSTOMER P. O. :
CUSTOMER TAG:
MOTOR PART NO. : 1MJ01844XW21

TYPE : RGZZESD
HORSEPOWER : 5
VOLTAGE : 230/460
PHASE : 3
HERTZ : 60
FRAME : 184T
SYNCH. RPM : 1800
FULL LOAD RPM : 1730
EFFICIENCY :
1/2% 87.5
3/4% 88.2
F. L. % 87.5
POWER FACTOR :
1/2 63.0
3/4 75.0
F. L. 82.0
FULL LOAD AMPS : 13/6.5
LOCKED ROTOR AMPS : 92/46
FULL LOAD TORQUE (FT LB) : 15
STARTING TORQUE (% of Full Load) 260%
BREAKDOWN TORQUE (% of Full Load 300%
INSULATION : F
SERVICE FACTOR : 1.15
AMBIENT TEMP : 55
NEMA DESIGN : B
KVA CODE : J
OPTIONS:

3

BSM ROTARY GEAR PUMPS
S-SERIES
FT. MTD. PUMP
S-Series pumps are designed to operate at standard motor speeds and are suitable for pumping oils, inert chemicals,
petroleum products and various other liquids in transfer, circulation, lubrication, and liquid pressurization applications.
Design: Drive speeds to 1800 rpm; discharge pressures Lubrication: Self lubricating using the pumped liquid. Also
to 200 psi; flow rate to 32.0 gpm; foot or flange mounted; available for handling non-lubricating liquids.
with or without integral relief valve.
Rotation: Pumps are available for clockwise or counter-
Material: Cast Iron casings with precision machined, clockwise rotation. Discharge is always on the side of the
heat treated gears and case hardened shafts. Pumps are pump toward which the top of the shaft rotates. Specify at time
also available in Ductile Iron and Steel. of order.
Bearings: Replaceable iron sleeve bearings. Also Liquid Viscosities: 32 ssu to 100,000 ssu. Adaptable for
available with carbon graphite or bronze bearings. handling liquids from water soluble to molten lead.
Seal: Mechanical seal. Also available with compression Suction Lift: 28" Hg / 31 feet depending on the type of liquid
packing or lip seal. Mechanical seal and lip seals available being pumped.
with different elastomers for pumping different types of
liquids. Drive Options: E-Drive (pump close coupled to motor); A-
Drive (pump connected to c-face motor with adapter bracket
and coupling); D-Drive (pump coupled to motor mounted on
baseplate);GR-Drive (pump coupled to gear reducer coupled to
motor mounted on baseplate); B-Drive (pump and motor
connected by V-belt and pulleys mounted on baseplate).
Accessories: Repair Kits; Gear Sets; Bearing Kits; and Seal

Kits. Refer to Section 13.
BSM Pump Corp. - MANUFACTURING SOLUTIONS TO PUMPING PROBLEMS FOR OVER 100 YEARS.
(3.1)
DIMENSIONAL DATA S-SERIES
FT. MTD. PUMP FLG. MTD. PUMP
DIMENSIONS (INCHES)
Model A B C D E F G H J K L M N O Keyway
1S 3.00 3.69 1.78 2.00 0.39 7.50 6.25 4.56 0.56 2.38 0.75 3/8 4 7/8 3/8-16 1/8 x 1/16
2S 3.44 4.53 2.31 2.50 0.39 8.47 7.22 5.00 0.68 3.00 0.88 1/2 " 3/8-16 3/16 x 3/32
3S 4.44 5.72 2.88 3.00 0.45 10.50 8.88 6.19 0.75 3.88 1.25 3/4 " 3/8-16 3/16 x 3/32
4S 4.44 5.91 2.88 3.00 0.45 10.50 8.88 6.19 0.75 3.88 1.25 1 " 3/8-16 3/16 x 3/32
5S 5.00 5.97 2.88 3.00 0.45 10.50 8.88 6.69 0.75 3.88 1.25 1 1/4 " 3/8-16 3/16 x 3/32
OPERATING CHARACTERISTICS
Displmnt Drive 0 50 75 100 200

Model gals. per Slip Speed psi psi psi psi psi
rev. gpm/psi rpm gpm hp gpm hp gpm hp gpm hp gpm hp
600 1.6 .03 1.5 .08 1.4 .11 1.3 .15 1.1 .33
860 2.3 .04 2.1 .13 2.07 .18 2.0 .23 1.8 .49
1S .00262 .0024
1140 3.0 .06 2.9 .17 2.8 .23 2.7 .30 2.5 .63
1725 4.5 .14 4.4 .29 4.3 .36 4.28 .48 4.0 .95
600 3.1 .05 3.0 .15 2.9 .24 2.8 .31 2.4 .65
860 4.5 .08 4.3 .22 4.2 .34 4.1 .45 3.8 .93
2S .00521 .0035
1140 5.9 .13 5.8 .31 5.7 .41 5.6 .51 5.2 1.0
1725 9.0 .44 8.8 .64 8.7 .78 8.6 .94 8.3 1.6
600 5.7 .08 5.6 .34 5.5 .47 5.4 .60 5.2 1.1
860 8.1 .25 8.0 .54 7.9 .68 7.8 .83 7.6 1.5
3S .00947 .0026
1140 10.8 .38 10.7 .77 10.6 .97 10.5 1.1 10.2 2.0
1725 16.2 .92 16.1 1.4 16.0 1.7 15.9 2.0 15.7 3.1
600 8.1 .30 7.9 .50 7.8 .60 7.7 .80 7.4 1.2
860 11.6 .40 11.3 .70 11.2 .90 11.1 1.1 10.7 1.8
4S .0135 .009
1140 15.3 .50 15.0 .90 14.8 1.20 14.7 1.45 14.2 2.3
1725 23.2 .80 22.7 1.40 22.5 1.80 22.3 2.2 21.4 3.5
600 11.1 .45 10.8 .55 10.6 .75 10.4 .95 9.7 1.6
860 15.9 .65 15.5 .80 15.2 1.0 15.0 1.3 14.0 2.3
5S .0186 .02
1140 21.1 .80 20.5 1.1 20.2 1.4 19.8 1.8 18.5 3.1
1725 32.0 1.30 31.0 1.6 30.5 2.1 30.0 2.7 28.0 4.7
*Delivery and input horsepower are based on liquid viscosity of 300 ssu at speed and pressures shown.
(3.2)
S-SERIES
OPERATING CHARACTERISTICS, 32 SSU LIQUID
G.P.M. No.1S PUMP HP G.P.M. No.2S PUMP HP

5 0.7 10 1.4
1725 1725
RPM 9 RPM
0.6 M 1.2
RP
M
8 5 RP
4 5 172
172
0.5 7 1
114 1140
3 0 RP 6 RPM
M 0.4 0.8
860 M 5
RPM 0 RP 0 RPM
114 0.3 860 R 114 0.6
2 4 PM
600 600 R
RPM 3 PM
0.2 PM 0.4
PM 860 R
1 860 R 2
0.1 M 0.2
1 600 RP
600 RPM
0 0 0 0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
P.S.I. P.S.I.
G.P.M. No.3S PUMP HP

20 3
1725 RPM M
5 RP 2.5
172
15
2
1140 RPM
10 1.5
860 RPM M
11 40 RP
600 RPM 1
M
5 860 RP
0.5
600 RPM
0 0
0 10 20 30 40 50 60 70 80 90 100
P.S.I.
SOLID LINE = GPM

BROKEN LINE = HP
(3.3)
S-SERIES

5 1 10 2
1725 RPM
0.9 1725 RPM
9
4 0.8
PM 8 1.5
2 5R 0.7 R PM
1140 RPM 17 725
M 7 1
3 0 RP 0.6
114
1140 RPM M
860 RPM 0.5 6 0 RP 1
114
2 0.4
600 RPM 5
RPM PM
860 0.3 860 RPM 860 R
4 0.5
PM 0.2
1 600 R PM
600 R
0.1 3 600 RPM
0 0 2 0
0 20 40 60 80 100 120 140 160 180 200 0 20 40 60 80 100 120 140 160 180 200
P.S.I. P.S.I.

18 3.5
1725 RPM
16 3
14 PM 2.5
5R
172
12 2
1140 RPM
10 1.5
M
0 RP 860 R
PM
114
860 RPM
8 1
PM
6 600 R 0.5
600 RPM
4 0
0 20 40 60 80 100 120 140 160 180 200
P.S.I.
SOLID LINE = GPM

BROKEN LINE = HP
(3.4)
S-SERIES
OPERATING CHARACTERISTICS, 1,000 SSU LIQUID

5 1.2 10 2
1725 RPM 1725 RPM
4.5 9
1
4 M PM 1.5
RP 8 5R
5 172
172 0.8
3.5 7
M
0 RPM 0 RP
3
1140 RPM 114 1140 RPM 114
0.6 6 1
RPM PM
2.5 860 5 600 R
860 RPM 0.4 860 RPM RPM
860
2 PM
600 R 4 0.5
600 RPM 0.2 600 RPM

1.5 3
1 0 2 0
0 20 40 60 80 100 120 140 160 180 200 0 20 40 60 80 100 120 140 160 180 200
P.S.I. P.S.I.

18 4
1725 RPM
3.5
16
3
14 PM
R
1 725 2.5
12 M
1140 RPM 11 40 RP
2
10
PM
860 R 1.5
860 RPM
8
PM 1
600 R
6 600 RPM
0.5
4 0
0 20 40 60 80 100 120 140 160 180 200
P.S.I.
SOLID LINE = GPM

BROKEN LINE = HP
(3.5)
S-SERIES

1.62 0.4 3.12 0.8
1.6 M 0.35 3.1 M 0.7

600 0 RP 600 RP
60 0
RP RP 60
M 0.3 M 0.6
1.58 3.08
1.56 0.25 3.06 0.5
1.54 0.2 3.04 0.4
1.52 0.15 3.02 0.3
1.5 0.1 3 0.2
1.48 0.05 2.98 0.1

0 20 40 60 80 100 120 140 160 180 200 0 20 40 60 80 100 120 140 160 180 200
P.S.I. P.S.I.

5.72 1.6
5.7 1.4
600 R PM
RP
M 600
5.68 1.2
5.66 1
5.64 0.8
5.62 0.6
5.6 0.4
5.58 0.2
0 20 40 60 80 100 120 140 160 180 200
P.S.I.
SOLID LINE = GPM

BROKEN LINE = HP
(3.6)
S-SERIES

25 4 35 6
1725 RPM 1725 RPM
30 5
20
5 RPM 3
172 25
5 RP
M
1140 RPM 1140 RPM 172 4
15 RPM
1140 20 RPM
2 1140 3
860 RPM
15 860 RPM
10
600 RPM PM 600 RPM
860 R 2
10
1
5 PM
860 R PM 1
600 RPM 5 600 R
0 0 0 0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
P.S.I. P.S.I.

25 5 35 7
1725 RPM 1725 RPM
6
30 PM
4 5R
172
20
M 5
5 RP 25
172
RPM 3 RPM
1140 RPM 1140 1140 RPM 1140 4
15 20
860 RPM 3
2 860 RPM 860 RPM
860 RPM
15
2
10 600 RPM 600 RPM
1 600 RPM
600 RPM 10 1
5 0 5 0
0 20 40 60 80 100 120 140 160 180 200 0 20 40 60 80 100 120 140 160 180 200
P.S.I. P.S.I.
SOLID LINE = GPM

BROKEN LINE = HP
(3.7)
S-SERIES

25 6 35 7
1725 RPM 1725 RPM
6
5 30 PM
5R
20 25 R
PM 172
17 5
4 25 M
0 RP
1140 RPM 114 4
1140 RPM
15 3 20
RPM PM
1140 860 R 3
860 RPM 860 RPM
860 RPM
2 15
PM
600 R 2
10 600 RPM 600 RPM
600 RPM 1 10 1
5 0 5 0
0 20 40 60 80 100 120 140 160 180 200 0 20 40 60 80 100 120 140 160 180 200
P.S.I. P.S.I.

8.12 2.5 11.25 3
8.1 11.2
600 600 PM 2.5
RP
M 2 RP 0R
8.08 M 60
PM
0R 11.15
60 2
8.06
1.5 11.1
8.04 1.5
11.05
8.02
1
1
8 11
7.98 0.5 10.95 0.5

0 20 40 60 80 100 120 140 160 180 200 0 20 40 60 80 100 120 140 160 180 200
P.S.I. P.S.I.
SOLID LINE = GPM

BROKEN LINE = HP
(3.8)
S-SERIES CLOSE COUPLED MOTOR

DRIVEN ROTARY GEAR PUMPS (E-DRIVE)
BSM S-Series pumps are available direct coupled to the end bell of a foot mounted motor. This assembly, referred to as an
E-Drive, ensures accurate alignment and requires less space than a pump connected to the C-Face of a motor. BSM S-Series
Close Coupled Motor Driven Rotary Gear Pumps are available in motor speeds of 860, 1140 & 1725 rpm with capacities to
32.0 gpm and pressures to 200 psi.
DIMENSIONS (INCHES)
Model No. Motor A B C D E F G H K L M

Frame
1S-E 182 3.00 9.00 3.90 7.50 .406 17.94 16.69 7.88 7.06 4.50 3/8
182 3.44 9.00 3.81 7.50 .406 18.91 17.66 8.31 7.06 4.50 1/2
2S-E 184 3.44 9.00 3.81 7.50 .406 19.91 18.66 8.31 7.06 5.50 "
213 3.44 10.38 4.56 8.50 .406 21.47 20.22 9.12 7.94 5.50 "
182 4.44 9.00 3.50 7.50 .406 20.94 19.31 9.50 7.06 4.50 3/4
184 4.44 9.00 3.50 7.50 .406 21.94 20.31 9.50 7.06 5.50 "
3S-E
213 4.44 10.38 4.25 8.50 .406 23.50 21.88 10.31 7.94 5.50 "
215 4.44 10.38 4.25 8.50 .406 24.00 22.38 10.31 7.94 7.00 "
182 4.44 9.00 3.50 7.50 .406 20.94 19.31 9.50 7.06 4.50 1
184 4.44 9.00 3.50 7.50 .406 21.94 20.31 9.50 7.06 5.50 "
4S-E 213 4.44 10.38 4.25 8.50 .406 23.54 21.88 10.31 7.94 5.50 "
215 4.44 10.38 4.25 8.50 .406 24.00 22.38 10.31 7.94 7.00 "
254U 4.44 12.38 5.25 6.03 .406 26.19 24.56 12.49 9.81 8.25 "
182 5.00 9.00 3.47 7.50 .406 21.94 20.31 10.00 7.06 4.50 11/4
184 5.00 9.00 3.47 7.50 .406 22.94 21.31 10.00 7.06 5.50 "
5S-E 213 5.00 10.38 4.22 8.50 .406 24.50 22.88 10.81 7.94 5.50 "
215 5.00 10.38 4.22 8.50 .406 25.00 23.38 10.81 7.94 7.00 "
254U 5.00 12.38 5.22 6.03 .406 27.19 25.56 12.99 9.81 8.25 "
(3.9)
S-SERIES MOTOR DRIVEN

ROTARY GEAR PUMPS (A-DRIVE)
BSM S-Series pumps are available direct coupled to a Nema C-Face foot mounted motor. This assembly, referred to as an
A-Drive, ensures accurate alignment and requires less space and is less costly than a pump and motor mounted on a
baseplate. BSM S-Series Motor Driven Rotary Gear Pumps are available in motor speeds of 860, 1140 & 1725 rpm with
capacities to 32.0 gpm and pressures to 200 psi.
DIMENSIONS (INCHES)
Model No. Motor Frame A B C D E F G H K L M

1S-A 56C 3.00 6.88 2.91 4.88 0.34 19.81 18.56 9.81 8.31 3.00 3/8
145TC 3.00 6.88 2.91 5.50 0.34 21.53 20.28 10.12 8.56 5.00 3/8
182TC 3.00 8.69 3.91 7.50 0.41 23.12 21.87 11.75 9.81 4.50 3/8
2S-A 56C 3.44 6.88 2.81 4.88 0.34 20.78 19.53 10.25 8.31 3.00 5/8
145TC 3.44 6.88 2.81 5.50 0.34 22.50 21.25 10.56 8.56 5.00 5/8
182TC 3.44 8.69 3.81 7.50 0.41 24.09 22.84 12.19 9.81 4.50 5/8
184TC 3.44 8.69 3.81 7.50 0.41 25.09 23.84 12.19 9.81 5.50 5/8
3S-A 56C 4.44 6.88 2.50 4.88 0.34 22.82 21.19 11.43 8.31 3.00 3/4
145TC 4.44 6.88 2.50 5.50 0.34 24.54 22.91 11.75 8.56 5.00 3/4
182TC 4.44 8.69 3.50 7.50 0.41 26.13 24.50 13.37 9.81 4.50 3/4
184TC 4.44 8.69 3.50 7.50 0.41 27.13 25.50 13.37 9.81 5.50 3/4
213TC 4.44 10.25 4.25 8.50 0.41 29.04 27.41 14.25 12.16 5.50 3/4
215TC 4.44 10.25 4.25 8.50 0.41 30.54 28.91 14.25 12.16 7.00 3/4
4S-A 56C 4.44 6.88 2.50 4.88 0.34 22.82 21.19 11.43 8.31 3.00 1
145TC 4.44 6.88 2.50 5.50 0.34 24.54 22.91 11.75 8.56 5.00 1
182TC 4.44 8.69 3.50 7.50 0.41 26.13 24.50 13.37 9.81 4.50 1
184TC 4.44 8.69 3.50 7.50 0.41 27.13 25.50 13.37 9.81 5.50 1
213TC 4.44 10.25 4.25 8.50 0.41 29.04 27.41 14.25 12.16 5.50 1
215TC 4.44 10.25 4.25 8.50 0.41 30.54 28.91 14.25 12.16 7.00 1
5S-A 56C 5.00 6.88 2.50 4.88 0.34 23.20 21.57 11.63 8.31 3.00 1 1/4
145TC 5.00 6.88 2.50 5.50 0.34 24.92 23.29 11.95 8.56 5.00 1 1/4
182TC 5.00 8.69 3.50 7.50 0.41 26.51 24.88 13.57 9.81 4.50 1 1/4
184TC 5.00 8.69 3.50 7.50 0.41 27.51 25.88 13.57 9.81 5.50 1 1/4
213TC 5.00 10.25 4.25 8.50 0.41 29.42 27.79 14.45 12.16 5.50 1 1/4
215TC 5.00 10.25 4.25 8.50 0.41 30.92 29.29 14.45 12.16 7.00 1 1/4
254TC 5.00 12.88 5.25 10.00 0.53 37.26 35.63 16.19 16.09 8.25 1 1/4
(3.10)
S-SERIES BASE MOUNTED

ASSEMBLIES (D-DRIVE)
BSM S-Series pumps are available as base mounted pump and motor assemblies. Each assembly includes the base, flexible
coupling, coupling guard, riser blocks, (if required) lifting eye-bolts, and mounting hardware. The fabricated steel or channel
iron bases are available with optional features such as drip-lip construction, drain plugs, mounting lugs, casters, etc..
DIMENSIONS (INCHES)
Model No. Motor Frame A B C D E F G H K L M

1S-D 56C 12.00 9.00 24.00 22.00 2.94 0.28 0.56 1.50 1.00 2.91 6.88
145TC 12.00 9.00 26.00 24.00 2.94 0.28 0.56 1.50 1.00 2.91 6.88
182TC 12.00 9.00 30.00 28.00 2.94 0.28 0.56 1.50 1.00 3.91 8.69
2S-D 56C 12.00 9.00 24.00 22.00 2.94 0.28 0.56 1.50 1.00 2.81 6.88
145TC 12.00 9.00 26.00 24.00 2.94 0.28 0.56 1.50 1.00 2.81 6.88
182TC 12.00 9.00 30.00 28.00 2.94 0.28 0.56 1.50 1.00 3.81 8.69
184TC 15.00 12.00 32.00 30.00 3.41 0.41 0.56 1.50 1.00 3.81 8.69
3S-D 56C 12.00 9.00 24.00 22.00 2.94 0.28 0.56 1.50 1.00 2.50 6.88
145TC 12.00 9.00 26.00 24.00 2.94 0.28 0.56 1.50 1.00 2.50 6.88
182TC 12.00 9.00 30.00 28.00 2.94 0.28 0.56 1.50 1.00 3.50 8.69
184TC 15.00 12.00 32.00 30.00 3.41 0.41 0.56 1.50 1.00 3.50 8.69
213TC 15.00 12.00 34.00 32.00 3.41 0.41 0.56 1.50 1.00 4.25 10.25
215TC 15.00 12.00 36.00 34.00 3.41 0.41 0.56 1.50 1.00 4.25 10.25
4S-D 56C 12.00 9.00 24.00 22.00 2.94 0.28 0.56 1.50 1.00 2.50 6.88
145TC 12.00 9.00 26.00 24.00 2.94 0.28 0.56 1.50 1.00 2.50 6.88
182TC 12.00 9.00 30.00 28.00 2.94 0.28 0.56 1.50 1.00 3.50 8.69
184TC 15.00 12.00 32.00 30.00 3.41 0.41 0.56 1.50 1.00 3.50 8.69
213TC 15.00 12.00 34.00 32.00 3.41 0.41 0.56 1.50 1.00 4.25 10.25
215TC 15.00 12.00 36.00 34.00 3.41 0.41 0.63 2.00 1.00 4.25 10.25
5S-D 56C 12.00 9.00 24.00 22.00 2.94 0.28 0.56 1.50 1.00 2.50 6.88
145TC 12.00 9.00 26.00 24.00 2.94 0.28 0.56 1.50 1.00 2.50 6.88
182TC 12.00 9.00 30.00 28.00 2.94 0.28 0.56 1.50 1.00 3.50 8.69
184TC 15.00 12.00 32.00 30.00 3.41 0.41 0.56 1.50 1.00 3.50 8.69
213TC 15.00 12.00 34.00 32.00 3.41 0.41 0.56 1.50 1.00 4.25 10.25
215TC 15.00 12.00 36.00 34.00 3.41 0.41 0.56 1.50 1.00 4.25 10.25
254TC 18.00 15.00 42.00 40.00 3.95 0.45 0.56 1.50 1.00 5.25 12.88
(3.11)
"PUMPAC" WITH MOTOR DRIVEN

ROTARY GEAR PUMPS
The precision-built, positive displacement pump has heat treated steel gears supported by substantial bearings to ensure
continuous service. Pump shaft seal requires no adjustment. Motor is continuous duty type. Rabbeted assembly guarantees
accurate alignment of pump and motor. Drive is through flexible coupling. Rigid welded sheet steel tank, 16 or 32 gallons,
has tank cover plate supporting pump and motor resting on rubber gasket for vibration free service. Without disturbing pump
assembly or piping, an access cover can be easily removed to check strainer and condition of oil. Return lines extending
below liquid level and a baffle in tank are supplied to prevent turbulence. Other standard built-in extras include a pressure
gage, relief valve, strainer, and suction piping to pump, also a bypass line from relief valve to tank. When ordering, specify
pump number, RPM, H.P., and tank capacity desired.
(3.12)
flow-captor C
flow-captor Type 4114.73

The flow-captor type 4114.30 / 4115.30 is a flow switch for industrial l AC or DC Operation.
applications which can be installed into any pipe, allowing flow-
sensing with minimum obstruction of the flow stream. As the housing l High accuracy under low
and sensor surface is of stainless steel (WN 1.4305) this small, flow conditions.
compact flow-captor is very resistant to aggressive media.
l Simple installation by
Available for AC and DC applications (voltage range from 90 to 265
V AC/DC), the flow-captor type 4114.73 operates accordingly to a union nut.
new calorimetric principle, providing a wide measuring range. l Rugged stainless steel
The measurement accuracy at low flow rates is considerably better construction.
than all other contending measurement technologies. Because of the
very short integration time, even at low flow, this analog flow-captor is l LED-display for set-point.
ideally suited for quick control loops. l ISO 9002 certified
Completely epoxy resin encapsulated, this flow-captor is a compact, manufacturing.
rugged, shock and vibration resistant flow sensor with proven
reliability and long-term stability, even under the harshest l CE approval
environmental conditions.
Sensing-Data
Media liquid and pasty ( aggressive media on request )
Measuring range adjustable from 2 - 200 cm/s (related to water)
Adjustable potentiometer logarithmical to flow rate
Accuracy N/A
Repeatability < 1%
Hysteresis < 15%

flow-captor
Type 4114.73
Electrical Data
Compact flow switch
Operating voltage 90V - 265V AC / DC
Switching current max. 150 mA
Power consumption max. 3 W
Electrical connection 2 m moulded oilflex cable, 4 x 0.5 mm²
LED 2-colored : green: flow rate > Setpoint
red: flow rate < Setpoint
Mechanical Data
Protection class IP 65 (DIN 40050)
Sensor head and housing stainless steel WN 1.4305 ( V2A, 303 Ti ),
alternative: WN 1.4571 ( V4A, 316 Ti )
Sensor head sealing FP ( VITON )
Thread of union nut G 1 ¼ A SW 50 mm DIN 259 ISO 228
Pressure max. 30 bar (435 PSI)
Medium temperature -10°C to +80 °C (14 F to 176 F)
Ambient temperature -10°C to +60 °C (14 F to 140 F)
Sensor Data
Measuring range adjustable from 2 to 200 cm/s ( related to water )
Adjustable potentiometer logarithmical to flow rate
Accuracy N/A
Repeatability < 1%
Hysteresis < 15%
Technical data is subject to change 11/2002 - 4114.73-US © Copyright 2002 by captor Management Inc.
L 1/
brown
black
blue UB / VS 90 - 275 V AC/DC
yellow / green
N/
Flow-Network - 5065 Vail Drive • Acworth, GA 30101 Telephone: (770) 917-0940 Website: www.FLow-Netowrk.com
.
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GEK-91696D
H86005
22 APR 2009
AC ELECTRIC DRIVE
DRILLING MOTORS
FOR
ELLIS WILLIAMS
MUD PUMP
GE 5GEB22D2
HORIZONTAL DRILLING MOTOR
Customer Order No. 4690565

GE Requisition No. 420-55463
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.
Hunt Engine, Inc. H86005
Page 1 of 3 22 APR 2009
TABLE OF CONTENTS
TAB DESCRIPTION REFERENCE
A. MAINTENANCE
1. GEB22D2 DRILLING MOTOR GEK-91696D
2. SIRA CERTIFICATE 01 ATEX 3197X
3. GE TEST REPORT S/N RR08110059
B. RENEWAL PARTS
1. GEB22D2 DRILLING MOTOR PB-31107-007
2. COVER ASSEMBLY - UNUSED

CONNECTION BOX PORT
A. RENEWAL PARTS LIST RPL4303
B. HUNT DRAWING 4303B
3. COVER ASSEMBLY - UNUSED

SPACE HEATER PORT
A. RENEWAL PARTS LIST RPL4302
B. HUNT DRAWING 4302B
C. CONNECTION BOX (4722G1-4)
1. RENEWAL PARTS LIST RPL4722G1-4
2. ILLUSTRATION-RENEWAL PARTS LIST 4722G01-4RPL
3. GENERAL ARRANGEMENT DRAWING 4722G01-4S
4. WIRING DIAGRAM 4218WD, REV
D. PRESSURE SWITCH (5117G02)
1. INSTALLATION & MAINTENANCE INSTRUCTIONS UNITED ELECTRIC
2. CERTIFICATE OF CONFORMITY
3. DEMKO CERTIFICATE 03 ATEX 0305048

Page 2 of 3 22 APR 2009
E. SPACE HEATER APPLICATION (4239G2)
1. DRAWING - GENERAL ARRANGEMENT 4239S
2. RENEWAL PARTS LIST RPL4239G2
3. ILLUSTRATION-RENEWAL PARTS LIST 4239RPL
4. CERTIFICATES
A. HEATER 03 ATEX 1221
B. TERMINAL BOX KEMA 00ATEX8500X
C. CABLE GLANDS BAS01ATEX2070X
F. AIR OUTLET DUCT ASSEMBLY
1. GENERAL ARRANGEMENT DRAWING 4369G2S
G. BLOWER MOTOR ASSEMBLY – AIRDYNE (4849G09-2)
1. INSTALLATION, OPERATING AND

MAINTENANCE INSTRUCTIONS FILE: AIRIOMI
2. RENEWAL PARTS LIST RPL4849G09-2
3. ILLUSTRATION – RENEWAL PARTS LIST 4849G09RPL
4. OPERATING INSTRUCTIONS SCHORCH/ATB
5. DRAWING – SCHORCH MOTOR M 4-160.0001
6. MOTOR DATA SHEET CD 160M 1-2
7. INSPECTION CERTIFICATE 484401001-030
8. DECLARATION OF CONFORMITY
9. WIRING DIAGRAM PN5267
10. PTB CERTIFICATE 98ATEX 1106
11. GENERAL ARANGEMENT DRAWING 4849G09-2
12. BLOWER TEST PROCEDURE QCW4-10-01E
13. TEST REPORTS S/N 86005-1 THRU 86005-6 QCD129
14. HUNT ENGINE WARRANTY

Page 3 of 3 22 APR 2009
H. SPEED SENSOR (4976G08)
1. GENERAL ARRANGEMENT DRAWING 4976S
2. RENEWAL PARTS LIST RPL4976G08
3. ILLUSTRATION – RENEWAL PARTS LIST 4976G08RPL
4. INCREMENTAL ENCODER BEI MODEL HS35
5. REGULATIONS & CERTIFICATIONS
6. ATEX CERTIFICATION
7. DECLARATION OF CONFORMITY

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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2
GEK-91696D
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
a
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
C
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
Pr
GE
3
GEK-91696D
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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Figure 1. 5GEB22 Drilling
a
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.
4
GEK-91696D
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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.
5
GEK-91696D
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)
f
WITH 600 VOLTS MAINTAINED ABOVE 820 RPM
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CONSTANT HP 800–2400 RPM (690 VOLT L–LINE SUPPLY)
C
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).
6
GEK-91696D
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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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
P r
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).
7
GEK-91696D
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)
nfo
TABLE 3. 5GEB22 DUTY CYCLES
ia lI
t
en
Duty Reference Specification
A
id
120 seconds on at 800 rpm, 1400 HP, 9200 lb/ft torque, followed by 90 seconds on at 80
f
rpm, no load. (S9 duty)
o n
B
C
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
C a n
32 seconds on at 800 rpm, 1400 HP, 9200 ft/lb torque, followed by 30 seconds on at 800
r y
rpm, no load. (S9 duty)
t a
1.4.3.
r e
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
8
GEK-91696D
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
i o n
Compact AC Drive P1180 with or without a smoothingatfilter
Offshore & Marine ASA
r m filter
o
Compact AC Drive P1300 with or without a smoothing
f
n
Compact AC Drive P1500 with or withoutI a smoothing filter
l
t i a
M&I Type AC1350
e n
Type OIDM G5M-5C00 id
n f
Omron
C o
Type OIDM G5M-5900
Type 875TCX d
Stadt Automasjon
a n6G2N0-AFE (limited to 586 Amps)
Stadt/ABB
r y Type 2000-6-AC-2-00
Converter
t a Converter
Alstom e
ri 6SE7241-IFQ20-3AB0-Z PWM Inverter
MV3000
o p
Pr
GE
Siemens Sinamics S120 Bluedrive
6SE704 1-**** (see Figure 5 below)
9
GEK-91696D
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
M a
L
rm
nfo
DIGIT 2 OR 6
ia lI
t
id en E-50871
n f
Figure 5. Siemens Drive Nomenclature.
1.4.4. Grounding Instructions C o
n d
a
Grounding motor frames is required to safeguard personnel from electric shock in the event of an insulation
y
failure in the machine.
ar
i t
WARNING: Failure to properly groundeelectrical equipment may expose personnel to a potentially hazardous
condition in which serious or fatalrinjury from electrical shock is possible.
o p
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.
10
GEK-91696D
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
io n
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.
r m
1.4.6. Motor Coupling and Alignment
n fo
l I
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

e
reduced downtime.
o n
1.4.6.1. Coupled Drives
d C
a n unitconstruction
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.
y
r when using either solid (rigid) or flexible couplings, is essential to
a
t or shaft failures.
CAUTION: Careful alignment of machines,
e
prevent excessive vibration, hot ibearings,
r
p
used between motorP roshaft and
Couplings must be properly sized to be capable of driving maximum machine torque. Interference fits should be
coupling.
G E
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
11
GEK-91696D
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.
io n
CAUTION: Over−tightening to avoid this slippage may result in early failures of belts, shafts, and bearings.
at
Belt tension should be checked and adjusted following the belt manufacturer’s recommendations.
m
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
i a
t life results if the belts and sheaves are kept
n
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
f i d
1.4.6.3. Grouting
o n
d
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.
r ie
r op Procedure
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
12
GEK-91696D
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
it on
5GEB22A1 Original design 5GEB22.
5GEB22A2
a
Same as 5GEB22A1 except new rotor shaft material.
5GEB22A3 Same as 5GEB22A2 except new CE bearing.
rm
5GEB22A4
nfo
Same as 5GEB22A2 except stator terminal alignment.
5GEB22A5 lI
Same as 5GEB22A3 except stator terminal alignment.
ia
5GEB22C1 t
Same as 5GEB22A2 except shaft lengthened and CE insulated bearing.
5GEB22D1
id en
Same as 5GEB22A3 except rotor shaft diameter increase.
5GEB22D2
n f
Same as 5GEB22D1 except without ABS shaft certification.
5GEB22D3
C o
Same as 5GEB22D1 except stator terminal alignment.
5GEB22D4
nd
Same as 5GEB22D2 except stator terminal alignment.
y a
2. CONTROLS AND INDICATORS r
a 5GEB22. Refer to drive system instruction publications for controls and indi-
t
Not Applicable to drill motoremodel
cators.
p ri
3.
P ro
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.
13
GEK-91696D
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.
it on
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
a
equipment as specified by applicable federal or state safety regulations. Failure to do so may result in injury or
death. rm
nfo
lI
3. Use clean, dry compressed air and blow the dirt and dust from the interior of the machine.
t ia
4. Check exterior covers to ensure the felt seals are intact. Replace seals if missing, broken, deformed or hard-
en
ened.
f id
5. Install the covers into position on the machine. Torque the cover bolts to 58 ±2 lb.–ft. (79 ±2,7 Nm).
o n
4.1.2. Power Cable Inspection
d C
Inspect the power cables for: a n
During inspection of the power cables and associated hardware, replace any components that are damaged.
r y
t a
1. Inspect the cable terminals for discoloration from heat, arc damage, cracks or fractures. Replace terminals
r ie
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
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
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
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
r y
t a
ri e
p
P ro
GE
Figure 6. Rotor Lock Bolts.
17
GEK-91696D
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
ALLOW CONTAINER
CLEARANCE FROM
MOTOR ON BOTH ENDS
it on
a
rm
nfo
ia lI
t
iden
f
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
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
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.
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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
± ±
± ±
it on
a
rm
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ia lI
t
iden
n f
C o
n d
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
± ±
it on
a
rm
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±
n
±
ia lI
t
id en
n f
C o
n d
y a
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
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:
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
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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
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
±
±
it on
a
rm
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ia lI
t
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
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
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
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
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.
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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
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
5.6.2. Connection–End (CE) Frame Head Installation

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
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
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
op
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
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
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
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
o
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
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
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
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
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:
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
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
a
rm
c. Run the motor for forty minutes on 61 Hz 572 volts rms line−to−line. The average amperage of the
fo
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
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
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
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
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
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
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
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
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
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
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
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
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
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
°
° °
°
°
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
°
°
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
r op Figure
P
GE
55
GEK-91696D
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
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
° °
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
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
ie t
r
r op
P
GE
59
GEK-91696D
° °
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
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
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
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
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
r op
P
GE
64
GEK-91696D
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
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
t a
r ie
r op
P
GE E-50834
Figure 36. CE Dummy Bearing Cap 41C689896.
66
GEK-91696D
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
r
BREAK ALL SHARP CORNERS WITH .062 (1.575) RAD
a
ie t
CARBURIZE, HARDEN, AND GRIND (G) SURFACES AS SHOWN
r
r op
P
GE E-50835
Figure 37. DE Bearing Guide.
67
GEK-91696D
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
r ie
op
MEASUREMENT IN INCHES (MILLIMETER IN PARENTHESES)
Pr
GE E-50836
Figure 38. DE Dummy Bearing Cap 6796493P3.
68
GEK-91696D
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
it on
a
rm
nfo
ialI
t
iden
n f
C o
n d
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
CERTIFICATION
1 EC TYPE-EXAMINATION CERTIFICATE
2 Equipment intended for use in Potentially Explosive Atmospheres Directive 94/9/EC
3 Certificate Number: Sira 01ATEX3197X Issue: 17
4 Equipment: 5GEB22 and 5GEB22D AC Squirrel Cage Induction Motors
5 Applicant: GE Transportation Systems
6 Address: 2901 East Lake Road
Erie
Pennsylvania 16531
USA
7 This equipment and any acceptable variation thereto is specified in the schedule to this certificate and
the documents therein referred to.
8 Sira Certification Service, notified body number 0518 in accordance with Article 9 of Directive 94/9/EC
of 23 March 1994, certifies that this equipment has been found to comply with the Essential Health and
Safety Requirements relating to the design and construction of equipment intended for use in
potentially explosive atmospheres given in Annex II to the Directive.
The examination and test results are recorded in the confidential reports listed in Section 14.2.
9 Compliance with the Essential Health and Safety Requirements, with the exception of those listed in the
schedule to this certificate, has been assured by compliance with the following documents:
EN 50014:1997 (incl amendments A1 and A2) EN 13463-1:2001
EN 50019:2000 PrEN 13463-5:2000
10 If the sign ‘X’ is placed after the certificate number, it indicates that the equipment is subject to special
conditions for safe use specified in the schedule to this certificate.
11 This EC type-examination certificate relates only to the design and construction of the specified
equipment. If applicable, further requirements of this Directive apply to the manufacture and supply of
this equipment.
12 The marking of the equipment shall include the following:
II 2 G c
EEx e II T3 (Tamb = -40°C to +45°C) or
EEx e II T3 (Tamb = -40°C to +55°C)
Project Number 51A17849 C Ellaby

C. Index 01 Certification Officer
This certificate and its schedules may only be
reproduced in its entirety and without change.
Sira Certification Service

Rake Lane, Eccleston, Chester, CH4 9JN, England
Page 1 of 7
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Fax: +44 (0) 1244 681330
Email: info@siracertification.com
Operation and Maintenance Manual Page 183 Web: www.siracertification.com
CERTIFICATION
SCHEDULE
EC TYPE-EXAMINATION CERTIFICATE Sira 01ATEX3197X

Issue 17
13 DESCRIPTION OF EQUIPMENT
The equipment under assessment is a three-phase ac squirrel cage induction motor rated at 690 V line
to line voltage (equivalent to a dc link voltage of 930 V) 3000 rpm 759 HP (1328 ft/lb torque) at 690 V
or 746 HP (1305 ft/lb torque) at 600V.
The motors are to be used on the following duty cycles:
Duty reference Specification
A 120 seconds on at 800 rpm, 1400 HP, 9200 ft/lb torque, followed by 90 seconds
on at 80 rpm, no load. (S9 duty)
B 144 seconds on at 669 rpm, 1150 HP, 9025 ft/lb torque, followed by
116 seconds on at 80 rpm, no load. (S9 duty)
C 32 seconds on at 800 rpm, 1400 HP, 9200 ft/lb torque followed by 30 seconds
no load at 800 rpm. (S9 duty)
The motor is intended to be used for oil drilling applications and is to be supplied as a standard motor
requiring forced air cooling at 3000 CFM and adequate ingress protection such that the certification is
not invalidated.
Motor ratings: Maximum ambient temperature (°C) Maximum current (A)
45 1120
55 1048
The 5GEB22 motor to be equipped with a closed circuit water cooler (CACW) as an alternative to the
open ventilated cooler arrangement. The CACW cooler arrangement has an ingress protection rating of
IP56.
The machine consists of a wound stator with class H insulation within a carbon steel frame and a
squirrel cage rotor mounted via bearing assisted end plates in the centre of the stator.
The 5GEB 22 can be used with the following range of Siemens converters:
6SE7241-IFQ20-3AB0-Z PWM as indicated below:
Rated current indicator: 6SE704 1- * * * *

0 = 1000 A (M chassis)
2 = 1200 A (L or M chassis)
5 = 1500 A (M chassis) dc link voltage indicator:
V = 930 V (690 V line – line)
U = 780 V (600 V line – line)
Chassis indicator:
M
Digit 2 or 6
L
Alternatively any of the drives listed in Special Condition for Safe Use clause 15.3 may be used:

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Form 9400 Issue1
CERTIFICATION
SCHEDULE

Issue 17
Design Options
An alternative connection to the endshield profile that allows the external mounting of a suitably
certified shaft mounting device
An alternative method of insulating the rotor using swage and powder coating process
An alternative 4100 steel shaft
An alternative shaft diameter for belt driven Mud Pumps.
Variation 1 - This variation introduced the following changes:
i. The alternative association of the existing motor with the Type Ross Hill Model 6000 a.c drive
system manufactured by National Oilwell and the modification of the corresponding special
condition for safe use to recognise this fact.
i. The alternative association of the existing motor with the MV3000 Converter a.c drive system
manufactured by Alstom and the modification of the corresponding special condition for safe use
to recognise this fact.
i. The 5GEB22 AC Squirrel Cage Induction Motors to be marked EEx e II T3 (Tamb = -40°C to
+45°C) to recognise that they can operate in a lower ambient temperature of –40°C. This change
has been introduced to specifically alter the marking, the design of the motors remains unaltered.
i. The label for the water-cooled units to state that the maximum internal air temperature of the
motor is 45oC; as a result, the cooler parameters (maximum water temperature and minimum flow
rate) are removed from the label and specified in the installation instructions for each unit.
i. The alternative association of the existing motor with the Stadt/ABB Converter Type 2000-6-AC-2-
00 a.c drive system and the modification of the corresponding special condition for safe use to
recognise this fact.
i. The alternative association of the existing motor with an Omron Type OIDM G5M-5C00 or Type
OIDM G5M-5900 a.c drive system and the modification of the corresponding special condition for
safe use to recognise this fact:
ii. The ingress protection rating of the terminal box to be recognised as IP56.
i. The introduction of an alternative arrangement with side mounted cooling air inlet that is fitted to
the side opposite the main terminal box.
i. An alternative association of the motor with an a.c. drive system type AC 1350 manufactured by
M & I and the modification of the corresponding special condition for safe use to recognise this fact.

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Issue 17

i. The RTD trip level to be raised from 170°C to 190°C.
i. An alternative association of the motor with an a.c. drive system Types – Compact AC Drive
P1500, P1300, P1180 or P1030 manufactured by Offshore & Marine ASA and the modification of
the corresponding special condition for safe use to recognise this fact. The following duty cycle is
applicable for this application:
Duty Cycle – Specification
32 seconds on at 800 rpm, 1400 HP, 9200 ft/lb torque followed by 30 seconds no load at 800 rpm.
(S9 duty)
i. The motor output power to be de-rated to allow the ambient to be raised from 45oC to 55oC, the
description was changed accordingly.
i. An alternative association of the existing motor with a variable frequency drive system Type Nov
Ross Hill Model ABB ACS800 manufactured by National Oilwell Varco and the modification of the
corresponding special condition for safe use to recognise this fact.
i. The modification of the air outlet duct assembly to maintain IP 44.
ii. A change in the GEB 22 termination box arrangement to allow entrance of two 3-core conductor
cables through glands installed on the lower gland plate.
i. An alternative association of the existing motor with a variable frequency drive system, Type ABB
Model ABB ACS800, manufactured by ABB and the modification of the corresponding special
ii. An increase in the shaft diameter from 4.75” to 5.65” on the 5GEB22 (forming the 5GEB22D) for
belt driven Mud Pumps.
i. An alternative association of the existing motor with an a.c. drive system Type ACS 600
manufactured by ABB.
i. Alternative associations of the existing motor 5GEB22 with a variable frequency drive system. Type
Siemens Sinamics S120 Bluedrive inverter and the modification of the corresponding special
i. The use of an alternative terminal enclosure was allowed.
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Form 9400 Issue1
CERTIFICATION
SCHEDULE

Issue 17
14 DESCRIPTIVE DOCUMENTS
14.1 Drawings
Refer to Certificate Annexe.
14.2 Associated Sira Reports and Certificate History
Issue Date Report/File no. Comment
0 26 June 2002 R53A7672B The release of prime certificate.
1 25 July 2002 R53A8690A The introduction of Variation 1, re-issued 20 September 02
to correct a typographical error.
2 29 July 2002 R53A9251A The introduction of Variation 2, re issued 20 September 02
to correct a typographical error.
3 30 September 2002 53V9338 The introduction of Variation 3.
4 1 October 02 53V9177 The introduction of Variation 4.
5 2 October 02 R53A9056A The introduction of Variation 5.
6 3 December 02 R53A9474A The introduction of Variation 6.
7 16 May 03 53V10056 The introduction of Variation 7.
8 10 September 03 53V10557 The introduction of Variation 8.
9 10 December 04 R51V12352A The introduction of Variation 9.
10 16 December 04 R51A12397A The introduction of Variation 10.
11 21 April 05 R53A12138A The introduction of Variation 11.
12 23 November 05 R51A13862A The introduction of Variation 12.
13 23 November 05 R51A12667A The introduction of Variation 13.
14 25 September 06 R51A15628A The introduction of Variation 14.
15 1 August 07 R51A17022A The introduction of Variation 15.
16 6 February 2008 R51A17208A This Issue covers the following changes:
• All previously issued certification was rationalised
into a single certificate, Issue 16, Issues 0 to 15
referenced above are only intended to reflect the
history of the previous certification and have not
been issued as documents in this format.
• The introduction of Variation 16.
17 18 February 2008 R51A17849A The introduction of Variation 17.

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Form 9400 Issue1
CERTIFICATION
SCHEDULE

Issue 17
15 SPECIAL CONDITIONS FOR SAFE USE (denoted by X after the certificate number)
15.1 The motor shall be supplied continuously with at least 3000 SCFM of cooling air.
15.2 The RTD devices within the equipment shall be supplied from and suitably certified intrinsically safe
source.
15.3 The 5GEB22 motor shall be used with one of the following drives and the maximum drive output shall
not exceed the load current shown below:
Type Max Drive Output
GE, GE AC 2000AW Variable Speed Drive 1500 A
Siemens, Model 6SE7241-IFQ20-3AB0-Z PWM Inverter 1500 A
Siemens, Model 6SE704 1- * * * * Inverters 1500 A
Cegelec Bauteil, Type GD3000E a.c. Drive System 1500 A
Unico Inc, Type 2400 Series (part# 109341) with or without a smoothing inductor 1500 A
National Oilwell, Type Ross Hill Model 6000 1500 A
Alstom, MV3000 Converter 1500 A
Stadt Automasjon, Type 875TCX 6G2N0-AFE 586 A
Stadt/ABB, Converter Type 2000-6-AC-2-00 1500 A
Omron, Type OIDM G5M-5C00 1500 A
Omron, Type OIDM G5M-5900 1500 A
M & I Type AC 1350 1500 A
Offshore & Marine ASA Compact AC Drive P1500 with or without a smoothing filter 1500 A
Type NOV Ross Hill Model ABB ACS800 manufactured by National Oilwell Varco 1800 A
Type ABB Model ABB ACS800 manufactured by ABB 1800 A
Type ABB Model ABB ACS600 manufactured by ABB 1800 A
Siemens Sinamics S120 Bluedrive inverter 1800 A
15.4 When the motor is equipped with a water cooler and used in accordance with the duties defined in this
certificate, the water cooler shall be supplied with coolant in accordance with the following tables:
Either
Duty Minimum water flow rate Maximum coolant temperature (at cooler inlet)
S1 (continuous) 100 US galls/min 33.0 deg C
S9 (Duty A) 100 US galls/min 33.0 deg C
S9 (Duty B) 100 US galls/min 37.7 deg C
Or
Duty Minimum water flow rate Maximum coolant temperature (at cooler inlet)
S1 (continuous) 100 US galls/min 33.0 deg C
S9 (Duty A) 100 US galls/min 33.0 deg C
S9 (Duty B) 88 US galls/min 36.0 deg C

Page 6 of 7 Tel: +44 (0) 1244 670900

Fax: +44 (0) 1244 681330
Form 9400 Issue1
CERTIFICATION
SCHEDULE

Issue 17
16 ESSENTIAL HEALTH AND SAFETY REQUIREMENTS OF ANNEX II (EHSRs)

The relevant EHSRs that are not addressed by the standards listed in this certificate have been
identified and individually assessed in the reports listed in Section 14.2.
17 CONDITIONS OF CERTIFICATION
17.1 The use of this certificate is subject to the Regulations Applicable to Holders of Sira Certificates.
17.2 Holders of EC type-examination certificates are required to comply with the production control
requirements defined in Article 8 of directive 94/9/EC.
17.3 An electrical strength test of 3500 Vrms shall be applied between all live parts and the case for at least
60 s and no more than 63 s as required by clause 6.1 of EN 50019: 2000.
17.4 When motors are supplied for use on a duty cycle the rating marked on the label shall be modified to
read: ‘Continuous / S9’.

Page 7 of 7 Tel: +44 (0) 1244 670900

Fax: +44 (0) 1244 681330
Form 9400 Issue1
Certificate Annexe
Certificate Number: Sira 01ATEX3197X
Equipment: 5GEB20 and 5GEB20IDS AC Squirrel Cage
Induction Motors CERTIFICATION
Applicant: GE Transportation Systems
Issue 0
Number Sheet Rev. Date Description
41E603966 1 of 3 B 13 Jul 01 Certification drawing
84D706976 1 of 1 - 13 Nov 98 Connection box
499A915KC* 1 of 2 C 27 Jun 01 Nameplate
499A915KC* 2 of 2 C 27 Jun 01 Nameplate
499A915KF 1 of 2 F 12 Jun 02 Nameplate
499A915KF 2 of 2 F 12 Jun 02 Nameplate
41H144022 1 of 1 A 26 Mar 99 Schematic Of AC Drilling Motor And Its Drive And Cooling Arrangement
* These drawings were amended by Sira on 25 June 2002.
Issue 1
No new drawings were introduced.
Issue 2
Issue 3
499A915KF 1 of 2 G 23 Aug 02 Nameplate - 5GEB22
499A915KF 2 of 2 G 23 Aug 02 Nameplate - 5GEB22
Issue 4
499A915KC 1 of 2 D 13 Sept 02 Nameplate - GEB22
499A915KC 2 of 2 D 13 Sept 02 Nameplate - GEB22
Issue 5
Issue 6
Issue 7
41E903966 4 - 21 Feb 03 Alternative Air Inlets
Issue 8
Issue 9
499A915KF 1 of 2 J 25 Oct 04 Nameplate
499A915KF 2 of 2 J 25 Oct 04 Nameplate

Page 1 of 2 Tel: +44 (0) 1244 670900

Fax: +44 (0) 1244 681330
Form 9400 Issue 1
Certificate Annexe
Certificate Number: Sira 01ATEX3197X
Equipment: 5GEB20 and 5GEB20IDS AC Squirrel Cage
Induction Motors CERTIFICATION
Applicant: GE Transportation Systems
Issue 10
Issue 11
499A915KC 1 of 2 E 18 Jan 05 Nameplate
499A915KC 2 of 2 E 18 Jan 05 Nameplate
499A915KF 1 of 2 L 21 Feb 05 Nameplate
499A915KF 2 of 2 L 21 Feb 05 Nameplate
Issue 12
Issue 13
(Sira stamp)
4236G2S 1 of 1 2 16 Nov 05 Air outlet duct assembly for GE22A2 IP 44 certified
4722SIRA 1 to 2 0 16 Nov 05 Main connection box
41E903966 1 of 4 1 16 Nov 05 Certification drawing
41E903966 F of 4 - 16 Nov 05 Certification drawing
Issue 14
41E903966 1 of 5 2 13 Sep 06 Certification drawing
Issue 15
Issue 16
(Sira stamp)
499A915KF 1&2 M 04 Feb 08 Certification Plate
Issue 17
(Sira stamp)
4805 Sira 1 to 2 0 14 Feb 08 Terminal box details

Page 2 of 2 Tel: +44 (0) 1244 670900

Fax: +44 (0) 1244 681330
Form 9400 Issue 1
GE Rail
Propulsion and
Specialty Services
CERTIFICATE OF ACCEPTANCE
The below listed part numbers and quantities were subject to GE Rail’s Quality
Systems requirements and were found to be acceptable. This document is to
certify that the listed parts were inspected and tested in accordance with, and
meet, the applicable drawing and specification requirements cited below.
Part Number Name Serial Number
5GEB22D2 AC Motor RR08110059
TESTED PER: SI-10001
INSPECTED PER: 41E903966
1 April 2009
GE Representative Date
Sara E. Thomsen
GE Transportation
Propulsion
Quality Technical Advisor
P: 814-875-3547
DC: 8*348-3547
F: 866-420-0618
E: Sara.Thomsen@ge.com
2901 East Lake Rd., B6-1

Erie, PA 16531
GE Transportation

RR08110059
*****SHOP SUPPORT*****
SERIAL QC ANSWER SHEET
SERIAL # RR08110059 DWG. # 5GEB22A3 REV. D METH. 1 OPER. 0260

PROD. ID TRACTION MOTOR COMP/WKSTA 64639-0394
ITEM # SEQ. # ANSWER

885 1 0109.3000
RECORD RESISTANCE OF THE THERMAL SENSOR (RTD) CIRCUIT.WITH MACH COLD.
UPPER LIMIT 116 OHMS LOWER LIMIT 107 OHMS
EACH RTD HAS 3 LEADS 2 OF SAME COLOR (USUALLY WHITE ) AND THE 3Rd OF
A DIFFERENT COLOR (USUALLY RED). *** MEASURE THE RESITANCE BETWEEN THE
LATTER (RED) LEAD AND ANY OF THE OTHER (WHITE ) LEADS
885 2 0109.1000

885 3 0109.3000

885 4 0109.5000

885 5 0109.2000
885 6 0109.6000

919 7 0000.0100
RECORD THE RESISTANCE CORRECTED TO 25C FOR T1-T2
MAX .0108 MIN .0088 (OHMS)
922 8 0000.0100
MAX .0108 MIN .0088 (OHMS)
Page 1

RR08110059
923 9 0000.0100
MAX .0108 MIN .0088 (OHMS)

887 10 0024.0000
BEARING & HEATING-UP RUN.
DRIVE MACHINE AT 572V (L-L),61HZ ,
*
RECORD ROOM TEMPERATURE AT END OF 40 MINUTE HEAT RUN
50 11 0029.0000
Record PE bearing temperature rise above room.
(55 DEG. C. MAX)
888 12 0005.0000
Record OPE bearing temperature rise above room.
(55 DEG. C. MAX)

1099 13 0409.0000
RUN FOR 2 MINUTE AT NO LOAD @ 41HZ AND 572V LINE, APROX 800 RPM
RECORD THE AVERAGE OF THREE LINE CURRENTS
MAX 453A MIN 368A
TEST: NL (A)

1050 14 0146.0000
MAX 150A MIN 130A
TEST: NL (A)
1124 15 3085.0000
OVERSPEED TEST.
DRIVE MOTOR FOR TWO MINUTES AT APROX 155HZ AND 540V (L-L)
ADJUST FREQUENCY TO OBTAIN DESIRED SPEED
MAX 3090 MIN 3080

1126 16 0000.0900
RECORD MAXIMUM VIBRATION ON DE @ 150HZ, 540V (L-L), 3000 RPM
.44 MAX (IN./SEC.)****ADJUST HZ TO OBTAIN 3000 RPM****
*
** TEST: VIBRATION. - VERTICAL
1127 17 0000.1600
*
** TEST: VIBRATION - HORIZONTAL

1128 18 0000.0900
*
Page 2

RR08110059
** TEST: VIBRATION - AXIAL
1129 19 0000.0900
RECORD MAXIMUM VIBRATION ON CE @ 150HZ, 540V (L-L), 3000 RPM
*
** TEST: VIBRATION - VERTICAL

1130 20 0000.0800
*
** TEST: VIBRATION. - HORIZONTAL

1131 21 0000.1600
*
** TEST: VIBRATION. - AXIAL

1088 22 0000.1300
Continuation of Bearing Noise Test PER QSI-11411. REV. BM ( 7/31/02)
RUN MOTOR @ 1200 RPM
RECORD DE BEARING NOISE DEMODULATION "DEMOD" VALUE ( MAX 1.49G )

891 23 0000.5700
Continuation of Bearing Noise Test PER. QSI-11411. REV.BM (7/31/02)
*
*
Record OPE BEARING NOISE demodulation "DEMOD" VALUE ( MAX 1.49g )
925 24 Y
*HIPOT TEST
DID UNIT PASS THE HIPOT OF ANY TERMINAL TO GROUND AT 3500V, 60HZ,
FOR 1 MINUTE?
1132 25 Y
AFTER DIELECTRIC TEST GROUNG ANY TERMINAL TO FRAME TO INSURE WINDING
IS DISCHARGED. WITH THE TERMINALS ISOLATED FROM GROUND MEASURE INSULA
TION RESISTANCE BETWEEN ANY TERMINAL AND THE FRAME WITH A 500VDC
MEGGER. DID INSULATION RESISTANCE HAVE A MINIMUM OF 1 MEGOHM?
76 26 Y
IS THE UNIT FREE OF ALL OTHER DEFECTS PERTAINING TO YOUR OPERATION
OR ANY OTHER NOTICEABLE DEFECTS FROM A PREVIOUS OPERATION?
1155 27 9999.9999
INSULATION RESISTANCE. AFTER DIELECTRIC TEST, GRUOND ANY TERMINAL TO
FRAME TO INSURE WINDING IS DISCHARGED. WITH THE TERMINALS ISOLATED
FROM GROUND, MEASURE INSULATION RESISTANCE BETWEEN ANY TERMINAL AND
FRAME WITH A 500 VDC MEGGER. RECORD THE VALUE IN MEGOHM
ENTER 1 FOR 1 MEGOHM, 9999 FOR INFINITY
Page 3

RR08110059
* * * * * E N D O F R E P O R T * * * * *
Page 4

GE Rail
Propulsion and
Specialty Services
1 April 2009
Sara E. Thomsen
GE Transportation
Propulsion
P: 814-875-3547
DC: 8*348-3547
F: 866-420-0618

Erie, PA 16531
GE Transportation

RR08110068
SERIAL # RR08110068 DWG. # 5GEB22D2 REV. D METH. 1 OPER. 0260


885 1 0111.0000
885 2 0111.2000

885 3 0111.3000

885 4 0111.0000

885 5 0111.1000
885 6 0111.4000

919 7 0000.0100
MAX .0108 MIN .0088 (OHMS)
922 8 0000.0100
MAX .0108 MIN .0088 (OHMS)
Page 1

RR08110068
923 9 0000.0100
MAX .0108 MIN .0088 (OHMS)

887 10 0027.0000
*
50 11 0025.0000
(55 DEG. C. MAX)
888 12 0006.0000
(55 DEG. C. MAX)

1099 13 0406.9000
MAX 453A MIN 368A
TEST: NL (A)

1050 14 0144.1000
MAX 150A MIN 130A
TEST: NL (A)
1124 15 3090.0000
OVERSPEED TEST.
MAX 3090 MIN 3080

1126 16 0000.0016
*
1127 17 0000.0010
*

1128 18 0000.0010
*
Page 2

RR08110068
1129 19 0000.0012
*

1130 20 0000.0011
*

1131 21 0000.0010
*

1088 22 0000.1600

891 23 0000.6400
*
*
925 24 Y
*HIPOT TEST
FOR 1 MINUTE?
1132 25 Y
76 26 Y
1155 27 9999.9999
Page 3

RR08110068
* * * * * E N D O F R E P O R T * * * * *
Page 4

GE Rail
Propulsion and
Specialty Services
1 April 2009
Sara E. Thomsen
GE Transportation
Propulsion
P: 814-875-3547
DC: 8*348-3547
F: 866-420-0618

Erie, PA 16531
GE Transportation

RR08120045


885 1 0112.2000
885 2 0112.3000

885 3 0112.3000

885 4 0112.3000

885 5 0112.2000
885 6 0112.3000

919 7 0000.0099
MAX .0108 MIN .0088 (OHMS)
922 8 0000.0099
MAX .0108 MIN .0088 (OHMS)
Page 1

RR08120045
923 9 0000.0099
MAX .0108 MIN .0088 (OHMS)

887 10 0024.0000
*
50 11 0028.0000
(55 DEG. C. MAX)
888 12 0010.0000
(55 DEG. C. MAX)

1099 13 0407.0000
MAX 453A MIN 368A
TEST: NL (A)

1050 14 0144.0000
MAX 150A MIN 130A
TEST: NL (A)
1124 15 3087.0000
OVERSPEED TEST.
MAX 3090 MIN 3080

1126 16 0000.1200
*
1127 17 0000.2000
*

1128 18 0000.1400
*
Page 2

RR08120045
1129 19 0000.1500
*

1130 20 0000.1400
*

1131 21 0000.2200
*

1088 22 0000.2400

891 23 0000.4000
*
*
925 24 Y
*HIPOT TEST
FOR 1 MINUTE?
1132 25 Y
76 26 Y
1155 27 9999.9999
Page 3

RR08120045
* * * * * E N D O F R E P O R T * * * * *
Page 4

GE Rail
Propulsion and
Specialty Services
1 April 2009
Sara E. Thomsen
GE Transportation
Propulsion
P: 814-875-3547
DC: 8*348-3547
F: 866-420-0618

Erie, PA 16531
GE Transportation

RR08120080


885 1 0109.3000
885 2 0109.5000

885 3 0109.6000

885 4 0109.6000

885 5 0109.1000
885 6 0109.4000

919 7 0000.0100
MAX .0108 MIN .0088 (OHMS)
922 8 0000.0100
MAX .0108 MIN .0088 (OHMS)
Page 1

RR08120080
923 9 0000.0100
MAX .0108 MIN .0088 (OHMS)

887 10 0025.0000
*
50 11 0020.0000
(55 DEG. C. MAX)
888 12 0007.0000
(55 DEG. C. MAX)

1099 13 0408.6000
MAX 453A MIN 368A
TEST: NL (A)

1050 14 0144.5000
MAX 150A MIN 130A
TEST: NL (A)
1124 15 3085.0000
OVERSPEED TEST.
MAX 3090 MIN 3080

1126 16 0000.0800
*
1127 17 0000.1200
*

1128 18 0000.0700
*
Page 2

RR08120080
1129 19 0000.0900
*

1130 20 0000.0900
*

1131 21 0000.1000
*

1088 22 0000.1300

891 23 0000.5800
*
*
925 24 Y
*HIPOT TEST
FOR 1 MINUTE?
1132 25 Y
76 26 Y
1155 27 9999.9999
Page 3

RR08120080
* * * * * E N D O F R E P O R T * * * * *
Page 4

GE Rail
Propulsion and
Specialty Services
1 April 2009
Sara E. Thomsen
GE Transportation
Propulsion
P: 814-875-3547
DC: 8*348-3547
F: 866-420-0618

Erie, PA 16531
GE Transportation

RR08120086


885 1 0109.9000
885 2 0110.3000

885 3 0110.4000

885 4 0110.2000

885 5 0110.6000
885 6 0110.5000

919 7 0000.0100
MAX .0108 MIN .0088 (OHMS)
922 8 0000.0100
MAX .0108 MIN .0088 (OHMS)
Page 1

RR08120086
923 9 0000.0100
MAX .0108 MIN .0088 (OHMS)

887 10 0026.0000
*
50 11 0026.0000
(55 DEG. C. MAX)
888 12 0007.0000
(55 DEG. C. MAX)

1099 13 0412.0000
MAX 453A MIN 368A
TEST: NL (A)

1050 14 0144.0000
MAX 150A MIN 130A
TEST: NL (A)
1124 15 3090.0000
OVERSPEED TEST.
MAX 3090 MIN 3080

1126 16 0000.1300
*
1127 17 0000.2000
*

1128 18 0000.0900
*
Page 2

RR08120086
1129 19 0000.1900
*

1130 20 0000.1300
*

1131 21 0000.2200
*

1088 22 0000.1800

891 23 0000.6400
*
*
925 24 Y
*HIPOT TEST
FOR 1 MINUTE?
1132 25 Y
76 26 Y
1155 27 0500.0000
Page 3

RR08120086
* * * * * E N D O F R E P O R T * * * * *
Page 4

GE Rail
Propulsion and
Specialty Services
1 April 2009
Sara E. Thomsen
GE Transportation
Propulsion
P: 814-875-3547
DC: 8*348-3547
F: 866-420-0618

Erie, PA 16531
GE Transportation

RR09010050


885 1 0110.4000
885 2 0110.5000

885 3 0110.4000

885 4 0110.3000

885 5 0110.2000
885 6 0110.5000

919 7 0000.0100
MAX .0108 MIN .0088 (OHMS)
922 8 0000.0100
MAX .0108 MIN .0088 (OHMS)
Page 1

RR09010050
923 9 0000.0100
MAX .0108 MIN .0088 (OHMS)

887 10 0029.0000
*
50 11 0027.0000
(55 DEG. C. MAX)
888 12 0005.0000
(55 DEG. C. MAX)

1099 13 0406.7000
MAX 453A MIN 368A
TEST: NL (A)

1050 14 0144.7000
MAX 150A MIN 130A
TEST: NL (A)
1124 15 3086.0000
OVERSPEED TEST.
MAX 3090 MIN 3080

1126 16 0000.0800
*
1127 17 0000.1500
*

1128 18 0000.0800
*
Page 2

RR09010050
1129 19 0000.1400
*

1130 20 0000.1200
*

1131 21 0000.1800
*

1088 22 0000.2600

891 23 0000.3600
*
*
925 24 Y
*HIPOT TEST
FOR 1 MINUTE?
1132 25 Y
76 26 Y
1155 27 9999.9999
Page 3

RR09010050
* * * * * E N D O F R E P O R T * * * * *
Page 4

PB-31107-007
GE Renewal Parts
--------------------------------------------------------------------------------------------------------------------------------
Use original equipment parts for reliability
PARTS BULLETIN
UNCONTROLLED COPY See On-Line Master for Current Revision

--------------------------------------------------------------------------------------------------------------------------------
AC MOTOR
MODEL 5GEB22D2
08-FEB-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–31107–007
GE Proprietary and Confidential Information
2 34
4 9
42
43
15 22
14 6 7
8
17 3 10
18 13 12
19 23 30
21 11 38 24 31
36
16 37 32
38 33
39 35 20 41
40 29
26
27
28
25
Ref. 1
(Representative Illustration)
FIG. 1
-1-
PB–31107–007
47
47
TOP VIEW
47
44
45 46
SIDE VIEW
(Representative Illustration)
FIG. 2
-2-
UNCONTROLLED COPY PB-31107-007
AC MOTOR MODEL 5GEB22D2
See On-Line Master for Current Revision
--------------------------------------------------------------------------------------------------------------------------------
FIG. REF.
NO. NO. PART NO. QTY DESCRIPTION
--------------------------------------------------------------------------------------------------------------------------------
1 1 5GEB22D2 1 AC MOTOR (SEE PB-31107-007)
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 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 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 84C620926G10 1 ROTOR ASSEMBLY
1 35 84D730356P3 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
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 84B519250P1 1 HUB
--------------------------------------------------------------------------------------------------------------------------------------------
08-FEB-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
RPL 4302
COVER ASSEMBLY
LOWER UNUSED HEATER PORT
SPEC 4302
HUNT PART
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
RENEWAL PARTS LIST PAGE 1
FILE: RPL4722G1/4 JUNCTION BOX ASSEMBLY

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

IMP120-12
120 Series
Explosion-Proof Pressure and
Differential Pressure Switches
UNITED ELECTRIC
CONTROLS
Types
J120, J120K, H121, H121K, H122, Installation and Maintenance
H122K, H122P Instructions
Please read all instructional literature carefully and thoroughly before starting. Refer to the final page for the listing of Recommended
Practices, Liabilities and Warranties.
GENERAL actuates a SPDT, DPDT or dual SPDT snap-acting microswitch(es),

which convert the pressure signal into an electrical signal. Control
MISUSE OF THIS PRODUCT MAY CAUSE EXPLOSION AND set point(s) may be varied by turning the internal adjustment hex
PERSONAL INJURY. THESE INSTRUCTIONS MUST BE (J120 models) or the external knob and pointer(s) (H121, H122, H122P
THOROUGHLY READ AND UNDERSTOOD BEFORE UNIT IS models) according to the procedures outlined.
INSTALLED.
Please refer to product bulletin for product specifications. Product
THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, bulletins may be found at www.ueonline.com.
DIVISIONS 1 & 2, GROUPS B, C AND D; CLASS II, DIVISIONS
1 & 2, GROUPS E, F AND G; CLASS III; OR NON-HAZARDOUS
LOCATIONS ONLY. Part I -Installation Tools Needed
Screwdriver
THIS EQUIPMENT IS ATEX CERTIFIED FOR EQUIPMENT Adjustable Wrench to 1-1/2”
CATEGORY 2. SUITABLE FOR APPROPRIATE USE IN GAS ZONE
1 & DUST ZONE 21 APPLICATIONS. MOUNTING
0539 DEMKO 03 ATEX 0305048 THE CONNECTION OF THE DEVICE SHALL BE MADE BY
II 2 G EEx d IIC T6 CABLE ENTRIES OR A STOPPING BOX OF A FLAMEPROOF
II 2 D T+ 85°C TYPE, CERTIFIED EEx d IIC. THESE ACCESSORIES SHALL

BE THREADED INTO THE RELEVANT OPENING(S) OF THE DEVICE,
WITH AT LEAST 5 THREADS ENGAGED AND WITH AT LEAST 8 mm
BEFORE INSTALLING, CHECK THE SENSOR MODEL SELECTED LENGTH OF THREAD ENGAGEMENT. THESE ACCESSORIES ARE NOT
FOR COMPATIBILITY TO THE PROCESS MEDIA IN CONTACT INCLUDED WITHIN THIS ASSOCIATED HAZARDOUS LOCATIONS/ZONE 1
WITH THE SENSOR AND WETTED PARTS. ATMOSPHERES APPROVAL.
PROOF PRESSURE* LIMITS STATED IN THE LITERATURE AND TO PREVENT IGNITION, SEAL ALL CONDUIT RUNS WITHIN 18
ON NAMEPLATES MUST NEVER BE EXCEEDED, EVEN BY INCHES OF ENCLOSURE.
SURGES IN THE SYSTEM. OCCASIONAL OPERATION OF UNIT
UP TO MAXIMUM PRESSURE IS ACCEPTABLE (E.G., START-UP, TESTING). ALWAYS HOLD A WRENCH ON THE PRESSURE HOUSING HEX
CONTINUOUS OPERATION SHOULD NOT EXCEED THE DESIGNATED WHEN MOUNTING UNIT. DO NOT TIGHTEN BY TURNING
OVER RANGE PRESSURE. ENCLOSURE. THIS WILL DAMAGE SENSOR AND WEAKEN
SOLDER OR WELDED JOINTS.
*Proof Pressure: The maximum pressure to which a pressure sensor
may be occasionally subjected, which causes no permanent damage INSTALL UNITS WHERE SHOCK, VIBRATION AND TEMPERATURE
(e.g., start-up testing). The unit may require re-gapping. (See Part FLUCTUATIONS ARE MINIMAL. MOUNT UNIT TO PREVENT
II- Adjustments) MOISTURE FROM ENTERING THE ENCLOSURE. IT IS
IMPERATIVE TO USE PROPERLY RATED EXPLOSION-PROOF SEALING
THESE PRODUCTS DO NOT HAVE ANY FIELD REPLACEABLE
FITTINGS FOR ELECTRICAL WIRE ENTRY. DO NOT MOUNT UNIT IN
PARTS. ANY SUBSTITUTION OF COMPONENTS MAY IMPAIR
AMBIENT TEMPERATURES LOWER THAN -40°F (-40°C) OR HIGHER
SUITABILITY FOR CLASS I, DIVISION 1.
THAN 160°F (71°C).
TO PREVENT IGNITION OF HAZARDOUS ATMOSPHERES,
DISCONNECT SUPPLY CIRCUITS BEFORE OPENING. KEEP J120 ENCLOSURES ARE PROVIDED WITH TWO 3/4” NPT
COVER TIGHT WHILE CIRCUITS ALIVE. ELECTRICAL CONDUIT OPENINGS, EITHER OF WHICH OR BOTH
CAN BE USED DURING INSTALLATION. A 3/4” EXPLOSION
The 120 Series pressure and differential pressure switches are PROOF PLUG IS PROVIDED FOR PROPERLY SEALING THE UNUSED
actuated when a bellows, diaphragm or piston sensor responds to CONDUIT OPENING. THE EXPLOSION PROOF PLUG MUST BE
a pressure change. This response at a pre-determined set point(s) PROPERLY SEALED DURING PRODUCT INSTALLATION.
Operation and Maintenance Manual Page 234 IMP120-12
www.ueonline.com
Types J120, J120K, H121, H121K, H122, H122K, H122P
Figure 1a: Figure 1b

H121, H121K, H122, H122K, H122P J120, J120K
Mount controls vertically (pressure connection facing down, see Figure

Use 75°C copper
1a) or horizontally (see Figure 1b). Control may be surface mounted via conductors only.
the four 1/4” screw holes on the enclosure or mounting bracket. It can Recommended
also be mounted directly to a rigid pipe using the pressure connection. tightening torque for
field wiring terminals
Controls with Breather Drain (Option M450) is 7-17 in-lbs.
Type J120, J120K Models 455-559

Mount with breather drain facing down (See Figure 1b). The conduit
Figure 3
connection must be “potted” for this type of installation.
Types H121, H122 & H122P, All Models
Mount in vertical position with pressure assembly and breather drain
WIRING
facing down (See Figure 1a). SUPPLY LEADWIRES MUST BE RATED 75°C MINIIMUM COP-
PER CONDUCTOR ONLY.
Differential Pressure Types J120K, H121K, H122K
Opposed Sensor Models 36-39, (S)147(B)-(S)157(B), 367 DISCONNECT ALL SUPPLY CIRCUITS BEFORE WIRING UNIT.
“Opposed sensor” differential pressure switches should be mounted WIRE UNITS ACCORDING TO NATIONAL AND LOCAL ELECTRI-
with their pressure connection in the horizontal position (See Figure 2). CAL CODES. MAXIMUM RECOMMENDED WIRE SIZE IS 14 AWG.
This will properly orient the 1/4” NPT venting conduit at the bottom of THE RECOMMENDED TIGHTENING TORQUE FOR FIELD WIRING TERMI-
the third compartment (standardly supplied with plastic plug). NALS IS 7 TO 17 IN-LBS.
ELECTRICAL RATINGS STATED IN LITERATURE AND ON NAME-
PLATES MUST NOT BE EXCEEDED—OVERLOAD ON A SWITCH
CAN CAUSE FAILURE ON THE FIRST CYCLE.
TO PREVENT SEIZURE OF ENCLOSURE COVER, DO NOT
REMOVE LUBRICANT. THREADS SHOULD ALSO BE FREE OF
DIRT, ETC.
THE EXTERNAL GROUNDING TERMINAL IS NOT TO BE USED
AS THE PRIMARY EQUIPMENT GROUNDING TERMINAL. THE
INTERNAL GROUNDING TERMINAL SHALL BE USED AS THE
PRIMARY EQUIPMENT GROUNDING MEANS AND THE EXTERNAL
GROUNDING TERMINAL IS ONLY FOR A SUPPLEMENTAL (SECONDARY)
GROUNDING CONNECTION WHERE LOCAL AUTHORITIES PERMIT OR
REQUIRE SUCH A CONNECTION.
Figure 2
Opposed Sensor Models Remove cover and wire control (See Figure 3). Replace cover and
hand tighten to fully engage cover O-ring.

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Types H122P
Part II - Adjustments Individual switches may be set together or separately by up to 60%
Tools Needed of range. The front switch is set by turning the internal calibrating
Screwdriver screw to the right for lower set point and turning to the left for higher
5/8” Open End Wrench set point. When not set together, the front switch should never be set
5/64” Allen Wrench higher than the rear switch. Turning the external knob will increase or
decrease both switch settings simultaneously without disturbing their
AFTER COMPLETING ADJUSTMENTS ON TYPE H121 AND H122 relationship.
CONTROLS, BE SURE TO RE-INSTALL ADJUSTMENT COVER.
DO NOT OVER TIGHTEN COVER SCREWS. Controls with Options
For set point adjustment and gapping, connect control to a calibrated Option 1519 and other models with an Adjustable Deadband
pressure source. Switch
Types J120 (All) and J120K Models 455-559 (See Figure 4a) This microswitch has an integral adjustment wheel. Turning this
Remove cover. Loosen phillips screw adjustment lock. Adjust set point wheel raises and lowers the pressure rise set point. The fall set point
by turning 5/8” hex adjustment screw clockwise (IN) to raise set point, remains constant. Consult factory for additional information.
or counterclockwise (OUT) to lower set point. Secure adjustment Type J120, Option 1530, Manual Reset
screw by tightening adjustment lock. This microswitch, when actuated, remains actuated until the pressure
drops sufficiently to allow the reset knob (located on the left side of
J120K: Opposed Sensor,
Models 36-39, 147-157, S147B,
the control) to be manually turned to reset the microswitch.
S157B, 367 Option M210
Figure 4a Figure 4b
Figure 5
DO NOT TURN
Option M210 Indicator for
Differential Pressure Controls, Span Adjustment
(See Figure 5). To adjust indication for maximum accuracy at any
desired set point, follow steps 1 thru 3 listed below:
1) Remove front window and gasket (four screws) to gain access
to span adjustment.
2) Connect control to calibrated gauges and set required differential
Type J120K Models 36-39,147-S157B, & 367 (See Figure 4b) pressure.
Remove front cover and gasket from sensor 3) Using a screwdriver, slowly turn the span adjustment to obtain
assembly located below enclosure by unscrewing 4 phillips screws. required indication. Remount the front gasket and window.
Loosen phillips screw adjustment lock. Adjust set point by turning 5/8”
hex screw clockwise (IN) to increase setting or counterclockwise (OUT) NOTE: Spanning adjustment will not affect the mid-range indication.
to decrease setting. Adjusting screw should be locked by tightening The adjustment is factory calibrated and sealed to indicate tampering.
adjustment lock. DO NOT FORCE SPAN ADJUSTMENT, SINCE PERMANENT
Types H121, H121K DEFORMATION OF THE LINKAGE MECHANISM MAY RESULT.
Adjust set point by turning external knob and pointer to desired
setting on scale.
Types H122, H122K
Individual microswitches may be set together or separately by up
to 100% of range. The front (Low) microswitch should never be
set higher than the rear (High) microswitch. Turning external
knobs will increase or decrease each switch setting independently.

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RE-GAPPING PROCEDURE
Tools Needed
5/8” Open End Wrench
3/16” Open End Wrench (2)
GAPPING IS FACTORY-SET AND CRITICAL TO THE FUNCTION

OF THE SWITCH. THIS PROCEDURE SHOULD ONLY BE
PERFORMED IF THE PLUNGER HAS ACCIDENTALLY BEEN
ADJUSTED.
1) Loosen adjustment lock.
2) Turn 5/8” hex adjustment screw IN, to approximately midrange.
This puts a load on the sensor and exposes the plunger flats.
(See Figure 6).
3) Using a 3/16” wrench on the plunger flats and a 3/16” wrench on
the plunger hex screw, turn hex OUT from plunger until micro-
switch actuates. If microswitch has already actuated, turn plunger
hex screw IN until microswitch deactuates.
4) Continue per following instructions, depending on model.
Models 171-174, 521-525, 531-535, and 540-548
Turn hex (IN) an additional 1-1/2 flats from this point. This will provide
a 5-9 mil gap.
Models 680, 701-705, 356-376, 612, 616, 270, 274
Turn hex (IN) 3 flats from this point (approximately 1/2 turn). This will
provide a 14-16 mil gap.
Models 183-189, 190-194, 483-489, 490-494,565-567
Turn hex (IN) 1 flat from this point. This will provide a 4-7 mil gap.
CONTACT FACTORY FOR ASSISTANCE WITH MODELS

NOT SHOWN ABOVE.
Re-Gapping Procedure for J120/J120K
Figure 6

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Types J120, J120K
Dimensions Models
Dimension A
Inches mm NPT
Pressure
Internal Set Point Adjustment 126-164 7.25 184.2 1/4
Types J120, J120K S126B-S164B 7.63 193.8 1/2
171-174 8.72 221.5 1/2
183-186, 483-486 8.41 213.6 1/2
188-189, 488-489 7.47 189.7 1/2
190-194, 490-494 7.44 189.0 1/2
270-274 8.13 206.5 1/4
358-376 8.09 205.5 1/4
450, 452 8.81 223.8 1/4
451, 453, 454 8.06 204.7 1/4
520-525 9.25 235.0 1/2
530-535 8.84 224.5 1/2
550, 552 8.81 223.8 1/4
551, 553-555 8.34 211.8 1/4
560-564 7.53 191.3 2” Sanitary
565-567 7.53 191.3 1-1/2” Sanitary
612, 616 7.88 200.2 1/4
680 8.13 206.5 1/4
701-705, 15622 7.44 189.0 1/4
Differential Pressure
36-39, 147-157, 367 7.59 192.8 1/4
External Set Point Adjustment S147B-S157B 7.59 192.8 1/2
Types H121, H122, H121K, H122K, H122P 455-457, 559 8.44 214.4 1/4
540-543 9.34 237.2 1/8
544-548 9.41 239.0 1/8
Types H121, H122, H121K, H122K, H122P

Dimension A
Models Inches mm NPT
Pressure
126-164 8.09 205.5 1/4
S126B-S164B 8.50 215.9 1/2
270-274 7.88 200.2 1/4
358-376 7.81 194.4 1/4
450, 452 9.69 246.1 1/4
453, 454 8.94 227.1 1/4
550, 552 9.75 247.7 1/4
553-555 9.31 236.5 1/4
612, 614 8.75 222.3 1/4
701-705 8.31 211.1 1/4
147-157 8.44 214.4 1/4
S147B-S157B 8.44 214.4 1/2
456-457, 559 9.31 236.5 1/4
Surface Mounting kit Pressure

6361-704
Models 126-164 Models S126B-S164B
Models 171-174 Models 183-186, Models 188-194,

483-486 488-494

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RECOMMENDED PRACTICES AND WARNINGS
United Electric Controls Company recommends careful consideration
of the following factors when specifying and installing UE pressure and
temperature units. Before installing a unit, the Installation and Maintenance
instructions provided with unit must be read and understood.
6Q CXQKF FCOCIKPI WPKV RTQQH RTGUUWTG CPF OCZKOWO VGORGTCVWTG NKOKVU
UVCVGF KP NKVGTCVWTG CPF QP PCOGRNCVGU OWUV PGXGT DG GZEGGFGF GXGP D[
Models 560-564 Models 565-567 UWTIGU KP VJG U[UVGO 1RGTCVKQP QH VJG WPKV WR VQ OCZKOWO RTGUUWTG QT
temperature is acceptable on a limited basis (e.g., start-up, testing) but
continuous operation must be restricted to the designated adjustable range.
'ZEGUUKXG E[ENKPI CV OCZKOWO RTGUUWTG QT VGORGTCVWTG NKOKVU EQWNF TGFWEG
sensor life.
#DCEMWRWPKVKUPGEGUUCT[HQTCRRNKECVKQPUYJGTGFCOCIGVQCRTKOCT[
WPKV EQWNF GPFCPIGT NKHG NKOD QT RTQRGTV[ # JKIJ QT NQY NKOKV UYKVEJ KU
necessary for applications where a dangerous runaway condition could
result.
6JG CFLWUVCDNG TCPIG OWUV DG UGNGEVGF UQ VJCV KPEQTTGEV KPCFXGTVGPV QT
malicious setting at any range point cannot result in an unsafe system
condition.
+PUVCNN WPKV YJGTG UJQEM XKDTCVKQP CPF CODKGPV VGORGTCVWTG HNWEVWCVKQPU
J120 Models H121/H122 Models Models 450-454, will not damage unit or affect operation. Orient unit so that moisture does
270-376, 680 270-376 550-555 not enter the enclosure via the electrical connection. When appropriate,
this entry point should be sealed to prevent moisture entry.
7PKV OWUV PQV DG CNVGTGF QT OQFKHKGF CHVGT UJKROGPV %QPUWNV 7' KH
modification is necessary.
/QPKVQT QRGTCVKQP VQ QDUGTXG YCTPKPI UKIPU QH RQUUKDNG FCOCIG VQ WPKV
UWEJCUFTKHVKPUGVRQKPVQTHCWNV[FKURNC[%JGEMWPKVKOOGFKCVGN[
2TGXGPVCVKXG OCKPVGPCPEG CPF RGTKQFKE VGUVKPI KU PGEGUUCT[ HQT ETKVKECN
applications where damage could endanger property or personnel.
(QTCNNCRRNKECVKQPUCHCEVQT[UGVWPKVUJQWNFDGVGUVGFDGHQTGWUG
'NGEVTKECN TCVKPIU UVCVGF KP NKVGTCVWTG CPF QP PCOGRNCVG OWUV PQV DG
GZEGGFGF1XGTNQCFQPCUYKVEJECPECWUGFCOCIGGXGPQPVJGHKTUVE[ENG
Wire unit according to local and national electrical codes, using wire size
Models 520-525 Models 530-535 Models 612-616, 701-705,
recommended in installation sheet.
15622 &QPQVOQWPVWPKVKPCODKGPVVGORGZEGGFKPIRWDNKUJGFNKOKVU
LIMITED WARRANTY
Seller warrants that the product hereby purchased is, upon delivery, free from
FGHGEVUKPOCVGTKCNCPFYQTMOCPUJKRCPFVJCVCP[UWEJRTQFWEVYJKEJKUHQWPF
VQDGFGHGEVKXGKPUWEJYQTMOCPUJKRQTOCVGTKCNYKNNDGTGRCKTGFQTTGRNCEGFD[
5GNNGT
'ZYQTMU (CEVQT[ 9CVGTVQYP /CUUCEJWUGVVU +0%16'4/5 RTQXKFGF
however, that this warranty applies only to equipment found to be so defective
within a period of 24 months from the date of manufacture by the Seller (36
OQPVJUHQTVJG5RGEVTCCPF1PG5GTKGURTQFWEVUOQPVJUHQT6GORGTCVWTG
Sensors). Seller shall not be obligated under this warranty for alleged defects
YJKEJ GZCOKPCVKQP FKUENQUGU CTG FWG VQ VCORGTKPI OKUWUG PGINGEV KORTQRGT
storage, and in any case where products are disassembled by anyone other
VJCPCWVJQTK\GF5GNNGT¶UTGRTGUGPVCVKXGU':%'26(146*'.+/+6'&9#44#06;
Models 540-543 Models 544-548 1( 4'2#+4 #0& 4'2.#%'/'06 56#6'& #$18' 5'..'4 &+5%.#+/5 #..
9#44#06+'5 9*#651'8'4 9+6* 4'52'%6 61 6*' 241&7%6 +0%.7&+0)
#.. +/2.+'& 9#44#06+'5 1( /'4%*#06#$+.+6 ; 14 (+60'55 (14 #0;
2#46+%7.#4274215'
LIMITATION OF SELLER’S LIABILITY
Seller’s liability to Buyer for any loss or claim, including liability incurred in
EQPPGEVKQP YKVJ
K DTGCEJ QH CP[ YCTTCPV[ YJCVUQGXGT GZRTGUUGF QT KORNKGF
(ii) a breach of contract, (iii) a negligent act or acts (or negligent failure to
act) committed by Seller, or (iv) an act for which strict liability will be inputted
to seller, is limited to the “limited warranty” of repair and/or replacement as
J120K Models 367 Models 455-457, 559 so stated in our warranty of product. In no event shall the Seller be liable for
CP[ URGEKCN KPFKTGEV EQPUGSWGPVKCN QT QVJGT FCOCIGU QH C NKMG IGPGTCN PCVWTG
KPENWFKPIYKVJQWVNKOKVCVKQPNQUUQHRTQHKVUQTRTQFWEVKQPQTNQUUQTGZRGPUGUQH
any nature incurred by the buyer or any third party.
UE specifications subject to change without notice.
J120K Models 36-39
180 Dexter Avenue, P.O. Box 9143

Watertown, MA 02471-9143 USA
Telephone: 617 926-1000 Fax: 617 926-2568
Models 147 & 157 Models S147B & S157B http://www.ueonline.com
CP01095000
www.ueonline.com
RPL 4239G2
SPACE HEATER APPLICATION
100 WATT - 110/240 VOLT ATEX
SPEC 4239G2
HUNT PART
1.00 1 SPACE HEATER 3781AP07
2.00 1 COVER ASSEMBLY 4248B
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
STB Range
Small Sheet steel enclosures
18 Operation and Maintenance Manual Page 254

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
Operation and Maintenance Manual Page 255 19

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 4849G9 HUNT AIRDYNE BLOWER ASM
MODEL 22A2 - 17.4CW - 36440
SPEC 4849G9-2
SEE ILLUSTRATION DWG 4849RPL
HUNT PART
1.00 1 ELECTRIC MOTOR - 55 Deg.C 5267
2.00 1 MOTOR BASE ASM 4700
3.00 1 WHEEL ASM - BLOWER 3379APO6
4.00 1 HOUSING ASM - BLOWER 4701B
5.00 1 AIR INTAKE LOUVER ASSEMBLY4340
5.06 2 LOUVER 4323APO1 Rev.1
5.08 8 FLAT WASHER - 5/16' USS L502
5.09 8 HEX NUT - 5/16-18 NYLOCK L303
6.00 1 SEAL - MOTOR FACE 2516
7.00 1 GSKT.- HOUSING - INLET SIDE 2525.02B
8.00 1 GSKT.- HOUSING - DRIVE SIDE 2525.02B
9.00 1 GSKT.- HOUSING - DISCHARGE 4590.04B
10.00 1 NAMEPLATE - ROTATION 2968A
11.00 1 NAMEPLATE - MODEL, S/N, ETC. 2709A
12.00 31 NUT - 3/8-16 LA102
13.00 31 FLAT WASHER - 3/8 L514
14.00 31 LOCK WASHER - 3/8 L530
15.00 4 BOLT - 1/2-13 X 2 L664
16.00 4 LOCK WASHER - 1/2 L532
17.00 4 FLAT WASHER - 1/2 SAE L516
18.00 4 HEX NUT - 1/2 - 13 LA104
Operating Manual
Explosion-Proof
F&G Three-Phase-Motors
II2G EEx d(e) IIC(B) T3-6
II2D T80–120°C IP 65(66)
I BA01.05-E
under license of
MOTORENTECHNIK GMBH

Any and all brands and product names herein are trademarks or registered
trademarks of the relevant holders.
1. 2001 Edition, Date of Publication 02/ 01

© ATB Motorentechnik GmbH, Nordenham
Author: Wolfgang Sobel
All rights on this manual and its translation reserved.
No part of this manual can be reproduced in any form whatsoever (print,

photocopy, microfilm or any other means) or processed electronically without
the prior written permission of the ATB Motorentechnik GmbH Company,
Nordenham
All changes reserved.
Printed on paper chlorine-free and acid-free bleached cellulose.
I
Warning!
Hazardous electrical current!
Ensure protection against
explosions!
Before installing
Switch off the power to the device.

Make sure that device cannot be The personnel must be duly instructed
switched on again by accident. to proceed with caution and according
Make sure that the device is de- to regulations during shipping, hoisting,
energized. and positioning and while repairing the
Connect to earth and short out. motor.
Cover or close off any neighboring live Do not lift the motor together with the
parts with a barrier. drive equipment by the motor lifting
Follow carefully the assembly eyebolts.
instructions provided for the device. Do not use the supplied lifting eye bolts
Only qualified personnel as per EN at ambient temperatures below –20°C,
50110-1/-2 (VDE 0105, part 100) can in accordance with DIN 580. Lower
perform any work on this temperatures could lead to the ring
device/system. screws breaking and consequent
The electrical connections are to be breaking and consequent injury to
made as per the relevant specifications personnel and/ or damage to the
(e.g. cross-section of the supply line, installation.
fuses, protective connection). Do not load the eyebolts as per DIN
Opening the motor - save for the 580 no more than 45° compared to the
terminal box - during the warranty screwing direction. The use of
period without the manufacturer's crossbeams is recommended. See the
permission shall lead to the termination operating instructions for the layout
of the warranty. dimensions of the lifting eyebolts and
Original spare parts are to be used for the minimum dimensions of the loading
the approved repairs or repairs not crossbeams and chain lengths.
falling under the warranty. In the case of motors with built-in brake
Live and rotating parts of electrical appropriate safety measures are to be
motors can cause major or deadly adopted against the possible failure of
injuries. the brake especially in applications
Any shipping, installation, start-up and involving the pulling of loads.
maintenance works are to be carried Operating the motor with the supplied
out only by qualified personnel (follow shaft protection cover alone is
carefully any regulations on explosion forbidden.
protection such as EN 60079-14 and Contact with the capacitor for the start-
SeitenEN 50821-1-2 as well as any up and running of single-phase motors
other national accident prevention is to be avoided until the unloading
regulations). procedure is carried out securely.
As regards any equipment subject to If a high-voltage test is necessary, the
these guidelines, it is important to adopt procedures and precautionary
the necessary safety precautions to measures set forth in accident
protect the personnel against possible prevention regulations are to be
injuries. followed.
I
Table of Contents
About this Manual 4

Target audience 4
Abbreviations and symbols 4
1 Explosion-protected Motors 6
Intended use 6
Liability and Warranty Guarantee 6
Servicing 7
- Spare Parts 7
Delivery, Storage, Transport 7
- Delivery 7
- Storage 8
- Transport 8
2 Installation 10
Mechanical checks 10
Site 10
Mounting 12
Mains supply and connections 15
- Mains connection of explosion-protected motors 16
- Motors with direct line lead-in 16
- Terminal box 16
- Cable and line lead-ins 19
- Motors with terminal boxes whose mains lead is located in 20
the layer separating the upper and lower parts
- Mains and guard circuit connection 21
- Motors with unidirectional fan 25
- Motors with separate cooling via separately powered 25
external fans
- Motors with temperature monitoring 25
- Motors with space heater 26
- Motors for operating on frequency converters 26
- Motors with built-in frequency converter (compact drive) 29
- Motors with brake 37
- Motors with brake or tachometer mounted under the 37
ventilator hood
- Motors with water cooling 38
Connection diagrams 39
- Brake motors with incorporated brake 40
2
3 Operation and Repairs 39
Duty types and thermal protection 42
Special operating conditions 42
Motors with backstop 43
Heat input through the driven machine 43
Start-up 43
Maintenance 43
- Inspection 45
- Lubrication 45
Explosion protection 47
- Instructions for ensuring explosion protection during 47
operation
Repairs 48
4 Additional dust protection requirements 49

(application in zone 21 and 22)
Intended use 49
Installation and Operation 49
-Cable and line lead-ins 49
-Operation and Repairs 49
3
About this Manual
These operating instructions apply to AC motors of the following series:

CD...; dCD...; CEIGL...; BD... and dBD....
Besides the general assembly instructions, these guidelines are to be

followed for the installation, start-up and maintenance of explosion-protected
AC motors with a degree of protection of "pressure-resistant encapsulation"
marked: (II..), EEx de II. T or EEx d II. T.
Any independent manufacturing equipment mounted on or built into the
motors like brakes, rotary encoders or frequency converters, etc. have their
own operating instructions which are to be duly followed.
Target audience
This manual is addressed to the specialists in charge of installing, operating

and servicing the motors. Besides conventional technical training they must
possess knowledge in the field of explosion protection.
Abbreviations and symbols

This manual uses abbreviations and symbols having the following meanings:
> indicates handling instructions
Î draws your attention to interesting tips and

additional information
Please note!
warns against minor damages to property.
Caution!
warns against major damages to property and
minor injuries.
4
Warning!
warns against major damages to property and
major injuries or death.
All of the dimensions are in mm unless otherwise specified.
In order to ensure clarity, at the top of every page you will find the name of
the chapter on the left hand and the current section on the right hand; the
only exceptions are the first page of each chapter and the blank pages at the
end of the chapter.
5
1 Explosion-protected Motors
Intended use
The motors are to be operated only according to the data specified on the
rating plate. According to the relevant marking on the rating plate, the motors
are fit for use in areas subject to explosion hazards.
The motors are fit to be built into another machine. Start-up is forbidden until
the conformity of the final product with Directive 89/392/EEC as amended by
98/37/EC is determined.
Liability and Warranty Guarantee
We cannot be held liable for any damage or malfunctions resulting from

assembly errors, the failure to follow these operating instructions or improper
repairs.
Original spare parts are manufactured and tested specifically for these
motors.
We recommend that you obtain any spare parts and accessories only from
the manufacturer.
We hereby specify that any spare parts and accessories not supplied by the
manufacturer require our approval.
Under any circumstances the mounting and use of third-party products can
negatively affect the motor's original structural properties and impair the
safety for persons, the motor or other real values (explosion protection).
The manufacturer shall not be liable for any damages resulting from the use
of spare parts or accessories not authorized by the manufacturer.
Any unauthorized conversions and alterations to the motor shall not be
approved for safety reasons and the manufacturer cannot be held liable for
any resulting damages.
6
Servicing
For any technical information on F&G motors ATB’s customer service is

always at your disposal.
Should any difficulties with our motors be encountered, please contact our
factory or local branch office. Log on to our website to find at the address of
our local branch office nearest your.
ATB Motorentechnik
Helgoländer Damm 75
D-26954 Nordenham
Tel.: +49 (0) 47 31/ 3 65-0

Fax.: +49 (0) 47 31/ 3 65-1 59
E-Mail: info@atb-nordenham.de
Internet: www.atb-nordenham.de
Spare parts
When ordering spare parts, besides the name of the required part, specify
also the motor type and serial number.
Delivery, Storage, Transport
Delivery
> Check the motor for damages during transportation.
In case of damage during transportation an investigation of fault is to be

performed by the forwarding agent.
> Report any covert damages to the forwarding agent or manufacturer no

later than seven days from the transfer of the motor.
The entire packaging material can be recycled by means of the Dual

System.
7
Storage
Storage up to a maximum of 36 months is possible in the following

conditions:
• In order to prevent a drop in the insulation resistance, the surrounding

environment must be dry and dust-free.
• The room temperatures should not drop below +5 °C or exceed +30 °C
with an air humidity of < 70 % and register changes in temperature greater
than 10 °C/day.
• In order to prevent damage during storage any occurring oscillations must
amount to Veff < 0.2 mm/s.
• For motors with regreasing systems repress an amount of grease double
that specified on the motor at standstill before storage.
Please note!
In case of storage conditions deviating from those specified
above the measures set forth in the separate AR9 storage
instructions must be adopted.
Transport
Do not lift the motor together with mounted driven machines such as, for
instance, pumps, gearing, etc. by the motor lifting eyebolts.
Do not use eyebolts as per DIN 580 at ambient temperatures lower than –
20 °C.
At these temperatures the eyebolts may break and hence injure the
personnel and/or damage the machinery. Do not load the eyebolts as per
DIN 580 no more than 45° compared to the screwing direction. The use of
crossbeams is recommended. Layout dimensions of the lifting eyebolts and
the minimum dimensions of the loading crossbeams and chain lengths.
(Î Fig. 1).
Please note!
When mounting vertical motors from the horizontal position,
the shaft must not touch the floor to avoid damaging the
bearings.
8
Figure 1: Eyebolt dimensions
Table 1: Minimum dimensions for lifting eyebolts and crossbeams

Frame size Ø t horizontal vertical
e h e h
90 20 167 100 220 187
100 20 185 112 242 201
112 20 202 103 262 236
132 25 243 170 307 247
160 30 262 206 314 293
180 30 294 223 402 372
200 35 390 219 451 399
225 40 366 230 510 490
250 40 435 282 546 548
280 40 498 301 600 574
315 50 640 337 700 595
355 60 629 397 816 893
400 60 790 312 890 771
450 60 833 317 980 660
9
2 Installation
Mechanical checks
After removing the shipping braces and shaft blocks (see also the marking
on the motor), the motor shaft must be rotated by hand. In the case of
brakemotors the brake must be vented at standstill (maximum of 10 min).
This must be performed after applying voltage as per the circuit diagram
from page 39.
Please note!
Save the shipping braces and shaft blocks for subsequent
transportation, as the bearings risk being damaged during
transportation.
Site
The completely closed motors are intended for operating sites in which they
are exposed to soiling, humidity and other open air conditions as per the
relevant degree of protection.
The motors must be installed in a place with ambient temperatures of –20 °C
to a maximum of +40 °C and a max. of 1000m above sea level. Any
permissible ambient temperatures (Ta) and heights (MSL) other than those
indicated above must be specified on the rating plate. Lower temperatures
and values not found on the rating plate require the use of space heaters.
Î Section 3 “Operation and Repairs”
Please note!
The ventilator hood air inlet and outlet must not be obstructed,
as there is the risk of heating beyond the permissible
temperature class and of reducing the life of the winding
insulation Î Fig. 2 and Î Table 2.
This applies in particular to the use of soundproof covers. The

air ducts must checked and cleaned regularly in factories with
heavy soiling.
10
Table 2:
Minimum distance (LE) of an obstacle from the air opening, see Fig. 2.
Shaft height LE [mm]
up to 160 35
180 to 225 85
over 250 125
Figure 2: Minimum distance of obstacles from the air opening
The motors are intended for use in areas subject to explosion hazards. The
following data on the rating plate distinguish the motor as explosion-
protected equipment:
• Degree of protection
• Explosion group
• Temperature class
Depending on the appliance category the motor is assigned to the relevant

zone of the operating site.
11
Mounting
The motors are mounted either on the motor feet or on the flange at the
installation site. All motors with shaft heights of up to 355 mm can be
mounted either horizontally or vertically thanks to their bearing layout. This
applies also for motors to be mounted with the feet on roofs and side walls.
Motors with reinforced bearings are to be operated at a minimum load to
ensure the smooth operating of the anti-friction bearings (Î Table 3).
Table 3: Minimum load on the shaft collar for motors with reinforced bearing
Shaft Minimum Shaft Minimum Shaft Minimum
height load height load height load
112 1100N 200 3400N 315 8000N

132 1600N 225 3800N 355 2000N
160 1900N 250 4900N 400 2000N
180 2700N 280 5500N 450 2300N
The bearings may be damaged if the minimum load is exceeded. Trial runs
with no-load should last only a few minutes.
You can find the max. permissible loads in our catalogue "Explosion-
Protected High and Low Voltage AC Motors" or contact the manufacturer.
Align the motors according to the requirements of the coupling or pulley

manufacturer. The feet are to be positioned evenly and, if necessary, lined.
Please note!
Make sure that the fastening screws are duly dimensioned.
Data on the foundation loading generated by the motor can be requested

from the manufacturer by specifying the motor number. The fastening
screws must be duly tightened according to their layout and secured to
prevent loosening during operation and hence the damaging of the drive.
(Î Table 4, page 17).
12
Figure 3: Motor Fastening
c Large-surface Washer
In order to achieve an adequately large contact surface, apply a large-
surface washer under each nut or screw head
(Fig. 3).
Î Alternatively use flange nuts or bolts.
If the motors shaft end points up or down (vertical mounting arrangement), it

is necessary to fit an appropriate cover to prevent any foreign bodies from
dropping in the driven machine through the air inlet and outlet openings in
the ventilator hood.
Please note!
The flow of cooling air through the motor must not be limited
by said cover (Î Section "Site", page 10).
The balance of the motors is specified on the shaft end plate and/or on the
rating plate (H = half key, F = full key, N = no key).
The design of the coupling or pulley must match the motor's balance.
13
Please note!
If balancing with half key (H), work on the vertical (visible) key
components on the shaft diameter or cover these with washers
with keyway along the relevant length.
If the coupling is longer than the key, it is necessary to fill the

keyway in the remaining part of the coupling.
In case of failure to comply with the foregoing, out-of-balances

liable of causing excessive vibrations may occur.
Please note!
Mount the pulleys or couplings only through the threaded bores in
the shaft end to avoid damaging the anti-friction bearings
(Î Fig. 4).
Fig. 4: Fastening of the pulley or coupling
> Screw the threaded bolts in the threaded bore.
> Then mount the pulley or coupling on the shaft end: make sure to screw
a nut with a washer having at least the same diameter of the pulley hub
or coupling on the threaded bolt.
14
Use the utmost care in mounting dynamically balanced pulleys or couplings
on the shaft end. Machines to be connected to the motor by means of
couplings are to be aligned according to the specifications of the coupling's
manufacturer.
Î Only use flexible couplings!
Mains and other electrical connections
The motors work as per VDE 0530 with mains voltage oscillations of up to
±10 % or frequency oscillations of up to –5 % to +3 %. The mains ratings
must match the voltage and frequency data specified on the ratings plate.
Connect the motors according to the connection diagrams attached to the
terminal box (Î Figure 11 page 34). Use only the supplied original
connection components, (Î Section " Mains and guard circuit connection",
page 21).
Please note!
Carry out the motor, controller, overload protection and
earthing connection operations in compliance with local
installation requirements.
Please note!
If the accidental starting of the system may expose the
personnel to danger, do not use any automatically restarting
motor protective equipment.
15
Mains connection of explosion-protected motors
Besides any general installation regulations, follow carefully EN 60079-14

and EN 50281-1-2. Afterwards suitable overload protection is to be provided
either with a motor circuit breaker or similar protective devices. These may
include also PTC thermistors with tripping devices (Î Section "Motors with
temperature monitoring“, page 25). These must be specified on the rating
plate together with a tripping time tA.
In addition, any "Special Requirements" specified in the test certificate are to

be complied with. These are marked with an "X" after the test certificate
number on the rating plate.
Motors with direct line lead-in
The free end of the cable inserted in the motor must be connected according
to the regulations in force concerning the connection area. If the line lead-in
used on the motor is provided with pull relief, the cable can be laid freely;
otherwise the cable must be secured with a pull relief device in the near
vicinity.
The maximum operating temperature at the line lead-in must not

exceed 90° C.
Terminal box
Open the box by loosening the screws on the cover (Fig. 5) or, in the case of
models with grub screw (Fig. 6), by turning the grub screw counter-clockwise
and then loosening the tapped cover.
Close the terminal box again after connecting the mains by following the
same instructions in the opposite order.
In order to change the position of the cable and line lead-ins, you can turn
the terminal box by 4 x 90°.
> Loosen either

– the four fastening screws (ÎFig. 5 ) or
– the anti-rotation pins by means of the grub screw (Î Fig. 6 ).
> Turn the terminal box to the desired position.

16
Figure 5: Terminal box with fastening screw c
Figure 6: Terminal box with grub screw c
> Then tighten the fastening components to the relevant torque, see the
following table.
Table 4: Torque values for 8.8-type screws
Thread size Torque
M5 6 Nm
M6 10 Nm
M8 25 Nm
M10 49 Nm
M12 85 Nm
M16 210 Nm
M20 425 Nm
17
Please note!
Terminal boxes fastened as per Fig. 6 are to be turned
counter-clockwise by a maximum of one turn away from the
thread end stop. Screwed-on covers must be duly secured.
Anti-corrosion protection can be achieved with non-hardening sealing

materials or sealing grease in particular on the processed sealing surfaces of
the covers of terminal boxes having the following degree of protection:
"pressure-resistant encapsulation, EEx d IIC(B) marking".
The approved sealing materials are:
• For threads and surfaces:

Hylomar, by Marston-Domsel or
• for surfaces:
Admosit and Fluid-D, by Teroson.
Please note!
In the case of "increased safety" terminal boxes the gaskets
used are included in the approval. Only original gaskets are
to be used.
Please note!
"Pressure-resistant encapsulation“ terminal boxes must be
sealed by means of approved cable or line lead-ins.
18
Cable and line lead-ins
Connect the motors with cable and line lead-ins or by means of a duct
system as per EN 60079-14. These must meet the following requirements:
• EN 50019 for wiring spaces with a degree of protection of "increased

safety", (EEx e II marking on the component)
• EN 50018 for a degree of protection of "pressure-resistant encapsulation”,
(component EEx d IIC(B) marking on the component)
Specific test certificates must be provided for cable and line lead-ins.
Please note!
In case of motors complying with the new Directive 94/9/EC,
(e.g. marking II 2G ...), these must be mounted only with the
supplied original lead-ins or lead-ins that meet the
requirements of the new directive.
Any openings that are not used must be closed with sealing plugs for which
the relevant test certificates and/or the aforementioned markings must be
provided.
The supplied sealing plugs for the line lead-ins serve only as protection
during transportation and are not an approved sealing means. This applies
also for the storage of motors outdoors. In this case additional rain protection
is required.
The lead-ins supplied as a standard (version 1) are used for the insertion of
firmly secured lines.
Version 3 available as a special accessory, with additional pull relief, is used

for the insertion of lines in movable motors.
Please note!
Cable lead-ins and sealing plugs that fail to meet these
requirements are prohibited. The cable and line diameters
used must comply with the clamping range specified on the
lead-in.
Follow carefully the operating instructions of the cable and line
lead-ins.
19
Motors with terminal boxes whose mains lead is located in the layer
separating the upper and lower parts
Use only the supplied original gaskets to ensure compliance with the “Ex e
II” degree of protection. Depending on the type (see marking on the plug),
the plugs are fit for the following diameters (ÎTable 5).
Follow carefully the operating instructions for the lead-in parts and sealing
plugs.
Table 5: Cable diameter

Type Cable diameter
RS-75 26 to 48 mm
RS-100 48 to 70 mm
> After connecting the mains lead close the terminal box with the upper
part.
> Strip the skins of the plugs so that the following condition is fulfilled:
By stripping the skin, the plugs are adapted to the cable diameter so
that a gap of less than 1 mm is obtained between the cable and the
plug applied on the cable.
Therefore, an extra layer of skin must be removed from one half of the
module compared to other.
> Lubricate the cutting edge and the sealing surfaces of the plug with the
supplied grease.
> Insert the plug halves over the cable and completely in the bushing
opening.
> Brace it with the screws until a perceivable resistance (maximum
torque: 6 Nm) is achieved.
20
Figure 7: Cable lead-in
c Maximum two line lead-ins, Roxtec, RS Type plugs
Mains and guard circuit connection
The mains can be connected either with or without cable lug both in models
with terminal board (Î Fig. 8) and in those with single-conductor bushings
(ÎFig. 9) (ÎSection "Connection Diagrams", page 39).
c Connect the power line to the relevant terminals as per the supplied
wiring diagram.
21
Figure 8: Line connection
c Connection without cable lug
d Clamp
e Connection with cable lug
f Single-wire conductor without cable lug
> When connecting a single-wire conductor without cable lug to

terminals with just one screw, bend the conductor end as illustratedf.
Figure 9: Conductor bushing

c Connection without cable lug
d Connection with two cable lugs
e Connection with one cable lug
22
Take note of the maximum connectable conductor cross-section for the
terminals. If no other data is available on the terminals, refer to the following
table.
Table 6: Rated cross-sections

Shaft height Rated cross-section [mm2]
63 to 112 4
132 to 160 10 (r)
180 to 225 70
250 to 280 120
315 150/ 300 (depending on the model)
over 355 300
In the case of "increased safety" terminal boxes, make sure to comply with
the clearances specified in EN 50019 (Î Table 7) between conductive parts
having different potentials. Tighten the screws and nuts on the live parts to
the specified torque (ÎTable 8).
Table 7: Clearances
Rated voltage, U [V] Minimum clearance [mm]
175 < U ≤ 275 5

275 < U ≤ 420 6
420 < U ≤ 550 8
550 < U ≤ 750 10
750 < U ≤ 1100 14
2200 < U ≤ 3300 36
5500 < U ≤ 6600 60
8300 < U ≤ 11000 100
23
Table 8: Torques and current intensities for live pins
Thread size Torque [Nm] Permissible continuous current [A]
Brass Copper
M4 1.2 16 -
M5 2 25 -
M6 3 63 -
M8 6 100 -
M10 10 160 200
M12 15.5 250 315
M16 30 315 400
M20 52 400 630
Depending on the model, additional terminals for instance for temperature

monitoring or space heater are located either in the main terminal box or in
additional terminal boxes; see the supplied wiring diagram.
Please note!
Take note of the rating data imprinted on the terminals.
Please note!
Keep the wiring diagram supplied in the terminal box in the
enclosure with the documents belonging to the drive.
24
Motors with unidirectional fan
Make sure that the fan's direction of rotation matches that of the motor.
Motors with separate cooling via separately powered external fans
Make sure by means of the electric control that the main motor can be
operated with the motor switched-on for separate cooling.
Motors with temperature monitoring
Terminals 1TP1-1TP2 or 2TP1-2TP2
The motors are equipped with PTC's as per DIN 44081. Take note of the
temperature data and tripping time tA on the rating plate.
Connect the PTC to an approved tripping device with marking PTB 3.53-
PTC/A or II(2) G.
Please note!
The tripping device is not explosion-protected. For this reason
install them outside the areas subject to explosion hazards.
The marking confirms whether the electrical data on the interface between
the temperature sensor circuit and the tripping device have been fulfilled. The
use of the tripping device with PTC temperature sensors as per DIN 44081 is
allowed for the thermal monitoring of explosion-protected electrical
machinery.
Being the only overload protection as set forth in EN 60079-14, the

temperature sensors herein described can be used together with an
approved tripping device only if the tripping time tA is specified on the
motor rating plate. (Refer to Section 3, Operation & Repairs, page 42)
25
Motors with space heater
Terminals HE1-HE2 or U1-V1
The rating data for the space heater are specified either on the rating plate
or on a separate plate. Depending on the model, there are two heating
variants:
• by means of heater bands powered via terminals HE1-HE2 or

• by means of the stator winding by feeding AC voltage to terminals U1-
V1.
Please note!
Make sure by means of the electric control that the motor
voltage and the heater voltage are not fed simultaneously.
Please note!
The heater is not explosion-protected. It must not be switched
on at motor temperatures below -20°C to heat the motor to at
least –20°C. On the contrary, its purpose is that of preventing
that the motor temperature falls below –20°C when idle.
Motors for operating on frequency converters
For operating on frequency converters, motors with temperature

monitoring must be protected by PTC temperature sensors (Î Section
"Motors with temperature monitoring", page 25). The rating data for this
operating mode are specified either on the rating plate or on a separate
plate. If the relevant plate is missing, see the data provided in the
manufacturer catalogue "Explosion-protected high and low voltage AC
motors in II 2 G/D EEx d(e) IIC(B) T4...T6“
(Î Torque curves see diagram 1 to 6, page 28+29).
Check the drive's "electromagnetic compatibility" as per EMC directive no.
89/336/EEC when operating on frequency converters.
Make sure when operating motors on frequency converters that the

admissible voltage peak value named below are not exceeded by the
26
periodically occurring commutation voltage peaks (threshold value for
terminals and winding insulation):
1. Terminals have effective clearance and creepage distances to withstand a

voltage of 750V based on DIN EN50019 - increased safety type "e". The
maximum transient over voltage from the frequency inverter to the motor is
2.15 kV (phase to phase and phase to earth).
2. Standing winding for 230/400V and 500V can withstand a peak voltage of
1.6 kV (phase to phase and phase to earth) with winding temperature rise
corresponding to class F, our standard windings can be used with frequency
inverters without the need for additional filter.
3. Standing winding for 400/690V can withstand a peak voltage of 1.6 kV

(phase to phase and phase to earth) with winding temperature rise
corresponding to class F, our standard windings can be used with frequency
inverters with additional filter.
4. Special winding for a single nominal voltage of 690V can withstand a

peak voltage of 2.15 kV (phase to phase and phase to earth) with winding
temperature rise corresponding to class F, this windings can be used with
frequency inverters without the need for additional filter. These motors will
be marked with an “U” in the type code on the rating plate.
In the case of a converter output non-galvanically separated from the mains

and with current limitation, follow the requirements of DIN EN 50178 and
VDE 0160 (equipment of high voltage installations with electronic devices) on
the overload protection of the protective earth conductor.
In rating the protective device in the outer conductors, bear in mind that the
protective earth conductor current can be greater than the outer conductor
current in fault condition. The protective earth conductor is to be dimensioned
according to this fault current.
Take note of all of the data of the converter manufacturer for said fault
condition.
27
Torque curves on frequency operation 2p=2
Diagram 1: frame size 63 - 160

1,1
1
0,9
M FU/M line
0,8 A
B
0,7
0,6
0,5
0,4
0 20 40 60 80 100
f [Hz]

1
0,9
0,8
M FU/M line
A
0,7
B
0,6
0,5
0,4
0 20 40 60 80
f [Hz]

1
0,9
0,8
M FU/M line
0,7 A
0,6
0,5
0,4
0 10 20 30 40 50 60
f [Hz]
A: Field weakening range above 50 Hz

B: Field weakening range above 87 Hz
28
Torque curves on frequency operation 2p=4 to 2p=8

1,1
1
0,9
0,8
M FU/M line
0,7 A
0,6 B
0,5
0,4
0,3
0,2
0 20 40 60 80 100 120
f [Hz]

1
0,9
0,8
M FU/M line
0,7
A
0,6
B
0,5
0,4
0,3
0,2
0 20 40 60 80 100 120
f [Hz]

0,9
0,8
0,7
M FU/M line
A
0,6 B
0,5
0,4
0,3
0 20 40 60 80
f [Hz]
A: Field weakening range above 50 Hz

B: Field weakening range above 87 Hz
29
Motors with built-in frequency converter
(compact drive)
Please note!
Wait at least 3 min. after disconnecting the drive from the

mains before connecting it again; otherwise there is the risk of
damaging the input current limitation.
Warning!
After disconnecting the drive from the mains, the conductive

parts of the frequency converter and the connected conductor
may still be live for up to 180 sec. Wait at least 3 min. after
disconnecting before opening the casing or touching the drain
screw. Follow the operating instructions or the instructions
provided in the converter's manual as well as the relevant
safety regulations.
In some models an automatic restarting of the drive takes
place after a power failure.
Parameter setting
The parameters of the incorporated converter were set by the manufacturer

for the relevant application.
This setting does not correspond to the original factory setting made by the
converter manufacturer. A list of parameters is found in the attached converter
manual. Changing specific parameters can cause a drive operation in a critical
area. This may lead to a fault trip of the converter or the tripping of the PTC
temperature monitoring. A change in the motor voltage and clock frequency
parameters is prohibited. The motors can be operated in a frequency range of
2 Hz (limited torque) to 100 Hz. The converter's clock frequency amounts to
4 kHz.
30
The parameters can be changed with the keypad according to the
instructions provided in the converter manual. Insert the keypad plug in the
test socket of terminals 5-6-15-16.
The keypad is not approved for use in the area subject to explosion risk.
Operating on unearthed network (IT)
Motors with an incorporated CEIGL ... IT type frequency converter can be

operated on the IT network. In case of a short circuit in the drive the tripping
must take place as quickly as possible.
Explosion protection
The explosion protection is ensured in all conditions, since the motor and
converter are to be monitored by the PTC temperature sensors (ÎSection
"Motors for operating on frequency converters" , page 26). In the case of
motors with incorporated frequency converter equipped with a PTC tripping
device and relay, said protection is provided for without external tripping.
All the screws are to be tightened to the envisaged torque (Î Table 4,

page 17) and just as many screws as necessary for the envisaged fastening
boreholes are provided. Any damaged screws are to be replaced only with
screws of the same dimensions and quality (at least 8.8).
Relay and PTC tripping device
Motors with incorporated frequency converters can be equipped either with a

relay or a PTC tripping device to ensure protection against overheating as
required by IEC 60079-14. The PTC tripping device is accessible by means
of a hexagon locking screw (SW 67) on the upper face of the pressure-
resistant casing. The locking screw must be completely screwed in during
operation and is to be secured with anaerobic adhesive for screws.
31
Figure 10: PTC tripping device
c Rated control supply voltage (A1-A2)

d Normally closed auxiliary contacts (21-22)
e Test/Reset
f Manual/automatic reset
g Thermistor (T1-T2)
h Mains LED (green)
i Remote reset (Y1-Y2)
j Trip LED (red)
k Normally open auxiliary contact (13-14)
32
In case of a device with shared power and control voltage supply (Î Fig. 12)
no automatic restarting of the drive takes place after a power failure or the
tripping of the protective device.
Caution!
In case of a device with a separate control voltage supply
(ÎFig. 13) an automatic restart of the drive takes place after
a failure in the power supply.
After a power failure in the control voltage supply there is no
automatic restart of the drive.
A failure in the control voltage triggers the reset of the PTC
tripping device.
Warning!
The compact drive feeds voltage also when the device is off.
Before performing work on the device or external control unit,
disconnect the mains line.
33
G1: Frequency converter
R: approx. 0Ω in TN and TT
network version
R = 10M Ω in IT network
version
L1, L2, L3: Power supply
input
K11, K12, K14: Converter
relay outputs
Br 1, Br 2: Brake rheostat
2TP1, 2TP2:
PTC connection
5, 6, 15, 16: Keypad
connection (parameter
setting)
c PROFIBUS-DP at choice
d Systembus (CAN) at
choice
e Interbus at choice
f Standard I/O at choice
g Applications I/O at choice
Figure 11:
Overview circuit diagram of the compact drive

without relay and PTC tripping device for all
network versions.
For details, see the converter installation instructions
and the circuit diagram for functional unit 1-5
34
G2: Relay
G3: PTC tripping device
L1, L2, L3, N: Power
supply input: converter,
relay, PTC tripping device
14, 13/32, 31: I/O keys
Y1, Y2: PTC tripping
device reset
21, 2N: "Failure" message
14, 2N: "On" message
relay outputs
5, 6, 15, 16: Keypad
setting)
c PROFIBUS-DP at
choice
choice
g Applications I/O at
choice
Figure 12:
Overview circuit diagram of the compact drive with

relay, PTC tripping device and internal control voltage
supply for the TN network.
For details, see the converter installation instructions
and the circuit diagram for functional unit 1-5
35
R: approx. 0 Ω for the TN
and TT network versions
R = 10M Ω for IT-network
version
G2: Relay
G3: PTC tripping device
L1, L2, L3: Power supply
input: power and control
N/-, L/+: control voltage
220 - 240V~ or 24V=, fuse
maximum 16A
14, 13/32, 31: I/O keys
Y1, Y2: PTC tripping
device reset
21, 2N: "Failure" message
14, 2N: "On" message
relay outputs
5, 6, 15, 16: Keypad
setting)
c PROFIBUS-DP at
choice
choice
g Applications I/O at
choice
Figure 13:
Overview circuit diagram of the compact drive with

relay, PTC tripping device and separate power
supply of the control voltage for all of the network
versions. For details, see the converter installation
instructions and the circuit diagram for functional unit
1-5
36
Motors with brake
The mains line in the version with incorporated brake is connected in the
motor terminal box and in the version with the built-on brake in the separate
brake terminal box. Observe the supplied connection diagram and the rated
voltage visible on the rating plate. In the presence of an AC connection the
brake coil is energized by means of a silicon rectifier accommodated inside
the explosion-proof encapsulation.
Î The temperature sensors applied both in the motor and brake

are to be connected as envisaged in Section "Motors with
temperature monitoring", page 25.
Motors with brake or tachometer mounted under the ventilator hood
In order to connect brakes or tachometers mounted under the motor

ventilator hood, the latter must be disassembled.
Unscrew any shock pulse sensors or regreasing devices. Loosen the
fastening screws on the hood and remove the hood from the motor.
Connect the brake of tachometer as per the attached circuit diagram and
pass the cable along the shortest route through the motor fins towards the
main terminal box. It is recommended to insert a protective tube over the
connection cable in the fin area to prevent wearing.
Fit the ventilator hood back on the motor and check the position of the
boreholes for any shock pulse sensors and regreasing devices. In the case
of motors with an axial fan running into a nozzle, make sure that there is a
uniform air gap all around between the fan and nozzle. Secure the hood with
the fastening hoods, (torque as per Table 4, page 17)
Check manually that the fan runs freely once the mounting is completely.
37
Motors with water cooling
Before connecting, check the cleanness of the cooling water (max.

permissible content of deposits: 30 mg/l). The water connections are to be
connected according to the signs on the motor. The quantity of cooling water
necessary for cooling the motor is to be complied with (see the sign on the
water inlet). To eliminate any entrapped air, the motor's counter-drive side is
provided with a bleed valve. The cooling water quantity control must shut off
the motor if there is less cooling water than required.
The water chambers must be cleaned regularly depending on the content of
deposits. They can be cleaned without disassembling the motor. After
unscrewing the sealing ring on the motor casing's counter-drive side, it is
possible to clean the casing. The explosion protection is not affected by
unscrewing the sealing ring, as the water chamber is not located in the
pressure-resistant section.
Make sure by means of the electric control that the motor can be operated
only with the water flow on and that the water jacket is always perfectly
vented. The maximum inflowing water temperature amounts to 30 °C.
38
Connection diagrams
The circuit diagram on the motor is to be followed.
Single-speed – one pole
Y circuit ∆ circuit
Pole changing
Low rpm High rpm

Dahlander connection
Low rpm High rpm

Dahlander connection
Low rpm High rpm
1TP1- Pre-alarm PTC U>2.5V not allowed Use tripping device with PTB
1TP2 number or
2TP1- Tripping PTC marking II (2)G
2TP2
1R1-R2 PT 100 resistance temperature sensor
HE1-HE2 Space heater
39
Brakemotors with incorporated brake
Brake connection via motor winding
Y circuit
Terminals BA1-BA2 can be connected

directly to the motor terminals to supply
the brake. Compare the motor/brake
voltages to determine whether the
connection is to be made on U1-U2 or
U1-V1.
Terminals BA3-BA4 must be bridged.
Y circuit An external power supply can be applied

Brake on terminals BA1-BA2. Check the
voltage data on the rating plate.
Terminals BA3-BA4 must be bridged.
For a rapid engagement of the brake

(DC-voltage side tripping) bridge BA3-
BA4 can be replaced by a contact. The
contact must be tripped simultaneously
with the brake power supply.
∆ circuit In order to provide for the emergency

venting of the brake, e.g. to turn the
motor manually, you can apply a DC
voltage source to terminal BA1 + BA4
(remove any other wiring before hand
and observe the polarity).
U voltage = = U~ x 0.45
U voltage~see brake voltage on the
rating plate.
BA1-BA4 Brake
1TP1- Pre-alarm PTC U>2.5V not allowed Use tripping device with
1TP2 PTB number or
2TP1- Tripping PTC marking II(2)G
2TP2
40
TB1-TB2 Temperature monitoring: Microtherm T 10
Brake connection via external power supply
Y circuit ∆ circuit Brake connection
Brake power
supply via
terminals BA1-
Pole changing BA2. Observe
Low rpm High rpm the voltage data
Y circuit Y circuit on the rating
plate. Terminal
BA3-BA4 must
be bridged.
For a rapid
engagement of
the brake (DC-
voltage side
Pole changing Dahlander connection tripping) bridge
Low rpm High rpm BA3/ BA4 can be
replaced by a
∆ circuit Y Y circuit
contact. The
contact must be
tripped
simultaneously
with the brake
power supply.
BA1-BA4 Brake
BD1-BD2
1TP1- Pre-alarm PTC U>2.5V not allowed Use tripping device with
1TP2 PTB number or
2TP1- Tripping PTC marking II (2)G
2TP2
TB1-TB2 Temperature monitoring: Microtherm T 10
41
3 Operation and Repairs
Duty types and thermal protection

• In S1 duty class motors a temperature sensor (TS) can be used in addition
to the motor circuit breaker as required by DIN EN 60079-14, VDE 0165.
• If in S1 duty cycle motors protection is to be provided against overheating

only by means of the TS, a proven combination of TS and tripping device
is to be used for said purpose.
• In the case of non-S1 duty cycle motors proven combinations of TS and

tripping device must be used as protection against overheating.
• The supplying of power to the motors via the frequency converter is

permissible only if a proven combination of TS on the windings and
tripping device is used.
The temperature sensors must be connected as specified in the Section

"Motors with temperature monitoring", page 25.
Special operating conditions

The operating of the motors at ambient temperatures outside the generally
valid range of –20 to +40 °C is allowed also without heater if an appropriate
temperature range – e.g. –55 °C ≤ Tamb ≤ 60 °C – is specified on the rating
plate.
Operation at less than –20°C is allowed also without any additional

indication if the temperature of the entire motor is maintained at least at
-20 °C by means of a space heater.
At motor temperatures of less than -20°C the heater must not be started, as
these are not explosion-protected.
(Î Section "Motors with space heater", page 26).
42
Motors with backstop
Motors with built-in backstop must be operated at a minimum rpm higher

than the value specified on the rating plate – e.g. FXM 850 min –1 – to
prevent excessively high temperatures.
Heat input through the driven machine
It must be ensured that no quantities of heat greater than the maximum

heating values specified in table are conveyed from a mounted machine to
the interface with the motor (e.g. shaft and motor flange). This way it is
guaranteed that no point of the motor exceeds the temperature class.
Table 9:
Permissible surface heating at an ambient temperature of 40°C:
Temperature class
T6 = 85°C T5 = 100°C T4 =135°C
Permissible heating on the shaft 30K 45K 65K
Permissible heating on the flange 30K 45K 65K
Start-up
Please note!
Before mounting or start-up the insulation resistance is to be
measured by qualified technicians. The resistance must be
greater than 1 MΩ. A critical value is reached at 0.5 MΩ. If this
value is not reached, the motors must be dried.
The best way to do it is in an oven at temperatures up to 100 °C. To

eliminate any humidity, open the motor. To be entitled to any warranty
claims, contact the manufacturer in advance.
These works must be carried out by qualified technicians; in the course of

said works the manufacturer shall instruct said technicians on how to ensure
the explosion protection during reassembly. For the assembly and
disassembly, see the relevant repair instructions.
43
• Check the direction of rotation and operation during idle running. In case of
unidirectional external fans (axial fans) observe the sign for the direction of
rotation on the motor. If the direction of rotation needs to be changed,
invert the two power lines and the fan.
• If the motor was stored and an additional quantity of grease was applied in
the anti-friction bearings, the motor must be run with no load for at least
0.5 h to ensure an adequate distribution of the grease and to avoid the
overheating of the anti-friction bearings.
• Make sure that the operating current matches the specified current values
on the rating plate.
The protective equipment required as per EN 60079-14 is to be set

according to the motor rating values specified on the rating plate. The
specified current value on the rating plate must not be exceeded in
continuous duty conditions.
Please note!
Run the motor with load for at least 1 hour and check that
there is no unusual noise or heating exceeding the specified
temperature class values.
Relubricate motors with regreasing equipment with the specified amount of

grease during start-up.
Vibration severity values of Veff ≤ 3.5 mm/s (PN ≤15 kW) or 4.5 mm/s
(PN > 15 kW) in coupled operating mode are not allowed. In case of
deviations from normal operating conditions – e.g. higher temperatures or
greater noise and vibrations – find the cause and, if necessary,
contact Producent.
Please note!
The protective equipment must always be kept in service also
during trial runs. In case of doubt switch off the machine.
44
Maintenance
Inspection
• The motors are to be constantly monitored depending on the operating

conditions.
• Keep the motors clean and the venting openings free
(Î Section "Site", page 10)
Any national regulations valid for the maintenance/repair of electrical

equipment in areas subject to explosion hazards - e.g. in Germany the
Operational Safety Order, etc - are to be complied with.
During maintenance especially those parts on which the degree of protection

depends must be checked; these include, for instance, the integrity of the
lead-in components and gaskets.
Lubrication
Please note!
In order to avoid damage the bearings and grease must be
kept clean.
The deep groove ball bearings of motors up to frame size 280 are sealed on
both sides and filled by the bearing manufacturer with a grease which is
enough for normal operating conditions in 4 or multi-pole motors for 40000
operating hours or in 2-pole motors for 20000 operating hours.
When changing the bearings, change also the shaft seals. To do so,
dismount the motor so that the winding can be cleaned at the same time.
Disassembly and assembly as per the specific manufacturer repair
instructions.
Motors starting from frame size 315 and motors with reinforced bearings are
to be equipped with regreasing devices. The bearings are to be regreased
preferably with the motor running with a grease gun through the grease
nipples located over the bearing plates or bearing caps.
45
The drip space in the bearing cap for outflowing old grease is large enough
to collect the outflowing grease during the nominal bearing service life with
state-of-the art regreasing.
See the plate on the motor for the specified lubricating intervals and the type
and quantity of grease to be used. The manufacturer normally uses ESSO
Unirex N3, a lithium complex soap/mineral oil grease.
Table 10: Standard regreasing intervals in hours

Ambient Rpm up Rpm up
–1
temperature to 1800 min to 3600 min–1
40 °C 5000 h 2500 h
50 °C 2500 h 1000 h
Please note!
In motors with enhanced performance (motor type ...X), in
heavy drive conditions like belt and gear drive with additional
bearing loads and in vertical designs the lubricating intervals
are to be reduced by 50%.
Observe the specified quantity of grease. Overgreasing can

lead to a sharp increase in the bearing temperature and hence
to the failure of the bearing.
Caution!
If regreasing is carried out while the motor is running, provide for
adequate protection against rotating parts!
Only resin-free and acid-free anti-friction bearing grease with a
drop point of approx. 200°C is to be used.
46
Explosion protection
The marking (II2G), EEx de IIC T4, for instance, indicates where the motor
is to be used and that it has been designed, built and approved according to
the relevant European standards required for operation in areas subject to
explosion hazards.
Please note!
The motor must not be altered in any way whatsoever and the
operating instructions set forth herein are to be complied with
always.
If the motor is altered or repairs need to be made, these are to be performed

by the manufacturer or by repair workshops or factories that possess the
necessary know-how. Before the starting the motors again, conformity with the
requirements of EC directives 76/117/EEC or 94/9/EC and 99/92/EC by said
sites is to be ascertained and confirmed by means of an appropriate marking
on the motor or by issuing a test report.
If these requirements are not met, the motor is no longer classified as

explosion-protected and the marking - see above - is to be removed.
Instructions for ensuring explosion protection during operation
• All of the contact screws and nuts of the electrical connections are to be
tightened securely to prevent excessively high contact resistance values that
may lead to an excessive degree of overheating of the contact point; torque
values (Î Table 8, page 24).
• Use the utmost caution when connecting the mains cable. Observe the creep
distances and clearances. Use duly the sealing parts of the cable lead-ins and
connections spaces as well as the lead-in parts envisaged for the pull relief or
as protection against torsion in order to maintain the degree of protection of the
connection spaces
(Î Section "Mains and guard circuit connection ", page 21).
• Eliminate any damages immediately and use only original spare parts. The
proper performance of the works by the aforementioned sites is to be
examined as per the relevant EC directives, in Germany by a qualified expert
as per “Betriebssicherheitsverordnung”, abroad as per the relevant national
regulations in force and to be confirmed by means of an appropriate marking
47
on the motor or by issuing a test report.
• The surfaces of ignition-protected gaps must not be reworked. Keep these

surfaces metallically clean. Corrosion protection can be achieved by means of
non-hardening sealing materials or sealing grease. The approved sealing
materials include besides the corrosion protection greases available on the
market: Hylomar, by Marston-Domsel
or Admosit and Fluid-D, by Teroson (follow the manufacturer's usage
instructions). This must be observed in particular for the openings in the cover
for connection spaces having a pressure-resistant encapsulation degree of
protection, marking EEx d IIC(B).
• All the screws are to be tightened to the envisaged torque (ÎTable 4,

page 17) and just as many screws as necessary for the envisaged fastening
boreholes are provided. Any damaged screws are to be replaced only with
screws of the same dimensions and quality (at least A2-70).
Repairs
Repairs and changes to explosion-protected machines are to be carried out by
one of the aforementioned sites as per EC directives 94/9/EC and 99/92/EC, in
Germany in compliance with the “Betriebssicherheitsverordnung” as well as
with the safety regulations and requirements of the repair instructions.
Any works relating to the explosion protection must be carried out by the
manufacturer or by a specialized workshop for electrical machinery. If said
works are not performed by the manufacturer, these must be surveyed by an
authorized qualified person.
In Germany a written certificate as per the Operational Safety Order is required
for restarting. In foreign countries the national regulations in force are to be
complied with.
48
4 Additional dust protection requirements
(application in zones 21 and 22)
Intended use
A marking of at least IP 65 and II 2D T …° C must be found on the motor's

rating plate.
Installation and Operation

Cable and line lead-ins
Separately approved lead-ins belonging to category 2G with at least IP 65 or

category 2D are to be used. Any openings that are not used are to be closed with
duly approved plugs.
Operation and Repairs
The motors must not be operated with excessive dust deposits, as these may
lead to the exceeding of the admissible surface temperature. Regular cleaning
must be performed.
The radial shaft seal rings are included in the approval. Only original gaskets are
to be used.
49
ATB Motorentechnik GmbH
Helgoländer Damm 75
D-26954 Nordenham
info@atb-nordenham.de
www.atb-nordenham.de
© 2005 by ATB Motorentechnik GmbH

rights of modification reserved
BA 01.05
Printed in the Federal Republic of Germany (02/05)
under license of
MOTORENTECHNIK GMBH

Datenblatt für Drehstrom-Kurzschlußläufer-Motor
Data sheet for three-phase induction motor
Toleranz VDE 0530
tolerance VDE 0530
Typ CD 160M1-2
Type
IEC Baugröße 160
IEC Size
Bauform B3
Mounting design
Umgebungstemperatur -20 - +40 °C
Ambient temperature
Schutzart IP 56
Type of enclosure
Ex-Schutzart II 2 G EEx de IIC T4
Ex-protection
Wärmeklasse F
Insulation class
Bemessungsleistung 11 / 12,8 kW
Rated output
Betriebsart S1
Duty
Bemessungsspannung D400/Y690 V
Rated voltage
Frequenz 50 / 60 Hz
Frequency
Drehzahl 2925 / 3510 1/min
Speed rpm
Bemessungsstrom 20 / 20,5 A
Rated current
Anlaufstrom Ia/In 6,6 / 6,6
Starting current
Leistungsfaktor 0,89 / 0,89
Power factor
Wirkungsgrad 89 / 88,5 %
Efficiency
Bemessungsmoment 36 / 34,8 Nm
Rated torque
Anlaufmoment Ma/Mn 2,8/ 2,8
Starting torque
Kippmoment Mk/Mn 3,2 / 3,2
Breakdown torque
Gewicht 163 kg
Weight
Zusatzschild/ Add. nameplate for 60Hz:
380-420V/ 660-690V: 11kW at 40°C F/B and 11kW at 50°C/ 55°C F/F
440-480V: 12,8kW at 40°C F/B and 11kW at 50°C/ 55°C F/F

under license of
Abnahmeprüfzeugnis 3.1 EN 10204

Inspection certificate 3.1 EN 10204
Serienprüfung / Serial test Motorentechnik
Kunde: The Rosekrans Group LLC Auftrags-Nr.: 484401
Client: Order-No.:
Leistungsschilddaten: 3 ∼ Motor Type: CD 160 M1-2
Name-Plate-Data:
Spannung/Voltage: Y 690 V Δ 400 V
Strom/ Current: Y 11,7 A Δ 20 A
Leistung/ Power: 11 kW Upm/ Rpm : 2925 1/min
Frequenz/Frequency: 50 Hz cos ϕ 0,89
Wärmekl./ Isol.cl.: F IP 56
Anlaufstrom: 6,6 Betriebsart: Kühlmitteltemp: 40°C
Starting Current Ratio: Rating: Ambient Temp.:
Bauform: B3 Kaltleiter: 145°C Ansprechzeit: 46 sec

Mounting: PTC Response Time:
II 2G EEx de IIC T4 PTB-Nr.: 98 ATEX 1106
Certificate-No.:
Leerlaufprüfung/ No Load Test
Hochspannungsprüfung/ High Voltage Test
Isolationsmessung/ Insulationtest
Motor-Nr.: V Hz A kW kV MΩ
484401013 396,4 50 6,01 0,921 2,9 >50
484401014 396,1 50 6,01 0,818 2,9 >50
484401016 401,2 50 6,33 0,807 2,9 >50
484401017 400,5 50 6,25 0,784 2,9 >50
484401018 404,5 50 6,37 0,829 2,9 >50
484401019 404,9 50 6,33 0,879 2,9 >50
484401020 401,4 50 6,20 0,789 2,9 >50
484401021 401,3 50 6,31 0,818 2,9 >50
484401022 405,3 50 6,31 0,838 2,9 >50
484401023 405,0 50 6,36 0,795 2,9 >50
484401024 404,5 50 6,23 0,748 2,9 >50
>
>
Bemerkungen / Remarks :
Geprüft nach : IEC 60034 / VDE 0530

Tested according to:
Nordenham, 18.08.2008 Prüfer:Eichler
Tester:
Dieses Zeugnis wurde elektronisch erstellt und ist auch ohne Unterschrift gültig. This certificate was created electronically and is valid without signature.

23.06.05 H:\ORDERS\Software\2008\RG08.053\484401-1.doc
under license of

Client: Order-No.:
Name-Plate-Data:
Spannung/Voltage: Y 690 V Δ 400 V
Strom/ Current: Y 11,7 A Δ 20 A
Frequenz/Frequency: 50 Hz cos ϕ

Certificate-No.:
Motor-Nr.: V Hz A kW kV MΩ
484401015 405,0 50 6,38 0,821 2,9 >50
484401010 405,6 50 6,42 0,779 2,9 >50
484401011 400,6 50 6,23 0,806 2,9 >50
484401012 405,4 50 6,40 0,859 2,9 >50
484401007 400,3 50 6,25 0,868 2,9 >50
484401008 401,5 50 6,41 0,844 2,9 >50
484401009 396,9 50 6,09 0,747 2,9 >50
484401004 396,7 50 6,39 0,885 2,9 >50
484401005 401,3 50 6,53 0,778 2,9 >50
484401006 405,8 50 6,36 0,815 2,9 >50
484401001 400,6 50 6,32 0,886 2,9 >50
>
>

Tester:

under license of

Client: Order-No.:
Name-Plate-Data:
Spannung/Voltage: Y 690 V ∆ 400 V
Strom/ Current: Y 11,7 A ∆ 20 A
Frequenz/Frequency: 50 Hz cos ϕ

Certificate-No.:
Motor-Nr.: V Hz A kW kV MΩ
484401002 405,2 50 6,48 1,006 2,9 >50
484401003 397,5 50 6,21 0,882 2,9 >50
484401025 398,5 50 6,03 0,777 2,9 >50
484401026 396,9 50 6,13 0,781 2,9 >50
484401027 396,6 50 6,15 0,801 2,9 >50
484401028 405 50 6,31 0,850 2,9 >50
484401029 397 50 6,08 0,769 2,9 >50
484401030 399 50 6,11 0,851 2,9 >50
>
>
>
>
>

Tester:

------_..•
IIIDder licenseof
MOTORENTECHNIK GMBH
Erklarung der EG-Konfornntat

Declaration of EC-Conformity
Attestation de confermite CE
Wir erklaren in alleiniger
Verantwortung, dass
We declare that it is our sole
responsibility that
CE Nous attestons SOlIS notre
seule responsabilite
Drehstrommotoren Three-Phase-Motors Moteurs a courant triphase

Typ CD .•• und dCD ... Type CD ... and dCD ... Type CD ... et dCD ..•
auf die sich diese Erklarung
to which this declaration se referent acette attestation
bezieht, den Bestimmungen
relates is in accordance with correspondent aux dispositions
der folgenden Richtlinie
the provision ofthe des directives suivantes
entsprechen
following directives
94/91EG 94/91EEC 94/9/CEE

89/3361EWG 89/3361EEC 891336/CEE
98/371EG 98137IEEC 98/37/CEE
und mit fulgenden
and is in conformity with the ct sont conformes aux
Normen iibereinstimmen.
following standards. nonnes.
EN 50014:1997 EN 50014:1997 EN 50014:1997

EN 50018:1994 EN 50018:1994 EN 50018:1994
EN 50019:1994 EN 50019:1994 EN 50019:1994
EN 50281:1998 (nurbei II 2D) EN 50281:1998 (only at II 2D) EN 50281:1998 (seulement aII 2D)
EN 60034-1,5,6,7,8,9,12,14 EN 60034-1,5,6,7,8,9,12,14 EN 60034-1,5,6,7,8,9,12,14
IEC60072 IEC 60072 IEC60072
Kennzeichnung Marking Marquage
(E 0032 112 G EEx d IIC T3...T6 bzw. EEx de IIC T3•..T6

und wahlweise I and optional I et au cboix II 2D IP 6X T...oC
PTO 98 ATEX 1106
Das bezeichnete Produkt ist zum Einbau in The indicates product is intended for Le produit indique est prevu pour me
eine andere Maschine bestimmt. Die installation into a different machine. integre dans une machine. La mise en
Inbetriebnabme ist solange untersagl, bis Operation is prohibited until the final service n"est autorisee que Iorsque la
die Konformitat des Endproduktes mit der product concurs with the 98/37IEEC conformite du produit final selon la
Richtlinie 98/37IEG festgestellt ist. regulations. directive 98137/CEE a ete verifiee.
Diese Erklarung ist keine Zusicherung von This statement does not warrant any Cette declaration ne constitue pas une
Eigenschaften im Sinne der characteristics regarding product liability. assurance des proprietes au sens de la
Produkthaftung. responsabilite produit.
Die Sicherheitshinweise der Safety instructions stated in the production Les consignes de securite rappelees dans la
Produktdokumentation sind zu beachten. records have to be adhered to. documentation du produit doivent etre
respectees,
Nordenham, den 22. April 2003
ATB - MOTORENTECHNIK GMBH

HELGOlANOER OAMM 75
0-26954 NOROENHAM Wolfgang Sobel

Leiter Konstruktion
.._'- ...- - - . - - - - - - . - - - - - - - - - - - - - - - - r - - - - - - - - -..., - - -

Physikalisch-Technische Bundesanstalt
Braunschweig und Berlin
PrB
(1) EC-TYPE-EXAMINATION CEIRTIFICATE

(Translation)
(2) Equipment and Protective Systems Intended for Use in
Potentially explosive Atmospheres - Directive 9419/EC
(3) EC-type-examlnatlon Certificate Number:
PTB 98 ATEX 1106

(4) Equipment: Three-phase motor type: CD 56" CD 80, CD 90, CD 100, CD 112,
CD 132, CD 160, CD 225, CD 2:50, CD 280, CD 315,dCD 63,
dCD 71, dCD 225, dCD 355
(5) Manufac;turer: Felten & Guilleaurne Antriebstec:hnik GmbH
(6) Address: Helgolander Damm 75, D-26941~5 Nordenham
(7) This equipment and any acceptable variation thereto are specified in the schedule to this certificate and
the documents therein referred to.
(8) The Physikallsch-Technlsche Bundesanstalt, notified body No. 0102 In accordance with Article 9 of the
Council Directive 94/9IEC of 23 March 1994, certifies that this equipment has been found to comply with
the Essential Health and Safety Requirements relating to the des~Jn and construction of equipment and
protective systems Intended for use In potentially explosive atmospheres, given in Annex II to the
Directive.
The examination and test results are recorded In the confidential report PTB Ex 98-18152.
(9) Compliance with the Essential Health and Safety ReqUirements has: been assured by compliance with:
EN 50014:1997 EN 50018:1994 EN 50019:1994
(10) If the sign ")(" is placed after the certificate number,lt Indicates that the equipment is subject to special
conditions for safe use specified In the schedule to this certificate.
(11) This EG-type-examinatlon Certificate relates only to the design and construction of the specified
equipment In accordance with Directive 9419/EC. Further requlrernents of this Directive apply to the
manufacture and supply of this eqUipment.
(12) The marking of the equipment shall include the following:'
@ 112 G EEx d IIC T3•••T6 resp. EEx de IIC T3•••T6
Zertifizierungsstelle Explosionsschutz Braunschweig, December 17, 1998
By order:
(signature)
Dr.-Ing. U. Klausmeyer
Regienmgsdirektor
sheet 1/2
II
eG-type-examlnalion Certificates withoutsignature and officialstamp shall not bel valid. The certificates may be Circulated
only withouta1terallon. Extractsor alterallonsaresubjed to approvalby the Ptl}'SlkaDsch-TechnlscheBundesanstalL
1
In case of dispute, the Germantext shall prevail.
Physlkallsch-Technlsche Bundesanstalt· Bundesallee 100' D1-38116 Braunschweig
.------ .,-------- I

(13) 5 C H E D U L I:
(14) EC-TYPE-EXAMINATION CERTIFICATE PTB 98 ATEX 1106
(15) Description of equipment

Three-phase motors in the type of protection flameproof enclosure " d " with terminal
compartment or direct cable entries. The terminal compartment is carried out In the type of
protection flameproof enclosure" d " or increased safety nen.
(16) Test report PTB Ex 98-18152
(17) Special conditions fgr safe use
none
(18) Essential health and safety requirements
met by compliance with standards
Zertifizierungsstelle Explosionsschutz Braunschweig, December 17, 1998

By order.
(signature)
Dr.-Ing. U.KJausmeyer
Regierungsdirektor
sheet 2/2
EC-type-examlnaUon CerUllcates without signature and officialstampshall not be YaRd. The certificates may be circulated
only withoutalterallon. Extracts or afteraUons aresubject to approVal by !he Physikallsch-Technlsche Bundesanstalt.
In caseof dispute.!he Gennan textshad prevaU.
Physlkal\sch-Techn\sche Bundesanstell o Bundesallee 100 ° 0·38116 BraunschweIg
~_ .. _--~--_._--------

Physikalisch-Technische Bundesanstalt pTe
Braunschweig und Bertin
1. SUP P L EM E NT
according to Directive 94191EC Annex 111.6
to EC-TYPE-EXAMINATION CERTIFICATE PTB 98 ATEX 1106
(Translation)
Equipment: Three-phase motor type CD 280
Marking: ® II 2 G, EEx d IIC 13 - 16 resp. EEx de IIC 13 ·16
Manufacturer: Felten & Guilleaume Antriebstechnik GmbH
Address: 0-26945 Nordenham
Description of supplements and modifications
Changes of the instructions for manufacture and operation for the three-phase motor of size 280.
Test report PTB Ex 99-19073
Zertifizierungsstelle Explosionsschutz Braunschweig, May 10. 1999

By order:
(signature)
Oberregierungsrat
Sheet 1/1
EC-type-examination Certificates without signature and official stamp shall not be valid. The certificates may be cirwlated
only without alteration. Exlracls or alterations are subject to approval by the Physikallsch-Technlsche Bundesanstalt.
In case of dispute, the German text shall prevail.
Physikalisch-Technische Bundesanstalt • Bundesallee 100 • D-38116 Braunschweig

Physikalisch-Technische Bundesanstalt pTe
2. SUP P L E MEN T
according to Directive 9419/EC Annex 111.6
to EC-TYPE-EXAMINATION CERTIFICATE PTa 98 ATEX 1106
(Translation)
Equipment: Three-phase motor type CD 225
Marking: @ II 2 G, EEx d IIC T3 - T6 rasp. EEx de IIC T3 • T6
Address: Helgolander Oamm 75

0-26945 Nordenham
Changes of the instructions for manufacture and operation for the three-phase motor of size 225.
Zertifizierungsstelle Explosionsschutz Braunschweig•• July 08.1999

By order:
(signature)
Or.-Ing. U. Klausmeyer
Regierungsdirektor
Sheet 1/1
EC-lype-examination certificates without signature and official stamp shall not be valid. The certificates may be circulated
only without alteration. Extracts or alterations are subject to approval by the Physikalisch-Technische Bundellanstalt
In case of dispute, the German lext shaUprevail.
Physikalisch-Technische Bundesanstalt· Bundesa'ee 100·0-38116 Braunschweig

3. 5 U P P L E MEN T
according to Directive 9419/EC Annex 111.6
to EC-TYPE-EXAMINATION CERTIFICATE PTa 98 ATEX 1106
(Translation)
Equipment: Three-phase motor type CD 56, CD 80, CD 90, CD 100, CD 112, CD 132, CD 160,
CD 225, CD 250, CD 280, CD 315, dCD 63, dCD 71, dCD 225. dCD 355
Marking: <G II 2 G, EEx d IIC 13 • 16 resp. EEx de IIC 13 ·16

Address: Helqolander Damm 75

0-26945 Nordenham
Modification of the permitted ambient temperatures down to -40°C or -55°C in connection with a
routine test with increased pressure.
Zertifizierungsstelle Explosionsschutz Braunschweig, July 20, 2000

By order:
(signature)
Regierungsdirektor
Sheet 1/1
EC-type-examination Certificates without signature and official stamp shall not be valid. The certificates may be circulated
only without alteration. Extracts or alterations are subject to approval by Ihe Physikalisch-Technische Bundesanstalt.
In case of dispute, the German lexl shall prevail.
Physikalisch-Technische Bundesanstalt· Bundesanee 100' 0-38116 Braunschweig

Physikalisch.Technische Bundesanstalt
pTe
4th SUPPLEMENT
according to Directive 94I9IEC Annex 111.6
to EC-TYPE-EXAMINATION CERTIFICATE PTB 98 ATEX 1106
(Translation)
Equipment: Three-phase motors types CD 56, CD 80, CD 90, CD 100, CD 112,

CD 132, CD 160, CD 225, CD 250, CD 280, CD 315, dCD 355
Marking: @ 112G1D EEx d IIC T3 - T6 resp. EEx de IIC T3 - T6 IP 6X T••• °C
Manufacturer: ATB Motorentechnik GmbH
Address: HelgolAnder Damm 75

26954 Nordenham
DesqjPtion of sUPPlementsand modffications
The type approval is extended by area II 0 (dust explosion protection).
The name of the manufacturer is changed to ATB Motorentechnik GmbH (previoUSly Felten &
Guilleaume Antriebstechnik GmbH).
Test report: BVS PP 03.2055 EG
Zertiftzierungsstelle Explosionsschutz Braunschweig, May 26, 2003

r:
Sheet 1/1
EC-type.examinatlon certIlIc:ate8 without signature and oflldal stamp shall not be vallet The cer1ItIcallls may be draJlated
only without alterallon. ExIrads or alteraUons are subjectto approval by the Physlkallsch-Technl8d1e BundesanstaIt.
Incase of dIapute. the German text shall prevaH.
Physlicallscb-Technlsche BundesansIaIt· Bundesallee 100·0-38118 Braunsd1welg

8 7 6 5 4 3 2 1
1
2
46.586
3
25.524 4
D D
0.566 0.584
4323AP01
17.938
17.625
4340R1-ASM
0.544 0.563
C C
2525.02B
7.125 220186-005R1
L632
8.231
VIEW SHOWING FAN/HOUSING CLEARANCES
4701
3379AP06 LA102
L530
L514
30.000 16.813 8.500 21.274
2968A
15.000 6.000 Ø1.500
5267
2516A
12.500
B B

15.059
4.434
L664
L532
L516
20.500
LA104
4700
9.935 4590.04B
A NOTE:
HUNT ENGINE A
HOUSTON, TEXAS
1. ALL DIMENSIONS ARE IN INCHES HUNT
UNLESS NOTED OTHERWISE.
ENGINE GENERAL ARRANGEMENT
HUNT AIRDYNE ASSEMBLY
MODEL 22A2-17.4CW-36440
THIS DRAWING AND THE INFORMATION CONTAINED HEREIN IS
-
THE SOLE PROPERTY OF HUNT ENGINE, INC. AND MAY NOT - JCW 4849G09-2 -
BE REPRODUCED, VARIED OR USED WITHOUT THE EXPRESS
WRITTEN CONSENT OF HUNT ENGINE, INC. FEBRUARY 7, 2008 -
BK 1 OF 1
8 7 6 5 4 3 2 1
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

Renewal Parts List
Drawing Number: 4976G08
Drawing Title: SPEED SENSOR APPLICATION KIT
Drawing Description: GEB22A1 & 2 ATEX APPLICATIONS
1024 W/CONNECTOR
Part Number Component Quantity
4593G01 BEARING CAP ASSEMBLY - GEB22 (AVTRON/BEI) 1
4732368P1 GASKET - BEARING CAP 1
4812BP02.1 CONNECTOR - MS, SEALED 1
4812BP10 SPEED SENSOR - BEI HOLLOW SHAFT TYPE 1
4827.04AB BEARING RETAINER CLAMP ASSEMBLY FOR GEB22 1
L616 SCR - 5/16-18UNC-2BX.75 LG 1
LA529 LOCK WASHER - SLT - .3125 NOM 1
Operation and Maintenance Manual Page 375 Page 1 of 1

22 | HS35 Incremental Optical Encoder
Mechanical Specifications
Shaft Bore: 1.00", 0.875", 0.750", 0.625", 0.500". Diameters
under 0.875" are supplied with insulating sleeves.
Allowable Misalignment: 0.005” T.I.R. on mating shaft 0.75"
from shaft end
Bore Runout: 0.001" T.I.R maximum
Starting Torque at 25°C: Through shaft version (SS) = 7 in-oz
(max); Blind shaft version (BS) = 4 in-oz
Bearings: 52100 SAE High carbon steel
Shaft Material: 416 stainless steel
Bearing Housing: Die cast aluminum with iridite finish
Cover: Die cast aluminum with iridite finish
Bearing Life: 7.5 X 109 revs (50,000 hrs at 2500 RPM)
Maximum RPM: 6,000 RPM (see Frequency Response below)
Moment of Inertia: 0.019 oz-in-sec2
Weight: 18 oz typical
Electrical Specifications
Code: Incremental
Output Format: 2 channels in quadrature, 1/2 cycle index gated
with negative B channel
The HS35 combines the rugged, heavy-duty features usually associated with
Cycles Per Shaft Turn: 1 to 10,000 (see table A, page 23).
For resolutions above 5000 see interpolation options on pages shafted encoders into a hollow shaft style. Its design includes dual bearings and
32 and 33 shaft seals for NEMA 4, 13 and IP65 environmental ratings, a rugged metal
Supply Voltage: 5 to 24 VDC available (see note 5)
housing, and a sealed connector or cable gland. The HS35 accommodates shafts
Current Requirements: 100 mA typical +output load, 250 mA (max)
up to 1” in diameter. With optional insulating inserts, it can be mounted on
Output Device: (see note 5)
4469: Line Driver, 5 – 15 VDC, Vout = Vin smaller diameter shafts. It can be mounted on a through shaft or a blind shaft
7272: Line Driver, 5 – 28 VDC, Vout = Vin
7272: Line Driver, 5 – 28 VDC, Vout = 5 VDC (special feature)
with a closed cover to maintain its environmental rating. Applications include
7273: Open Collector, accepts 5 – 28 VDC motor feedback and vector control, printing industries, robotic control, oil service
Protection Level: Reverse, overvoltage and output short circuit industries, and web process control.
(See note 5)
Frequency Response: 150 kHz (up to 5000 cpt resolution; 300
KHz above 5000 cpt, also see Note 7)
Output Terminations: See Table 1 page 51 Figure 1 Output Waveform Certifications
Note: Consult factory for other electrical options The HS35 Incremental Encoder is available
1 CYCLE
with the following certifications:
90 Deg.
Environmental Specifications HI EN 55011 and EN 61000-6-2
Enclosure Rating: NEMA 4 & 13 (IP65) when ordered with A LO
shaft seal (on units with an MS connector) or a cable gland CENELEC EEX ia IIC T4
(on units with cable termination) B
Temperature: Operating, 0º to 70º C; extended temperature U.S. Standards Class I, Group A,B,C & D;
testing up to 105º C available (see note 8); Storage, -25º to Z
Class II Group E,F & G
90º C unless extended temperature option called out Canadian Standards
A
Shock: 50 g’s for 11 msec duration C Class I, Zone 0, Group IIC
Vibration: 5 to 2000 Hz @ 20 g’s B
See Regulatory Information on pages 47– 49
Humidity: 98% RH without condensation for further certification details.
Z
NOTES & TABLES: All notes and tables referred to in the

text can be found on pages 50 and 51. CCW Rotation Viewing Face

Copyright 2006 by BEI Technologies, 1-800-ENCODER, www.beiied.com
Incremental Encoders | 23
MS Connector Termination Cable Termination R1 Tether Block and Pin
MS3102R18-1P
CONNECTOR .45 .50
SLOT BLOK™
TETHER CABLE GLAND
0.50 OPTIONAL (R1)
0.45 0.063 .96
0.75 Ø 0.2502 0.75
0.2500 .388
DOWEL PIN .50
0.249
0.247
1.50 ± 0.1" .83 (REF)

Ø 3.50 Ø 1.90 Ø 2.250 1.450 1.75
Ø 3.50 1.75R .480
1.125R
0.31
COLLET
CLAMPING RING S
0.125 MAX SHAFT
Ø 1.80 PENETRATION
1.500 0.54 S
2.04
ON BLIND SHAFT
(1.60 ON 1.00" SHAFT BORE)
R2 Tether Arm 1.00 R.225
.50
.020
.45 1.10
Ø 0.2502
0.2500
DOWEL PIN 2.75
PIN 2.05 .81 6.25
Ø 3.50
15.0° .58
ENCODER BORE 1.36

ENCODER BORE
Ø 1.0002 / 1.0007 1.0002 / 1.0007 15° (typ)
30°(typ)
1.75
Ø .218 THRU
10-32UNF-2B X 0.38 DEEP 10-32UNF-2B X 0.38 DEEP 12 PLACES
SHOWN WITH (3) ON A Ø 3.000 B.C. (3) ON A 3.000 Ø B.C. ON A Ø 3.00 B.C.
Ø 0.625
SHAFT INSERT 15°
TOLERANCES: .XX = ± 0.01, .XXX = ± 0.005 (typ)
Table A HS35 Disc Resolutions

32 100 250 360 500 512 600 1000 1024 1200 1650 1800 2000 2100 2048 2500 2881 2884 3600 4096 5000
For interpolation please specify the multiplied output (up to 10,000 for the HS35) in the model number, i.e. 10,000-T2. Other resolutions available–consult factory.
HS35 Incremental Ordering Options FOR ASSISTANCE CALL 800-350-2727

Use this diagram, working from left to right to construct your model number (example: HS35F-100- R1-SS-2048-ABZC-7272-SM18).
All notes and tables referred to can be found on pages 50-51.
HS35
SHAFT BORE: SPECIAL
TYPE: 100 = 1.00" CYCLES PER COMPLEMENTS: OUTPUT IC: FEATURES:
HS = Hollow Shaft 87 = 0.875" TURN: C = Complementary 4469 S= Special
35 = 3.5” Encoder 75 = 0.75" (Enter Cycles) Outputs 7272 features specified
Diameter 62 = 0.625" See table A on See note 4 7273 on purchase order
50 = 0.50"etc. this page (consult factory)
Metric bores TETHER: See note 6
available R1 = Tether Block OUTPUT TERMINATION:
HOUSING CONFIG: and Pin SHAFT SEAL NO. OF CHANNELS:
F = Standard SM18 = 10 Pin MS3102R18-1P
R2 = Tether Arm CONFIGURATION: A = Single Channel SCS = Shielded, Jacketed Cable
Blank = None SS = Dual Shaft Seals AB = Dual Quad. Ch. with cable gland seal and
BS = Blind Shaft with ABZ = Dual with Index cable length in inches.
single seal and cover AZ = Single with Index (i.e. SCS18 = 18 inches)
See note 2 See note 3 TB = Terminal Block
See table 1 & note 9
®
EXPRESS ENCODERS Items highlighted with are standard Express Encoders and ship in one to three days.
T2 option is available as a standard HS35 Express Encoder. See page 32-33.
50 | Notes and Tables
1. Mounting is usually done either using the D-style square flange 7273
mount, E- or G-style servo mounts, or one of the standard face Open Collector: Current sink of 80 mA max. Current sourced by
mounts, F1 for example. Consult factory for additional face mount external pull-up resistor. Output can be pulled up to voltage other
options. than supply voltage (30 V max). Input voltage 5 to 28 VDC stan-
dard. Supply current is 120 mA typical. This replaces prior IC’s
2.The shaft seal is recommended in virtually all installations. The
with designations of 3904, 7406, 3302, 681 and 689.
most common exceptions are applications requiring a very low
starting torque or those requiring operation at both high tempera- 7406 (R)
ture and high speed. Open Collector: Current sink of 40 mA max. Current sourced by
external pull-up resistor. When called out as 7406R, pull-ups are
3. Non-standard index widths and multiple indices are available by
internal and sized at approximately 100 ohms/volt and current
special order. Consult factory.
sink is limited to 30 mA. Output can be pulled up to voltage other
4. Complementary outputs are recommended for use with line driver than supply voltage (30 V max) when the 7406 is used without
type (source/sink) outputs. When used with differential receivers, internal pull-ups. Voltage regulator can be used to allow supply
this combination provides a high degree of noise immunity. voltage up to 28 V (called out as a special feature). Supply current
5. Output IC’s is 100 mA typical, 120 mA with internal pull-ups. The 7406R is
replaced by the 4469 or the 7272 in system upgrades, or with
Output IC’s are available in either Line Driver (LD) or Open
the 7273 if external pull-ups are used.
Collector (OC) types. Open Collectors require pull-up resistors and
so have higher output impedance. In general it is recommended 3904 (R)
to use a Line Driver style of output. They can either source or sink Open Collector: Current sink of 80 mA max. Current sourced by
current and their lower impedance mean better noise immunity external pull-up resistor. When called out as 3904R, pull-ups are
and faster switching times. Our applications specialists would be internal and sized at approximately 100 ohms/volt and current
sink is limited to 70 mA. Output can be pulled up to voltage other
pleased to discuss your system requirements and the compatibility
than supply voltage (30 V max) when the 3904 is used without
of your receiving electronics with Line Driver type outputs.
internal pull-ups. Supply Current is 80 mA typical, 100 mA with
7272 internal pull-ups. The 3904R is replaced by the 4469 or the 7272
Multi-voltage Line Driver: 100 mA source/sink. Input voltage 5 to in system upgrades, or with the 7273 if external pull-ups are used.
28 VDC standard (Note: Vout = Vin). Available with
6. Special –S at the end of the model number is used to define a
voltage regulator for 5 to 28 VDC input/TTL output (called out as variety of non-standard features such as special shaft lengths,
a special feature)*. This driver is TTL compatible when used with voltage options, or special testing. Please consult the factory to
5 volt supply or with a voltage regulator option. Supply lines are discuss your special requirements.
protected against overvoltage to 60 volts and reverse voltage.
7. Higher frequency response may be available. Please consult with
Outputs are short circuit protected for one minute. Supply current
the factory.
is 120 mA typical (plus load current). This is the recommended
replacement for 3904R and 7406R open collector outouts with 8. Extended temperature ratings are available in the following
ranges: -40 to 70°C, -40 to 85°C, –20 to 105°C and –40 to 105°C
internal pullup resistors. This is also a direct replacement for any
depending on the particular model. Extended temperature ranges
4469, 88C30, 8830 or 26LS31 line driver
can affect other performance factors. Consult with factory for
4469 more specific information.
Multi-voltage Line Driver: 100 mA source/sink. Input voltage 5
9. Mating straight plug receptacles may be ordered from
to 15 VDC standard (Note: Vout = Vin ). Available with voltage
the factory:
regulator for 5 to 28 VDC input/5V output (called out as a special
feature)*. TTL compatible when used with 5 volt supply or with For M12 use MS3116F12-10S
voltage regulator. Supply lines are protected against overvoltage For M14 use MS3106F14S-6S
For M14/19 use MS3116F14-19S
to 60 volts and reverse voltage. Outputs are short circuit protected
For M16 use MS3106F16S-1S
for one minute. Supply current is 90 mA typical (plus load current).
For M18 use MS3106F18-1S
This is the replacement for 3904R and 7406R outputs for systems For M20 use MS3106F20-29S
operating at 15 volts and below. This is also a direct replacement
For additional Accessories refer to page 46.
for any 88C30, 8830, or 26LS31 Line Driver.
For standard pinouts, refer to the facing page.
* Regulated Output Option:
Limit signal output current to 50 mA per channel on Supply voltages above 15 VDC.
Operation
Operation andlevels
above the stated Maintenance Manual
may result in thermal shutdownPage 379
of the regulator.

| 51
Table 1: Incremental Output Terminations
The connector style will determine pinouts. For example, an encoder with M18 CONNECTOR
ABC channels and an M18 connector uses the table to the right. PIN CHANNEL
M14 CONNECTOR M16 CONNECTOR CHANNELS DESIGNATED IN MODEL NO. A A
PIN PIN ABZ ABC B B
E A A A C Z
D B B B D +V
C C Z A E —
B D +V (SUPPLY VOLTAGE) F 0V
F E — B G CG
A F 0 V (CIRCUIT GROUND) H A
G CASE GROUND (CG) (except H20) I B
J Z
WIRE COLOR DA 15P CHANNELS DESIGNATED IN MODEL NO.

(22AWG) CONNECTOR ABZ ABC ABZC M12 CONNECTOR
YEL 13 A A A PIN CHANNEL
BLUE 14 B B B A A
ORN 15 Z — Z B B
W-Yel 10 — A A C Z
D +V
W-Blu 11 — B B
E —
W-Orn 12 — — Z
F 0V
RED 6 +V (SUPPLY VOLTAGE)
G CG
BLK 1 0 V (CIRCUIT GROUND) H A
GRN 9 CASE GROUND (CG) (except H20) J B
WHITE SHIELD DRAIN (Shielded Cable Only) K Z
Table 2: Disc Resolutions for Incremental Encoder Models H25, H38, H40, L 25, E25
®
Resolutions highlighted with are available as standard Model H25 EXPRESS ENCODERS that ship in one to three days.
1, 2, 3, 5, 6, 7, 8, 10, 13, 16, 20, 24, 25, 26, 30, 32, 33, 34, 36, 37, 40, 45, 48, 50, 51, 56*, 60, 64, 66, 72, 75, 80, 86, 88, 90, 100, 102, 120, 122,
125, 127, 128, 132, 144, 148, 150, 158, 160, 175, 176, 180, 187, 192, 200, 202, 204*, 217, 220, 240, 250, 254, 255, 256, 264*, 274, 280, 283,
288, 292, 300, 312, 320, 321, 325, 360, 366, 372, 375, 377, 380, 381, 384, 385, 393, 400, 430, 432, 450, 462, 480, 490, 500 502, 508, 512, 522,
530, 550, 560*, 576, 598, 600, 604, 625, 628, 635, 638, 640, 660, 672, 676, 680, 687, 690, 700, 720, 725, 735, 740, 744, 748, 750, 762, 768, 780, 785,
800, 812, 825, 850, 864, 878, 888, 900, 912, 914, 938, 942, 955, 960, 1000, 1016, 1024, 1030, 1035, 1036, 1040, 1054, 1056, 1074, 1076, 1080,
1088, 1100, 1101, 1125, 1136, 1200, 1237, 1250, 1257, 1270, 1280, 1300 1314, 1332, 1333, 1390, 1400, 1414, 1427, 1440, 1484, 1500, 1562,
1570, 1596,1600, 1650, 1666, 1680, 1718, 1745, 1774, 1800, 1840*, 1850, 1855, 1875, 1894, 1920, 1952, 1968, 1979,1995, 2000, 2048, 2080,
2094, 2100, 2160, 2164, 2199, 2200, 2250, 2356, 2400, 2485, 2500, 2514, 2519, 2540, 3000, 3600,4000, 4096, 5000
*AB or ABC output only. NOTE: Resolutions up to 72,000 are available.
For Model H20 Resolutions See Table A on Page 18. For Model HS35 Resolutions See Table A on Page 23.
For Model HS25 Resolutions See Table A on Page 20. For Model L15 Resolutions See Table A on Page 31.
For Model HS45 Resolutions See “Cycles per Turn” in Ordering Information.
48
48 || Page Title and Certifications
Regulations
Table 1 NEMA Status of BEI Industrial Encoder Division Encoders

NEMA Design Class
NEMA
1 2 3 3R 3S 4 4X 6 12 13 UL indicates that the encoders have been
tested by Underwriters Laboratories for a
Encoder Minimum Requirement: Shaft Seal, Diecast
Type Cover and MS Connector or Cable Seal specific enclosure type.
H40 X X X X UL UL X X X indicates that the encoder is designed
to meet the UL requirements but has not
H38 X X X X UL UL X X
been submitted for testing.
H25 X X X X X X X X
H20 X X X X X X X X Encoders used in a Type 12 environment
HS25 X X X X X X X X should be ordered with the hard anodize
HS35 X X X X X X X X finish to meet 200 Hour Salt Spray Test.
L25 X X All H38’s are hard anodized.
E25 X X
The following tables list the approvals that are available for use of encoders in hazardous locations:
Table 2.1 European and North American Intrinsic Safety Approvals
C
Encoder Output Input U.S. Standards U.S. Standards Canadian Standards
Type Driver VDC CENELEC/ATEX Class I, Div I,Group Class II, Div I,Group Class I, Div I, Zone 0 System Diagram
H25, L25, 4469 5 EEx ia IIC T4 A, B, C, D E, F, G Group IIC 924-08062-003
E25, HS25*,
H35, HS35, 3904R 5 EEx ia IIC T4 A, B, C, D E, F, G Group IIC 924-08063-001 or 002
H37, H38, 3904 5 EEx ia IIC T4 A, B, C, D E, F, G Group IIC 924-08064-001 or 002
or H40 3904 9 EEx ia IIB T4 C, D E, F, G Group IIB 924-08064-001 or 002
*Rating only available with 4469 output driver
Table 2.2 Canadian Standards Association (CSA) Intrinsic Safety approvals Table 3 CE Certification
Encoder Output Input Class I, System EN 55011
Type Driver VDC Div I,Group Diagram Encoder Termination EN 61000-6-2
Connector, Metal OK
H25 Incremental 7406(R) 5 C, D 924-08035
Conduit (H38, H40) OK
H25 Incremental 8830 5 C, D 924-08035
Connector, Plastic See Factory
H20 Incremental 3904(R) 5 A, B, C, D 924-08035 Pigtail See Factory
H25 8 bit Absolute 7406(R) 5 D 924-08035 Shielded/Jacketed See Factory
Cable
Table 2.3 European and North American “Explosion Proof” Approvals Table 4 Haz Environment Groups
GAS GROUPS DUST GROUPS
C US C US Class I Class II
NEMA 7 U.S.Standards NEMA 7 U.S.Standards Division 1 & 2 Zone 0,1 & 2 Division 1 & 2
Encoder Type CENELEC/ATEX Class I, Div I, Group: Class II, Div I, Group:
A (acetylene) IIC (acetylene E (metals)
H38 (Standard) D & hydrogen)
H38 (with Labyrinth Seal) EExdIIB,T4 C,D E, F, G B (hydrogen) F (coal)
H40 D C (ethylene) IIB (ethylene) G (grain)
D (propane) IIA (propane)

QA-FRM-002
Rev. 02
ABS Pump Test
Released: 11/01/2007
Page 1 of 2
Test Equipment Used:

• Detroit Diesel 1600HP 16V149 w/ Allison S-9800 Transmission
• Pumps to be tested with customer’s pressure gauge, relief valve, and Pulsation Dampener (if equipped)
• 10,000 PSI 4” Choke Valve
• 6x8 diesel driven charge pump 80PSI
• Original equipment electric lube pump
• Shop Water for Liner Wash
• Filled with 80/90 wt gear oil to proper level
Test Sequence All Pumps
Action Duration
1) Slow roll machine for warm up 30 minutes
2) 50% Full Speed 50% Full Pressure 30 minutes
3) 100% Rated Speed 100% Rated Pressure 60 minutes
Note: If Horsepower is not available for Step 3 use the following
a) 100% Rated Speed @ max available Pressure 60 minutes
b) Max available speed @ max available Pressure 60 minutes
4) Bearing Temps recorded every 15 minutes after warm-up
5) Oil Drained and sampled
Pump Model__2200___________ S/N___22002509______ Liner Size __5”______________
Max Rated SPM____110__________ Max Liner Pressure __7500_______________
Ambient Temperature____85°F ________ Water Temp. __*F

15Min: *F
Step 1. Warm up 30 minutes 30Min: *F
Step 2. SPM___57.7_____ Pressure___3500_____ Pinion Speed__279.80_______

Main Brg L (15min) _87___ °F R (15min) _86__ °F L (30 Min) _90____ °F R (30min) 86 ____°F
Pinion Brg L (15min) _95___°F R (15min) _90__ °F L (30 Min)__97____°F R (30min) _93____°F
Stub Rod 1 (15min) ___ ___°F 2 (15min) __ ___°F 3 (15 Min) ________°F
1 (30min) ____ _°F 2 (30min) __ ___°F 3 (30 Min) __ _____°F
Step 3. SPM____110________ Pressure___3700________ Pinion Speed__533.26________
Main Brg L (15min) _94_____ °F R (15min) 90__ ___°F L (30 Min) __96_ __°F R (30min) _94__ _ °F
L (45min) _101_ ___°F R (45min) _96____°F L (60min) __ 102___°F R (60min) _96__ ___ °F
Pinion Brg L (15min) _ 101__ °F R (15min) _114___°F L (30 Min) _104__ °F R (30min) _115___ °F
L (45min) __106__ °F R (45min) _125___°F L (60 Min) _108__°F R (60min) _125_ °F
Stub Rod 1 (15min) __ ______ °F 2 (15min) __ ______°F 3 (15 Min) __ _____ °F

1 (30min) _________ °F 2 (30min) ________ °F 3 (30 Min) ____ ___ °F Water Temp.
1 (45min) _________ °F 2 (45min) ________ °F 3 (45 Min) _____ __ °F 15Min: *F
1 (60min) _________ °F 2(60min) ________ °F 3 (60 Min) _______ °F 30Min: *F
45Min: *F
1Hr: *F

QA-FRM-002
Rev. 02
ABS Pump Test
Page 2 of 2
Water Temp. 15Min: ___*F 30Min: ___*F 45Min: *F 1Hr: *F
Step 4. SPM___63.5________ Pressure___7400_______ Pinion Speed__307.62_______

Main Brg L (15min) _108__ °F R (15min) _99_ ____ °F L (30 Min) _109____°F R (30min) _100_°F
L (45min) _110_ °F R (45min) _102____ °F L (60min) __111____ °F R (60min) 102 _°F
Pinion Brg L (15min) __112__°F R (15min) _121______°F L (30 Min) _119____ °F R (30min) _123_ °F
L (45min) ___122 °F R (45min) _125 __ °F L (60 Min) _125____ °F R (60min) _127_ °F
Stub Rod 1 (15min) __ ____ °F 2 (15min) __ ____ °F 3 (15 Min) __ ___ °F

1 (30min) __ ____ °F 2 (30min) ___ __ °F 3 (30 Min) __ ___ °F
1 (45min) ___ ___ °F 2 (45min) ___ __ °F 3 (45 Min) ___ ___ °F
1 (60min) ___ ___ °F 2 (60min) __ ___ °F 3 (60 Min) ___ ___ °F
#1 #2 #3
_81
Liners 89 _88
97_ 94_ 95_ 101 104

_97
S/N___22002509_____
Technician__Tim Lougee____________ Date: _4-22-09____________
ABS Rep________________________ Date: ____________________
3rd Party (Customer) ___________________ Date: ____________________

QC-FRM-003
Laser Alignment Procedure Rev. 00

Ellis Williams Pump
Division Page 1 of 1
1. Install all (6) Crosshead guides. Torque all (6) bolts in SI___ ____ ____
each upper guide to specs & torque (4) corner bolts in
each lower guide to spec.
2. Install Crankshaft into pump. SI___ _____ _____
3. Install #2 Crosshead. SI___ _____ _____
4. Install Wrist Pin, Torque & Tie-Wire retainers to spec. SI___ Bert_ B____
5. Install Ponyrod, Torque & Tie-Wire to specs. SI___ Bert_ B____
6. Install Alignment Liner & Liner Lock Flange. SI___ Bert_ B____
7. Rotate pump until crosshead is in the middle of the stroke
with the conrod in the up position. MM__ B___ B____
8. Install Brass Ring on Ponyrod. MM__ B___ B____
9. Mount “S” Laser on Liner & “M” Laser on Ponyrod. MM__ B___ Tim__
10. Connect Cables to Laser Units and Laser Computer. MM__ B___ Tim__
11. Turn on Laser Computer & type “11”. MM__ B___ Tim__
12. Align Lasers to Bulls-eyes then open target. MM__ B___ Tim__
13. Take needed measurements and record on Alignment
record page. MM__ B___ Tim__
14. Enter measurements into Laser Computer. MM__ B___ Tim__
15. Move Lasers to 9:00 and press enter. MM__ B___ Tim__
18. If horizontal alignment is within ±.005” then proceed, if
not, then make displayed adjustments. MM__ B___ Tim__
19. Log horizontal information on Alignment Record Page. MM__ B___ Tim__
20. Move lasers to 12:00 and hold down the “5” until picture
changes. MM__ B___ Tim__
21. Loosen Guide Bolts, insert needed Shims and re-torque bolts
to spec. MM__ B___ Tim__
22. If displayed values are within ±.005 then proceed, if not,
repeat step 21. MM__ B___ Tim__
23. Verify clearance at the top of Crosshead (if clearance is
≥.018 proceed; if clearance is ≤.018, remove shims to
achieve clearance.) MM__ B___ Tim__
24. Shut down Laser Tool and remove. MM__ B___ Tim__
25. Install #1 Crosshead and steps 4 thru 24. _____ B___ _____
26. Install #3 Crosshead and steps 4 thru 24. _____ ____ Tim__

(Weatherford)EWECO TEST LAB
CUSTOMER: PPL UNIT: 2200 JOB: 449
DATE TESTED: 4/22/2009 WEATHER CONDITIONS: clear AMB. DEG. 85°F

COMMENTS:
ENGINE TRANS. ENG. ENG. TRANS. TRANS. PUMP PUMP PUMP PINION RUN
RPM GEAR TEMP. OIL TEMP. OIL DISCHG. OIL SPM SPEED TIME
DEG.*F PSI. DEG.*F PSI PSI PSI RPM
662 1 110 30 cold 225 0 20 79.18 30 min
1611 2 170 55 190 250 3600 20 57.7 279.8 30 min
1651 4 185 55 200 175 3700 20 110.1 533.26 1 hr
1745 2 190 60 205 240 7400 20 63.5 307.62 1 hr
ENGINE: Detroit Diesel 16V 149 S/N: TEST TECHNICIAN: Tim Lougee
TRANSMISSION: Allison S-9800 S/N: TEST DATE: 4/22/2009
PUMP: E2200 S/N: 22002509 WITNESS: John Kenjura
PLUNGER / LINER SIZE: 5" DATE: 4/22/2009

ELLIS WILLIAMS ENGINEERING COMPANY
E‐2200 PINION ASSEMBLY FORM
PINION SERIAL # _____________________________ DATE ___ 4/19/09
PUMP FRAME SERIAL # _2200________________________ MECHANICS NAME _ Eric Edwards
LEFT RIGHT
SIDE SIDE
Required and recorded torque values
**All external and internal threads to be clean and dry before applying Loctite #262
Right Side
Location No. of Required Installed Mechanic
Fastener Location Capscrew size Tiewire
# bolts torque torque initials
Carrier, Pinion Bearing 1 1‐8 UN x 3 1/2" LG. 8 530 ft‐lbs 530 Ft‐lbs NO Eric Edwards
Plate, Seal 2 3/4 ‐ 10 UNC x 2" LG. 8 200 ft‐lbs 200 Ft‐lbs NO Bert
Plate, Retainer, oil 3 5/8‐11 UNC x 1 1/4" LG. 4 125 ft‐lbs 125 Ft‐lbs YES Tom
Left Side
Carrier, Pinion Bearing 1 1‐8 UN x 3 1/2" LG. 8 530 ft‐lbs 530 Ft‐lbs NO Tom Myers
Plate, Retainer, oil 3 5/8‐11 UNC x 1 1/4" LG. 4 125 ft‐lbs 125 Ft‐lbs YES Tom
E‐2200 CROSSHEAD ASSEMBLY FORM
CRANKSHAFT SERIAL # _____________________________ DATE ____4/09____________________
PUMP FRAME SERIAL # ___2200______________________ MECHANICS NAME Matt/Bert_____
LEFT RIGHT SIDE
SIDE
Required and recorded torque values **All
external and internal threads to be clean and dry before applying Loctite #262
CROSSHEAD ASSEMBLY #1 (Right
side when viewed from the fluid end)
Location No. of Required Installed torque (use
Fastener Location Capscrew size bolts Tiewire Mechanic initials
# torque torquewrench)
Rod, Pony 1 1‐8 UNC x 2 1/2" LG. 6 280 ft‐lbs 280 Ft‐lbs YES Bert
Plate, Cover, Stuffing Box 2 5/8‐11 UNC x 1 1/2" LG. 6 125 ft‐lbs 125 Ft‐lbs NO Bert
Retainer, Wristpin to Crosshead 3 1‐8 UNC x 2 3/4" LG. 4 250 ft‐lbs 250 Ft‐lbs YES Bert
Retainer, Wristpin to Wristpin 4 7/8‐9 UNC x 2 1/2" LG. 2 350 ft‐lbs 350 Ft‐lbs YES Bert
Guide, Crosshead 7 1‐8 UNC x 2 1/2" LG. 12 150 ft‐lbs 150 Ft‐lbs NO TM
Retainer, Wristpin, Inner 8 3/4‐10 UNC x 2 1/4" LG. 4 200 ft‐lbs 200 Ft‐lbs YES Bert
Stuffing Box 9 3/4‐10 UNC x 1 3/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO Bert
Plate, Diaphram 10 3/4 ‐ 10 UNC x 2 1/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO Bert
CROSSHEAD ASSEMBLY #2
Fastener Location Capscrew size
# bolts torque torquewrench) Tiewire Mechanic initials
Rod, Pony 1 1‐8 UNC x 2 1/2" LG. 6 280 ft‐lbs 280 Ft‐lbs YES SI
Plate, Cover, Stuffing Box 2 5/8‐11 UNC x 1 1/2" LG. 6 125 ft‐lbs 125 Ft‐lbs NO KA
Retainer, Wristpin to Crosshead 3 1‐8 UNC x 2 3/4" LG. 4 250 ft‐lbs 250 Ft‐lbs YES SI
Retainer, Wristpin to Wristpin 4 7/8‐9 UNC x 2 1/2" LG. 2 350 ft‐lbs 350 Ft‐lbs YES SI
Retainer, Wristpin, Inner 8 3/4‐10 UNC x 2 1/4" LG. 4 200 ft‐lbs 200 Ft‐lbs YES SI
Stuffing Box 9 3/4‐10 UNC x 1 3/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO Bert
Plate, Diaphram 10 3/4 ‐ 10 UNC x 2 1/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO Bert
CROSSHEAD ASSEMBLY #3 (Left
Rod, Pony 1 1‐8 UNC x 2 1/2" LG. 6 280 ft‐lbs 280 Ft‐lbs YES Tim
Plate, Cover, Stuffing Box 2 5/8‐11 UNC x 1 1/2" LG. 6 125 ft‐lbs 125 Ft‐lbs NO Tim
Retainer, Wristpin to Crosshead 3 1‐8 UNC x 2 3/4" LG. 4 250 ft‐lbs 250 Ft‐lbs YES Tim
Retainer, Wristpin to Wristpin 4 7/8‐9 UNC x 2 1/2" LG. 2 350 ft‐lbs 350 Ft‐lbs YES Tim
Retainer, Wristpin, Inner 8 3/4‐10 UNC x 2 1/4" LG. 4 200 ft‐lbs 200 Ft‐lbs YES Tim
Stuffing Box 9 3/4‐10 UNC x 1 3/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO Tim
Plate, Diaphram 10 3/4 ‐ 10 UNC x 2 1/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO Tim
Plate, Crosshead Cover 5 3/4‐10 UNC x 2 1/4" LG 10 200 ft‐lbs 200 Ft‐lbs NO Jeff

E‐2200 CRANKSHAFT ASSEMBLY FORM
CRANKSHAFT SERIAL # ___2200______________________ DATE ________________________
PUMP FRAME SERIAL # ___2200______________________ MECHANICS NAME ________Alex/Stevo
LEFT RIGHT SIDE
SIDE
Shim quantities and main bearing clearances
Mechanic
left side
Initials
Shim thickness installed _____.000________ Inches SI
Final bearing clearance (.003" ‐
Inches SI
.005" required) _____.004________
Mechanic
Right side
Initials
Shim thickness installed ______.000_______ Inches SI
Inches SI
.005" required) ______.0035______
Gear, Bull 1 1 1/2‐8 UN x 5 1/2" LG. 16 1000 ft‐lbs 1000 Ft‐lbs NO HZ
Retainer, Bearing Race , Inner Eccentric #1
YES
(inside and outside) 2,4 3/4 ‐ 10 UNC x 2 1/4" LG. 24 200 ft‐lbs 200 Ft‐lbs HZ
Retainer, Bearing Race , Inner Eccentric #2 6 3/4 ‐ 10 UNC x 2 1/4" LG. 12 200 ft‐lbs 200 Ft‐lbs YES HZ
Retainer, Bearing Race , Inner Eccentric #3 8 3/4 ‐ 10 UNC x 2 1/4" LG. 12 200 ft‐lbs 200 Ft‐lbs YES HZ
Retainer, Bearing Race , outer Eccentric #1
YES
(inside and outside) 3 5/8‐11 UNC x 2" LG. 12 125 ft‐lbs 125 Ft‐lbs HZ
Retainer, Bearing Race , outer Eccentric #2 5 5/8‐11 UNC x 2" LG. 12 125 ft‐lbs 125 Ft‐lbs YES HZ
Retainer, Bearing Race , outer Eccentric #3 7 5/8‐11 UNC x 2" LG. 12 125 ft‐lbs 125 Ft‐lbs YES HZ
Retainer, Bearing Race , inner main (Left) 12 1‐8 UN x 2 3/4" LG. 8 530 ft‐lbs 530 Ft‐lbs YES SI

Retainer, Bearing Race , outer main (Left) 13 3/4 ‐ 10 x 2 1/4" LG. 8 200 ft‐lbs 200 Ft‐lbs YES SI
Retainer, Bearing Race , inner main (Right) 14 1‐8 UNC x 2 3/4" LG. 8 530 ft‐lbs 530 Ft‐lbs YES SI
Retainer, Bearing Race , outer main (Right) 9 3/4 ‐ 10 x 2 1/4" LG. 8 200 ft‐lbs 200 Ft‐lbs YES SI
Cover, bearing, main (left and right) 10 3/4 ‐ 10 x 2 1/4" LG. 24 200 ft‐lbs 200 Ft‐lbs NO SI
Skid, pump 11 1 1/4‐7 UNC x 4 1/2"LG. 20 1000 ft‐lbs __________Ft‐lbs NO

3 1/2‐8 Superbolt
**15 jackbolts per **
YES
Use special assembly lube
cap, bearing, main (left and right) not shown for jackbolts 30 233 ft‐lbs 233 Ft‐lbs SI
PUMP ASSEMBLY FORM
PUMP MODEL # ___E2200_______ DATE ___4/8/09_____________________
PUMP FRAME SERIAL # ____________________ MECHANICS NAME ____Tom Myers_____________
Crosshead Guide Dimensions
Location Crosshead Guide #1 Crosshead Guide #2 Crosshead guide #3

Front (A) 22.464 22.461 22.469
Front (B) 22.529 22.464 22.468
Front (C) 22.493 22.465 22.472
Center (A) 22.410 22.466 22.465
Center (B) 22.520 22.468 22.468
Center (C) 22.419 22.469 22.473
Back (A) 22.505 22.470 22.460
Back (B) 22.552 22.468 22.464
Back (C) 22.510 22.474 22.467
Crosshead Dimensions
Location Crosshead O.D. #1 Crosshead O.D. #2 Crosshead O.D. #3
Front 21.997 21.996 21.995 21.997 .998 .999 .997
Middle 21.997 21.997 21.997 21.997 .998 .999 .998
Back 21.995 21.996 21.996 21.997 .997 .998 .997
Piston to Liner Lock Runout (TIR)
Location Liner lock #1 Liner lock #2 Liner lock #3

Right (A)
Top (B)
Left (C)
EWECO(Weatherford)
Crankshaft BuildSheet Pump Model: 2200 Serial Number: Job: 449
Crankshaft: ECC. #1 28.501 OD ECC. #2 28.502 OD ECC. #3 28.502 OD
Conn. Rods ID #1 ECC. 35.743 ID #2 ECC. 35.743 ID #3 ECC. 00036 ID
#1 W/P 12.998 ID #2 W/P 12.996 ID #3 W/P 12.998 ID
ECC. BRG. #1 Bench 0.019 OD 35.751 ID 28.491 #2 Bench 0.020 OD 35.750 ID 28.491 #3 Bench 0.019 OD 35.750 ID 28.491
Wrist Pin Brg. #1 Bench 0.006 OD 13.000 ID 9.499 #2 Bench 0.008 OD 13.000 ID 9.499 #3 Bench 0.007 OD 13.000 ID 9.499
Wrist Pin #1 9.501 OD #2 9.503 OD #3 9.502 OD
Pinion Shaft Left 9.844 OD Right 9.844 OD
Pinion Brg. Left 0.007 Bench 16.140 OD 9.841 ID Right 0.008 Bench 16.140 OD 9.841 ID
Pinion Carrier Left 19.244 OD 16.137 ID Right 19.245 OD 16.137 ID
Main Brgs. Left 21.259 OD Right 21.259 OD
Main Brg. Carrier Left 25.000 OD 21.257 ID Right 25.000 OD 21.258 ID
Shim Pac Installed Left 0.000 Right 0.000
Installed Running Clearance Crank Serial Number:
Eccentric #1 0.001 #2 0.001 #3 0.001
WristPin #1 0.002 #2 0.001 #3 0.002
Pinion Left 0.001 Right 0.002 Name: Alex
Main Brgs. Left 0.004 Right 0.035 Date: 4/18/2009

QA-FRM-002
Rev. 02
ABS Pump Test
Page 1 of 2

Action Duration
Pump Model___2200__________ S/N____22002608_____________ Liner Size ____5”____________
Max Rated SPM____ 110_________ Max Liner Pressure ____7500________________
Ambient Temperature___77°F_________ Water Temp. __*F

15Min: *F
Step 2. SPM__55________ Pressure___3800_____ Pinion Speed__270__________

Main Brg L (15min) _63___ °F R (15min) _58__ °F L (30 Min) _66____°F R (30min) _60___°F
Pinion Brg L (15min) _67___°F R (15min) __69_ °F L (30 Min)__ 69__°F R (30min) ___72_°F
Stub Rod 1 (15min) ___ ___°F 2 (15min) __ ___°F 3 (15 Min) _______°F
1 (30min) ____ __°F 2 (30min) __ ___°F 3 (30 Min) __ _____°F
Step 3. SPM___110_________ Pressure___2500________ Pinion Speed___535__________
Main Brg L (15min) _75_____ °F R (15min) __67 ___ °F L (30 Min) _80__ __°F R (30min) _74__ _ °F
L (45min) _88__ ___°F R (45min) __79____ °F L (60min) _90_____°F R (60min) _82__ ___ °F
Pinion Brg L (15min) _78____ °F R (15min) _88_____°F L (30 Min) _84____ °F R (30min) _93 ___ °F
L (45min) _89_____ °F R (45min) _99_____°F L (60 Min) 96_ ___°F R (60min) _105_ °F

45Min: *F
1Hr: *F

QA-FRM-002
Rev. 02
ABS Pump Test
Page 2 of 2
Step 4. SPM__56___________ Pressure____7500______ Pinion Speed____275________

Main Brg L (15min) _98___ °F R (15min) _92_ ____ °F L (30 Min) _101____°F R (30min) _96___ °F
L (45min) _103_ °F R (45min) _97______ °F L (60min) _105____ °F R (60min) 100_ _ °F
Pinion Brg L (15min) _98____°F R (15min) _92_______°F L (30 Min) 100_____ °F R (30min) 95____ °F
L (45min) _101 °F R (45min) 98 __ °F L (60 Min) __103____ °F R (60min) 100_°F

1 (30min) __ ____ °F 2 (30min) ___ __ °F 3 (30 Min) __ ___ °F
1 (45min) ___ ___ °F 2 (45min) ___ __ °F 3 (45 Min) ___ ___ °F
1 (60min) ___ ___ °F 2 (60min) __ ___ °F 3 (60 Min) ___ ___ °F
#1 #2 #3
96_
Liners 100 _99
95_ 92_ 90_ _94 _95

_96
S/N__22002608______
Technician_John Kenjur___________ Date: ___4-25-09_ _________
ABS Rep________________________ Date: ____________________

QC-FRM-003

Ellis Williams Pump
1. Install all (6) Crosshead guides. Torque all (6) bolts in TL___ ____ ____
2. Install Crankshaft into pump. TL___ _____ _____
3. Install #2 Crosshead. TL___ _____ _____
4. Install Wrist Pin, Torque & Tie-Wire retainers to spec. TL___ B____ B____
5. Install Ponyrod, Torque & Tie-Wire to specs. TL___ B____ B____
6. Install Alignment Liner & Liner Lock Flange. TL___ B____ B____
with the conrod in the up position. TL___ B____ B____
8. Install Brass Ring on Ponyrod. TL___ B____ B____
9. Mount “S” Laser on Liner & “M” Laser on Ponyrod. TL___ B____ B____
10. Connect Cables to Laser Units and Laser Computer. TL___ B____ B____
11. Turn on Laser Computer & type “11”. TL___ B____ B____
12. Align Lasers to Bulls-eyes then open target. TL___ B____ B____
record page. TL___ B____ B____
14. Enter measurements into Laser Computer. TL___ B____ B____
15. Move Lasers to 9:00 and press enter. TL___ B____ B____
not, then make displayed adjustments. TL___ B____ B____
19. Log horizontal information on Alignment Record Page. TL___ B____ B____
changes. TL___ B____ B____
to spec. TL___ B____ B____
repeat step 21. TL___ B____ B____
achieve clearance.) TL___ B____ B____
24. Shut down Laser Tool and remove. TL___ B____ B____
25. Install #1 Crosshead and steps 4 thru 24. TL___ B____ B____
26. Install #3 Crosshead and steps 4 thru 24. TL___ B____ B____

CUSTOMER: PPL UNIT: 2200 JOB: 449
DATE TESTED: 4/25/2009 WEATHER CONDITIONS: overcast AMB. DEG. 77°

COMMENTS: Good test!!
685 1 120 35 cold 200 0 20 82 30 min
1528 2 160 55 180 250 3800 20 55 270 15 min
1653 4 180 55 195 175 2500 20 110 535 15 min
1548 2 180 55 200 250 7500 20 56 275 15 min
ENGINE: Detriot Diesel 1600HP 16V149 S/N: TEST TECHNICIAN: John Kenjura
TRANSMISSION: Allison S-9800 S/N: TEST DATE: 4/25/2009
PUMP: 2200 S/N: 22002608 WITNESS: Corey Amendt

PINION SERIAL # _____________________________ DATE ________________________
PUMP FRAME SERIAL # ____PPL 2200_________________ MECHANICS NAM Eladio Veneros/Bert
LEFT RIGHT
SIDE SIDE
Right Side
Carrier, Pinion Bearing 1 1‐8 UN x 3 1/2" LG. 8 530 ft‐lbs 530 Ft‐lbs NO Bert‐EVM
Plate, Retainer, oil 3 5/8‐11 UNC x 1 1/4" LG. 4 125 ft‐lbs 125 Ft‐lbs YES E.V.M
Left Side
Carrier, Pinion Bearing 1 1‐8 UN x 3 1/2" LG. 8 530 ft‐lbs 530 Ft‐lbs NO Bert‐EVM
Plate, Retainer, oil 3 5/8‐11 UNC x 1 1/4" LG. 4 125 ft‐lbs 125 Ft‐lbs YES E.V.M
CRANKSHAFT SERIAL # ____PPL#2_________________________ DATE ________________________
PUMP FRAME SERIAL # ____2200_____________________ MECHANICS NAME Tim/Eladio/Matt
LEFT RIGHT SIDE
SIDE
Rod, Pony 1 1‐8 UNC x 2 1/2" LG. 6 280 ft‐lbs 280 Ft‐lbs YES MATT
Plate, Cover, Stuffing Box 2 5/8‐11 UNC x 1 1/2" LG. 6 125 ft‐lbs 125 Ft‐lbs NO MATT
Retainer, Wristpin to Crosshead 3 1‐8 UNC x 2 3/4" LG. 4 250 ft‐lbs 250 Ft‐lbs YES MATT
Retainer, Wristpin to Wristpin 4 7/8‐9 UNC x 2 1/2" LG. 2 350 ft‐lbs 350 Ft‐lbs YES MATT
Guide, Crosshead 7 1‐8 UNC x 2 1/2" LG. 12 150 ft‐lbs 150 Ft‐lbs NO EVM
Retainer, Wristpin, Inner 8 3/4‐10 UNC x 2 1/4" LG. 4 200 ft‐lbs 200 Ft‐lbs YES MATT
Stuffing Box 9 3/4‐10 UNC x 1 3/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO MATT
Plate, Diaphram 10 3/4 ‐ 10 UNC x 2 1/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO MATT
Rod, Pony 1 1‐8 UNC x 2 1/2" LG. 6 280 ft‐lbs 280 Ft‐lbs YES EVM
Plate, Cover, Stuffing Box 2 5/8‐11 UNC x 1 1/2" LG. 6 125 ft‐lbs 125 Ft‐lbs NO EVM
Retainer, Wristpin to Crosshead 3 1‐8 UNC x 2 3/4" LG. 4 250 ft‐lbs 250 Ft‐lbs YES EVM
Retainer, Wristpin to Wristpin 4 7/8‐9 UNC x 2 1/2" LG. 2 350 ft‐lbs 350 Ft‐lbs YES EVM
Retainer, Wristpin, Inner 8 3/4‐10 UNC x 2 1/4" LG. 4 200 ft‐lbs 200 Ft‐lbs YES EVM
Stuffing Box 9 3/4‐10 UNC x 1 3/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO EVM
Plate, Diaphram 10 3/4 ‐ 10 UNC x 2 1/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO EVM
Rod, Pony 1 1‐8 UNC x 2 1/2" LG. 6 280 ft‐lbs 280 Ft‐lbs YES TL
Plate, Cover, Stuffing Box 2 5/8‐11 UNC x 1 1/2" LG. 6 125 ft‐lbs 125 Ft‐lbs NO TL
Retainer, Wristpin to Crosshead 3 1‐8 UNC x 2 3/4" LG. 4 250 ft‐lbs 250 Ft‐lbs YES TL
Retainer, Wristpin to Wristpin 4 7/8‐9 UNC x 2 1/2" LG. 2 350 ft‐lbs 350 Ft‐lbs YES TL
Retainer, Wristpin, Inner 8 3/4‐10 UNC x 2 1/4" LG. 4 200 ft‐lbs 200 Ft‐lbs YES TL
Stuffing Box 9 3/4‐10 UNC x 1 3/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO TL
Plate, Diaphram 10 3/4 ‐ 10 UNC x 2 1/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO TL
Plate, Crosshead Cover 5 3/4‐10 UNC x 2 1/4" LG 10 200 ft‐lbs 200 Ft‐lbs NO MATT

CRANKSHAFT SERIAL # _____________________________ DATE ___ 04/20/09
PUMP FRAME SERIAL # _____________________________ MECHANICS NAME _ Alex
LEFT RIGHT SIDE
SIDE
Mechanic
left side
Initials
Shim thickness installed ______.055_______ Inches AR
Inches SI
.005" required) ______5.5________
Mechanic
Right side
Initials
Shim thickness installed ______.050________ Inches AR
Inches SI
.005" required) ______.004_______
Gear, Bull 1 1 1/2‐8 UN x 5 1/2" LG. 16 1000 ft‐lbs 1000 Ft‐lbs NO AR
YES
(inside and outside) 2,4 3/4 ‐ 10 UNC x 2 1/4" LG. 24 200 ft‐lbs 200 Ft‐lbs AR
Retainer, Bearing Race , Inner Eccentric #2 6 3/4 ‐ 10 UNC x 2 1/4" LG. 12 200 ft‐lbs 200 Ft‐lbs YES AR
Retainer, Bearing Race , Inner Eccentric #3 8 3/4 ‐ 10 UNC x 2 1/4" LG. 12 200 ft‐lbs 200 Ft‐lbs YES AR
YES
(inside and outside) 3 5/8‐11 UNC x 2" LG. 12 125 ft‐lbs 125 Ft‐lbs AR
Retainer, Bearing Race , outer Eccentric #2 5 5/8‐11 UNC x 2" LG. 12 125 ft‐lbs 125 Ft‐lbs YES AR
Retainer, Bearing Race , outer Eccentric #3 7 5/8‐11 UNC x 2" LG. 12 125 ft‐lbs 125 Ft‐lbs YES AR
Retainer, Bearing Race , inner main (Left) 12 1‐8 UN x 2 3/4" LG. 8 530 ft‐lbs 530 Ft‐lbs YES SI

Retainer, Bearing Race , outer main (Left) 13 3/4 ‐ 10 x 2 1/4" LG. 8 200 ft‐lbs 200 Ft‐lbs YES SI
Retainer, Bearing Race , inner main (Right) 14 1‐8 UNC x 2 3/4" LG. 8 530 ft‐lbs 530 Ft‐lbs YES SI
Retainer, Bearing Race , outer main (Right) 9 3/4 ‐ 10 x 2 1/4" LG. 8 200 ft‐lbs 200 Ft‐lbs YES SI
Cover, bearing, main (left and right) 10 3/4 ‐ 10 x 2 1/4" LG. 24 200 ft‐lbs 200 Ft‐lbs NO

3 1/2‐8 Superbolt
YES
cap, bearing, main (left and right) not shown for jackbolts 30 233 ft‐lbs 233 Ft‐lbs SI
PUMP ASSEMBLY FORM
PUMP MODEL # _______________ DATE ____4/09____________________
PUMP FRAME SERIAL # __2200 PPL #2_______ MECHANICS NAME ____Eladio .V______________________

Front (A) 22.077 22.077 22.072
Front (B) 22.07 22.069 22.069
Front (C) 22.075 22.071 22.074
Center (A) 22.078 22.081 22.074
Center (B) 22.077 22.072 22.075
Center (C) 22.076 22.078 22.075
Back (A) 22.074 22.075 22.073
Back (B) 22.066 22.069 22.069
Back (C) 22.075 22.072 22.073
Front 21.996 21.998 21.996
Middle 21.997 21.997 21.996
Back 21.994 21.996 21.995

Right (A)
Top (B)
Left (C)
EWECO(Weatherford)
Conn. Rods ID #1 ECC. 35.745 ID #2 ECC. 35.745 ID #3 ECC. 35.746 ID
#1 W/P 12.998 ID #2 W/P 12.998 ID #3 W/P 12.999 ID
Wrist Pin #1 9.502 OD #2 9.503 OD #3 9.503 OD
Main Brg. Carrier Left 25.001 OD 21.255 ID Right 24.998 OD 21.256 ID
Shim Pac Installed Left 0.060 Right 0.050
Eccentric #1 0.003 #2 0.004 #3 0.002
WristPin #1 0.0025 #2 0.003 #3 0.003
Main Brgs. Left 5.500 Right 0.004 Date: 4/20/2009

QA-FRM-002
Rev. 02
ABS Pump Test
Page 1 of 2

Action Duration
Pump Model____2200_________ S/N___22002709______ Liner Size ____5”____________
Max Rated SPM____ _110________ Max Liner Pressure ______7500______________
Ambient Temperature____70°F________ Water Temp. __*F

15Min: *F
Step 2. SPM___55_______ Pressure___3400_____ Pinion Speed___268_________

Main Brg L (15min) 93____ °F R (15min) 93___ °F L (30 Min) _93____ °F R (30min) _94____°F
Pinion Brg L (15min) 97_____°F R (15min) 97___ °F L (30 Min)__97____°F R (30min) _101___°F
Stub Rod 1 (15min) ___ ___ °F 2 (15min) __ ___°F 3 (15 Min) ________°F
1 (30min) ____ __°F 2 (30min) __ ___°F 3 (30 Min) __ _____°F
Step 3. SPM__110__________ Pressure___2700________ Pinion Speed____534_________
Main Brg L (15min) _94_____ °F R (15min) _94_ ___ °F L (30 Min) _96__ __°F R (30min) _ 98_ _ °F
L (45min) _101 ___°F R (45min) __99____ °F L (60min) __ 104___ °F R (60min) __100 __ °F
Pinion Brg L (15min) _99____ °F R (15min) _110____°F L (30 Min) _108___ °F R (30min) 115 ___ °F
L (45min) _110____ °F R (45min) _119____°F L (60 Min) _115___°F R (60min) _120_ °F

45Min: *F
1Hr: *F

QA-FRM-002
Rev. 02
ABS Pump Test
Page 2 of 2
Step 4. SPM____61_________ Pressure__7400________ Pinion Speed__300__________

Main Brg L (15min) _106__ °F R (15min) _100 ____ °F L (30 Min) _114____°F R (30min) _103__ °F
L (45min) _114_ °F R (45min) _103____ °F L (60min) __114___ °F R (60min) _104 _ °F
Pinion Brg L (15min) _117___°F R (15min) __122_____°F L (30 Min) _121____ °F R (30min) 123_ °F
L (45min) _124 °F R (45min) __126_ °F L (60 Min) __126____ °F R (60min) 128_ °F

1 (30min) __ ____ °F 2 (30min) ___ __ °F 3 (30 Min) __ ___ °F
1 (45min) ___ ___ °F 2 (45min) ___ __ °F 3 (45 Min) ___ ___ °F
1 (60min) ___ ___ °F 2 (60min) __ ___ °F 3 (60 Min) ___ ___ °F
#1 #2 #3
96_
Liners 95 _92
93_ 92_ _91 93_ 94_

93_
S/N__22002709______
Technician__ John Kenjura ________ Date: __5-01-09___________
ABS Rep________________________ Date: ____________________

QC-FRM-003

Ellis Williams Pump
1. Install all (6) Crosshead guides. Torque all (6) bolts in Matt_ ____ ____
2. Install Crankshaft into pump. M____ _____ _____
3. Install #2 Crosshead. M____ _____ _____
4. Install Wrist Pin, Torque & Tie-Wire retainers to spec. M____ Matt_ Matt_
5. Install Ponyrod, Torque & Tie-Wire to specs. M____ Matt_ Matt_
6. Install Alignment Liner & Liner Lock Flange. M____ Matt_ Matt_
with the conrod in the up position. M____ M____ M____
8. Install Brass Ring on Ponyrod. M____ M____ M____
9. Mount “S” Laser on Liner & “M” Laser on Ponyrod. M____ M____ M____
10. Connect Cables to Laser Units and Laser Computer. M____ M____ M____
11. Turn on Laser Computer & type “11”. M____ M____ M____
12. Align Lasers to Bulls-eyes then open target. M____ M____ M____
record page. M____ M____ M____
14. Enter measurements into Laser Computer. M____ M____ M____
15. Move Lasers to 9:00 and press enter. M____ M____ M____
not, then make displayed adjustments. M____ M____ M____
19. Log horizontal information on Alignment Record Page. M____ M____ M____
changes. M____ M____ M____
to spec. M____ M___ M____
repeat step 21. M____ M____ M____
achieve clearance.) M____ M____ M____
24. Shut down Laser Tool and remove. M____ M____ M____
25. Install #1 Crosshead and steps 4 thru 24. _____ M____ _____
26. Install #3 Crosshead and steps 4 thru 24. _____ _____ M____

CUSTOMER: PPL UNIT: 2200 JOB: PPL #3
DATE TESTED: 5/1/2009 WEATHER CONDITIONS: clear AMB. DEG. 70°

COMMENTS:
659 1 130 20 cold 200 0 20 78 30
1553 2 155 60 170 250 3400 20 55 268 30
1635 4 175 60 200 175 2700 20 110 534 60
1712 2 190 60 200 250 7400 20 61 300 60
ENGINE: Detroit Diesel 1600HP 16V149 S/N: Test TECHNICIAN: John Kenjura
TRANSMISSION: Allison S-9800 S/N: Test DATE: 5/1/2009
PUMP: 2200 S/N: 22002709 WITNESS: Corey Amendt

PINION SERIAL # _______2200__________________ DATE ___4/29/09_________
PUMP FRAME SERIAL # _____2200____________________ MECHANICS NAME _____________________________
LEFT RIGHT
SIDE SIDE
Right Side
Carrier, Pinion Bearing 1 1‐8 UN x 3 1/2" LG. 8 530 ft‐lbs 530 Ft‐lbs NO MM
Plate, Seal 2 3/4 ‐ 10 UNC x 2" LG. 8 200 ft‐lbs 200 Ft‐lbs NO MM
Plate, Retainer, oil 3 5/8‐11 UNC x 1 1/4" LG. 4 125 ft‐lbs 125 Ft‐lbs YES MM
Left Side
Carrier, Pinion Bearing 1 1‐8 UN x 3 1/2" LG. 8 530 ft‐lbs 530 Ft‐lbs NO MM
Plate, Seal 2 3/4 ‐ 10 UNC x 2" LG. 8 200 ft‐lbs 200 Ft‐lbs NO MM
Plate, Retainer, oil 3 5/8‐11 UNC x 1 1/4" LG. 4 125 ft‐lbs 125 Ft‐lbs YES MM
CRANKSHAFT SERIAL # _____________________________ DATE ____4/28/09___________________
PUMP FRAME SERIAL # ____2200_____________________ MECHANICS NAME __________________Matt/Eric
LEFT RIGHT SIDE
SIDE
Rod, Pony 1 1‐8 UNC x 2 1/2" LG. 6 280 ft‐lbs 280 Ft‐lbs YES ERIC
Plate, Cover, Stuffing Box 2 5/8‐11 UNC x 1 1/2" LG. 6 125 ft‐lbs 125 Ft‐lbs NO EE
Retainer, Wristpin to Crosshead 3 1‐8 UNC x 2 3/4" LG. 4 250 ft‐lbs 250 Ft‐lbs YES EE
Retainer, Wristpin to Wristpin 4 7/8‐9 UNC x 2 1/2" LG. 2 350 ft‐lbs 350 Ft‐lbs YES EE
Guide, Crosshead 7 1‐8 UNC x 2 1/2" LG. 12 150 ft‐lbs 150 Ft‐lbs NO EE
Retainer, Wristpin, Inner 8 3/4‐10 UNC x 2 1/4" LG. 4 200 ft‐lbs 200 Ft‐lbs YES EE
Stuffing Box 9 3/4‐10 UNC x 1 3/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO EE
Plate, Diaphram 10 3/4 ‐ 10 UNC x 2 1/4" LG. 8 150 ft‐lbs 150 Ft‐lbs NO EE
Rod, Pony 1 1‐8 UNC x 2 1/2" LG. 6 280 ft‐lbs 280 Ft‐lbs YES EE
Plate, Cover, Stuffing Box 2 5/8‐11 UNC x 1 1/2" LG. 6 125 ft‐lbs 125 Ft‐lbs NO EE
Retainer, Wristpin to Crosshead 3 1‐8 UNC x 2 3/4" LG. 4 250 ft‐lbs 250 Ft‐lbs YES EE
Retainer, Wristpin to Wristpin 4 7/8‐9 UNC x 2 1/2" LG. 2 350 ft‐lbs 350 Ft‐lbs YES EE
Guide, Crosshead 7 1‐8 UNC x 2 1/2" LG. 12 150 ft‐lbs 150 Ft‐lbs NO MATT
Rod, Pony 1 1‐8 UNC x 2 1/2" LG. 6 280 ft‐lbs 280 Ft‐lbs YES MATT
Plate, Cover, Stuffing Box 2 5/8‐11 UNC x 1 1/2" LG. 6 125 ft‐lbs 125 Ft‐lbs NO MATT
Retainer, Wristpin to Crosshead 3 1‐8 UNC x 2 3/4" LG. 4 250 ft‐lbs 250 Ft‐lbs YES MATT
Retainer, Wristpin to Wristpin 4 7/8‐9 UNC x 2 1/2" LG. 2 350 ft‐lbs 350 Ft‐lbs YES MATT
Guide, Crosshead 7 1‐8 UNC x 2 1/2" LG. 12 150 ft‐lbs 150 Ft‐lbs NO MATT
Plate, Crosshead Cover 5 3/4‐10 UNC x 2 1/4" LG 10 200 ft‐lbs 200 Ft‐lbs NO ERIC

CRANKSHAFT SERIAL # _____________________________ DATE _______ 4/29/2009
PUMP FRAME SERIAL # ___2200 PPL__________________ MECHANICS NAME ________Matt/Eric
LEFT RIGHT SIDE
SIDE
Mechanic
left side
Initials
Shim thickness installed _____.035________ Inches Alex
_____.0055_______ Inches Bert
.005" required)
Mechanic
Right side
Initials
Shim thickness installed _____.055________ Inches Alex
Inches Bert
.005" required) _____.0055_______
Gear, Bull 1 1 1/2‐8 UN x 5 1/2" LG. 16 1000 ft‐lbs 1000 Ft‐lbs NO Alex
YES
(inside and outside) 2,4 3/4 ‐ 10 UNC x 2 1/4" LG. 24 200 ft‐lbs 200 Ft‐lbs Alex
Retainer, Bearing Race , Inner Eccentric #2 6 3/4 ‐ 10 UNC x 2 1/4" LG. 12 200 ft‐lbs 200 Ft‐lbs YES Alex
Retainer, Bearing Race , Inner Eccentric #3 8 3/4 ‐ 10 UNC x 2 1/4" LG. 12 200 ft‐lbs 200 Ft‐lbs YES Alex
YES
(inside and outside) 3 5/8‐11 UNC x 2" LG. 12 125 ft‐lbs 125 Ft‐lbs Alex
Retainer, Bearing Race , outer Eccentric #2 5 5/8‐11 UNC x 2" LG. 12 125 ft‐lbs 125 Ft‐lbs YES Alex
Retainer, Bearing Race , outer Eccentric #3 7 5/8‐11 UNC x 2" LG. 12 125 ft‐lbs 125 Ft‐lbs YES Alex
Retainer, Bearing Race , inner main (Left) 12 1‐8 UN x 2 3/4" LG. 8 530 ft‐lbs 530 Ft‐lbs YES Bert

Retainer, Bearing Race , outer main (Left) 13 3/4 ‐ 10 x 2 1/4" LG. 8 200 ft‐lbs 200 Ft‐lbs YES Bert
Retainer, Bearing Race , inner main (Right) 14 1‐8 UNC x 2 3/4" LG. 8 530 ft‐lbs 530 Ft‐lbs YES Bert
Retainer, Bearing Race , outer main (Right) 9 3/4 ‐ 10 x 2 1/4" LG. 8 200 ft‐lbs 200 Ft‐lbs YES Bert
Cover, bearing, main (left and right) 10 3/4 ‐ 10 x 2 1/4" LG. 24 200 ft‐lbs 200 Ft‐lbs NO Bert

3 1/2‐8 Superbolt
YES
cap, bearing, main (left and right) not shown for jackbolts 30 233 ft‐lbs 233 Ft‐lbs EVM/ERIC
PUMP ASSEMBLY FORM
PUMP MODEL # ___2200________ DATE ________________________
PUMP FRAME SERIAL # ____________________ MECHANICS NAME __________________________

Front (A) 25.042 25.042 25.041
Front (B) 25.043 25.043 25.042
Front (C) 25.041 25.043 25.042
Center (A) 25.042 25.042 25.041
Center (B) 25.043 25.043 25.042
Center (C) 25.041 25.043 25.042
Back (A) 25.043 25.043 25.041
Back (B) 25.043 25.043 25.041
Back (C) 25.041 25.043 25.042
Front 21.998 21.997 21.996 21.998 21.997 21.998 21.995 21.997 21.997
Middle 21.998 21.997 21.995 21.998 21.996 21.997 21.995 21.996 21.989
Back 21.998 21.992 21.995 21.998 21.996 21.996 21.992 21.997 21.996

Right (A)
Top (B)
Left (C)
EWECO(Weatherford)
Conn. Rods ID #1 ECC. 35.744 ID #2 ECC. 35.745 ID #3 ECC. 00036 ID
#1 W/P 12.997 ID #2 W/P 12.997 ID #3 W/P 12.997 ID
Wrist Pin #1 9.502 OD #2 9.502 OD #3 9.502 OD
Main Brg. Carrier Left OD 21.254 ID Right OD 21.256 ID
Shim Pac Installed Left Right
Eccentric #1 0.002 #2 0.003 #3 .000-.001
WristPin #1 0.002 #2 0.003 #3 0.003
Main Brgs. Left Right Date: 4/24/2009

PPL Manual R3 - Hull 2023 - Chain

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PPL Manual R3 - Hull 2023 - Chain

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Operating and Maintenance Manual

Customer Name:___PPL Shipyard___P2023____

339 Magnolia Business Park Dr.· Magnolia, TX 77354

Operation and Maintenance Manual Page 1

This manual is provided for guidance of those who wish to install,

Each pump is a combination of a basic design and optional features.

Specifications are in accordance with engineering design and should be

The material used in the construction of the pump is satisfactory for

1. Maintenance of pH 10 or higher to neutralize H2S in the drilling

EWECO reserves the right to change, discontinue or

Operation and Maintenance Manual Page 2

1.Read manufacturers manual prior to operation or

2.Shut down or disengage the pump power source.

3.Shut down all pump accessory equipment.

4.Relieve or “bleed off” all pressure from the pump

5.Do not use a high-pressure air or nitrogen source

6.Do not pipe the relief valve by-pass line into

7.Always use the rig hoist, lifting appliance, or

8. Always wash the inside of a pump fluid end if

Operation and Maintenance Manual Page 3

Operation and Maintenance Manual Page 4

Table of Contents (cont’d)

STEEL FASTENER TORQUE SPECIFICATIONS (LUBED)______________________ 39

Section 2 – Model Specific

Section 3 – Serial Number Specific

Operation and Maintenance Manual Page 5

1. Discharge Manifold – Provides connections for pulsation dampener,

2. Chain Drive – Multiple strand roller chain running on sprockets,

3. Discharge Dampener – A pulsation dampener mounted in the discharge

4. Discharge Strainer Cross – A strainer screen installed in a flanged

5. Electric Drive Motors – DC traction type motors or AC variable

6. External Lube Oil Pump – Electric powered pump providing lubrication

7. Fluid End – Mud pumping system containing modules (fluid cylinders),

9. Inspection Cover – Crosshead compartment – An opening for access to

10. Inspection Cover – Crank Case Cover – An opening for inspection of

11. Liner Wash Pump – An electric powered centrifugal pump circulating

Operation and Maintenance Manual Page 6

15. Power End – Mechanical conversion of rotary input motion to

19. Suction Dampener – A pulsation dampener usually charged with low

20. Suction Manifold – A distribution pipe bolted to the inlet openings

21. V-belt Drive – Multiple, high capacity, 8V size belts arranged in

Operation and Maintenance Manual Page 7

Operation and Maintenance Manual Page 8

Operation and Maintenance Manual Page 9

COMMON SUCTION MANIFOLD

SUCTION LINE VALVES

PRESSURE RELIEF VALVE

Operation and Maintenance Manual Page 10

The discharge piping can be simplified by using the forged discharge

Pressure Relief Valve

All adjustments should be made with the valve at normal operating

Operation and Maintenance Manual Page 11

Power End Lubrication

* Moly-lube or oil containing Molybdenum should not be used

Operation and Maintenance Manual Page 12

PISTON AND RODS

Operation and Maintenance Manual Page 13

Light Weight Triplex Pumps Oil Capacity

EWECO Triplex Pumps Oil Capacity

Quintuplex Pumps Oil Capacity

Chain Drive Lubrication

Operation and Maintenance Manual Page 14

Liner Spray Lubrication

Customer Name:_PPL Shipyard_P2023____