GEK-91696C

H84461
30 NOV 2006

AC ELECTRIC DRIVE
DRILLING MOTORS
FOR

DRILLMEC

GE 5GEB22A2
HORIZONTAL DRILLING MOTOR

Customer Order No. ................

GE Requisition No. ..............

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

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

Verify numbers for parts, tools or material by using the Renewal Parts or Tool Catalogs or contact your General Electric
representative for assistance.
Do not order from this publication.
 GEK–91696C

HORIZONTAL DRILL MOTOR

MODEL 5GEB22

CONTENTS
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ATEX CERTIFICATION . . . . . . . . . . . . . . . . . . . . . . . 2
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5GEB22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GROUNDING INSTRUCTIONS . . . . . . . . . . . . . . . . 5
GROUNDING PROCEDURES . . . . . . . . . . . . . . . . 5
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ROTOR BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . 6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MONTHLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LOCKING ROTOR FOR SHIPPING . . . . . . . . . . . 7
SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FIG. 1. 5GEB22 DRILLING MOTOR. E–43806.
CLEANING AND SLUSHING . . . . . . . . . . . . . . . . . 8
SKIDDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 BRAZING CONNECTIONS . . . . . . . . . . . . . . . . . 15
PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CONNECTION–END FRAME HEAD
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PLACING INTO STORAGE . . . . . . . . . . . . . . . . . . 8 ROTOR ASSEMBLY PROCEDURES . . . . . . . . . . . 16
REMOVING FROM STORAGE . . . . . . . . . . . . . . . 8 ROTOR BALANCING . . . . . . . . . . . . . . . . . . . . . . 16
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ROTOR BEARING ASSEMBLIES . . . . . . . . . . . . 16
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ROTOR INSTALLATION INTO FRAME . . . . . . . 20
DEFECT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . 9 ROTOR BEARING ASSEMBLIES CHECKS . . . 20
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 9 ROTOR SHAFT END–PLAY CHECK . . . . . . . . . 21
STATIC ELECTRIC TESTS . . . . . . . . . . . . . . . . . . 9 FINAL ASSEMBLY OF ROTOR DRIVE–END . . 21
MEGOHMMETER (“MEGGER”) TESTS . . . . . . 10 FINAL ASSEMBLY OF ROTOR
HIGH–POTENTIAL (“HI–POT”) TESTS . . . . . . . 10 CONNECTION–END . . . . . . . . . . . . . . . . . . . . . . 22
HUB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 CABLE LEADS AND CONNECTIONS . . . . . . . . . . 22
ROTOR DISASSEMBLY PROCEDURES . . . . . . . 10 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ROTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 10 CABLE TERMINAL REPLACEMENT . . . . . . . . . 22
BEARING ASSEMBLIES REMOVAL . . . . . . . . . 11 COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ROTOR SHAFT INSPECTION . . . . . . . . . . . . . . 13 ELECTRICAL RUNNING TEST . . . . . . . . . . . . . . . 23
STATOR COILS AND BUS RINGS . . . . . . . . . . . . . 13 HUB MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CONNECTION–END FRAME HEAD REMOVAL 13 HUB FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CLEANING AND INSPECTION . . . . . . . . . . . . . . 13 HUB MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . 25
STRIPPING INSULATED CONNECTIONS . . . . 14 TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DISCONNECTING BRAZED CONNECTIONS . 14 SPECIAL TOOLS AND EQUIPMENT . . . . . . . . . . 26

Revisions are indicated by margin bars.

 Copyright 1998, 2001, 2002 General Electric Company. All rights reserved. This copyrighted document may be reproduced free of charge by
General Electric Company customers, if such reproduction is used exclusively in connection with equipment used in that customer’s internal
operation
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 mainte-
nance. 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 material. 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.
GEK–91696C, Horizontal Drill Motor, Model 5GEB22

INTRODUCTION
This publication provides basic instructions for main-
tenance and overhaul – including inspection, lubrica-
tion, disassembly, repair, and reassembly – of the Model
5GEB22 drilling motor (Fig. 1).

ATEX CERTIFICATION
INSTRUCTIONS

WARNING: Installation should be in accordance

with the instruction as defined in EN
60079–14:1997 “Electrical apparatus for explo-
sive gas atmospheres, Part 14. Electrical installa-
tions in hazardous areas (other than mines)”.
Couplings, belts and chain guards should be
installed as needed to protect against accidental
contact with moving parts. Machines accessible
to the public should be further guarded by
screening, guard rails, etc., to prevent the public
from coming in contact with the equipment. Fail-
ure to observe these precautions may result in
personal injury.

1. This machine is suitable for operation in typical

oil well drilling industry rig environments
including offshore platforms and mobile drilling
FIG. 2. SAFE ELECTRICAL PARAMETERS
units. For other types of applications and
FOR 5GEB22. E–45045.
environments, please contact your GE repre–
sentative to determine suitability.
rameters for the 5GEB22. The motor may be op-
2. Periodic lubrication is not required on 5GEB22
erated in the presence of typical vibration levels
horizontal drilling motors between scheduled
encountered on land and offshore rigs.
overhaul periods because the bearings are
grease packed and permanently sealed. Motor
GEB22
bearings MUST be replaced after 25,000 hours
of operation which is 90 percent of calculated
1. The cable fitted to the equipment must be capa-
bearing life. All maintenance must be carried out
ble of withstanding maximum temperatures of
in accordance with:
108.5C at the cable entry point.
EN 60019–17:1997 – Electrical apparatus for
explosive gas atmospheres, Part 17. Inspection 2. The equipment must be supplied continuously
and maintenance of electrical installations in with at least 3000 CFM of cooling air. The cooling
hazardous areas (other than mines); arrangements must be suitable for the area in
which it is installed. When fitted to the equip-
IEC 60079–19:1993 – Electrical apparatus for
ment, the cooling arrangements must ensure
explosive gas atmospheres, Part 19. Repair and
that the equipment satisfies a degree of protec-
overhaul for apparatus used in explosive atmo-
spheres (other than mines or explosives). tion of at least IP24.

3. Figure 2 defines the safe electrical parameters 3. The 5GEB22 motor shall be used with one of the
and Figure 3 defines the safe environmental pa- drives indicated in the following table.

2
 Horizontal Drill Motor, Model 5GEB22, GEK–91696C

GE GE AC2000AW Variable Max. Coolant

Speed Drive Min. Water Temp.
Cegelec Bauteil Type GD3000E AC Drive Duty Flow Rate (at cooler inlet)
System S1 100 US gal/min 33.0 C
Unico, Inc. Type 2400 Series (Part (continuous)
No. 109341) with or with- S9 (Duty A) 100 US gal/min 33.0 C
out a smoothing inductor
S9 (Duty B) 100 US gal/min 37.7 C
Stadt Type 875TCX
6GN0–AFE AC Drive
5. This equipment must be supplied via a time/cur-
System
rent dependent device to monitor and limit the tE
Siemens See following illustration time to 37 seconds, or a thermal protective de-
for range of applicable
drives vice that limits the stator windings to 170C. In
both cases above the devices must be suitably
certified as compliant with European Directive
Siemens drive identification 6SE704 1– * * * * 94/9/EC as a Safety Related Device.
Rated current indicator: 6. RTD’s supplied with the motor are to be con-
0 = 1000A (M chassis)
2 = 1200 A (L or M chassis) nected to intrinsically safe circuits to meet com-
5 = 1500A (M chassis) pliance of the EEx c certification for operation in
hazardous locations.
dc link voltage indicator:
V = 930 V (690 V line – line)
U = 780 V (600 V line – line)

Chassis indicator:
M
L

Digit 2 or 6

The drive outputs shall be limited to 1500 amps

max.
The maximum load current shall be limited to 586
amps when supplied by the Stadt Type 875TCX
6GN0–AFE AC Drive System.

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 FIG. 3. SAFE ENVIRONMENTAL
with coolant in accordance with the following PARAMETERS FOR 5GEB22. E–45046.
table:

3
 GEK–91696C, Horizontal Drill Motor, Model 5GEB22

DATA
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEB–22–A1
Application Motor Rating
Speed Torque Horsepower Ventilation IPH Time
(rpm) (lb.–ft) (scfm) Amps
0 10,600 0 3,000 1470 15 seconds
800 9,200 1,400 3,000 1,300 60s on, 30s off
1,600 3,773 1,150 3,000 1,100 Continuous
Weight (lbs):
Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5693 (2582kg)
Rotor Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1623 (736kg)
Max. Permissible Speed (rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2300
Max. Permissible Vibration (Connection End) (in./sec.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.44 (.01118m/s)
Resistance at 25C (Ohms) Min. Max.
Each pair of terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0088 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0108
RTDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Ω Platinum
Rotor Bearings
Diametral Clearance, Assembled (in.)
Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 (0.127mm) . . . . . . . . . . 0.009 (0.229mm)
Connection End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0005 (0.0127mm) . . . . . . . 0.0035 (0.089mm)
Rotor Balance
Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50–gram–inches
Connection End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50–gram–inches
Runout Measured from Shaft to Outer Race (in.)
Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.001 (0.0254mm)
Connection End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.001(0.0254mm)
Lubrication
Rotor Bearing Grease Capacities (oz)
Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.5
Connection End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GE–D6A2C10
Grease Specification
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.
Specifications:
Worked Consistency, 77F, MM/10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220–240
Dropping Point, Degrees F (Min) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Mineral Oil Viscosity at 100F, SSU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475–525
Free Alkali, Percent (Max) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50
Free Acid, Percent (Max) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nil
Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amber
Base (With Antioxidant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lithium
Oxidation Resistance Time to Reach 20 psi Drop at 210F, Hr. (Min) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Must Pass
Approved Vendor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shell Oil
Brand Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cyprina RA
Megger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Min. 2 megohms

4
 Horizontal Drill Motor, Model 5GEB22, GEK–91696C
DESCRIPTION
The Model 5GEB22 drilling motor (Fig. 4.) is a force–
ventilated, three–phase alternating–current induction
motor designed for use in the oil and gas industry to
power off–shore and land based drilling rigs. The mo-
tor’s normal function is to provide power for mud pumps
and drawworks duty.
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 re-
versing the phase rotation in the motor stator.
The motor is force ventilated by a top–mounted blower
unit.
GROUNDING INSTRUCTIONS
Grounding motor frames is required to safeguard
personnel from electric shock in event of an insulation
failure in the machine.
ALTERNATE
POSITION
MAIN
CONNECTION
BOX
FIG. 4. 5GEB22 DRILLING MOTOR. E–48504.
WARNING: Failure to properly ground electrical
equipment may expose personnel to a potentially
hazardous condition in which serious or fatal inju
ry from electrical shock is possible.
Grounding conductors must be provided between
the machine frame and the supporting structure to avoid
hazardous potential difference between the machine
frame and the adjacent surface on which a person may
be standing while touching the machine.
NOTE: This type of ground connection is re-
ferred to in electrical standards as “equipment
grounding” or “enclosure grounding” which is
not to be confused with “system” or “circuit”
grounding. Drilling drive systems normally do
not have intentional circuit ground connec-
tions, except through high impedance detec-
tors.
Grounding conductors must be provided on drilling
units on which the construction of the unit and/or the in-
stallation of the machines do not inherently insure posi-
tive 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. (References: ABS Rules for Building and
Classing Steel Vessels, Section 35.9.6, and IEEE Stan-
dard 45–1977, Recommended Practice for Electrical In-
stallations on Shipboard, Section 21.4.)
GROUNDING PROCEDURES
The GEB22 has a ground block attached to the
frame as shown in Fig. 5. The mounting stud is 3/8–16
thread.
1. To attach a ground cable to the ground block, ob-
tain a 3/8–16 nut and a lockwasher. Also obtain a
cable lug to fit the ground cable and large enough
for the 0.375 diameter bolt.
2. Prepare a ground conductor* long enough to run
from the motor frame to an existing ground con-
ductor system or to a suitable equipment ground
point as defined by the National Electrical Code
5
GEK–91696C, Horizontal Drill Motor, Model 5GEB22
GROUND BLOCK
FIG. 5. GROUND BLOCK LOCATION. E–43582.
Article 250 or other applicable regulation. Check
that the system ground detector is also con-
nected to the Common ground point for the rig
and make connection if necessary.
3. Install terminal lugs on cable. Remove paint, rust
and oil from all surfaces to which the cables are
to be attached and bolt the lugs securely to these
surfaces (torque to 25 ft.lbs.)
LUBRICATION
ROTOR BEARINGS
The drill motor’s rotor anti–friction bearings are
packed with grease at motor assembly, and require no
attention until overhaul.
INSPECTION
MONTHLY
Covers, Seals, Latches
Clean the outside of the machine and remove the in-
spection covers. Use clean, dry compressed air and
blow the dirt and dust from the interior of the machine.
*Use 4/0 size or larger copper cable for GEB20 ma
chines. (Reference: National Electrical Code, 1978
Edition, Table 250-95.)
6
WARNING: When using compressed air for clean
ing 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, personal protective equip
ment as specified by applicable federal or state
safety regulations.
Check exterior covers to be sure felt seals are intact.
If seals are missing or covers are damaged, replace
seals or covers as necessary. Make sure covers fit prop-
erly and are bolted securely.
Power Cables
Inspect the power cables and terminals for signs of
excessive heating, poor insulation, chafing, or mechani-
cal damage. Verify that all cable connections are tight,
and that cables are secured. Check for damaged cable
bushings, loose or missing cable cleat hardware, etc.
Insulation
Measure the insulation resistance with a
megohmmeter (Megger) to determine the condition of
the insulation. If reading is low, make a further inspec-
tion to determine if insulation failure or excessive mois-
ture is causing the low megohmmeter reading. Correct
the cause of low readings before returning the motor to
service.
Megohmmeter tests will determine the condition of the
insulation to ground or between windings by testing for
high resistance paths. Megohmmeter readings are
most affected by moisture, dirt build–up, or carbon
tracking. When a low megohmmeter reading is ob-
tained, the reading may be raised by cleaning and bak-
ing the components. If the reading does not rise, disas-
sembly is required.
Apply a 500–volt megohmmeter test between the drill
motor TA lead and the cleaned ground connection on
the cable cleat of the stator frame to determine the
condition of the stator coil insulation. Ohmic values less
than 2 megohms indicate a dirt and/or moisture prob-
lem. Refer to CLEANING section of this publication.
 Horizontal Drill Motor, Model 5GEB22, GEK–91696C

Ground Cable

1
Ensure that the ground cable is bolted securely to the 2
drilling motor and base equipment mounting surface.
3

Mounting Bolts

Check all mounting bolts to assure tightness. Ob-

serve for cracking, deformities, looseness, or other ob-
vious damage.

FIG. 6. ROTOR LOCKING ARRANGEMENT.

CLEANING
It is essential that the drilling motor be kept as clean
as possible, both inside and outside. When the drilling
motor assembly has been removed from it’s machinery
base, any accumulation of oil or grease–soaked dirt
should be removed from both inside and outside.
E–43581.
LOCKING ROTOR FOR SHIPPING
CAUTION: The drill motor rotor must be locked
when it’s transported (other than from station to
station during processing) to prevent damage to
the bearings from shock and vibration.

Clean the drilling motor as follows: Before shipping the drill motor, see Fig. 6 and lock the
rotor as follows:
WARNING: Personnel performing cleaning oper-
ations must wear protective clothing, gloves and 1. Remove two bolts diametrically opposite on
eye protection to avoid injury. To prevent per- 9.50in diameter bolt circle.
sonal injury when cleaning with compressed air,
observe all Government safety regulations. 2. Assemble 5/8–11 jam nut (1), and 5in bolt (2),
and insert into vacant holes.
1. Cover the air inlet and outlet openings in the mo- 3. Torque part 2 to 30 ft–lbs and tighten part 1.
tor frame with heavy plastic and tape.
4. Paint heads of part 2 yellow.
CAUTION: Alkali and chlorinated hydrocarbon 5. Place hardware removed in step 1 into the bag
cleaning solutions are not recommended for tag (3), and attach to part 2.
cleaning traction motors due to their adverse af-
fect on the motor insulation system.
CAUTION: To avoid damage, do NOT attempt to
turn the rotor with the locking bolts in place.
2. Steam clean the exterior surfaces. Avoid forcing
moisture inside the motor. Recommended Remove the shipping bolts as follows:
cleaning compounds are: CHEMICAL METH-
ODS, INC., 809 OR 809–NP:DuBois U.S.A., Je- 1. Release the jam nuts on the yellow–headed
tacin or Dusqueeze. bolts, and remove these bolts from the traction
motor frame.
3. Remove the protective coverings from the motor 2. Replace the two regular bolts and washers from
openings. the attached bag in the motor frame. Torque
each bolt to 56 to 60 lb.–ft. (76 to 81 N–m).
4. Using compressed air, blow out the interior of the
motor to remove all dirt and moisture. Apply heat 3. Place the long bolts and jam nuts into the bag,
if necessary to dry the motor thoroughly. and save for future use.

7
GEK–91696C, Horizontal Drill Motor, Model 5GEB22

SHIPPING PROTECTION
Whenever drilling motors are to be shipped, they When any apparatus is shipped in the open, it should
must be properly skidded and secured to prevent any be fully protected from rain, snow, dirt, etc., by covering
damage in transit. with some suitable weatherproof material.

HANDLING
To avoid damage to the machine during handling, re-
view the following cautionary statements:
1. Do not lift motors by the shaft extension of the
Rotor.
2. Do not allow the rotor to bump another object.
3. Do not tighten coupling assembly bolts with an
air wrench or by pounding.
4. Do not remove rotor end–play by any other
means than axial blocking.
5. Do not load the rotor radially (strap down) for
shipment.
CLEANING AND SLUSHING
Before skidding the machine for shipment, all ex-
posed finished surfaces not already painted should be
cleaned and slushed as follows:
1. Remove all corrosion.
2. Wipe off the surface with clean rags and wet with
petroleum spirits GE–D5B8.
3. Follow with a clean rag wet with methanol, then
wipe dry. DO NOT touch the cleaned surface
with bare hands.
4. Slush immediately after cleaning with
GE–D6C6A1 slushing compound.
SKIDDING
STORAGE
PLACING INTO STORAGE
When placing GE drilling motors into storage, the fol-
lowing preparations should be performed to prevent
damage to the equipment as a result of the storage.
Machines should be placed on a pallet and stored in-
doors if possible. A clean, dry ambient of 60F is pre-
ferred. In a high humidity environment, an ambient of
70F is recommended. Every attempt should be made
to avoid widely varying temperatures and high humidity.
REMOVING FROM STORAGE
Before placing a stored motor in service, perform the
following:
1. Blow dust and dirt accumulation out of the stator
coil with clean, dry air.
2. Visually inspect for corrosion and general de-
fects.
3. Check stator coil insulation continuity to ground
with a 500 volt megger. If the megger reading is
less than 2 megohms, the stator should be baked
or dried until the moisture content is sufficiently
reduced to raise the megger reading to 2
megohms.
4. An electrical source of heat is best for drying as it
can be easily regulated and is clean. Proceed as
follows:
NOTE: Before drying stator coils, consider-
ation must be given to bearings and lubricants.
Not only can bearing lubricants be damaged by
heat, but they can also deteriorate with age. For
this reason, it is usually best to remove bear-
ings before drying and repack with new grease
before reassembly.

Use yellow pine timbers large enough to support the a. Remove the rotor from the frame and remove
weight of the machine. bearings from the rotor shaft.

8
 Horizontal Drill Motor, Model 5GEB22, GEK–91696C
b. Heat the frame and rotor until dried sufficient-
ly to obtain the 2 megohm reading.
c. Pack bearings with new grease. Refer to the
DATA table for the proper grease. Refer to
the appropriate bearing illustration for the
proper amount of grease.
d. Reassemble the motor.
e. If facilities are available, give the reas-
sembled machine a running test to check the
bearings.
OVERHAUL
Overhaul intervals will depend on the severity of ser-
vice seen by the machine. However, General Electric
Co. recommends that an overhaul be performed every
25,000 hours on all machines subjected to normal oper-
ation.
The motor should be removed, disassembled,
cleaned, inspected and reconditioned as necessary (in-
cluding varnish treatment of rotor and stator, and fields).
Motor bearings should be replaced.
CLEANING
After the exterior of the drill motor has been cleaned,
steam clean the internal metal and insulated parts as fol-
lows:
WARNING: Personnel performing steam cleaning
operations must wear protective clothing, gloves
and eye protection to avoid injury.
CAUTION: Alkali and chlorinated hydrocarbon
cleaning solutions are not recommended for
cleaning traction motors due to their adverse
effect on the motor insulation system.
NOTE: Do NOT exceed 30 to 40 psi (207 to 276
kPa) steam pressure.
1. Use steam in combination with a commercial
non–caustic cleaner, such as CHEMICAL
METHODS, INC., 809S.
2. Suspend the motor in a position accessible from
all directions to a direct flow of steam from the
hose.
3. Rinse all residue from the motor with a mixture of
clean steam and water.
4. Bake the motor for at least four hours at 302F
(150C) to remove all moisture from insulated
parts.
DEFECT RECORDS
Prior to beginning an overhaul, record the following in-
formation to aid in tracking the drill motor and compo-
nent parts and to determine the defects:
1. Log the motor frame serial number. After tear-
down, record the rotor serial number also.
2. Visually inspect the motor for defects
3. Test the motor as outlined in STATIC ELEC-
TRICAL TEST section of this publication.
4. Fill out a defect sheet for the motor frame, and
another defect sheet for the motor rotor. These
sheets should list defects found in the electrical
test, visual inspection, and inspections defined in
specific sections of this publication. The defect
sheets should travel through the shop with the
frame or rotor. Defects should be added when
found, and marked off when repaired.
VISUAL INSPECTION
Visually inspect the drill motor as follows:
1. Examine the stator for damaged coils, insulation
and wedges.
2. Inspect the stator for blistered, flaked or cracked
coil–insulating varnish.
3. Examine the bus rings for loose or burnt connec-
tions and cables.
STATIC ELECTRICAL TESTS
WARNING: Electrical shock can cause serious or
fatal injury. Proper precautions should be taken
and observed by personnel performing testing to
avoid such injury.
9
GEK–91696C, Horizontal Drill Motor, Model 5GEB22
MEGOHMMETER (MEGGER") TESTS
Megohmmeter (“Megger”) tests will determine the
condition of the insulation to ground or between wind-
ings by testing for high resistance paths. Megohmmeter
readings are most affected by moisture, dirt build–up, or
carbon tracking. When a low megohmmeter reading is
obtained, the reading may be raised by cleaning and
baking the components. If the reading does not rise,
disassembly is required.
Apply a 500–volt megohmmeter test between the drill
motor TA lead and a cleaned ground connection on the
stator frame to determine the condition of the stator coil
insulation. Ohmic values less than 2 megohms indicate
a dirt and/or moisture problem. Refer to CLEANING
section of this publication.
HIGH-POTENTIAL (HI-POT") TESTS
WARNING: High–potential (“HI–POT”) testing
can cause serious injury or death. Strict safety
regulations must be observed during such
testing.
High–potential (“HI–POT”) tests evaluate the insula-
tion dielectric strength (ability to insulate) of motor com-
ponents. A high–potential test set applies high voltage
between the windings and ground or between windings.
CAUTION: Always test with a megohmmeter first.
High–potential test only after megohmmeter tests
show two megohms resistance or higher.
High–potential test only after the windings have
been cleaned and baked dry. If a failure occurs as
a result of a high-potential test, the motor will be
permanently damaged.
Apply an AC high–potential test at the voltage given in
DATA section of this publication between the drill motor
TA lead and the cleaned ground connection on the cable
cleat of the stator frame.
ROTOR REMOVAL
HUB REMOVAL
When removing a hub, use a suitable puller, similar
follows:
to Part 41B535703G1, Fig. 7. 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.
10
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.
NOTE: Capacity of the pump is 40,000 psi. It
holds sufficient oil to remove eight to ten hubs;
check at each use. Periodically, remove the fill-
ing plug and refill with SAE–10 lubricating oil.
6. Open the relief valve, disconnect the pump from
adapter, remove the adapter and backing plate
from the shaft, and lift off the hub. Reinsert the
plug to prevent clogging the hole.
CAUTION: Special precautions should be tak
en to avoid damage to the rotor, bearings, or
bearing fits, when lifting the rotor in the vertical
position or turning rotor to a horizontal posi
tion.
ROTOR DISASSEMBLY PROCEDURES
Remove the drill motor rotor from the stator frame as
NOTE: Numbers in parenthesis () refer to part
numbers in Fig. 8 of this publication, unless
otherwise noted.
 Horizontal Drill Motor, Model 5GEB22, GEK–91696C
1. Place the drill motor in a horizontal position.
2. Remove the eight bolts and flat washers (31) se-
curing the connection–end bearing housing to
the connection–end frame head. Remove the
connection–end bearing cap.
3. Screw two long guide studs through the frame
head and into the connection–end bearing hous-
ing 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 dam-
aging the bearings 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 1in.–8 steel lifting eyebolt (GE Tool
N672P39) into the threaded hole in the drive–
end of the rotor shaft (5).
7. Align the hoist cable with the centerline of the ro-
tor, and attach the hoist hook to the lifting eye.
NOTE: The connection–end bearing and hous-
ing and the drive–end frame head, bearing and
housing are removed with the rotor as an as-
sembly.
FIG. 7. HYDRAULIC COUPLING HUB PULLER. E–23829.
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 assem-
bly.
9. With the rotor in the horizontal position, remove
the two long guide studs from the connection–
end bearing housing.
10. Remove and service the rotor bearings accord-
ing to instructions in BEARING ASSEMBLIES
REMOVAL section of this publication
BEARING ASSEMBLIES REMOVAL
Connection–End Bearing
NOTE: Numbers in parenthesis () refer to part
numbers in Fig. 9 of this publication, unless
otherwise noted.
1. Remove the two set screws (40) from the rotor
bearing nut (33). Attach the spanner wrench
(GE Tool 9945228) to the rotor bearing nut. Us-
ing a dead blow hammer, tap the wrench handle
in a counter–clockwise direction to loosen the
nut. Remove the spanner wrench, and remove
the bearing nut from the rotor.
2. Assemble the bearing puller (GE Tool
41D736059G3), and use the hydraulic jack to
11
GEK–91696C, Horizontal Drill Motor, Model 5GEB22

17 24 25 26
19

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

9 29

30
8

7
39
6 31

5 6

32

33

3 2 1 18 35 34 40
4 38 37 36

REF. DESCRIPTION REF. DESCRIPTION

1 D.E. SHAFT COLLAR 21 MOTOR FRAME
2 FLINGER 22 STATOR CORE
3 ROLLER BEARING 23 ROTOR CORE
4 SLEEVE 24 BUS RING SUPPORT
5 ROTOR SHAFT 25 TAP BLOCK
6 PIPE PLUG 26 BUS RINGS
7 BEARING CAP (OUTER) 27 C.E. FRAME HEAD
8 BOLT AND HARD WASHER 28 BOLT AND HARD WASHER
9 GASKET 29 BUS RING CLAMPS
10 BOLT AND HARD WASHER 30 BOLT AND INSULATING SLEEVE
11 D.E. FRAME HEAD 31 BOLT AND HARD WASHER
12 BEARING CAP (INNER) 32 C.E. BEARING CAP
13 STATOR AIR BAFFLE 33 BEARING RETAINING NUT
14 FELT (AIR DAM) 34 ROLLER BEARING
15 TIE RING 35 C.E. BEARING HOUSING
16 STATOR COIL 36 COLLAR (ROTOR LOCKING)
17 ROTOR END RING 37 SHAFT NUT
18 BALANCE WEIGHT 38 SHAFT WASHER
19 ROTOR BAR 39 GASKET
20 ROTOR CAGE STOP PIN 40 SET SCREW

FIG. 8. 5GEB22A1 DRILL MOTOR LONGITUDINAL SECTION. E-43585.

12
 Horizontal Drill Motor, Model 5GEB22, GEK–91696C

pull the connection–end bearing housing (35)
and bearing (34) from the rotor shaft.
3. Position the bearing housing – with the bearing
down – on a flat surface. Reassemble the bear-
ing puller (to GE Tool 41D736059G4), and use
the hydraulic jack to push the bearing from the
bearing housing.
Drive–End Bearing
NOTE: Numbers in parenthesis () refer to part
numbers in Fig. 10 of this publication, unless
otherwise noted.
1. 1Remove the eight bolts (8) and flat washers
from the outer bearing cap (7).
2. Support the weight of the drive–end frame head
(11) with a hoist, taking care not to lift the rotor off
its support. Assemble the bearing puller (GE
Tool 41D736059G2); and use the hydraulic jack
to pull the frame head (11), roller bearing (3),
bearing flinger (2), outer bearing cap (7), outer
sleeve (4), and inner bearing cap (12) from the
rotor shaft.
NOTE: If out–of–limit measurements or exces-
sive damage are observed, the rotor must be re-
placed.
STATOR COILS AND BUS RINGS
CONNECTION–END
FRAME HEAD REMOVAL
NOTE: Numbers in parenthesis () refer to part
numbers in Fig. 9 of this publication, unless
otherwise noted.
Removal of the connection–end frame head (27) may
be required to gain access to the bus rings and stator
coil connections. Remove the eight bolts and flat wash-
ers (28) holding the frame head to the motor frame, and
then remove the frame head.
CLEANING AND INSPECTION
Prior to performing disassembly or repair operations,
clean and inspect the stator as follows:
1. Ensure that the motor is clean as specified in
CLEANING section of this publication.
27
28

3. Use an arbor press and fixtures to separate the

bearing assembly components.

NOTE: Remove the collar (1) only if damaged, if

outside of inspection limits, or if the shaft must
be removed from the rotor. If necessary, use a
puller tool to remove the collar.
39
ROTOR SHAFT INSPECTION
31

1. Measure both rotor–shaft bearing mounting di- 36 6

ameters. Ensure that the rotor shaft centers are
not damaged.
32
2. Place the rotor shaft and core on centers in a
lathe, and measure the bearing fit surface runout 33
on each end with a dial indicator. Runout must 35 34 40
not exceed 0.001 in. (0.025 mm).
FIG. 9. CONNECTION–END BEARING DETAILS.
3. Visually check the shaft for defects such as E–43583.
burrs, upset metal, damaged threads, etc.

13
GEK–91696C, Horizontal Drill Motor, Model 5GEB22

WARNING: To prevent personal injury when

cleaning parts with compressed air, observe all
government safety regulations.

2. Blow out the inside of the stator with clean, dry

compressed air. Dirt and dust tend to collect in
the stator, and – if allowed to accumulate – can in
time cause an electrical failure.

WARNING: If commercial cleaning solvents are

used, the precautions cited by the manufacturer
regarding toxicity, flammability and ventilation
MUST BE STRICTLY FOLLOWED to prevent
serious or fatal injury to personnel.
3. If oil or grease is on a coil or connection, wipe off
with a cloth dipped in commercial cleaning sol-
vent.
FIG. 11. CONNECTION BOX INTERIOR DETAILS.
E–43805.
and the varnish surface. Evidence of burned or
charred insulation from an overheating condition
usually indicates a defective coil.

CAUTION: Do NOT use too much solvent, as the STRIPPING INSULATED CONNECTIONS
solvent may soak into the insulation with
damaging effects. Insulation is removed from connections by cutting, re-
quiring the use of a hammer, knife, chisel, screwdriver
4. Examine the bus rings for damaged or loose con- and Channel–Lock pliers.
nections. Observe the condition of coil insulation
1. Position the stator frame to obtain the best work-
21 ing position for the connections to be cleaned.
12
2. Use the chisel, knife and hammer to cut the in-
11 sulation. Cut the insulation down to the copper
10 the full length of the connection.
9 3. After cutting the insulation the full length, pry the
insulation away from the connection using the
knife or screwdriver.
8
4. Brazing tool heat can be used to soften the in-
7
sulation for final cleaning. Alternately heat the in-
sulation, and scrape off all material until reaching
6 bare copper.

5 DISCONNECTING BRAZED
CONNECTIONS

Use the resistance brazing machine (GE Tool

4 3
FIG. 10. DRIVE–END BEARING DETAILS.
E–43584.
41D780746–1) and tongs (GE Tool 41D780746–11) to
2 1 produce the heat necessary to separate the connection.
Typical tongs are shown in Fig. 12. Heat is produced by
passing current through the brazing carbons and the
metal to be separated.

14
 Horizontal Drill Motor, Model 5GEB22, GEK–91696C

CAUTION: Power is to be applied in pulses ONLY.

This enables the heat to spread out gradually,
providing a more even heating of the area, and
eliminating any intense hot spots.

CLAMPING
HANDLE 3. Apply power to the brazing tongs in pulses ONLY
until the heat melts the brazing material in the
joint, then shut off the power.

4. QUICKLY remove the brazing tongs, and – using

the screwdriver or pry bar – spread the parts be-
COOLING WATER
AND POWER fore the solder cools and re–solidifies.
LINE

BRAZING CONNECTIONS
COOLING WATER
LINES (TO COOL The basic rules for a good brazed connection are:
JAWS)
1. ALWAYS be sure that the material is clean.

2. ALWAYS be sure that parts being brazed are flat

against each other to prevent voids.
JAWS
3. ALWAYS apply enough heat to allow all of the
brazing solder to flow.

4. NEVER remove the brazing tongs immediately

BRAZING CARBON after brazing; leave the tongs clamped until the
brazing solder has solidified.

FIG. 12. BRAZING TONGS. E-29740.
NOTE: Read this entire procedure first to be-
come familiar with these steps.
1. The area of the joint to be disconnected must be
clean and free of dirt, oil and insulating material
such as varnish and tape.
WARNING: To prevent personal injury when
using compressed air, observe all government
safety regulations.
2. Position the brazing tong on the connection that
is to be opened. Keep an air supply nozzle on
hand to cool parts after separation occurs. The
air supply also is used to cool the surrounding
area by dissipating heat from the area being
heated.
Use the resistance brazing machine (GE Tool
41D780746–1) and tongs (GE Tool
41D780746–11) to produce the heat necessary
to braze the connection. Typical tongs are
shown in Fig. 10. Heat is produced by passing
current through the brazing carbons and the
metal to be separated.
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 in squares or rect-
angles 0.06 in. (1.6 mm) larger than the conduc-
tors – 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.
5. The area of the material to be brazed must be
clean and free of dirt, oil, and insulating materi-
als.
6. If necessary, bend the soft copper connecting
straps to align the connection.

15
GEK–91696C, Horizontal Drill Motor, Model 5GEB22
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.
7. Insert a brazing strip between the two connect-
ing straps being brazed.
8. Position the brazing tongs on the area to be
brazed, and clamp in place.
WARNING: To prevent personal injury when
using compressed air, observe all government
safety regulations.
CAUTION: Power is to be applied in pulses ONLY.
This enables the heat to spread out gradually,
providing a more even heating of the area, and
eliminating any intense hot spots.
9. Apply power to the brazing tongs in pulses ONLY,
and heat until the brazing solder flows freely. Us-
ing an air nozzle, blow air on the surrounding
area while heating to dissipate heat from the
area being brazed.
NOTE: When brazing, silver solder in rod form
will be required to fill areas where the strip may
have dripped out or to fill voids.
10. Remove power from the tongs, but do NOT re-
lease the tongs until the silver solder has cooled
enough to hold the connection. Blowing com-
pressed air on the brazed area will speed the
cooling.
CONNECTION–END FRAME
HEAD INSTALLATION
NOTE: Numbers in parenthesis () refer to part
numbers in Fig. 9 of this publication, unless
otherwise noted.
To assemble the connection–end frame head (27),
install and hand–tighten the eight bolts and flat washers
(28) holding the frame head to the motor frame. Then
torque the bolts evenly in a diametrically opposite se-
quence to 468
28 ft.lbs.
16
Removal of the connection–end frame head (27) may
be required to gain access to the bus rings and stator
coil connections. Remove the eight bolts (28) and flat
washers holding the frame head to the motor frame, and
then remove the frame head.
ROTOR ASSEMBLY PROCEDURES
ROTOR BALANCING
Dynamic balance of the rotor assembly is required for
smooth operation and low vibration. If not corrected, an
out–of–balance rotor will lead to complete motor failure.
The rotor must be balanced to within 50 gram–in. at
both ends of the rotor.
NOTE: For best results, dynamic balancing
should be done with the drive–end bearing col-
lar (item 1 in Fig. 10) in place. See BEARING AS-
SEMBLIES, DRIVE–END BEARING section of
this publication for spacer and collar assembly
instructions.
These instructions pertain only to the location and
method of attaching the balance weights. The set–up,
fixtures to hold components in the balance machine,
and the procedures required to obtain a balance within
specified limits is dependent on the type of balance ma-
chine. 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 plates.
Attach the balance weights as needed by welding to
the rotor end plates at a diameter of 10.90 in. (276.9
mm). Use welding rod GE Spec. B50E37, BRONZE
(AWS–E–Cu–Sn–C).
ROTOR BEARING ASSEMBLIES
Drive–End Bearing
NOTE: Numbers in parenthesis () refer to part
numbers in Fig. 10 of this publication, unless
otherwise noted.
 Horizontal Drill Motor, Model 5GEB22, GEK–91696C

FILL BEARING COMPLETELY

WITH 16 OZ (453.6 G)
OF GREASE (D6A2C10)

USE 8 OZ (226.8 G)
OF GREASE (D6A2C10)
USE 8 OZ (226.8 G) IN THIS CAVITY
GREASE (D6A2C10)
IN THIS CAVITY

FIG. 14. APPLYING GREASE TO DRIVE–END

SMEAR RUNNING SURFACES
WITH 0.50 0Z. (14 G)
OF GREASE (D6A2C10)
FIG. 13. DRIVE–END BEARING GREASE
DISTRIBUTION. E–45104.
1. Inspect to ensure that all mating surfaces of the
rotor drive–end bearing assembly parts are
clean and free of nicks and burrs.
2. If removed, heat the rotor drive–end collar (1) to
212F (100C) in an oven. With the rotor in the
horizontal position, apply the heated collar to the
rotor shaft, seating tightly against the rotor shaft
shoulder, and secure the collar in position until
cooled.
INNER BEARING CAP. E–27156.
the bearing inner race to the rotor shaft (5), seat-
ing tightly against the bearing flinger (2), and se-
cure the inner race in position until cooled (Fig.
15).
6. Pack the outer race (Fig. 16) and bearing rollers
of the rotor drive–end roller bearing (3) with 16
oz. (454 g) of GE Specification D6A2C10 grease
(Fig. 17).
NOTE: If proper press equipment is available,
cold pressing of the rotor drive–end roller bear-
ing outer race (3) into the frame head (11) is pre-
ferred. If proper equipment is NOT available,

3. Smear the inside diameter of the rotor drive–end

inner bearing cap (12) with GE Specification
D6A2C10 grease (Fig. 13), and pack the inner
cavity of the bearing cap with 8 oz. (227 g) of the
grease (Fig. 14). Install the inner bearing cap
over the collar.

4. Heat the rotor drive–end bearing flinger (2) to

212F (100C) in an oven. Apply the heated
flinger to the rotor shaft, seating tightly against
the collar (1), and secure the flinger in position
until cooled. FIG. 15. DRIVE–END INNER BEARING CAP,
FLINGER AND BEARING INNER RACE
5. Heat the inner race of the rotor drive–end roller INSTALLED. E–27157.
bearing (3) to 212F (100C) in an oven. Apply

17
GEK–91696C, Horizontal Drill Motor, Model 5GEB22

heat the frame head to 212F (100C) in an oven,

and install the bearing outer race in the heated
frame head.

7. Cold–press the rotor drive–end bearing outer

race and rollers (3) into the drive–end frame
head (11). Refer to Fig. 13 for the approximate
bearing race position in the frame head.

NOTE: Without the use of a rotor drive–end

bearing pilot, the upper–most rollers will drop
toward the center, making the assembly of roll-
ers over the inner race difficult. Refer to SPE-
CIAL TOOLS AND EQUIPMENT section of this
publication for the bearing pilot, guide stud and
dummy bearing cap part numbers.

8. Install the drive–end bearing pilot on the rotor

shaft (Fig. 18). Screw a guide stud into one of the
threaded holes in the inner bearing cap (12).

CAUTION: Ensure that the vent hole in the rotor

drive–end bearing cap, gasket and framehead all FIG. 16. GREASE IN DRIVE–END BEARING
line up when assembled. OUTER RACE. E–27158.

9. Apply the gasket (9) over the guide stud to the ro-
tor drive–end inner bearing cap (12).

10. Supporting the weight of the frame head (11) with

a hoist, slide the frame head, drive–end bearing
outer race and rollers assembly over the bearing
pilot and guide stud onto the rotor shaft (5), seat-
ing tightly against the drive–end inner bearing
cap (12) and gasket (Fig. 19). Hold the frame
head and bearing in place until the frame head is
bolted to the inner bearing cap in Step 11.1.

11. Remove the bearing pilot. Apply the gasket over

the guide stud to the drive–end frame head (11).
After removing the guide stud, secure the
dummy drive–end bearing cap and frame head
to the inner bearing cap with eight bolts and flat
washers (8).

NOTE: Do NOT assemble the additional rotor

drive–end bearing assembly parts until the ro-
tor has been assembled into the frame, and FIG. 17. GREASE IN DRIVE–END BEARING
bearing clearance and runout checks have ROLLERS AND OUTER RACE. E–27159.
been completed.

18
 Horizontal Drill Motor, Model 5GEB22, GEK–91696C

1. Inspect the rotor connection–end bearing hous-

ing (35) to ensure that both inside bores are
clean and free of nicks and burrs.

2. Fill the cavity of the rotor connection–end bear-

GUIDE STUD FOR ing housing (35) with 2.2 oz. (62.4 g) of GE Spec-
ASSEMBLING
FRAME- ification D6A2C10 grease.
HEAD BOLTS IN IN
NER BEARING CAP
3. Fully pack the rotor connection–end roller bear-
ing (34) with 5 oz. (142 g) of GE Specification
D6A2C17 grease.
BEARING PILOT USED
TO GUIDE FRAMEHEAD
(WITH OUTER RACE AND 4. Evenly heat the rotor connection–end bearing
ROLLERS) OVER THE IN
NER RACE. housing (35) to 212F (100C) in an oven. Place
the heated bearing housing on a flat surface, ex-
posing the bearing cavity. Immediately slip the
FIG. 18. DRIVE–END BEARING PILOT AND rotor connection–end roller bearing (34) into the
GUIDE STUD INSTALLED. E–27165. bore of the bearing housing.
Connection–End Bearing 5. Smear the running surfaces of the connection–
end of the rotor shaft with 0.25 oz. (7 g) of GE
NOTE: Numbers in parenthesis () refer to part
Specification D6A2C10 grease.
numbers in Fig. 9 of this publication, unless
otherwise noted. 6. Heat the rotor connection–end bearing and bear-
ing housing assembly to 212F (100C) in an
27

28

BEARING PILOT
FILL BEARING COMPLETELY
WITH 5.0oz (142g)
OF GREASE (D6A2C10)
USE 2.8oz (79.4g)
GREASE (D6A2C10)
USE 2.2 oz (62.4g) IN THIS CAVITY
GREASE (D6A2C10)
IN THIS CAVITY 39

31
GUIDE STUD

36 6
35

32

SMEAR .25oz (7g) 33

GREASE (D6A2C10) 34 40
ON THESE SURFACES.

FIG. 19. DRIVE–END FRAME HEAD AND FIG. 20. CONNECTION–END BEARING DETAILS.
BEARING ASSEMBLY. E–27166. E–45103.

19
GEK–91696C, Horizontal Drill Motor, Model 5GEB22
oven. Remove the heated assembly from the
oven, and immediately slide the assembly onto
the rotor shaft, seated tightly against the rotor
shaft shoulder, and secure the assembly in posi-
tion until cooled.
7. Thread the rotor bearing nut (33) into the end of
the rotor shaft, and hand–tighten as much as
possible. Attach the spanner wrench (GE Tool
9945228) to the rotor bearing nut. Using a brass
sledge hammer, strike two or three sharp blows
to drive the rotor bearing nut clockwise. Tighten
the nut until no further movement occurs; this
should be about one–quarter turn beyond the
hand–tightened position. Remove the spanner
wrench.
8. Install the two set screws (40) in the rotor bearing
nut, and tighten to the torque given in TORQUE
VALUES section of this publication. Using a
heavy center–punch, stake each set screw in
two places to ensure against loosening.
9. Apply the gasket, and assemble the dummy con-
nection–end bearing cap with the six bolts (31)
and flat washers.
NOTE: The rotor connection–end bearing as-
sembly is completed as part of the rotor instal-
lation.
ROTOR INSTALLATION INTO FRAME
NOTE: The connection–end bearing and hous-
ing and the drive–end frame head, bearing and
housing are installed with the rotor as an as-
sembly.
NOTE: Numbers in parenthesis () refer to part
numbers in Fig. 8 of this publication, unless
otherwise noted.
1. Inspect to ensure that all mating surfaces are
clean and free of nicks and burrs.
2. Place the motor frame (21) on a heavy–duty
stand with the drive–end up. Level the motor
frame so that the rotor can be lowered vertically
into the frame with a hoist without damaging the
bearings or bus rings.
20
3. Screw two long guide studs into the connection–
end bearing housing (35) in opposite holes.
These studs will help to guide the rotor into the
motor frame.
4. Screw a 1 in.–8 steel lifting eyebolt (GE Tool
N672P39) into the threaded hole in the drive–
end of the rotor shaft (5).
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.
5. Carefully lift the rotor assembly from the horizon-
tal position, attaching a hoist hook to the lifting
eye. Align the hoist cable with the centerline of
the motor frame (21), and slowly lower the rotor
into the motor frame, guiding the long studs
through the appropriate connection–end frame
head (27) holes.
6. Install and hand–tighten the eight bolts and flat
washers (10) holding the drive–end frame head
(11) to the motor frame (21). Then tighten the
bolts evenly in a diametrically opposite se-
quence to the torque given in TORQUE VAL-
UES section of this publication.
7. Remove the motor from the stand, placing the
motor in its normal horizontal position
8. Force the rotor as far toward the connection end
as possible. Remove the two long guide studs
from the connection–end bearing housing (35).
Install the six bolts and flat washers (31) securing
the connection–end bearing housing (35) to the
connection–end frame head (27), and tighten the
bolts to the torque given in TORQUE VALUES
section of this publication.
ROTOR BEARING ASSEMBLIES CHECKS
Connection–End Bearing Runout
1. Raise the connection end of the motor 4 to 6 in.
(102 to 152 mm), and force the rotor toward the
drive–end.
2. Clamp a dial indicator to the face of the rotor
shaft at the connection–end.
 Horizontal Drill Motor, Model 5GEB22, GEK–91696C
3. Zero the indicator ball on the face of the connec-
tion–end rotor bearing outer race. Then rotate
the rotor to determine the bearing runout. If the
bearing runout exceeds the runout given in
DATA section of this publication, retighten the
connection–end bearing housing and frame
head bolts; and repeat the runout check. If nec-
essary, disassemble the bearing assembly and
check for burrs or dirt. Replace the connection–
end bearing housing if the runout is still exces-
sive.
Drive–End Bearing Runout
1. Raise the drive–end of the motor 4 to 6 in. (102 to
152 mm), and force the rotor toward the connec-
tion end.
2. Clamp a dial indicator to the face of the rotor
shaft at the drive–end.
3. Zero the indicator ball on the face of the drive–
end rotor bearing outer race. Then rotate the ro-
tor to determine the bearing runout. If the bear-
ing runout exceeds the runout given in DATA
section of this publication, retighten the drive–
end bearing housing and frame head bolts; and
repeat the runout check. If necessary, disas-
semble the bearing assembly and check for
burrs or dirt. Replace the drive–end bearing
housing if the runout is still excessive.
Drive–End Bearing Radial Clearance
1. With drive–end of the motor raised 4 to 6 in. (102
to 152 mm), force the rotor toward the connec-
tion end.
2. Select a feeler gage thickness equal to the mini-
mum radial clearance given in DATA section of
this publication for the drive–end rotor bearing.
3. Place the feeler gage flat against the rolling sur-
face of the inner race of the drive–end rotor bear-
ing, just in front of the uppermost bearing roller.
Hand–turn the rotor shaft just enough to roll the
top bearing roller over the minimum radial clear-
ance feeler gage.
4. Repeat the minimum clearance check for each
bearing roller in the drive–end rotor bearing. Re-
ject the bearing 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 maxi-
mum radial clearance given in DATA section of
this publication for the drive–end rotor bearing.
Place the feeler gage flat against the rolling sur-
face of the inner race of the drive–end rotor bear-
ing. 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.
ROTOR SHAFT END–PLAY CHECK
1. With the motor horizontal, force the rotor to seat
at the drive–end.
2. Clamp a dial indicator to the motor frame at the
connection end or the dummy connection–end
bearing cap. Zero the indicator ball on the face of
the rotor bearing nut.
3. Force the rotor back to seat at the connection
end. The amount of rotor shaft end–play indi-
cated must not exceed the end–play given in
DATA section of this publication.
FINAL ASSEMBLY OF
ROTOR DRIVE–END
If the rotor bearings pass the bearing runout and radial
clearance checks, install the remaining drive–end as-
sembly parts as follows:
NOTE: Numbers in parenthesis () refer to part
numbers in Fig. 10 of this publication.
1. Remove the dummy drive–end bearing cap.
2. Pack the drive–end outer bearing cap (7) with 8.0
oz. (227 g) of GE Specification D6A2C10
grease. Assemble the bearing cap insert to the
pinion–end frame head (11) and inner bearing
cap (12) with eight bolts and flat washers (8), and
tighten the bolts to the torque given in TORQUE
VALUES section of this publication.
21
GEK–91696C, Horizontal Drill Motor, Model 5GEB22
3. Heat the outer sleeve (4) to 110 C (230 F) and
shrink it onto the shaft until it is tight against the
inner race of the bearing.
FINAL ASSEMBLY OF
ROTOR CONNECTION–END
NOTE: Numbers in parenthesis () refer to part
numbers in Fig. 8 of this publication.
1. Remove the dummy connection–end bearing
cap.
2. Apply 2.8 oz. (79.4 g) of GE Specification
D6A2C10 grease to the connection–end bearing
cap (32). Assemble the connection–end bearing
cap using six bolts and flat washers (31), and
tighten the bolts to the torque given in TORQUE
VALUES section of this publication.
CABLE LEADS AND CONNECTIONS
INSPECTION
Inspect and clean the motor cable leads and connec-
tions as follows:
1. The cable insulation near the terminal should be
free of splits, brittleness and charring. These
conditions indicate excessive heat in the area of
the terminal, which may be caused by a poor
crimp or loose or excessively tight assembly
bolts.
2. The tongue or tang of the terminal should be
checked for deformed assembly bolt holes or in-
dentations at or around the holes caused by
over–tightening of the bolts. Do NOT attempt to
smooth the surface with a file, as this will remove
the necessary plating on the tongue.
3. See that the mating surface of the terminal is flat,
and has no contaminants (dirt, grease or other
materials) that could interfere with the electrical
contact between the terminal and the surface to
which it is bolted.
4. Measure the external cable length between the
tip of the connector and the end of the clamp. All
cable leads must be within 0.5 in. (13 mm) in
length of each other.
22
5. Cable insulation should not be damaged, frayed
or worn. Carefully check areas where cables are
clamped or subjected to abrasion.
Inspect the ground cable connection on the cable cleat
on the motor frame to assure that the connection is
clean.
CABLE TERMINAL REPLACEMENT
Terminal crimping requires a hydraulic pump with
hose. The proper power cable crimping head and
crimping die also are required, depending on the termi-
nal type and cable size. Proceed as follows:
1. Remove the old terminal by cutting the cable as
close to the barrel of the terminal as possible.
NOTE: The knife or stripping tool must not nick
or score the outer strands of the cable. Nicked
or scored wires will break with vibration or flex-
ing of the cable.
2. Carefully remove the insulation from a length of
the copper cable equal to the depth of the new
terminal barrel.
3. Coat the inside of the new copper terminal barrel
with a thin protective coating of an oxidation inhi-
bitor such as T&B M–53 (GE Part
41A204944P1) to reduce oxidation and corro-
sion.
4. Carefully insert the bare cable into the new termi-
nal until the cable bottoms. Avoid unravelling the
outside strands of the bare cable. If the cable
strands unravel, retwist the strands as close to
their original shape as possible.
CAUTION: Tube terminal crimping dies must be
used ONLY with tube terminals; cast terminal
crimping dies must be used ONLY with cast
terminals. Intermixing types of crimping dies and
terminals will cause terminal and cable failures.
5. Crimp the terminal barrel with the proper die (Ta-
ble 1). Ensure the die code indicated on the bar-
rel of cast terminals is the code for the die that is
used.
NOTE: Tube terminals and cast terminals may
be bolted to like terminal types or to each other
without restriction.
 Horizontal Drill Motor, Model 5GEB22, GEK–91696C

TABLE 1. COPPER CABLE CRIMPING DIE AND HEAD CATALOG NUMBERS.

Tube Terminal Cast Terminal
Cable Size AMP Die AMP Head Die Code GE Die GE Head
225/24 54 2X5079 2X4945
375/24 46767-2 69099 60 2X5080 2X4945
450/24 46749-2 69099 60 2X5080 2X4945
550/24 46750-2 69099 76 2X4946 2X4945
650/24 76 2X4946 2X4945
775/24 46752-2 69099 76 2X4946 2X4945
925/24 46753-2 69099 87 2X4947 2X4945
69653 69082
1100/24 46754-2 69082 107 2X4950 2X4945
59872-1 68073-2
1325/24 46755-2 69082 107 2X4950 2X4945
59873-1 68073-2
1600/24 46756-2 69082 112 2X4952 2X4945
59869-1* 68073-2 112 1X8087 2X4133
1925/24 112 2X4952 2X4945
112 1X8087 2X4133
2000/24 125 2X4143 2X4133
2300/24 130 2X4144 2X4133
2750/24 150 2X4146 2X4133

* Double crimp die.

6. Inspect the crimp of the terminal barrel to the ca-
ble for a proper fit.
NOTE: Copper terminals may be soldered to
copper cables if the proper flux and solder is
available.
7. Apply two layers of GE All–Weather tape (GE
Part 41A216477P4) for 2 in. from the joint on
both the cable and terminal.
8. Slip shrinkable plastic tubing over the end of the
cable and the terminal barrel. Apply heat to
shrink the plastic tubing in place (Fig. 21).
COVERS
Assemble the covers to the motor frame, and check
for proper cover fit.
ELECTRICAL RUNNING TEST
WARNING: Electrical shock can cause serious or
fatal injury. Proper precautions should be taken
and observed by personnel performing testing to
avoid such injury.
After the motor has been reconditioned and reas-
sembled, make the following tests to ensure that the
motor will operate satisfactorily.
1. Use Duxseal putty to hold thermometers on
the drive–end and connection–end outer bearing
caps. Thermometers should contact the bearing
caps for best results.
2. No load tests (sinusoidal): Run the motor no load
for 2 minutes at 50 Hz and 1083.8 volts rms line–
to–line. The average of the three line currents
should be 245–275 amperes, and the motor
speed should be approximately 1000 rpm. Then
run the motor no load for 30 minutes at 50 Hz, not
 Duxseal is a trademark of Johns-Manville
Company.

23
GEK–91696C, Horizontal Drill Motor, Model 5GEB22
exceeding 812.8 volt rms line–to–line. The aver-
age of the three line currents should be 153–169
amperes, and the motor speed should be
approximately 1000 rpm. Bearing temperature
rise should not exceed 90F (50C) above the
room or enclosure temperature.
3. Overspeed test: Run the motor for 2 minutes at
approximately 225.3 Hz, not exceeding 812.8
volt rms line–to–line. Motor speed should be
4500–4510 rpm. Observe any unusual noise or
vibration.
4. Vibration test: With the motor running at 100 Hz
and 2000 rpm, measure the vibration at the
drive–end and connection–end bearings. Vibra-
tion should not exceed 0.004 in. (0,10 mm)
peak–to–peak. If vibration exceeds this amount,
re–balance the armature.
5. Bearing noise: Check the drive–end and con-
nection–end bearings for unusual noise. At 1084
volts line–to–line and 2000 rpm, the maximum
noise reading with the shock pulse meter set for
each bearing is 25dBn.
WARNING: High–potential (hi–pot) testing can
cause serious injury or death. Strict safety
regulations must be observed during such
testing.
6. Dielectric test: Apply a high–potential (hi–pot)
test to ground with all terminals connected to-
gether at the voltage given in DATA section of
this publication. See STATIC ELECTRICAL
TESTS section of this publication.
FIG. 21. COMPLETED POWER CABLE
TERMINAL. E–16355.
24
HUB MOUNTING
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 ta-
pered 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 re-
spect to the shaft.
4. Remove the hub from the shaft. A convenient
method of removal is by the use of two finely ta-
pered 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 satis-
factory. 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 light-
ly with a fine emery cloth such as No. 400A Trie-
mite.
7. Blue the hub bore again (see 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.
Generally, the fit will be improved, but the forego-
ing procedure may have to be repeated several
times to obtain a 75 percent fit.
Under no circumstances use a lapping com-
pound since lapping will produce a shoulder at
the large end of 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 posi-
tion.
8. 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.
 Horizontal Drill Motor, Model 5GEB22, GEK–91696C

HUB MOUNTING shaft temperature and hub temperature (temper-

ature rise) which will provide this advance is also
1. Thoroughly clean the hub fit on the shaft and given. The temperature difference is only an esti-
bore of the hub (see the procedure in the Clean- mate and should be adjusted (if necessary) to
ing section). Remove any scoring on the shaft or provide the advance within prescribed limits.
hub bore.
CAUTION: The temperature of the hub must
2. Spot the cold hub on the shaft by hand and check
not exceed 250 C (482 F); otherwise, the hub
for at least 75 percent fit. See the “Hub Fitting”
may become annealed.
section. If necessary, dress the shaft to obtain
this fit.
Degrees Rise
3. Trial mount the cold hub onto the shaft. Measure Part No. Advance Above Shaft
and record the position of the hub with respect to of Hub (in.) Temp.
the end of the shaft. Take measurements with a
micrometer advance gauge similar to that shown 493A471 0.120-0.130 215 C (419 F)
in Fig. 22. Zero the gauge. 41A237799 0.120-0.130 215 C (419 F)
Mark points of measurement, and mark across
the end of shaft and hub face so that the hub, Heat the hub in an oven until it has reached a uni-
when heated, can be mounted in exactly the form temperature (the desired number of de-
same angular position, and so the advance mea- grees above shaft temperature). For example, if
surement can be made from the same point. shaft temperature is 25 C (77 F), heat hub to
25 C (77 F) +215 C (419 F) = 240 C
(464 F).
CAUTION: Zero settings of advance gauge
must not be disturbed until all readings on the An accurate method must be provided for mea-
hub are completed. suring hub and shaft temperatures quickly be-
fore mounting the hub. This can best be done
with a hand pyrometer. In using the pyrometer,
4. Mount the hub hot onto the shaft so as to secure place points of the gauge inside the bore of the
an advance from the cold position to the hot posi- hub, Fig. 23.
tion along the axis of the shaft as indicated in this
section. The ESTIMATED difference between NOTE: The part must be left in the oven long
enough for the heat to penetrate throughout the
part.

Measure the temperature of the shaft and the

hub with the same instrument.

PLACE PYROMETER
POINTS IN BORE
OF HUB

FIG. 23. MEASURING TEMPERATURE OF

FIG. 22. METHOD OF USING ADVANCE COUPLING HUB WITH PYROMETER. E-5976.
GAUGE. E-5975A.

25
 GEK–91696C, Horizontal Drill Motor, Model 5GEB22

5. Insure that the hub bore and the shaft taper are
clean. Then, using adequate hand protection,
quickly mount the hot hub on the shaft in the
same angular position as when cold. When the
hub is nearly in engagement with the taper fit (not
in actual contact), snap it forcibly into place with a
quick push. It is important that the hot hub be in-
stantly snapped into position before it has
cooled; otherwise, it will freeze to the shaft and
cannot be adjusted further.
6. Check the hot or shrunk–on position of the hub
on the shaft. The advance from cold to hot posi-
tion along the axis of the shaft must be held with-
in the limits indicated. Check the actual advance
with an indicator gauge, located in the same rela-
tive position as used to measure the cold position
in Step 3, Fig. 22.
If the advance is not within specified limits, re-
move the hub and repeat the assembly proce-
dure.

TORQUE VALUES
Bolt torque values: lb.–ft. N–m
Cover, top (connection end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–24 30–33
Frame head, connection–end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448–496 607–672
Frame head, drive–end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448–496 607–672
Motor cover, lead entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56–60 76–81
Rotor bearing cap, connection–end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111–123 149–163
Rotor bearing cap insert, drive–end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111–123 149–163
Rotor bearing housing, connection–end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111–123 149–163
Rotor bearing nut, connection–end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500–520 678–705
Rotor bearing nut set screws, connection–end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38–42 52–57
SPECIAL TOOLS AND EQUIPMENT
Rotor shaft lifting eyebolt (1 in.–8 steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N672P39
Rotor dummy drive–end bearing cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6796493P3
Rotor drive–end bearing pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8849499P7
Rotor bearing nut spanner wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9945228
Rotor dummy connection–end bearing cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41C689896
Bearing assembly pullers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41D736059G1
Resistance brazing machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41D780746–1
Resistance brazing tongs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41D780746–11
Digital pyrometer kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2X3430
Megohmmeter (Megger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111X910 (or equivalent)
Long guide studs (2 required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A
Hub assembly gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41D790941G1
Hub puller (less pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41B535703G1
Pump (for hub puller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8843947G1

GE Transportation
Systems

NEW 06–98, GAS 2901 East Lake Road

Erie, Pennsylvania 16531 PRINTED
REV 09–98, MGC/DGK IN
U.S.A.
REV 12–01, GMD E
REV 10–02, GMD

26
 PB-31107-004

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

UNCONTROLLLED COPY See On-Line Master for Current Revision

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

MOTOR MODEL 5GEB22A2

15-OCT-2003

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

--------------------------------------------------------------------------------------------------------------------------------
(c) copyright 2002 General Electric Company. All rights reserved.This copyrighted document may be
reproduced free of charge by GeneralElectric Company customers ,if such reproductions are used
exclusively in connection with the operation and repair of GETS equipment used in that customer's
internal operation.
--------------------------------------------------------------------------------------------------------------------------------
 2 34
4 5 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




 47

47

47

44
45 46

(Representative Illustration)
FIG. 2

-2-
UNCONTROLLLED COPY PB-31107-004
MOTOR MODEL 5GEB22A2
See On-Line Master for Current Revision

--------------------------------------------------------------------------------------------------------------------------------
FIG. REF.
NO. NO. PART NO. QTY DESCRIPTION
--------------------------------------------------------------------------------------------------------------------------------
1 1 5GEB22A2 1 MOTOR, AC (SEE PB-31107-004)
1 2 41E903972G1 1 STATOR ASSEMBLY
1 3 41E903972G2 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 497A806P87 AR SEALANT
1 22 84D706971P1 1 FRAME HEAD
1 23 4732368P1 2 GASKET, 0.021 IN THK
1 24 334B761P1 1 BEARING CAP
1 25 8864951P119 1 ROLLER BEARING
1 26 84B515283P1 1 BEARING CLAMP
1 27 41B537660P6 4 WASHER, FLAT, 0.562 IN ID, 0.938 IN OD
1 28 N22P29020B13 4 BOLT, HEX HD, 1/2 IN-13, 1 1/4 IN LONG
1 29 84B515189P1 1 BEARING CAP
1 30 41B537660P9 8 WASHER, FLAT, 0.725 IN ID, 1 IN OD
1 31 N22P33048B13 8 BOLT, HEX HD, 5/8 IN-11, 3 IN LONG
1 32 N5700P21 2 PIPE PLUG, SQ HD, SOLID, 1/8 IN
1 33 497A806P87 AR SEALANT
1 34 84C620926G4 1 ROTOR ASSEMBLY
1 35 84D730122P2 1 SHAFT
1 36 8864959P130 1 LOCKWASHER
1 37 8864959P30 1 NUT
1 38 2766829ADP14 AR BALANCE WEIGHT, 5/8 IN WIDE
1 39 84A204808P1 1 SET SCREW, HEX SOC HD, 3/8 IN-24, SELF-LOCK
1 40 41A232821P1 1 SLEEVE
1 41 84B512988P1 1 COLLAR
1 42 N22P39032 12 BOLT, HEX HD, 1 IN-8, 2 IN LONG
1 43 41B537660P21 12 WASHER, FLAT, 1.063 IN ID, 2 IN OD
2 44 41A235078P57 2 STUD, 3/8 IN-16, 1 3/4 IN LONG
2 45 497A806P78 AR THREADLOCKER 271, HIGH STRENGTH
2 46 N5700P31 2 PIPE PLUG, SQ HD, 1/4 IN
2 47 N5700P51 2 PIPE PLUG, SQ HD, 1/2 IN
0 48 493A471P1 1 HUB, 9.120 IN OD, POWER TAKE-OFF

--------------------------------------------------------------------------------------------------------------------------------------------
15-OCT-2003
08/21/01 RENEWAL PARTS LIST PAGE 1

RPL 4303
COVER ASSEMBLY
UPPER UNUSED CONN BOX PORT
SPEC 4303

HUNT PART
ITEM QTY COMPONENT NUMBER

1.00 1 COVER PLATE 4303.01B

2.00 1 GASKET 4218.06B

3.00 1 NAMEPLATE - WARNING 41A 237902 P001

4.00 4 PIN N 532 P1106

5.00 12 BOLT L 661

6.00 12 LOCKWASHER L 532

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

RPL 4302
COVER ASSEMBLY
LOWER UNUSED HEATER PORT
SPEC 4302

HUNT PART
ITEM QTY COMPONENT NUMBER

1.00 1 COVER PLATE 4248.01B

2.00 1 GASKET 4239.01B

3.00 1 NAMEPLATE - WARNING 41A 237902 P001

4.00 4 PIN N 532 P1106

5.00 6 BOLT L 661

6.00 6 LOCKWASHER L 532

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

FILE: RPL4722G1/4 JUNCTION BOX ASSEMBLY

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

HUNT PART
ITEM QTY COMPONENT NUMBER

1.00 1 JUNCTION BOX ASSEMBLY 4749B

2.00 1 LID 4722.05

3.00 1 PLATE ASSEMBLY 4723

4.00 1 BUS BAR SUPPORT ASSEMBLY 4722.13B

5.00 2 BUS BAR PHS A & C 4722.09B

6.00 1 GASKET, LID 4722.10B

7.00 1 PARTITION 4722.11

8.00 1 MCT ASSEMBLY 4757

9.00 4 INNER GLASTIC INSULATION BUS BAR 4218.12B

10.00 4 OUTER GLASTIC INSULATION BUS BAR 4218.13B

11.00 2 BACKSIDE GASKET 4218.06B

12.00 1 RUBBER GROMMET 3373A

14.00 2 GASKET, TOP & BOTTOM COVER 4218.05B

22.00 1 JUMPER-BUSS BAR 4722.14B

23.00 1 JUMPER-BUSS BAR 4722.15B

24.00 1 JUMPER-BUSS BAR 4722.16B

25.00 2 GROUND STUD ASSEMBLY 4245A

28.00 1 DIN RAIL TERMINAL BOARD ASSEMBLY 4308B

29.00 17.5 RACEWAY-HORIZONTAL 4218.17B

30.00 1 COPPER BUS BAR 4218.19B

33.00 2 COVER, JUNCTION BOX TOP OR BOTTOM 4218.04B

34.00 2 STRAP INSULATOR 4722.17B

 Certificate of Conformance

We hereby certify that all items listed below were produced in conformance with
manufacturer’ss pe ci
fic ationsa n d/orot herappli
ca bledocume nts.

Rawson Order: 274058

Customer: Hunt Engine

Purchase order: 017243

Part Number Qty Mfg. Name Lot Number

J120-524-M201 9 United Electric N/A

Signature: Jay Schwausch Date: 10/26/05

Title: Inside Sales

Rawson, L. P.
2010 McAllister (77092) P.O. Box 924288 Houston, Texas 77292 -4288 Tel. (713) 684-1400 Fax (713) 684-1409
05/05/2004 RENEWAL PARTS LIST PAGE 1

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

HUNT PART
ITEM QTY COMPONENT NUMBER

1.00 1 SPACE HEATER 3781AP07

2.00 1 COVER ASSEMBLY 4248B

2.01 1 COVER PLATE 4248.01B

2.02 2 BRACKET 4248.02B

3.00 1 CONNECTION BOX 3775A

4.00 1 CABLE GLAND 4320AP02

5.00 LINE ITEM NOT USED

6.00 LINE ITEM NOT USED

7.00 2 BOLT L600

8.00 2 LOCKWASHER LA528

9.00 1 GASKET - COVER 4239.01B

10.00 1 NAMEPLATE - WARNING 41A237902P1

11.00 4 SCREW L3615-1206

12.00 1 GASKET - CONN BOX TO COVER PLATE 4239.02B

F:\WKSHEETS\EVERYONE\RPL\RPLFORM.WK4
 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
12/05/2006 RENEWAL PARTS LIST PAGE 1

RPL 4787G6 HUNT AIRDYNE BLOWER MOTOR ASM

MODEL 22A1 - 15CW - 30400/690
SPEC 4787G6
SEE ILLUSTRATION DWG 4787RPL

HUNT PART
ITEM QTY COMPONENT NUMBER

1.00 1 ELECTRIC MOTOR ASM 5056A

2.00 1 MOTOR BASE ASM 4591

3.00 1 WHEEL ASM - BLOWER 3832

4.00 1 HOUSING ASM - BLOWER 4590

5.00 1 AIR INTAKE LOUVER ASSEMBLY 4592R1

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 3989.04B

8.00 1 GSKT.- HOUSING - DRIVE SIDE 4591.04B

9.00 1 GSKT.- HOUSING - DISCHARGE 4590.04B

10.00 1 NAMEPLATE - ROTATION 2968

11.00 1 NAMEPLATE - MODEL, S/N, ETC. 2709

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

F:\WKSHEETS\EVERYONE\RPL\RPLFORM.WK4
12/05/2006 RENEWAL PARTS LIST PAGE 2

RPL 4787G6 HUNT AIRDYNE BLOWER MOTOR ASM

MODEL 22A1 - 15CW - 30400/690
SPEC 4787G6
SEE ILLUSTRATION DWG 4787RPL

HUNT PART
ITEM QTY COMPONENT NUMBER

F:\WKSHEETS\EVERYONE\RPL\RPLFORM.WK4
 Operating Instructions

N – R 445 en 09.03
Explosion-proof three-phase motors
with squirrel cage for low voltage,
with antifriction bearings,

Protection type “Flameproof Enclosure”

(to Directive 94/9/EC)
Types
DBG.-080..–.. to DBG.315..–..
DBH.-080..–.. to DBH.315..–..
DBL.-080..–.. to DBL.315..–..
DNG. 071..–.. to DNG. 15..–..
DNH.-071..–.. to DNH.315..–..
DNL.-100..–.. to DNL.315..–..
DNS.-090..–.. to DNS.560..–..
DNR.-630..–.. to DNR.800..–..
DNP.-090..–.. to DNP.560..–..
DNU.-100..–.. to DNU.560..–..
DNW.-132..–.. to DNW.560..–..
DVG.-071..–.. to DVG.315..–..
DWG.-132..–.. to DWG.315..–..
DWL.-132..–.. to DWL.315..–..
DWS.-132..–.. to DWS.560..–..
DWW.-132..–.. to DWW.560..–..

LOHER GmbH
P.O.Box 1164 S 94095 RUHSTORF
Hans–Loher–Str. 32 S 94099 RUHSTORF
GERMANY
Phone +49 8531 39-0 S Fax +49 8531 32895
E-mail: info@loher.de
http://www.loher.de
Table of contents

Page

1 Safety and commissioning instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 Instructions to protection type “Flameproof Enclosure” . . . . . . . . . . . . . . . . . . . 5

3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5 Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7 Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

8 Spare parts and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

9 Storage instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

10 Faults and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

11 EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Appendix 1; Grease life and grease quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Appendix 2; Alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Subject to modifications
Loher GmbH 2003
All rights reserved

Page 1 of 33 N–R 445 en 09.03

Safety and commissioning instructions

1 Safety and commissioning instructions

1.1 Warning symbols in these instructions
The symbols are used in these operating instructions to point out to particular dangers.

This symbol refers to a dangerous situation which can cause fatal or serious injuries or
considerable damage to property.
Danger

This symbol refers to a possibly dangerous situation which can cause injuries and damage to
property if it is not avoided.

1.2 General
Low voltage motors have dangerous, live and rotating parts, and probably hot surfaces. All
work for transport, connection, commissioning and maintenance is to be made by qualified,
responsible specialists
(EN 50110-1/VDE 0105 Part 1, IEC 60364 must be observed). An inadequate behaviour can
cause severe damages to persons and property.

1.3 Specified use

These low voltage motors are meant for use in industrial plants. They are in accordance with
the standards of the series EN 60034 (VDE 0530). For their use in hazardous areas the
additional instructions for protection type “d” have to be observed (pages 5 to 10).
The motors are suitable for ambient temperatures from –205C (–45F) to +405C (+1045F) as
well as altitudes v 1000 m above sea level. It is imperative to observe differing data on the
rating plate. The conditions at the site of application must comply with all indicated data on the
rating plate.

Low voltage motors are components to be installed into machines in accordance with
Directive 89/392/EEC.
Commissioning is not allowed as long as the conformity of the end product with this
directive is not established (EN 60204-1 has also to be observed).

1.4 Transport, storage

The carrier is immediately to be informed on damages found upon delivery; commissioning
must not be admitted, if required. Screwed-in eye bolts are to be tightened. They are suitable
for the weight of the low voltage motor, no additional loads are allowed to be attached.
If required, sufficiently dimensioned means of transport (e.g. rope guides) are to be used.
Prior to commissioning the transport locking devices are to be removed. Reuse for further
transports. For storage of low voltage motors, take care of a dry, dustfree and low-vibration
(veff v 0.2 mm/s) ambience (bearing damages with motor at standstill).
Before commissioning the insulation resistance is to be measured. In case of values v 1kΩ
per Volt of the rated voltage the winding must be dried. Observe the “Storage instructions”.

N–R 445 en 09.03 Page 2 of 33

Safety and commissioning instructions

1.5 Installation
Take care of an even ground, suitable fastening of feet or flange and an exact alignment for
direct coupling. Avoid that structure-dependent natural frequencies occur within the rotary
frequency and the double mains frequency. Turn rotor by hand, listen to abnormal frictioning
noises. Check direction of rotation before coupling (Observe section “Electrical connection”).
Pulleys and couplings are only allowed to be installed or removed with suitable devices
(Heating!) and to be covered with protection against accidental contact. Avoid inadmissible
belt tensions (Tech. List). The balance of the low voltage motor is indicated on the shaft end
face or on the rating plate (H = half key, F = full key). In case of a half key (H), the coupling
must also be balanced with a half key. In case of any protruding and visible part of the key
take care of the mass balancing.
If required, make the necessary pipe connections. Mounting types with the shaft end facing
upwards are to be provided with a cover by the customer, avoiding that foreign bodies fall into
the fan.

Ventilation must not be hindered and the

outgoing air – also from adjacent units – must
not be directly sucked in again.

1.6 Electrical connection

All work is only allowed to be done by qualified personnel with the low voltage motor and
driven machine at standstill, electrically dead and locked against restart.
This is also applicable to auxiliary circuits (e.g. space heater).
Check de-energizing!
A non-observance of the tolerances indicated in EN 60034-1/VDE 0530, part 1 – voltage "5%,
frequency "2%, curvature, symmetry – will result in an excessive heating and is influencing
the electromagnetic compatibility. Observe data on the rating plate as well as wiring diagram in
the terminal box.
Observe connection and differing data on the rating plate as well as the wiring data in the
terminal box.
Connection is to be made in such a way that a durably safe, electrical connection is
maintained (no uncovered wire ends); especially provided cable end equipment is to be used.
A safe earthing is to be made.
The minimum air gaps between uninsulated and live parts themselves and to earth must not be
lower than the following values: 8 mm at UN v 550 V, 10 mm at UN v 750 V, 14 mm at UN v
1100 V.
The terminal box must be free of foreign bodies, dirt as well as humidity. Unused cable entries
and the box itself are to be sealed against dust and water. Mains supply lines must be sealed
in the cable entries according to specifications. For trial operation without driving elements the
key is to be secured. For motors with brake it is to be checked before putting into operation, if
the brake is perfectly functioning.

Page 3 of 33 N–R 445 en 09.03

Safety and commissioning instructions

1.7 Operation
Vibration severities veff v 3.5 mm/s (PN v 15 kW) and 4.5 mm/s (PN > 15 kW) are not critical
in coupled operation. In case of changes compared with normal operation – e.g. higher
temperatures, noises, vibrations – the cause is to be found, if required, consult the
manufacturer. Even for trial operation the safety devices are not allowed to be put out of
function. In case of doubt switch off the low voltage motor.
In case of heavy dirt accumulation, the air ducts must be cleaned at regular intervals.
Bearings with regreasing devices are to be regreased with low voltage motor running.
Risk of accidents!
Pay attention to rotating parts. Observe saponification class! If grease drainholes are sealed
with a plug, remove these plugs before putting into operation. Boreholes have to be sealed
with grease. Replacement of bearings in case of permanent lubrication see Appendix 1 or
motor documentation.

1.8 Warranty
The Warranty is only applicable if all of these instructions for safety and putting into operation
as well as the following paragraphs of the operating instructions and the directions for possible
additional units are strictly observed.

N–R 445 en 09.03 Page 4 of 33

Instructions to electrical machines in
protection type “Flameproof Enclosure”

2 Protection type “Flameproof Enclosure”

Marking of the motors with EC–type–examination certificate to Directive 94/9/EC:
CE 0102 II 2 G EEx de IIC T4 resp. T or CE 0102 II 2 G EEx d IIC T4 resp. T
CE 0102 II 2 G EEx de IIB T4 resp. T or CE 0102 II 2 G EEx d IIB T4 resp. T
CE 0102 II 2 G EEx de ib IIC T4 resp. T or CE 0102 II 2 G EEx d ib IIC T4 resp. T
CE 0102 II 2 G EEx de ib IIB T4 resp. T or CE 0102 II 2 G EEx d ib IIB T4 resp. T

For explosion-proof motors in protection type “Flameproof Enclosure” acc. to EN 50014,

EN 50018, EN 50019 and EN 50020 the following items have to be observed:

2.1 General
The increased risk in hazardous areas requires a strict observance of the safety and
commissioning instructions.

2.2 Specified use

Explosion-proof electrical machines are in accordance with the standards of the series
EN 60034 as well as EN 50014 – 50020. In hazardous areas they are only allowed to be used
in accordance with the specifications of the competent supervising authority, which decides on
the explosion hazard and zone classification.
Additionally to the parameters as for instance power, voltage, current etc., the type of
protection, temperature class as well as special conditions are indicated on the rating plate and
in the EC–type–examination certificate respectively.
– Device group II (hazardous areas by gas), Category 2 (= Zone 1)

If the certificate number is supplemented by an X, the special conditions to be complied

with in the EC–type–examination certificate have to be observed.

This category includes electrical machines, e.g. also in protection type “Flameproof Enclosure”,
to be used in areas hazarded by an explosive atmosphere. Inverter operation has to be
certified. It is imperative to observe the separate manufacturer specifications.
It is possible that the size of the voltage peaks produced by the inverter are adversely affected
by the connection cable installed between inverter and electrical machine. In the system
inverter-cable-electrical machine the maximum value of the voltage peaks on the terminals of
the machine is not allowed to exceed the value mentioned in the separate manufacturer
specifications (ref. is also made to page 20 inverter operation).

Air-cooled and water–cooled types are suitable for ambient temperatures from –20°C (–4°F) to
+40°C (+104°F) as well as altitudes v 1000 m above sea level. It is imperative to observe
differing data on the rating plate. The conditions at the site of application must comply with all
indicated data on the rating plate.

Page 5 of 33 N–R 445 en 09.03

Instructions to electrical machines in
protection type “Flameproof Enclosure”

2.3 Installation and electrical connection

The installation and operation of electrical equipment in hazardous areas require the
observance of the applicable national and international rules, e.g. regulation for operational
safety (Betriebssicherheitsverordnung (Betr.SichV)):
“Decree for safety and health protection regarding the provision of work equipment and its use
at work, safety during operation of installations requiring supervision and the organization of
industrial safety”.

For belt drives only those belts may be used which are allowed for hazardous areas.

The general safety and commissioning instructions are applicable for the electrical connection.
Cable entries and the plugs (for openings which are not used) must be tested for hazardous
areas and approved by an EC–type–examination certificate according to Directive 94/9/EC.

For delivery the special threads will be sealed with non–certified plugs (transport protection
only). These plugs must in accordance with the corresponding protection type of the terminal
box be replaced by certified cable entries with EC–type–examination certificate according to
Direktive 94/9/EG.

When connecting the motors, the connections inside the terminal box are to be given special
care and attention. Furthermore a safe earthing connection has to be made (see Paragraph 1.6
and 2.8.5).
When the leads are inserted into the terminal box, care must be taken that the leads are
strain-relieved.
The inside of the terminal boxes must always be kept clean. The seals must be intact and fit
correctly.
In operation the terminal box must always be tightly closed.

For motors with cable entry (no terminal box at the motor) the cable (connecting lead) is to
be connected in a housing, which meets the requirements of an approved type of protection
according to EN 50014, if the motor is to be connected in an hazardous area.

2.4 Notes to “intrinsically safe circuits”

For the installation of intrinsically safe circuits the earthing is to be applied along the entire
“intrinsically safe circuit”.
Electrical data:
not intrinsically safe circuit Um = 700 V alternating voltage
intrinsically safe circuit in protection type “Intrinsic safety”
EEx ib IIB/IIC, only for connection to certified
intrinsically safe and isolated circuits.
Maximum values of the sum:
IIB% IIC%
e.g. for T4: Ui = 28 [V] Ui = 24 [V]
Ii = 300 [mA] Ii = 170 [mA]
Pi = 1.3 [W] Pi = 1.3 [W]
The effective internal inductivity and capacity are negligibly low.
Up to a peak value of the rated voltage of 1000 [V] the intrinsically safe circuits are isolated
from all circuits which are not intrinsically safe.
There is also an additional plate at the motor onto which the maximum values for “intrinsically
safe circuits” are stamped.

N–R 445 en 09.03 Page 6 of 33

Instructions to electrical machines in
protection type “Flameproof Enclosure”

2.5 Protective measures against overheating

The motors must only be used for the duty type stated on the rating plate.
Zone A in EN 60034-1 (VDE 0530, Part 1) – voltage "5%, frequency "2%, curvature, mains
symmetry – has to be observed, in order to keep the heating within the admissible limits.
Higher deviations from the rated values can cause an inadmissible heating of the electrical
machine and have to be stated on the rating plate. In particular, each motor must be protected
against overheating due to overload. The following notes must be observed:
According to EN 60079-14 all machines must be protected against overheating by a
current-dependent delayed circuit breaker with phase-failure protection in accordance with
EN 60947 or by an equivalent equipment in all phases. The protective device must be adjusted
to the rated current (Value must be indicated on the rating plate).
Furthermore, they must be selected in such a way that the motor is thermally protected even in
case of a blocked rotor.
Windings with delta-connection must be protected in such a way that the circuit breakers are
connected in series with the winding phases. For the selection and the adjustment of the circuit
breakers, the rated value of the phase current, i.e. 0.58 times the rated current of the motor
must be taken as basis. If such a connection is not possible, additional protective measures,
e.g. thermal motor protection, are required.
Thermal motor protection by means of a direct temperature monitoring of the winding is
admissible, when this is certified and indicated on the rating plate. It consists of temperature
sensors according to DIN 44081/44082. The PTC thermistors as sole protection ensure the
explosion protection together with functionally tested tripping devices with are provided with the
marking for the type of protection II (2) G.
If a continuity test of the temperature sensors should be required, it is not allowed to apply a
voltage exceeding 2,5 V!

For pole-changing motors, independent and interlocking protective devices are required for
each speed step. Recommended are devices which are tested and certified by a registered
testing authority.

2.6 Maintenance and repair

For maintenance, repair and modifications on explosion-proof machines the relevant national
rules, the regulation for operational safety (Betriebssicherheitsverordnung), the safety
instructions and descriptions of the general maintenance instructions have to be observed.
Any work directly influencing the explosion protection, like for instance
– repair work on stator or rotor winding and on the terminals,
– repair work on the ventilation system,
– disassembly of flameproof machines,
has to be made at the manufacturer or by an approved workshop for electrical machines.
This work has to be identified by an additional repair plate showing the following data:
– date
– company performing the work,
– kind of repair work
– identification symbol of the expert.

If the work is not done by the manufacturer, an approval by a licensed expert is required. He
must issue a written confirmation and the machine must be provided with his approval symbol
respectively.

Page 7 of 33 N–R 445 en 09.03

Measures to maintain the explosion
protection during operation

2.7 Spare parts

With the exception of standard, commercial and equivalent parts (e.g. screws) only original
spare parts are allowed to be used (see spare parts list); in particular this also applies to
gaskets.
Components like e.g. terminals, cable- and lead entries are only allowed to be replaced by
components with an EC–type–examination certificate.

2.8 Measures to maintain the explosion protection during operation

2.8.1 For explosion-proof motors in protection type “Flameproof Enclosure” according to
EN 50014 and EN 50018, the following points have to be observed:
2.8.2 The machined contact areas and fitting surfaces on the stator housing, end shields,
bearing caps, on the motor shaft, on the bushing plate of the terminal box and, if there are any,
the bushing plates of additional terminal boxes, must not be additionally machined or painted
afterwards. The surfaces are to be kept clean and protected against corrosion with a thin
grease layer. There must not be any sealings between those surfaces which are important for
the flameproofness.
2.8.3 All screws used to fix the end shields, the bearing caps, the bushing plates and the terminal
boxes must be available and securely tightened. Damaged screws are to be replaced
immediately by screws of the same type and perfect quality.
According to the ambient temperature only screws of the screw quality indicated in the
table are allowed to be used for motors without heating.
Screw quality for ambient temperature TA
–55 5C (–67 5F)  TA–40
Type/Frame size
– 40 5C (–40 5F)
5C (–40 5F)
Standard stainless screws Standard
071, 080, 090, 100, 112, 132, 160,
8.8 A4-70 A4-70
200, 225, 250, 280, 315
180 8.8 A4-80 A4-80
Screw quality for ambient temperature TA
–40 5C (–40 5F) 
Type/Frame size
– 20 5C (–4 5F)
TU –20 5C (–4 5F)
Standard stainless screws Standard stainless screws
355.K, 355.L, 355.M,355.N, 355.X 8.8 A4-70 8.8 A4-70
355.A, 355.B 8.8 A4-70 8.8 A4-80
400.K, 400.L, 400.M, 400.N, 400.X 8.8 A4-70 8.8 A4-70
400.A, 400.B, 400.C 8.8 A4-80 – –
450.K, 450.L, 450.M, 450.N, 450.X,
500.K, 500.L, 500.M, 500.N, 500.X, 8.8 A4-70 – –
560.K, 560.L, 560.M, 560.N, 560.X
710.A, 710.B, 710.C, 710.X 8.8 A4-70 – –
800.A, 800.B, 800.C, 800.D 8.8 A4-70 – –

Screw quality for ambient temperature TA
– 20 5C (–4 5F)

Type/Frame size
Standard stainless screws
DNGW-071.V to DNGW-132.V 8.8 A4–70
DNGW-071.W to DNGW-132.W 8.8 A4–70

2.8.4 If there are damages on the bushing plates, connection or entry parts, the damaged parts are
to be replaced immediately by original spare parts of perfect quality.

N–R 445 en 09.03 Page 8 of 33

Measures to maintain the explosion
protection during operation

2.8.5 When the motor is being connected, the connections inside the terminal boxes are to be given
special care and attention. The fittings for the mains supply which are screwed on the bushing
bolts for the stator winding connection are to be clamped in such a way that they are locked
against rotation on the bolts. The clamping screws of the connecting parts are to be securely
tightened without force being applied. They must be secured against automatic loosening.
Leakage paths and clearances in air according to EN 50014/50019 have to be observed.
2.8.6 After entry of the cable into the terminal box the glands and the parts used for the strain
relief are to be tightened with the corresponding torque in accordance with the data of the cable
gland manufacturer (also see Paragraph 5.5.5).

2.8.7 All unused cable entries (also see Paragraph 2.3) have to be closed tightly and secured
against automatic or unauthorized opening. The inside of the terminal boxes, particularly the
surface of the insulation parts, is to be kept clean. The sealings must be intact and must have
a correct fit. If there are machined contact areas and fitting surfaces on the terminal boxes and
the terminal box covers, they are also to be kept clean and protected against corrosion by a
thin grease layer.
The terminal boxes must always be tightly closed during operation.
For terminal boxes in protection type “Flameproof Enclosure”, Paragraph 2.8.11 is to be
observed.
2.8.8 If there are any O-sealing rings, attention is to be paid that the sealing rings (O-rings) which
are arranged between the individual parts are of a perfect quality and have a proper fit in the
slots provided.
2.8.9 If in case of d II motors a motor protection is realized exclusively by a direct temperature
monitoring with temperature sensors (thermal motor protection [TMP]), they must be connected in
such a way that in case of the responding temperature sensors the motor switches off
immediately. The design of the motor must be especially marked on the motor for this purpose.
2.8.10 The motors are suitable for ambient temperatures from –20°C (–4°F) up to +40°C (104°F)
resp. for the temperature range indicated on the rating plate.
In special design with installed heating or heating via the winding the motor is allowed to
be operated up to the minus temperature indicated on the rating plate.
In this case it must be observed that the heating is switched on at least 6 hours before
commissioning of the motor or motor starting.
Only when the housing temperature of –20°C (–4°F) is reached, the motor is allowed to be put
into operation. Prior to switch on the motor, the heating is to be switched off.
During motor operation the heating must not be switched on.
The heating data for voltage and current are indicated on the additional plate being attached to
the motor.
Motors in the mechanical special design “for low temperature” can be put into operation
up to the minus temperature indicated on the rating plate.

Cable-, lead entries and connecting cables must be suitable for ambient temperatures occurring.

Page 9 of 33 N–R 445 en 09.03

Measures to maintain the explosion
protection during operation

2.8.11 For terminal boxes in protection type d II, flameproof entries must be used, which are
tested and certified for this protection type (see Paragraph 2.3).
2.8.11.1 The motors are to be connected via suitable cable- and lead entries or to piping systems which
meet the requirements of EN 50018 and for which a separate test certificate is available.
2.8.11.2 Unused openings are to be sealed according to EN 50018.
2.8.11.3 Cable- and lead entries (screwed connections) as well as sealing plugs of simple types are not
allowed to be used.

2.8.12 The maintenance instructions for antifriction bearings specified by the motor manu-
facturers, especially for lubrication of the bearings, have to be observed.

2.8.13 Mechanical explosion protection

All machines being marked to Directive 94/9/EC have to be checked at regular intervals for
mechanical damages which can be an ignition risk.
Special attention must be paid that the intervals for bearing replacement and regreasing
intervals or grease change intervals as well as oil change intervals to be specified by the user
are observed.

When the rated service life is reached the bearings should either be replaced or proven by an
inspection that there are no mechanical damages.

– For bearings which cannot be regreased it is ensured that the rated service life will only be
reached clearly after attainment of the grease service life.

– The calculated rated service life of the bearings can be seen in the data sheet of the
machine, if it was specified particularly or for structural reasons specified for an individual
case.

– For machines which are exposed to forces applied externally (e.g. belt force or axial load
from the driven machine) the bearing service life is a minimum of 20.000 hours for the full
load indicated in the technical list.

– All of the other machines have a rated bearing service life of at least 40.000 hours.

– For bearings with separate oil supply the user is to watch suitably that the lubrication is
maintained.

N–R 445 en 09.03 Page 10 of 33

Description

3 Description
3.1 Overall construction
Mounting arrangement acc. to EN 60034-7: see dimension drawing or rating plate

Mounting dimensions up to frame size 315M acc. to

DIN 42673 (foot mounted)
DIN 42677 (flange mounted)
from frame size 315L to dimension drawing,
all frame sizes acc. to IEC 60072-1 or IEC 60072-2: see dimension drawing

Connection designations acc. to

DIN VDE 0530 part 8
IEC 60034-8: see wiring diagram

Enclosure acc. to
EN 60034-5: see rating plate

Cooling type acc. to EN 60034-6:

IC 411 Surface cooling (TEFC) or Hollow fin cooling
IC 511 or tube cooling
IC 71W Water jacket cooling

Details of the motor design are indicated in the valid technical catalogues.

3.2 Bearings
The motors are equipped with grease-lubricated antifriction bearings. The standard version of
the bearings in motors up to frame size 280 is permanently lubricated. The bearings of the
motors from frame size 315 are equipped with regreasing devices and automatic grease
quantity control.

3.3 Cooling

3.3.1 Surface cooling (TEFC), hollow fin cooling or tube cooling for all types except Type
D.W.–...
Design for fin and hollow fin or tube cooling, where an external fan takes in the cooling air
through the openings in the fan cover and presses the air over the surface or through the
cooling tubes of the stator housing. In case of hollow fin or tube cooling the heat dissipation is
supported by a closed cooling air circuit inside the motor.

3.3.2 Water jacket cooling for the Type D.W.–132..–.. to D.W.–560..–..

The stator housing has a double casing. For water channelling it is sub–divided by spirals
where the cooling water passes through. This results in a good heat dissipation. Additionally,
this reduces the danger that suspended matters carried along in the water can deposit.

Page 11 of 33 N–R 445 en 09.03

Description

3.4 Motor frame

3.4.1 Construction for surface cooling (TEFC), hollow fin cooling or tube cooling for all types
except Type D.W.–...
Depending on the frame size the stator frame and end shields are made of grey cast iron
or steel. The fan cover is made of sheet steel. The stator frame surface is provided with cooling
fins, hollow fins or tubes and mounted-on terminal box.

3.4.2 Construction for water jacket cooling (Type D.W.–132..–.. to D.W.–560..–..)

Stator frame and end shields are made of grey cast iron or steel.
The stator housing is designed as double casing, through which the cooling water is led.
The housing is provided with inlet and outlet for the cooling water.

3.5 Stator winding

The stator winding is executed in insulation class (see rating plate) acc. to EN 60034-1.
High-quality enamelled wires, suitable surface insulating materials and the type of insulation
provide a high level of mechanical and electrical stability with a high utilization factor and a long
service life.

3.6 Rotor
The rotor in motors of small frame sizes is equipped with a squirrel cage made of aluminium die
cast, in case of larger frame sizes with a cage in brazed version.
The rotor is dynamically balanced.
The balance is indicated on the shaft end or the rating plate, see Paragraph 5.1 “Installation”.
The motors in standard design meet the requirements of vibration level N acc. to
DIN VDE 0530-14/IEC 34-14, in special cases level R (reduced) or S (special).

3.7 Terminal boxes

If required, additional terminals for the monitoring devices are available inside the terminal box.
On special order an additional terminal box will be installed for larger motors (see dimension
drawing).
The number of available terminals is indicated in the wiring diagrams.

3.8 Monitoring devices

Monitoring devices are only available on special order.
See wiring diagram!

N–R 445 en 09.03 Page 12 of 33

Transport

4 Transport

For handling during transport the stator construction of the motor is equipped with lifting eyes,
where the lifting hooks can be fixed.
Check whether screwed lifting eyes are securely tightened.
Danger
Lift motors only by using these lifting eyes. Several lifting eyes must always be used
together.

Lifting of the motors on other parts (e.g. shaft ends, fan cuver) is not permitted, since this might
result in considerable damages.
The lifting eyes are only suitable for the motor weight. Additional loads attached to the
Danger
motor must never be lifted using these eyes.

4.1 Check before installation

Check whether the motor has been damaged during transport. If the packing is damaged to
such an extent that a motor damage is to be assumed, the packing should be removed in the
presence of a representative agent of the carrier.

4.2 Bearing lock

(for motors with cylindrical roller bearings only.)

The rotor of the motor is locked in order to avoid damages to bearings caused by vibrations
at standstill:
– by red marked locking screws in the bearing cap
– or by a transport locking mechanism fixed to the shaft end.
Before the motor is mounted, the locking screws must be loosened by 10 mm and the transport
locking device must be removed (see instruction plate on the motor).
After this, it must be possible to turn the shaft by hand.

We recommend loosening of the bearing lock only after the drive element has been fitted.

The transport locking mechanism has to be reused for further transports.

Prevent failures and thus avoid damages to persons and property.

The person responsible for the installation has to make sure, that
– safety- and operating instructions are available and observed

– operating conditions and technical data acc. to the order are observed

– protective equipment is used

– specified maintenance work is carried out.

Page 13 of 33 N–R 445 en 09.03

Installation and commissioning

5 Installation and commissioning

A most careful mounting and alignment of the motors on an absolutely even surface is impera-
tive to avoid distortions when the screws are being tightened. For machines which are to be
coupled it must be paid attention to a careful alignment. See Appendix 2 for alignment check.
As elastic as possible couplings should be used.

The motors with surface cooling (TEFC), hollow fin cooling or tube cooling
for all types except Type D.W.–...
Maximum permissible coolant temperature (ambient temperature on site) acc. to
EN 60034-1/IEC 60034-1 is 40°C (104°F) and a permissible altitude up to 1000 m above mean
sea level (other values see rating plate).
Care must be taken that the cooling air can flow without hindrance into the air inlet openings
and freely pass through the air outlet openings and cannot be directly sucked in again. Suction
and outlet openings must be protected from obstructions and coarse dust.

The motors with water jacket cooling for the Type D.W.–132..–.. to D.W.–560..–..
Before commissioning of water–cooled motors, the troublefree function of the cooling–water
circuit must be guaranteed. It must be ensured that the motor will only be switched on when
the cooling–water circuit is in operation. It must be kept functioning until the motor comes to
standstill after switching–off. Inlet and outlet openings are found on the motor housing.

The cooling water circuit is to be monitored. Normally, the motor is equipped with PTC thermi-
stor sensors, which switch off the motor if the cooling–water circuit fails. If the hosing is provi-
ded with vent plugs for the water chamber, venting is to be made for the first filling and thereaf-
ter at regular intervals.

Only clean, non–aggressive cooling water is to be used. Admissible content of suspended so-
lids is max. 10mg/1.

A most careful mounting and alignment of the motors on an absolutely even surface is impera-
tive to avoid distortions when the screws are being tightened. For machines which are to be
coupled it must be paid attention to a careful alignment. See Appendix 2 for alignement check.
As elastic as possible couplings should be used.

The inlet temperature of the cooling water should be at least 20°C (68°F).
Temperatures below 20°C (68°F) result in higher formation of condensation water and motor
failure.
Admissible inlet and outlet temperature, maximum pressure and the required amount of cooling
water are indicated on the motor plates.

The motors are only allowed to be operated at a coolant termperature over 0°C (32°F). For lo-
wer temperatures it is required to add an antifreeze due to reduced cooling effect. Consultation
with the motor manufacturer is required.

N–R 445 en 09.03 Page 14 of 33

Installation and commissioning

5.1 Mounting
Fitting of pulleys or couplings.
First the shaft end should be cleaned (not with emery cloth) and then greased. Pulley or
coupling should be fitted only with the aid of a fitting device. For this purpose the threaded
centering hole in the shaft end can be used. Insert a threaded bolt into the thread. Then place
the steel washer, the diameter of which is large enough to cover the hub borehole of the pulley
or coupling. The pulley and coupling is to be pulled up onto the shaft end by means of a nut or
a suitable hydraulic device.

The fitting of the drive elements by means of hammer blows is not permitted because of
the risk of bearing damages.
When replacing the bearings those must only be removed and reinstalled by means of
suitable devices using the shaft centering. Only original spare parts must be used.

The rotor of the motor is dynamically balanced. Balance is indicated on the shaft end face or
the rating plate. (H = half key, F = full key). Take care of the balance for installation of the drive
element!
The balancing of the transmission elements to be fitted must be adapted to the rotor balancing.
In case of half key balancing any protruding and visible part of the key has to be removed or
care to be taken of a mass balancing.

The motor must only be mounted and operated according to the specified mounting
arrangement (see rating plate).
In case of using e.g. pulleys, gears etc. care must be taken that the permissible radial and axial
shaft loads are not exceeded.
For explosion-proof motors only belts which are permissible for hazardous areas are allowed to
be used.

Page 15 of 33 N–R 445 en 09.03

Installation and commissioning

5.2 Connection, insulation resistance

Connection must only be made by an expert and in accordance with the valid safety
regulations. The relevant installation- and operating instructions as well as national and
international rules have to be observed.

Observe data on the rating plate!

Compare type of current, mains voltage and frequency (also see Paragraph 5.3.1)!
Observe connection!
Observe rated current for setting of the protective switch!
Connect motor in accordance with the wiring diagram provided in the terminal box!
The motor must be protected against excessive heating, see Paragraph 2.5.

For earthing the motor is provided with an earthing terminal, which depending on the mounting
arrangement is either located on the frame resp. on the flange end shield. In addition all motors
have a protective conductor terminal inside the terminal box.

As protection against dust and humidity unused cable entries in the terminal box must have a
torsionproof seal. All terminal screws and nuts have to be securely tightened to avoid
excessive transition resistances (see Paragraph 5.5).

Protective measures are to be taken.

In case of terminal boards with U-shaped terminal washers the

conductors to be connected have to be bent in U-shape and
placed underneath the terminal washers. See sketch!

In case of motors with terminal boxes which have ground surfaces between cover and base,
a thin grease film is to be applied for sealing and against corrosion.
After longer storage periods or standstill (see page 26) the insulation resistance of the winding
must be measured phase against phase and phase against ground before putting into
operation.
Humid windings might cause creeping currents, arcing and ruptures. In case of values v1 kW
per Volt of rated voltage measured at a winding temperature of 20°C (68°F) the winding must
be dried.

5.3 Rotational direction and designation of the terminals acc. to DIN VDE 0530-8/
IEC 60034-8

5.3.1 In standard design surface cooled (TEFC) motors up to frame size 315 are suitable for both
directions of rotation. Water–cooled motors are suitable for both directionc of rotation.
Motors suitable for one rotational direction only are identified by an arrow on the motor for the
correct direction. Terminals U1, V1, W1 connected to phase L1, L2, L3 (in alphabetical
sequence or natural sequence) always result in clockwise rotation. This rule applies to all
motors, even if they are not suitable for clockwise direction.

N–R 445 en 09.03 Page 16 of 33

Installation and commissioning

5.3.2 Change of rotational direction:

For DOL (direct on-line) starting and in pole-changing motors with separate windings the
direction of rotation can be reversed by exchanging two mains conductors on the terminal
board of the motor.
For motors with star/delta starting and pole-changing motors with Dahlander winding, 2 (two)
mains conductors at the input to the motor switch have to be exchanged.
For a machine with one shaft end only or with two shaft ends of different diameters, that
rotational direction of the rotor is considered as the direction of rotation, being noticed by
anybody when looking at the front end or thicker shaft end.

5.3.3 With forced ventilation the direction of rotation is separately marked by an arrow on the forced
ventilation itself.

5.4 Check before commissioning

– Observe data on the rating plate!
– Check whether voltage and frequency of the motor comply with the mains data!
– Check whether the bearing lock has been removed!
See Paragraph 4.2 “Bearing lock”!
– Check whether the rotational direction is correct and for inverter operation, that
the limit speed is not exceeded!
– Check whether the motor is protected as specified in the regulations!
– Check and make sure that in case of star/delta-starting, because of the risk of
inadmissible operational loads, the switching from star to delta can only be
executed after fading of starting current of the star step!
– Check whether the electrical connections are securely tightened and whether the
monitoring devices are correctly connected and adjusted!
– Check whether protective measures have been taken: earthing!
– Check coolant temperature!
– Check whether additional equipment – if existing – is functionable.
– Check whether the cooling air inlet openings and cooling surfaces are clean!
– For water–cooled motors it is to be checked whether the cooling water circuit is functioning!
– Check whether the motor is securely fixed!
– In case of a belt drive, check the belt tension!
– Check whether the cover of the terminal box is closed and whether the cable
entries are properly sealed.
– Check whether the cable glands and the plugs (for unused entry threads) are approved by an
EC–type–examination certificate according to Directive 94/9/EC.
– For forced-ventilated motors it is to be checked, whether the forced ventilation is
functionable and in operation when the main motor is in operation.

Page 17 of 33 N–R 445 en 09.03

Installation and commissioning

5.5 Tightening torques for screwed joints

5.5.1 General
If no other data are indicated the following torque limits (screw and nut) are applicable.
Note: Screws which become unusable have to be replaced by
new ones of the same strength class and type.

5.5.2 Screwed joints for electrical connections

Thread Tightening torque [Nm] Thread Tightening torque [Nm]

M4 1.2 M 12 15.5
M5 2 M 16 30
M6 3 M 20 52
M8 6 M 24 80
M 10 10 M 30 150

5.5.3 Screwed joints strength class 8.8 and A4-70

Tightening torques for screws of the strength class 8.8 and A4-70 (A4-80) only in components
with higher strength (e.g. grey cast iron, steel).

Thread Tightening torque [Nm] Thread Tightening torque [Nm]

M4 2.3 M 14 105
M5 4.6 M 16 160
M6 7.9 M 20 330
M8 19 M 24 560
M 10 38 M 30 1100
M 12 66 M 36 1900

5.5.4 Screwed joints strength class 5.6

Tightening torques for screws of the strength class 5.6, 4.6, A2 or for screws in components
with lower strength (e.g. aluminium).

Thread Tightening torque [Nm] Thread Tightening torque [Nm]

M4 1.1 M 14 49
M5 2.1 M 16 75
M6 3.7 M 20 150
M8 8.9 M 24 260
M 10 18 M 30 520
M 12 30 M 36 920

N–R 445 en 09.03 Page 18 of 33

Installation and commissioning

5.5.5 After entry of the cable into the terminal box the glands and the parts used for the strain
relief are to be tightened with the corresponding torque in accordance with the data of the cable
gland manufacturer.
The assembly torque limits depend on the used cable gland as well as the cable or supply line
and must therefore be determined by the user.

The Loher standard glands supplied with the motor have at least to be tightened according to
the table.

Table: Assembly torque limits for Loher standard cable glands [Nm]
Cable glands for EEx e II Cable glands for EEx d II
Type HSK-M Type ADL 1F, ADL 4F
Nominal size Union nut Threaded Union nut Threaded
connection connection
M12x1.5 5 7 – –
M16x1.5 5 7 – –
M20x1.5 5 7 15 20
M25x1.5 7 10 18 24
M32x1.5 7 10 20 27
M40x1.5 7 10 40 54
M50x1.5 7 10 80 107
M63x1.5 7 10 90 120
M75x1.5 – – 110 147

Cable glands for EEx e II

Type ADE 1F, ADE 4F
Normal size Gasket No. Union nut Threaded connection

M40x1,5 9 35 47
M40x1,5 10 52 70
M50x1,5 10 52 70
M50x1,5 11 55 74
M63x1,5 12 65 87
M63x1,5 13 75 100
M75x1,5 13 75 100
M75x1,5 14 104 139

Page 19 of 33 N–R 445 en 09.03

Installation and commissioning

5.6 Inverter operation

Inverter operation of explosion-proof low voltage three-phase motors in protection
type “Flameproof Enclosure” is possible, when the following requirements are met:
5.6.1 The output voltage of the inverter is to be adjusted in such a way that in the frequency range
up to the rated frequency of the motor an almost linear relationship between the (fundamental)
voltage and the (fundamental) frequency is kept, i.e. the practically constant motor flux must be
kept in accordance with the rated data.
Motors operating above the 1.1 fold rated frequency are only permitted if a corresponding
rating plate for inverter operation is fixed on the motor.
5.6.2 Icontin. is the value to which the inverter management limits the current in continuous duty.
Icontin. is to be adjusted to the continually permitted motor rated current as a maximum in
accordance with the rating plate for inverter operation attached to the motor or in conformity
with the value determined in the describing documents for inverter operation.
For motors in protection type “Flameproof Enclosure” which are only provided with one rating
plate for sine operation and sole protection, Icontin. is at a maximum to be adjusted to the rated
current indicated on the rating plate.

5.6.3 Ishort is the value to which the inverter management limits the current in case of a short-time
overload for a period of max. tshort.
Ishort is to be adjusted to 1.5 x Icontin. at a maximum.
5.6.4 tshort is the period for which the inverter allows an exceeding of Icontin.
tshort is to be adjusted to 60 s as a maximum.
5.6.5 The built-in temperature sensors (PTC thermistors) which must be suitable for sole protection are
to be connected to a tripping device provided with the EC–type–examination certificate according
to Directive 94/9/EC.

5.6.6 Voltage peaks (especially for PWM inverters with long motor cable)
a) The design of the terminal box concerning the air and creepage distances allows the inverter
operation with voltage peaks (ÛLL = Maximum value of the conductor-to-conductor voltage
and ÛLE= Maximum value of the line-to-earth voltage) up to Û = 1866 V.
b) To avoid the formation of partial discharges, the voltage at the motor terminals must be
limited, depending on the rise time tA, to values which are below the characteristic curve of
the chart “Dielectric strength curve” (see diagram below).

Dielectric strength curve

1500

1400

1300

1200

1100

1000

900
U
^

800
LL (V)

700

600

500

400

300

200

100

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5

tA (ms)

N–R 445 en 09.03 Page 20 of 33

Maintenance

6 Maintenance

The responsible for the facility must ensure that the specified maintenance work
is made adequately.

6.1 Bearings and greasing

6.1.1 The bearings in totally enclosed fan-cooled (TEFC) motors up to frame size 280 are
permanently lubricated. In case of deviations this is marked by indication plates on the motor.
For normal coolant temperatures (see EN 60034-1 or page 2 of these instructions) the motors
are greased in our plant, which under normal operating conditions must only be replaced after
several years (see Appendix 1).

6.1.2 Bearings of totally enclosed fan-cooled (TEFC) motors from frame size 315 (upon customer
request also for the range from frame size 160 to 280) are equipped with regreasing devices
and automatic grease quantity control. The regreasing of the bearings is done by means of a
grease gun through the nipples provided on the end shields.
Overfilling of the bearing chambers is not possible since in case of an extended regreasing the
used grease will be thrown off by a rotating disk in the outer grease chamber through an
aperture in the end shield or into a grease collecting chamber.

Regreasing during operation only!

Danger of accident! Pay attention to rotating parts.
Regreasing intervals, grease quantity and grease quality are indicated on the instruction plates
at the motor. Regreasing, however, is to be made at least once a year.

If the motor is equipped with grease removal rams, the used grease must be removed after
regreasing by pulling the ram at the bearing several times to the stop, with the motor in operation.

If the motor is equipped with grease collecting chambers, these chambers are to be dismounted
at motor standstill acc. to the intervals on the instruction plate and the used bearing grease is to be
removed. If this is not done, the grease piles up and the bearings are overheated.

Extending the regreasing intervals endangers the bearing and might risk a deterioration of the
sealing provided by the grease and thus the ingress of dust into the bearing. If the motors have
not been operated for a longer period we recommend even for new motors to regrease the
bearings before putting into operation, especially if due to congealing grease in the bearing
there are noises which are caused by vibrations of the bearing cage. In the course of running-in
increased bearing noises might occur for a short period. The bearing noise is not critical as
long as the operating temperature of the bearing is not yet reached and if the noise is caused
by the dynamic viscosity of the bearing grease.

The temperature of the bearings is continuously to be checked. Up to a room temperature of

40 °C/104 °F a heating-up of 80 K is acceptable if the recommended grease quality is used.

Page 21 of 33 N–R 445 en 09.03

Maintenance

We would like to point out that the grease quantity regulation can only work properly if the
grease types specified by us are used. Decisive is the plate fixed on the motor!
Only use antifriction bearing grease as specified for regreasing on the motor plate, i.e. for the
ambient temperature range from –25°C (–13°F) to +70°C (+158°F) lithium based grease (e.g
Shell Alvania RL3), for the ambient temperature range from –60°C (–76°F) to +80°C (+176°F)
special grease (e.g. Isoflex Alltime SL2). Admissible ambient temperature for the motors: See
Paragraph 1.3.
Motors for special operating conditions are supplied with a separate greasing plate stating the
grease quality to be used as well as the regreasing intervals.

Relubrication with grease of a different saponification basis. e.g. sodium saponified grease,
might cause a deterioration and elimination of the grease effect and thus a total damage of the
bearings.

In case of 2 and 4 pole motors it might happen that by the use of unsuitable greases the
grease quantity regulation fails and when pressing new grease into the bearings they get
abnormally hot due to overfilling. In such cases the bearings have to be cleaned thoroughly by
using cold-degreasing agent, and be refilled with suitable grease.

6.2 Terminal locations, terminals and ventilating passages

Depending on the operating conditions, the following should be done in certain intervals
– checking the cleanliness of terminal locations and terminals
– checking of the electrical connections with regard to tightness
(see Paragraph 5.5 for tightening torques)
– cleaning of the air-flow channels and the water chambers.
Both the cooling air inlets and the cooling surfaces must be protected against obstruction and
contamination.

If required, the water chambers are to be flushed and cleaned from deposits.
Never use sharp-edged tools for cleaning.

N–R 445 en 09.03 Page 22 of 33

Additional equipment

7 Additional equipment

On special order only.

7.1 Temperature monitoring*

The temperature sensors for monitoring e.g. of the stator winding temperature, the bearings,
the coolant must be connected to the additional terminals in the main terminal box or by one or
several terminal boxes.
The temperature sensors have to be connected according to the relevant connection diagram.
For connection the specifications and instructions acc. to Paragraph 5.2 “Connection” are
applicable.

7.2 Space heater*

Heating capacity and connection voltage: See special plate on the motor. The space heater
has to be connected by an additional terminal box acc. to the relevant connection diagram.
For connection the specifications and instructions acc. to Paragraph 5.2 “Connection” are
applicable.
An operation of the space heater is only allowed when the motor is switched off. The space
heater must never be switched on during motor operation.

7.3 Forced ventilation*

Observe direction of rotation! (see arrow for directional rotation.)
Forced ventilation is to be connected acc. to the wiring diagram inside the terminal box.
During operation of the main motor the forced ventilation must be switched on!
The forced ventilation is dissipating the heat loss during operation of the main motor. When
switching off the main motor a temperature-dependant follow-up run of the forced ventilation
is required.

7.3.1 To be checked when commissioning the main motor:

Check whether the forced ventilation is functioning and in operation when the main motor is
switched on!

* On special order only.

Page 23 of 33 N–R 445 en 09.03

Spare parts and components

8 Spare parts and components

When ordering spare parts or components please state the type and serial number of the motor.
Both data can be taken from the rating plate.

Standard version:

N–R 445 en 09.03 Page 24 of 33

Spare parts and components

1.00 Stator, complete 4.34 Resilient preloading ring, NDE

1.03 Stator core with winding 4.36 Grease guide disk, NDE
1.06 Stator housing 4.38 Centrifugal disk, NDE
1.10 Mounting feet, unmachined 4.42 Felt packing ring, NDE
(1 pair) 4.44 Outside gasket, NDE
4.46 Inner gasket, NDE
2.00 Rotor, complete (balanced)

3.01 End shield, DE 5.01 External fan, complete

3.02 Flange shield, DE 5.10 Fan cover, complete
3.08 Flange disk, DE 5.14 Protective grid, complete
3.21 End shield, NDE 5.30 Spring fastener

4.01 Bearing, DE
4.05 Bearing, NDE
4.10 Outside bearing cap, DE 6.03 Base of terminal box
4.12 Inner bearing cap, DE 6.04 Upper part of terminal box
4.14 Resilient preloading ring, DE 6.05 Terminal box cover
4.16 Grease guide disk, DE 6.07 Bushing plate
4.18 Centrifugal disk, DE 6.10 Cable entry
4.22 Felt packing ring, DE 6.15 Terminal board, complete
4.24 Outside gasket, DE 6.16 Bushing terminal
4.26 Inner gasket, DE 6.17 Accessory terminal
4.30 Outside bearing cap, NDE 6.20 Clamping
4.32 Inner bearing cap, NDE

The parts shown are available in different sets depending on type, size, mounting and enclosure. They are
available from our works.

When ordering spare parts, please state:

Spare part designation

Motor type
Serial number

Example: End shield DE

DNGW–280MB–04A
3 292 793

Type and serial number of the motor are indicated on the rating plate.

Page 25 of 33 N–R 445 en 09.03

Storage instructions

9 Storage specifications

9.1 For motors which have to be stored for a period of up to 2 years, the following is to be
observed:

9.1.1 Storage
9.1.1.1 The motors are to be stored dry, dustfree and at room temperature. In this case no special
packing is required. Otherwise the motors must be packed into plastic foil with humidity-absor-
bing substances (e.g. Branogel) or into an air-sealed foil. Protective cover against sun and rain
is to be provided.

9.1.1.2 In order to avoid secondary failures at the bearings caused by vibrations at standstill, for
example by adjacent running machines, the motors are only allowed to be stored in vibration-
less rooms.

9.1.1.3 For transport the motors with roller bearings have to be equipped with a bearing lock at the
driving end. It is to remain locked until commissioning resp. to be re-installed after an inspec-
tion or a trial operation. A locking device is not necessary and not available, if the bearing is
axially preloaded.

9.1.2 Commissioning
9.1.2.1 Before commissioning the insulation resistance of the winding must be measured by qualified
personnel phase against phase and phase against mass. Damp windings may cause leakage
currents, arcing and ruptures. In case of values v 1kW per Volt of the rated voltage measured
at a winding temperature of 20°C (68°F) the winding must be dried. Drying is possible by fee-
ding of the winding with single phase a.c. current. The voltage has to be adjusted in a way that
the recommended values of the heating current in accordance with Illustrations a) and b) are
not exceeded.
The temperature should reach approx. 80°C (176°F) and being active for several hours.
Drying is also possible in a drying kiln.

N–R 445 en 09.03 Page 26 of 33

Storage instructions

Recommended heating circuits and maximum heating currents

a) D b) Y
IMAX = 65 % Ir IMAX = 75 % Ir

9.1.2.2 On motors with bearing lock this one has to be removed before commissioning.

9.1.2.3 Antifriction bearings, lubrication

If adequately stored for a longer time it can be assumed that within 2 years the lubricating
grease in the bearings is not affected. Motors with permanent lubrication can be put into opera-
tion after having checked the insulation resistance of the winding and a short trial run.
For motors with insulation class F a lithium-saponified antifriction bearing grease with a drip-
ping point of at least 180°C (356°F) is used for normal ambient temperatures.
For the motors with insulation class H and certain special motors, the used special lubricating
grease is indicated on an instruction plate attached to the motor.

9.1.2.4 For motors with a regreasing device it is advisable to regrease both bearings shortly after
commissioning at running motor.
Grease type, grease quantity and regreasing intervals are marked on an additional plate
attached to the motor.
The data for grease service life with regreasing intervals can surely be expected for motors in
enclosure IP 55. The bearing is protected against the ingress of fine dust and of water in all
directions, e.g. for outdoor installation without additional protection.
For motors with enclosure IP 44 and IP 54 these data apply with the restriction that the
environmental load by dust and water is not exceeding the limits of EN 60034-5 with tests
according to EN 60034-5.

9.1.3 For motors which are transported and stored in assembled condition with the machine
to be driven the following must be observed:

9.1.3.1 Storage
a) The free shaft ends must be greased before installation of the motors as well as all of the
other blank metal parts, e.g. foot- and flange surfaces or supporting faces of terminal boxes
and covers. As protection against dust and humidity grease seals with antifriction bearing
grease are to be installed at the shaft opening.

b) A humidity-absorbing substance (e.g. Branogel) is to be filled into the terminal boxes of the
motors.
c) The machines are to be stored dry, dustfree and at room temperature.

d) For further measures the specifications according to the Paragraphs 9.1.1.2 – 9.1.1.3 are
applicable.

A bearing lock is not necessary, if the bearings are preloaded by means of belt drive (9.1.1.3).

Page 27 of 33 N–R 445 en 09.03

Storage instructions

9.1.3.2 Commissioning
Before commissioning the humidity-absorbing substance (e.g. Branogel) is to be removed from
the terminal boxes and the measures according to 9.1.2 are to be performed.
9.1.3.3 For outdoor storage it is additionally to be observed:
Protective cover against the influence of sun and rain is to be provided, exchange of air must
be possible to avoid condensation water.
After 2 months it must always be checked if the protective measures acc. to 9.1.3.1a are still
given and functionable.

9.2 For motors which are stored for more than 2 up to 4 years before commissioning
additionally applies:

9.2.1 Storage
9.2.1.1 The manufacturer must be informed on the storage time in the purchase order.
9.2.1.2 Shaft opening and terminal box cover are to be provided with grease seals of antifriction
bearing grease. The motor shafts are not allowed to be rotated, as otherwise the protective
grease coating is destroyed. If a movement of rotating parts is unavoidable, the protective
grease coating has to be renewed.
9.2.1.3 A humidity-absorbing substance (e.g. Branogel) must be in the terminal boxes.
9.2.1.4 In case of permanent lubrication the antifriction bearings must due to the long standstill be
greased with a special grease, e.g. “Klüber Staburags NBU 8 EP”.

9.2.2 Commissioning
9.2.2.1 Before commissioning the humidity-absorbing substance (e.g. Branogel) is to be removed
from the terminal boxes and the measures according to 9.1.2 are to be performed.
9.2.2.2 Antifriction bearings, lubrication
Motors with regreasing device must be relubricated immediately after commissioning with ab-
out the double grease quantity, until the used grease has been thrown out. Further greasing
can then be made with the bearing grease indicated on the lubrication plate. During the run-
ning-in period increased bearing noises may occur, which are not dangerous, when the opera-
ting temperature of the bearing has not been reached and the noise is caused due to the dyna-
mic viscosity of the bearing grease.

9.3 If motors (not Type D.W.–132..–.. to D.W.560..–..) are stored at temperatures to –505C
(–585F) the following must be observed in addition to the instructions according to Pa-
ragraph 9.1. and 9.2:

9.3.1 The standard antifriction bearing grease for the motors as per catalogue is suitable for
operating temperatures between –30°C (–22°F) and +130°C (+266°F). Temperatures to –50°C
(–58°F) are harmless for the antifriction bearing grease, when the motors are at standstill or
stored. (For an operation at –50°C (–58°F) a special grease, e.g. Klüber, Isoflex Alltime SL2, is
available for the bearings).
9.3.2 At putting into operation the motors with regreasing device are to be relubricated. Compared to
the indication on the lubrication plate the grease quantity has to be doubled.

N–R 445 en 09.03 Page 28 of 33

Storage instructions

9.4 If motors with water jacket cooling Type D.W.–132..–.. to D.W.–560..–..) are stored at
termperatures up to –205C (–45F) the following must be observed in addition to the
instructions of Paragraph 9.1 and 9.2:

The water has to be removed completely from the air–water coolers.

In any case the coolers have to be dried completely with hot air of max. 60°C (140°F) and then
to be sealed.

Motors with collers have to be stored in a dry and dustfree room.

At putting into operation the motors with regreasing device are to be relubricated. Compared to
the indication on the lubrication plate the grease quantity has to be doubled.

9.5 Further to these storage instructions all data of these operating instructions are to be
considered. The manufacturer‘s warranty is only applicable if all of the above mentio-
ned items are strictly observed.

Page 29 of 33 N–R 445 en 09.03

Faults and remedies

10 Faults and remedies

Fault Possible causes Remedy

Bearing is too hot Bearing noise* Motor runs unevenly

Too much grease in bearing Remove excess grease

Bearing dirty Replace bearing

Belt tension too high Reduce belt tension

Coupling forces are pulling Realign motor,

or pushing correct coupling

Coolant temperature above 40°C Adjust temperature of cooling air

(104°F)

Not enough grease in the bearing Grease according to

specifications

Motor incorrectly mounted Check mounting type of motor

Bearing grease dark coloured Check bearing currents

Scoring at bearing inner race, Replace bearing, avoid

e.g. caused by motor start vibrations at standstill
with locked bearing

Unbalance caused by pulley or

Exact balancing
coupling

Motor fastening unstable Check fastening

* If remedies described are insufficient, we recommend to replace the bearings.

Fault Possible causes Remedy

High Protective
Motor does Motor is
decrease in device
not start too hot
speed triggers

Countertorque too high Check motor- and load torque

Mains voltage too low Check mains conditions

Phase interruption Check mains supply

Observe wiring diagram

Wrong winding connection
and rating plate

Overload Compare data on rating plate

Too many starts per hour Observe rated duty type

Check ventilation passages,

Insufficient ventilation
check direction of rotation

Check in– and outlet–temperature

Insufficient cooling
of the cooling water

Ventilation passages or water Clean

chambers dirty

Short-circuit of winding
Measure insulation resistance
or terminal board

Starting time exceeded Check starting conditions

N–R 445 en 09.03 Page 30 of 33

EC Declaration of Conformity 1

11 EC Declaration of Conformity

Page 31 of 33 N–R 445 en 09.03

Appendix 1 2

Grease life and grease quantities

for antifriction bearings of explosionproof three-phase motors in protection type “Flameproof enclosure”, with
squirrel cage for low voltage, with permanent lubrication.

Grease life for permanent lubrication1 Grease quanti-

in operating hours at rated speed 1/min: ties in g per
bearing for
Frame size horizontal mounting (IM B) permanent
3600 3000 1800 1500 1200 v 1000 lubrication
71 5
80 33000 9
90 33000 11
100 15
33000
112 24000 25
132 33000 50
24000
160 33000 33000 80
180 17000 100
200 17000 130
225 190
24000
250 12000 260
12000 24000
280 260

vertical mounting (IM V)

3600 3000 1800 1500 1200 v 1000
71 33000 5
80 24000 9
33000
90 24000 33000 11
100 33000 15
17000 33000
112 25
17000
132 24000 50
160 12000 80
24000
180 100
12000 24000
200 17000 130
225 190
9000 24000
250 17000 260
9000 12000 17000
280 260

The indicated grease life is applicable for an ambient temperature of max. 40°C (104°F). For a temperature rise of
10°C (50°F) each the grease life is to be reduced by factor 0.7 of the chart value (max. 20°C/68°F = factor 0.5).

At an ambient temperature of 255C (775F) the double grease life can be expected, however, 33000
operating hours at maximum.
1 Independently of the operating hours the antifriction bearing grease and the bearing (2Z-bearing) has to be
replaced after 3–4 years at the latest.

N–R 445 en 09.03 Page 32 of 33

Appendix 23

Service report Page

Alignment check

Service No.: Order No.:

Type: Serial No.:

Coupling type: Diameter:

Recommended accuracy for alignment*

Speed (rpm) Parallel offset Angular offset
(1/100 mm) (1/100 mm each)
750 9 9
1500 6 5
3000 3 2.5

Measured values at the coupling

Parallel offset Angular offset

Measurement

Comments:

* If no values were specified by the coupling manufacturer

Page 33 of 33 N–R 445 en 09.03

 Satz Loher – Druck Loher 09.03 Printed in Germany

LOHER GmbH
P.O.Box 1164 S 94095 RUHSTORF
Hans–Loher–Str. 32 S 94099 RUHSTORF
GERMANY
Phone +49 8531 39-0 S Fax +49 8531 32895
E-mail: info@loher.de
http://www.loher.de
 Datenblatt
data sheet
Kunde Hersteller
Loher GmbH
Customer Manufacturer

Motor Typ Meßflächen -Schalldruckpegel Leerlauf Last

DNGW-160ML-02A
Motor type LpA in db(A) nach DIN 45 635 No load Load

IEC-Baugröße Polzahl Average sound pressure level 75+3

160M 2
IEC-Size Number of poles LpA acc. DIN 45 635

Bauform Schutzart Drehrichtung beide rechts links

IM B3 IP 56 X
Mounting design Type of enclosure Direction of rotation both cw ccw

Ex-Schutzart Lager AS/BS 6310-2Z/C3

II 2 G EEx de IIC T4
Ex-Protective system Bearing DE/NDE 6310-2Z/C3
Betriebsart Einschaltung direkt Schmiermittel
S1-7/9 Shell Alvania RL3
Duty type Starting d.o.l Lubrication

Umgebungstemperatur Schmierart Dauerschmierung

KT -20/+50 °C
Ambient temperature Type of lubrication Permanent lubrication
Wärmeklasse Ausnutzung Nachschmierfrist Menge
F F --- --- g
Thermal classification Temp. rise Relubrication term Quantity

Therm. Motorschutz 3KL145 Massblatt Nr.:

MLD16-0023FM
Therm. motor protection 3PTC145 Outline dimension drawing No.

Bemessungsleistung Lage des Klemmenkastens oben

13,2 kW
Rated output Location of terminal box on top

Bemessungsspannung Klemmenzahl
440-480 V 6+4
Rated voltage Number of terminals

Schaltung Kabeleinführungsgew. 2xM40x1.5

D
Connection Cable entry thread 2xM20x1.5
Frequenz Hz Drehzahl 1/min Gewicht ca
60 3525 140 kg
Frequency c/s Speed rpm Net weight approx.

Bemessungsstrom Abnahme:
21,5 A
Rated current (CR) Test:

Anlaufstrom (I A
/I N ) Sonstige Daten und Bemerkungen:
650 %
Starting current Additional data and remarks:

Leistungsfaktor (cos M ) 4/4 3/4 1/2 KL für Alleinschutz / PTC for sole protection
Power factor Für FU-Betrieb geeignet / suitable for inverter operation
0,88 0,84 0,75

Wirkungsgrad (%) 4/4 3/4 1/2 Heizung / heater: 210-250V, 50W

Efficiency
90,5 90,5 88,5
KT40°C - F/B
Bemessungsmoment
(M N
) 35,8 Nm
Rated torque

Anzugsmoment
M A / MN = 225 %
Starting torque

Kippmoment
M K / MN = 235 %
Break-down torque

Läuferklasse
HS5
Rotor class

Trägheitsmoment
0,037 kgm²
Moment of inertia 8805094
Drehmomentkurve-Nr. Motor-Nr./Motor-No. 3352523-546
---
Torque characteristic-No. PTB 02 ATEX 1081

Anlagen / Attachments --- EP-Nr. 2060244

Tag; Date Name; Name

Toleranzen nach/ Tolerances acc. to Nr.
Bearb.; Designed 01.06.06 IAV54
DIN IEC 38 - DIN EN 60 034-1 No. DBL 33662
Gepr.; Checked 01.06.06 IAV5

Ersatzteile
Drehstrommotoren
mit Käfigläufer
Zündschutzart
Druckfeste Kapselung "d“
Baugröße 71...560
Die aufgeführten Teile sind vom
Werk lieferbar. In welcher
Kombination sie im Motor
vorhanden sind, hängt von der
gelieferten Ausführung ab.
Normteile sind im freien Handel zu
beziehen.
D 001
Bei Bestellung bitte angeben: Ersatzteil, Typ und Motornummer.
Spare parts Typ: DNGW-160ML-02A
Piéces de rechange Nr.: 3 354 177-216
Explosion-proof Moteurs triphasés à cage
TEFC Three-phase motors Ventilation extérieur
with squirrel cage
Enveloppe antidéflagrante "d"
Flameproof enclosure "d" Hauteurs d'axe 71...560
Frame sizes 71...560
Above parts are available from our factory. Les pièces indiquées ci-dessus sont
Their combination, existing disponibles en usine. La mise en
in the motor, depends on the motor place de ces pièces dans le moteur
type supplied. depend du type fourni. Les pièces
The standard parts can be procured standard peuvent ètre
from local dealers. approvisionées dans le commerce.
When ordering spare parts, please state designation, motor type and serial number.
Prière d’indiquer, en cas de commande, la désignation de la pièce de rechange, le type et le numéro du moteur.
1.00 Ständer komplett
1.03 Ständerpaket mit Wicklung
1.06 Ständergehäuse
1.10 Füße, unbearbeitet (1 Paar)
2.00 Läufer komplett (gewuchtet)
3.01 Lagerschild AS
3.02 Flanschlagerschild AS
3.08 Flanschteller AS
3.21 Lagerschild BS
4.01 Lager AS
4.05 Lager BS
4.10 Fettkammerdeckel AS außen
4.12 Fettkammerdeckel AS innen
4.14 Ausgleichscheibe AS
4.16 Fettleitscheibe AS
4.18 Schleuderring AS
4.24 Dichtring AS außen
4.26 Dichtring AS innen
4.30 Fettkammerdeckel BS außen
4.32 Fettkammerdeckel BS innen
4.34 Ausgleichscheibe BS
4.36 Fettleitscheibe BS
4.38 Schleuderring BS
4.44 Dichtring BS außen
4.46 Dichtring BS innen
5.01 Lüfter komplett
5.10 Lüfterhaube komplett
5.14 Schutzgitter komplett
5.30 Toleranzring
6.00 AK komplett
6.03 AK-Unterteil
6.04 AK-Oberteil
6.05 AK-Deckel
6.06 AK-Zwischenplatte
6.07 Durchführungsplatte
6.08 AK-Stutzen
6.09 AK-Schelle
6.10 Kabeldurchführung
6.15 Klemmbrett komplett
6.16 Durchführungsklemme
6.17 Zusatzklemme
6.19 Leitungsdurchführung
6.20 Klemmstück
6.28 Dichtring
6.60 Zusatz-AK komplett
6.63 AK-Unterteil
6.64 AK-Oberteil
6.65 AK-Deckel
6.70 Kabeldurchführung
6.76 Leitungsdurchführung
6.77 Zusatzklemme
D 001
Beispiel: 3.01 Lagerschild AS
Example:
Exemple:
1.00 Stator, complete
1.03 Stator core with winding
1.06 Stator housing
1.10 Base board, uncut (1 pair)
2.00 Rotor, complete (balanced)
3.01 End shield, DE
3.02 Flange shield, DE
3.08 Flange disk, DE
3.21 End shield, NDE
4.01 Bearing, DE
4.05 Bearing, NDE
4.10 Outside bearing cap, DE
4.12 Inner bearing cap, DE
4.14 Resilient preloading ring, DE
4.16 Grease guide disk, DE
4.18 Centrifugal disk, DE
4.24 Outside gasket, DE
4.26 Inner gasket, DE
4.30 Outside bearing cap, NDE
4.32 Inner bearing cap, NDE
4.34 Resilient preloading ring, NDE
4.36 Grease guide disk, NDE
4.38 Centrifugal disk, NDE
4.44 Outside gasket, NDE
4.46 Inner gasket, NDE
5.01 External fan, complete
5.10 Fan cowl, complete
5.14 Protective grating
5.30 Spring fastener
6.00 Terminal box, complete
6.03 Base of terminal box
6.04 Upper part of terminal box
6.05 Cover of terminal box
6.06 Intermediate plate
6.07 Bushing plate
6.08 Cable box
6.09 Cable clamp
6.10 Cable entry
6.15 Terminal board, complete
6.16 Bushing terminal
6.17 Accessory terminal
6.19 Bushing terminal
6.20 Clamping device
6.28 Cable gasket
6.60 Accessory boxes, complete
6.63 Base of terminal box
6.64 Upper part of terminal box
6.65 Cover of terminal box
6.70 Cable entry
6.76 Bushing terminal
6.77 Accessory terminal
DNGW-200LB-04
3 124 566
1.00 Stator complet
1.03 Paquet de tôles du stator avec
enroulement
1.06 Carcasse du stator
1.10 Pieds, non usinées (1 paire)
2.00 Rotor complet (équilibré)
3.01 Flasque-palier, c.acc. c. acc. =
3.02 Flasque-bride, c.acc. côte accouplement
3.08 Disque à bride, c.acc. c. vol. =
3.21 Flasque-palier, c.vol. côte volant
4.01 Roulement, c.acc.
4.05 Roulement, c.vol.
4.10 Chapeau de palier extérieur, c.acc.
4.12 Chapeau de palier intérieur, c.acc.
4.14 Rondelle élastique, c.acc.
4.16 Disques directrice de graisse, c.acc.
4.18 Déflecteur, c.acc.
4.24 Rondelle de joint extérieure, c.acc.
4.26 Rondelle de joint intérieure, c.acc.
4.30 Chapeau de palier extérieur, c.vol.
4.32 Chapeau de palier intérieur, c.vol.
4.34 Rondelle élastique, c.vol.
4.36 Disque directrice de graisse, c.vol.
4.38 Déflecteur, c.vol.
4.44 Rondelle de joint, extérieure, c.vol.
4.46 Rondelle de joint, intérieure, c.vol.
5.01 Ventilateur extérieur, complet
5.10 Capot du ventilateur, complet
5.14 Grille de protection
5.30 Fixation à ressort
6.00 Boite à bornes, complet
6.03 Base de la boîte à bornes
6.04 Partie supérieure de la boîte à bornes
6.05 Couvercle de la boîte à bornes
6.06 Plaque intermédiaire
6.07 Plaque de traversée
6.08 Boite de câble .
6.09 Collier de câble
6.10 Entrée de câble
6.15 Plaque à bornes, complète
6.16 Borne.de traversée
6.17 Borne accessoire
6.19 Borne de traversée
6.20 Joue de serrage
6.28 Joint de câble
6.60 Boites accessoires, complet
6.63 Base de la boite à bornes
6.64 Partie supérieure de la boite à bornes
6.65 Couvercle de la boite à bornes
6.70 Entrée de câble
6.76 Borne de traversée
6.77 Borne accessoire
 Anschluss Die räumliche Anordnung der Klemmen braucht nicht mit dieser Darstellung übereinstimmen.
Connection The spacial arrangement of the terminals does not have to correspond with this drawing.
Branchement Il n`est pas nécessaire que la disposition des bornes dans la boîte corresponde à ce schéma.
Änderungs-Bemerkung
Änd.-Index
Teileklasse 20503

HE2
HE1
CAD-SE
letzte Änderung:
Name
Datum

HE1-HE2 : Stillstandheizung / Heater / Chauffage

Schaltbild
Bearb. 08.10.2004 s-feher
Gepr. 08.10.2004 TMT58
Name

Stillstandsheizung
Wiring diagram
Ersteller

Schéma de branchement
Datum

Heater

Chauffage X9001-0501 de/en/fr

 Werkszeugnis 2.2 / Test report 2.2
gem. EN 10204 / acc. EN 10204

Typ: Motor-Nr.:
DNGW-160ML-02A 3354177-216
Type: Motor-No.:

Bauform: Isolationsklasse:
IM B3 F/F
Mounting: Insulation class.:

Leistung: Cos I :
13,2 kW 0,88
Output: Power factor:

Spannung: Schaltung:
440-480 V D
Voltage: Connection:

Strom: Upm: -1
21,5 A 3525 min
Current: r.p.m.:

Frequenz: mech. Schutzart:

60 Hz IP 56
Frequency: Enclosure:

Umgebungstemp.: Anzugsmoment (M A/M N):

-20/+50 °C 225 %
Ambient. temp.: Starting torque:

Leerlaufstrom: Anlaufstrom (IA /IN ):

5,6 A 650 %
No load current: Starting current:

Motorschutz: 3KL145 Nennmoment (MN):

35,8 Nm
Motor protection: 3PTC145 Rated torque:

Ex-Schutz/ Ex-protection: PTB 02 ATEX 1081

II 2 G EEx de IIC T4
Vorschrift/ Specification: EN 60034-1 / EN 50 018

Bemerkung/ Remark: PTC for sole protectio / suitable for inverter operation
Heizung / heater: 210-250V, 50W
KT40°C - F/B

Durch unsere Qualitätssicherung wird sichergestellt, daß der Motor bei Lieferung elektrisch und
mechanisch geprüft wird und in einwandfreien Zustand unser Werk verläßt.

We ensure by our quality assurance system, that the motor is checked electrically and mechanically,
before leaving our factory in perfect condition.

Loher GmbH Abt. Dokumentation

Postfach 1164 IAV54
D-94095 Ruhstorf 01.06.06

Dieses Dokument wurde maschinell erstellt und ist ohne Unterschrift gültig / This document has been produced automatically and is valid without signature

Doc.-No.: 24352
Original: German Translation

Physikalisch-Technische Bundesanstalt PTB

Braunschweig und Berlin

(1) EC-TYPE-EXAMINATION CERTIFICATE

(Translation)
(2) Apparatus and protective systems for the specified use
in hazardous areas – Directive 94/9/EC

(3) EC-type-examination Certificate Number

PTB 02 ATEX 1081

(4) Equipment: Three-phase motor types D...-160..-..

(5) Manufacturer: Loher GmbH
(6) Address: Hans-Loher-Str. 32, 94099 Ruhstorf, Germany
(7) This equipment and any acceptable variation thereto are specified in the schedule to this
certificate and the documents therein referred to.
(8) The Physikalisch-Technische Bundesanstalt, notified body No. 0102 in accordance with Article 9
of the Council 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 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 02-12137.
(9) Compliance with the Essential Health and Safety Requirements has been assured by
compliance with:

EN 50014:1997 + A1 + A2 EN 50018:2000 EN 50019:2000

(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, examination and tests of the
specified equipment in accordance to the Directive 94/9/EC. Further requirements of the
Directive apply to the manufacturing process and supply of this equipment. These are not
covered by this certificate.
(12) The marking of the equipment shall include the following:

II 2 G EEx d IIC T3...T6 resp. EEx de IIC T3...T6

Zertifizierungsstelle Explosionsschutz Braunschweig, September 16, 2002

By order:

Dr.-Ing. U. Klausmeyer
Regierungsdirektor
Page 1/3
_____________________________________________________________________________________________________

EC Prototype Test Certificates without signature and official stamp shall not be valid.
This EC Prototype Test Certificate may be circulated only without alteration.
Extracts or alterations are subject to approval by the Physikalisch-Technische Bundesanstalt.

Physikalisch-Technische Bundesanstalt • Bundesallee 100 • D-38116 Braunschweig

Original: German Translation

Physikalisch-Technische Bundesanstalt PTB

Braunschweig und Berlin

(13) SCHEDULE
(14) EC-TYPE-EXAMINATION CERTIFICATE PTB 02 ATEX 1081

(15) Description of the apparatus

The apparatus is a rotating electrical machine in protection type flameproof enclosure „d“ for the
motor part or in protection type flameproof enclosure „d“ or increased safety „e“ for the terminal
box. The motor can optionally also be equipped with a separately certified direct cable entry. In this
case the motor can also be operated without terminal box. The flameproof housing is a cast
construction which is sealed with an end shield on both sides. The shaft is supported in anti-friction
bearings and forms the shaft gap with the end shields on the DE and NDE.
The following terminal boxes can be mounted on the motor:

Terminal box Ignition protection

9-108B162.01 e
9-108B162.02 e
9-108B162.03 e
9-108B213.32 d

Alternatively other terminal boxes can also be mounted to the motor if they have a separate
certificate showing at least the standards indicated on the cover sheet.
The electrical data of the motor incl. the specifications to comply with the temperature class are
fixed in a data sheet to this EC prototype test certificate.
Max. admissible range of ambient temperatures –55 °C/67°F to 60 °C/160 °F. This range can
be limited by the terminal boxes selected or by the data sheet on the electrical designs.

(16) Test Report PTB Ex 02-12137

Page 2/3
_____________________________________________________________________________________________________

EC Prototype Test Certificates without signature and official stamp shall not be valid.
This EC Prototype Test Certificate may be circulated only without alteration.
Extracts or alterations are subject to approval by the Physikalisch-Technische Bundesanstalt.

Physikalisch-Technische Bundesanstalt • Bundesallee 100 • D-38116 Braunschweig

Original: German Translation

Physikalisch-Technische Bundesanstalt PTB

Braunschweig und Berlin
SCHEDULE TO EC-TYPE-EXAMINATION CERTIFICATE PTB 02 ATEX 1081

(17) Special conditions

None;

Additional directions for safe operation:

For mounting and attachment of components (terminal boxes, entries, cable entries, connection
parts) only such components are allowed which technically comply as a minimum to the standard
mentioned on the cover sheet and are provided with a separate certificate. Special conditions of
the components have to be observed and if required the components have also to be type-tested.
Monitoring systems have to comply with the requirements in accordance to the Directive 94/9/EC,
and EN 1127-1.

If the motor is cooled with a separately driven fan care must be taken that it can only be operated
when the separately driven fan is switched on.

(18) Essential health and safety requirements

met by standards

Zertifizierungsstelle Explosionsschutz Braunschweig, September 16, 2002

By order:

Dr.-Ing. U. Klausmeyer
Regierungsdirektor

Page 3/3
_____________________________________________________________________________________________________

EC Prototype Test Certificates without signature and official stamp shall not be valid.
This EC Prototype Test Certificate may be circulated only without alteration.
Extracts or alterations are subject to approval by the Physikalisch-Technische Bundesanstalt.

Physikalisch-Technische Bundesanstalt • Bundesallee 100 • D-38116 Braunschweig

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