Vendor shall be required to perform a basic traction motor overhaul and conversion, ensuring that the rebuilt D87B motors are converted to D87BTR motors and are fully compatible with relevant locomotive systems in NCDOT’s locomotives. All components used must match the D87BTR design currently in use on NCDOT’s F59PHI locomotives. The items noted in this section shall be the minimum tasks required for overhaul of NCDOT traction motors. Vendor shall pick up the traction motors from the NCDOT facility after providing at least three (3) day notice. NCDOT shall be responsible for loading traction motors on the pre-arranged flatbed truck(s). The gear ratio of 56:21 and the 21-tooth pinion gear (EMD part # 9556213) must be installed and verified to match the operational performance of existing fleet motors. For any work scope tasks listed below, if components are determined to be failed or defective and unable to be re-qualified, refer to Section 5.1 Replacement Components for instructions on replacement or disposition. 5.5 OVERHAUL TASKS Items listed in this section are not required to be addressed in the order listed and shall be conducted in the order specified by the Vendors' standard procedure for traction motor overhauls and conversions. Component Inspections-All inspections shall be documented, and results must be compared to baseline performance data from existing D87BTR motors. Each test result must verify that the motor will meet the same operational parameters as the motors installed on NCDOT F59PHI locomotives. All inspection documentation and reports shall be provided to NCDOT. All inspections must ensure the requalification of components to meet the performance standards of the D87BTR traction motors in NCDOT’s F59PHI fleet. Specific tasks include: 1. Conduct a nomenclature inspection, inbound visual, and mechanical inspection and note results in the inbound inspection report. 2. Conduct inbound electrical testing and note defects and results in the inbound inspection report. 3. Conduct thorough failure analysis on motor, documenting any missing and/or damaged components in the failed/defective component report. 4. Conduct a thorough electrical evaluation of the motor including insulation to ground resistance test, winding insulation resistance test, surge comparison test, D.C. high potential test, bar to bar test and armature core loss test. Note results in the component test and inspection information sheet. 5. Conduct a total indicator runout (TIR) inspection on the shaft to ensure that it is not bent or cracked and note results in the component test and information sheet. 6. Conduct fastener/threaded hole inspection and note results in the component test and information sheet. 7. Conduct nose suspension lug inspection and note results in the component test and information sheet. 8. Conduct component condition inspection and note results in the component test and information sheet. 9. Conduct a thorough evaluation of all mechanical properties of the motor including all support bearing housing measurements, PE and OPE bearing journal and housing measurements and frame qualification. Note results in the component test and information sheet. 10. Perform final ground insulation inspection with all brushes engaged and note results in the post rebuild test report. 5.6 COMPONENTS Vendor shall ensure that all components used in the conversion are identical to those used in the D87BTR motors on NCDOT’s F59PHI locomotives. Specific tasks include: 1. Disassemble motor to a point where interior components can be thoroughly inspected, and conditions can be documented. 2. Remove existing 21-tooth pinion gear from existing shaft. 3. Re-qualify the existing shaft. 4. Install a new 21 tooth pinion gear on re-qualified shaft (EMD part #9556213), ensuring the material and specifications exactly match the pinions used in the existing D87BTR motors. 5. Clean all components removed for re-qualification and bake components in a temperature-controlled oven. 6. Resin-treat armature and stator. 7. Resurface commutator surface to proper finish and undercut commutator mica. 8. Balance armature to OEM specifications. 9. Supply and install new FAG motor bearings. 10. Supply and install new brushes. 11. Re-qualify/rebuild four (4) brush holders with maximum pressure springs. 12. Remove and retire all existing gaskets. Supply and install new gaskets. 13. Remove and retire all existing cable leads and lugs. Supply and install new external cable leads, including lugs and knife terminals. New lugs shall be a half clasp connector type. 14. Supply one (1) set (per motor) of cover gaskets designed to prevent moisture ingression. Bottom commutator end covers shall be latching type. Bolt-on style covers will not be accepted. 15. Remove the existing D87B stator frame and replace it with a new D87BTR stator frame. Re-qualified stator frames are not acceptable. 16. Assemble/convert existing motor by installing new or re-qualified components into the new D87BTR traction motor stator frame. 17. Confirm frame is equipped with a threaded speed probe sensor hole at the armature end to match the existing NCDOT D87BTR motors. If sensor hole is not present, a new speed sensor hole shall be drilled and threaded to accept an EMD part # 8496807 speed sensor. 18. Install new sealed FAG bearings to align with the maintenance intervals and performance standards of NCDOT’s F59PHI fleet. Only sealed bearings that match existing specifications will be accepted. 19. Ensure each motor is equipped with a threaded speed probe sensor hole at the armature end to match EMD part #8496807 (60 tooth). Re-qualify the existing speed probe gear if present to ensure compatibility with the D87BTR setup. If the sensor hole is missing or improperly located, drill and thread the hole to match existing D87BTR specifications. 20. Align brushes to make proper contact with the commutator surface and properly set brush holder bottom clearance to proper dimensions as noted in OEM specifications. 21. Paint traction motor frame black.
