GP/WSR Relay

Disassembly
a. Remove screw and washers to release the coil leads.
b. Remove screw and washers to separate the contact assembly portion of the relay from the pole
piece.
c. Remove screw and washers which attach the armature assembly to the spring bracket; this will
also free springs. Remove screws and washers to release finger support from the spring bracket.
d. To release the N.O. & N.C. contacts, remove screws and washers. With the N.O. & N.C. contacts
removed, the armature can be separated from the finger block after ends of the movable contact
finger shunts are taken off the screws. The fingers can be now be slid out of the spring bracket along
with the springs.
e. Removal of screw and washer will allow the disassembly of core and coil from the pole piece.
Assembly
Assemble the relay in the reverse order of disassembly.
MAINTENANCE OF CONTACTS
As the contact tips wear out or burn away, the contact gap becomes progressively greater and the
contacts over travel become less. Therefore, adjustment of the fixed contacts is necessary to restore
normal contact gap and over travel. Do not attempt to make adjustments when silver tip is worn
through. As this point, replace contact finger assemblies. Do not interchange relay cores between
relays of different types.
ARMATURE AND CONTACT ADJUSTMENT
Special tools required
a. Contact adjuster to Fig. 2
b. Contact overtravel gauge to Fig.3
c. Armature gap gauge checking the armature gap to Fig.4
Remove No.3 normally open contact and insert the armature gap gauge as shown in fig.5. The
proper gap gauge to be used can be determined from the minimum and maximum gap limits. The
armature gap can be adjusted by slightly bending the pole piece. Look for interference at the
armature knife edge before bending the pole piece.Replace contact removed in step 1 after
armature gap is adjusted.
Normally closed contacts
Install over travel gauge as shown in Fig. 6. Use contact adjuster and bend N.C. contacts at right
angle (see fig.7) until a 0.0 to 0.1 mm gap is obtained between all contacts. Use feeler gauge to
check the contact gap. Remove gauges and operate armature by hand and see that fingers make
contact at the same time.
Normally open contacts
Install overtravel gauge as shown in fig8. Block the armature is closed condition to hold the gauge in
position. Using contact adjuster, bend N.O. contacts at right angle (see Fig.9) until 0.0 to 0.1 mm gap
is obtained between all contacts. Use feeler gauge to check the contact gap. Remove gauges and
block from relay and operate armature by hand. See that fingers make contact at the same time.
 OVERHAULING PROCEDURE OF GROUND RELAY

Disassembly
a. Remove screws and washers to release coil leads. Remove screws and washers to separate the
interlock assembly portion of the relay from the pole piece and core.
b. Remove screws and washers which attach the armature and finger support assembly to the spring
bracket. This will also free springs. Remove screws and washers to release finger support from the
spring bracket.
c. To release N.C. & N.O. contacts, remove nuts and washers. With the N.C. & N.O. contacts
removed, the armature can be separated from the finger block after ends of the movable contact
finger shunts have been taken off the screws. Finger can now be slid out of the spring bracket along
with the spring.
Reassembly
Reassembly of the relay is in the reverse of disassembly.
Contact maintenance
As the contact tip wears out or burns away, the contact gap become progressively greater and the
contact over-travel decreases. Therefore, periodic inspection and adjustment of the fixed contacts
is necessary to restore normal contact gap and over travel. If the silver contact tips have worn or
burnt through or if experience shows tips will be worn through prior to the next inspection period,
replace the contacts.
ARMATURE AND CONTACT ADJUSTMENT
The following special tools are required in adjusting the contact and armature gaps.
a. Contact adjuster to Fig.2
b. Contact over travel gauge to Fig.3
c. Armature gap gauge checking the armature gap to Fig.4
Remove No.3 normally open contact and insert the armature gap gauge as shown in fig-5.The proper
gap gauge to be used can be determined from the minimum and maximum gap limits. If the gap is
excessive, check for a cracked or broken finger block or bent pole piece. Correct by replacing the
damaged parts. If the gap is less than allowable tolerance, check for any obstructions at the
armature pivot knife edge or where the armature extends through the finger block.
Normally closed contact adjustment
Install over travel gauge as shown in fig.6. Use the contact adjuster gauge and bend the N.C. contacts
at right angles until a 0.0 to 0.1 mm gap is obtained between all contacts (see Fig.7). Use a feeler
gauge for checking gap. Remove the gauges and operate the armature by hand. See that all contacts
make at the same time.
Normally open contact adjustment
Install the over travel gauge as shown in fig.8. Block the relay armature in the closed condition to
hold the gauge in position. Use the contact adjuster gauge and bend the N.O. contacts at right angle
as shown in fig.9 until 0.0 to 0.1 mm gap is obtained between all contacts. Use feeler gauge to check
the contact gap Remove the gauges and the block from the relay and operate the armature by hand.
See that all contacts make at the same time.