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CG TAO-659, Maintenance Handbook

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CAMTECH/97/E/TM/3.0

 

TM Maintenance Handbook                                                                                                                     January’97

 

 

37 

posed surface of V-cone of traction motor. 

18.  RDSO/WAM4/64 

Modification (type 1) to inspection covers of TAO-659 trac-

tion  motors.  (Alternative  modification  sheet  (Type  2)  which 

covers  use  of  mild  steel  inspection  cover  as  developed  by 

Gaziabad shed will be issued separately). 

19.  RDSO/WAM4/100 

Modification  to  the  protection  screen  of  air  outlets  of  TAO-

659 Traction Motor. 

20.  RDSO/WAM4/109 

Strengthening  of  Inter-turn  insulation  of  Armature  of  TAO-

659 Traction motor. 

21.  RDSO/WAM4/193 

Modification  to  head  light  circuits  of  WAM4/WAP/ 

WAG5/WAG7  Electric  Locomotives  for  working  of  head 

lights while passing neutral section. 

 

Summary of Contents for TAO-659

Page 1: ...CAMTECH 97 E TM 3 0 TM Maintenance Handbook January 97 MAINTENANCE HANDBOOK ON TRACTION MOTOR TAO 659 ...

Page 2: ...s and Brush holder 9 1 5 6 Rocker assembly 9 1 5 7 End shields 10 1 5 8 Pinoin 10 1 6 Principle of working ofD C Motor 11 Chapter 2 INSPECTION SCHEDULE 13 2 1 Maintenance activities with TM in position 13 2 2 During IA and IB schedule 13 2 3 During IS schedule 14 2 4 Flow chart for checking brush holder and Carbon brushes 16 2 5 Steps for Inspection of Tm TAO 659 17 2 6 overhauling Schedule 19 2 7...

Page 3: ...mature 28 2 8 4 Reassembly of Rocker Ring 29 2 8 5 Shrink fit of Pinion 29 Chapter 3 FAILURES AND TESTING 31 3 1 Common Failures Causes and Remedies 31 3 2 Testing of Traction Motor TAO 659 34 3 2 1 Insulation Resistance Test 34 3 2 2 Dielectric Test 34 3 2 3 Polarity Test 34 3 2 4 Voltage drop test forCommutator segments 35 3 2 5 Ovality Test 35 3 2 6 Heat Run Test 35 Appendix A LIST OF RDSO MODI...

Page 4: ... Therefore need is felt for developing a comprehensive Training Package which shall help the Artisans to learn about correct maintenance practices and which shall also serve as a useful guide to the Trainers of the Training Schools This training package is proposed to comprise of a maintenance handbook Do s Don ts booklet Lesson plan Transparencies Wall posters Videocassettes Since majority of tra...

Page 5: ...Length 390 mm Core OD 500 mm Laminations 0 5 mm thick Gr No 260 Net weight of 67 Kgs copper Winding Lap progressive Commutator Diameter New 380 mm Condemning 364 mm Useful length 140 mm Radial wear 8 mm max No of segments 276 Nos Mica thickness 1 2 mm between segments Mica under 1 8 0 2 0 cutting depth 0 Brushes Grade EG 367 or EG 105 No of holders 6 Nos Brush holder 3 Nos Size 2 x 8x43 Min height...

Page 6: ... Series Parallel Combination 3s 2p Motors on axles 1 4 2 are in series similarly Motors on axles 3 6 5 are in se ries These two series groups are con nected in parallel Though this combi nation is more economic but in case of failure of any one of the TM the loco power drastically reduces by 50 which is the main draw back of this combination This combination of Tration Motors is therefore being ph...

Page 7: ... provided which increases the number of auxiliaries and weight of the locomotive Number of contactors and links are increased Since advantages outweigh the disadvantages this combination is preferred 1 4 Fixing Arrangement The individual TM is mounted on the wheel set directly by coupling its counter part axle cap by means of o8 Nos of bolts size M 36 x 210 150 4mm pitch The Traction Motor is susp...

Page 8: ...s the bogie lugs For securing the gear case this frame is also facilitated two eyes on the top bottom and two inside threaded holes at the pinion end as shown in figure 1 4 The another counter part of the frame is axle cap which facilitated the axle bearings half of each PE CE oil pumps wickpads etc The two oil wicks containers are in communication with each other through an oil passage situated a...

Page 9: ...d to armature shaft Longitudi nal ventilating ducts are provided in the core to improve the cooling Assembled hot in a press the laminations are maintained by a cast steel armature head at pinion end and at other by the cast steel armature sleeves retained on the shaft by set ring and retaining ring at pinion end 1 5 2 1 Armature Winding It is composed of high conductivity electrolytic copper cond...

Page 10: ...mutator Commutator of TAO 659 TM consisting of a 276 nos of copper segments properly insulated from each other The function of a Commutator is to invert DC input wave to an AC wave in the armature winding It is built up of a number of small wedge shaped segments of high conductivity hard drawn copper insulated from each other by mica or micanite separators of about 0 8 mm thickness to avoid jumpin...

Page 11: ... current in the short circuit coil does not attain its full value in the reverse direction by the end of short circuit This is the basic cause of sparking at Commutator Hence the reactance voltage is mainly responsible for sparking at the brushes of DC machines 1 5 4 2 Method of improving Commutation Sparking at the brushes can be minimised with an improvement in the commutation by providing speci...

Page 12: ...1 7 where a spring presses it against the Commutator A flexible copper conductor securely fixed into brush is used to make the connection between brush and its brush holder The numbers of brush holders are usually equal to the number of main poles in DC machine The brush holder is one of the major component part of the rocker assembly One brush holder in TAO 659 contains set of 3 brushes 1 5 6 Roc...

Page 13: ...e TM TAO 659 has two nos of cast steel end shields at both the ends i e at pinion end at Commutator end Both are mounted with roller bearings for supporting the armature A grease nipple and bearing covers are also facilitated for greasing the bearings during maintenance schedule and for protecting the bearings from dust foreign bodies 1 5 8 Pinion It is made of high speed carbon steel shrinkly fit...

Page 14: ...inding is connected in series with armature as shown in figure 1 10 hence the armature current Ia and the field current are the same Back emf Eb of DC motor is given by Eb V Ia Ra Neglecting small field resistance Eb Ia VIa Ia 2 Ra Mechanical power developed Where VIa Total electrical power supplied Ia 2 Ra Power wasted in armature armature copper losses If Ta is the Torque developed by armature r...

Page 15: ...flattens out as shown in figure 1 11 Similarly we see that at low speeds high torque can be obtained and with increase in speed less torque is developed This characteristics is particularly useful for traction purposes because requirement of torque if high at starting whereas once the train is in motion the low friction resistance reduces the torque requirement for a given load This characteristic...

Page 16: ...reep Riser for solder run out and flexible contact as per SMI 34 Examine front cone for proper glaze TAO 659 TM C H E C K O F P A R T Commutator Brush Holder Rocker ring Carbon Brush Gearcase gears Motor suspension unit Connection lead wire connection bar terminal External appearance Ingress of rain water and dust Oil leakage Armature bearing Gearcase Motor suspension unit Blowing out with air and...

Page 17: ...dition to above the following points also to be inspected and work to be carried out during IC schedule 2 3 1 Commutator Clean commutator with sprit petrol and cloth Inspect visually commutator end banding and risers for any abnormality 2 3 2 Brush Gear Measure brush box to commutator clearance and adjust if required Measure spring pressure on brushes 2 2 to 2 4 kgs and check up condition Examine ...

Page 18: ...xamine outgoing interpole leads for any cracks etc Check the cover gasket of terminal cover replace if required Check connections tightness Check tightness of wooden cleats Check the gasket of inspection cover and ensure air tightness Check setting of inter pole and field both Meggering of TMs Greasing of both end bearing ...

Page 19: ...lead wire Turning of rocker ring Inspection of carbon brushes Inspection of brush holders Cleaning of insulating rod Putting brush springs on car bon brushes Rotate rocker ring in order to meet V slot U slot From CE side magnet frame Pull the lever turn the rocker ring Check the bolts for brushes terminals Repeat for each brush holder Tightening Dowel bolt Tightening rocker ring in bear ing bracke...

Page 20: ...new 380mm ii Eccentricity iii Inequality in diameter iv High bar or low bar v Under cutting depth vi Chamfering vii Width of riser viii Difference of voltage drop between bars ix Di electric test 3 Armature coil a Cleaning b Insulation test 364 mm 0 1 mm 0 06 mm 0 005 mm 1 8 mm 0 4 mm 5 0 0 0 0 0 0 0 0 0 0 0 0 4 Shaft bearing pinion a Diameter of shaft bear ing on pinion end b Diameter of shaft be...

Page 21: ...r coil lead wire and connector 0 0 0 6 Brush holder carbon brush a Cleaning checking b Spring pressure c Dimension of brush holder pocket i Thickness ii Width d Clearance from comm e Length of carbon brush f Chipping of carbon brush g Breakage of pigtail 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 7 Assembly testing a Bedding of carbon brush b Insulation resistance test c No load test Examine abnormal v...

Page 22: ... Handbook January 97 19 2 6 OVERHAULING SCHEDULE 2 6 1 Flow chart for Disassembly en Inspection cover Carbon brush Pinion bolt Pinion Outer bearing stopper pinion end Armature Magnet frame End Shield End shield Rocker ring Brush Holder ...

Page 23: ...ture lifting hook on the armature shaft at pinion side lift the ar mature by crane as shown in figure 2 2 screw the bolts in the taped holes of end shield and turn the armature slowly till the spigot joint magnet frame comes off and while checking to see that the armature is turned smoothly dismount the armature alongwith PE end shield from the stator Place the dismounted armature onthe table with...

Page 24: ...int on rocker ring and magnet frame 2 7 4 Disassembly of Armature Bearing 2 7 4 1 Pinion End Remove PE end shield from the armature the following parts are fitted on armature shaft pinion side i e inner bearing stopper bearing inner ring and outer bearing stopper After dismounting the outer bearing stopper dismount the inner bearing stopper and bearing inner ring simultaneously by using the exclus...

Page 25: ...ith handling oil power pump 1 NUT 2 PULLER 3 ABSORBER 4 DISTANCE PIECE 5 SUPPORT DISK 6 STAND 7 RAM WITH OIL POWER PUMP TOOLS ASSEMBLING PROCEDURE 1 Set Ram into stand 6 2 Screw support disk 5 on Ram 3 Put absorber 3 distance piece 4 on support disk 5 4 Set puller 2 on outer race 5 Put together outer race puller 2 on distance piece 6 Press piston up through puter race set nut 1 on piston 7 Catch r...

Page 26: ...lly for preventing the bearings from getting rusty 2 7 6 Checking of Armature Bearings Check visually for roughness scratch bruise discoloration rust etc on in ner outer race too Check while moving the rollers for wear of retainer looseness of rivets and make sure that there is no abnormality If any abnormality observed in either inner or outer ring replace with new set of bearings Check for inner...

Page 27: ...s is heavily blackened Where the Commutator surfaces is rough owing to minor flashover Procedure Apply a grindstone to the Commutator in the condition where the armature has been assembled in the motor The armature to be put on a lathe since there is possibility of eccentricity or unevenness being caused in the Commuta tor Moreover after completion of applying a grindstone blow away the stone powe...

Page 28: ...utator surface causes poor commutations The degree of turning of Commutator surface should be judged according to the conditions of commuter surface and it must be cut at minimum re quired limit 2 7 8 3 Mica under Cutting and Chamfering When the commutator surface is cut the slot between the Commutator bars shallows and chamfering of Commutator bars too become small Therefore af ter cutting under ...

Page 29: ...ter tape should be winded 2 8 REASSEMBLY OF TRACTION MOTOR TAO 659 2 8 1 Preparation for Reassembly Prepare all parts tools necessary for reassembly Clean all the parts Replace all gaskets spring washers Check the bearing conditions replace with new if required Megger stator rocker assembly and conduct High voltage High current tests 2 8 2 Reassembly of Roller Bearing Rings at PE CE 2 8 2 1 Inner ...

Page 30: ... to the stator Similarly lift the pinion end end shield by a crane to which the outer ring of roller bearing is forced fitted and filled with specified amount of grease Mount it to the pinion side of Armature shaft uniformly tighten the mounting bolts of size M12x20 mm in the following order as shown in figure 2 11 1 5 2 6 3 7 4 8 1 8 2 7 3 6 4 5 Fit all six brush holders to the rocker ring by mai...

Page 31: ...e and mount the end shield to which the outer ring of rotor bearing forced fitted duly filled with grease and fitted with grease cover to the commutator side of stator by means of tightening of bolts of size m 18x40 or m 18x45 without spring washer Now keep the stator vertically keeping commutator end shield at bottom with the help of a crane 2 8 5 Shrink fit of Pinion Wash and clean the pinion wi...

Page 32: ... the pinion has cooled off completely measure and record l dimen sion which is depth of shaft with respect to pinion outer surface Make sure that the allowance between the pinion and the armature shaft end is as follows I0 l entering allowance of pinion 1 9 to 2 2 mm where l0 dimension before shrink fitting l dimension after shrink fitting After making sure that the pinion entering allowance is sa...

Page 33: ...f carbon brushes iv Sticking of brushes Remove dust and check gap to holder case v Copper picking or spotting Copper powder sticks to commutator surface and oxygenated film becomes un equal Change grade of brush vi Unbalance of brush current Colour change in pigtail of brush Strike on commutator surface and contact of brush to be checked vii Wearing out of brushes Lift up of carbon brush causes sp...

Page 34: ... by dust and foreigner between bars Inspect and clean the commutator bars with petrol v Abnormal temperature rise Examine ventilation and load and adjust vi Black bar Adjust commutation vii Vibration Examine radial as well as lateral clearances of bearing vibration of Bogie frame unbalancing of armature 2 OVERHEAT BEARINGS i Bruise scratch rust Replace it with a new one ii Improper quality of grea...

Page 35: ...of insulation rub bing cutting marks on insulation DC component to be systematically examined so as to find troubled part Repair the damaged part according to insulation ii Armature bearing grease Examine the quality and quantity of grease Replace if required iii Gearcase Excess charge of gear oil Check the oil level in gearcase and maintain as prescribed Bad packing and oil sealing Replace condem...

Page 36: ...d to continue the safety operation for a considerable period without electric breakdown The test voltage to be supplied with testing transformer and duration for various parts of TM is given below HIGH VOLTAGE TEST STATOR 2 KV for 1 minute ROCKER 3 KV for 1 minute HIGH CURRENT TEST MAIN POLE 700 Amps for 2 minutes INTERPOLE 700 Amps for 2 minutes 3 2 3 Polarity Test The polarity test must be done ...

Page 37: ...s a thorough investigation must be made for the cause and the trouble must be repaired In making these tests please note that if an excessively large current is applied the winding will be over heated Precautions In case of carrying out voltage drop tests of the commutator segments particular care must be given to the fact that the current must not be switched ON and OFF by means of the electrodes...

Page 38: ...horough investigation must be made for the cause and the trouble must be repaired In making these tests please note that if an excessively large current is applied the winding will be over heated Precautions In case of carrying out voltage drop tests of the commutator segments particular care must be given to the fact that the current must not be switched ON and OFF by means of the electrodes in c...

Page 39: ...f comm pole of TAO 659 TM 08 RDSO WAM4 164 Prevention of suspension bearing oil leakage into the stator frame 09 RDSO WAM4 165 Provision of thread locking compound on bolts screws 10 RDSO WAM4 166 Modified support plate assembly for main pole core of TAO 659 TM 11 RDSO WAM4 167 Modified adjustment punching for main pole core assembly to TAO 659 TM 12 RDSO WAM4 168 Modified adjustment shim and sili...

Page 40: ...s use of mild steel inspection cover as developed by Gaziabad shed will be issued separately 19 RDSO WAM4 100 Modification to the protection screen of air outlets of TAO 659 Traction Motor 20 RDSO WAM4 109 Strengthening of Inter turn insulation of Armature of TAO 659 Traction motor 21 RDSO WAM4 193 Modification to head light circuits of WAM4 WAP WAG5 WAG7 Electric Locomotives for working of head l...

Page 41: ... traction motor 08 ELRS SMI 29 Resurfacing of commutator speed feed tool 09 ELRS SMI 31 Under cutting chamfering of TM commutator 10 ELRS SMI 39 Checking of airflow in the commutator of TAO 659 TM 11 ELRS SMI 41 Improving the insulation of the stator internal connection of TAO 659 TM Field Coil Ground Insulation 12 ELRS SMI 42 Non interchangeability of BHRR on TAO 659 TM 13 ELRS SMI 51 Bar to bar ...

Page 42: ...ocomotives 24 ELRS SMI 170 Checks on main pole and interpole coils of TAO 659 TM 25 ELRS SMI 171 Fitment of Mica lex insulator on TAO 659 Traction motor 26 ELRS SMI 174 Improved interconnector layout for TAO 659 Traction motor 27 ELRS SMI 180 Draft rehabilitation procedure for the mechanical portion of traction motor type TAO 659 of BG AC Electric Locomotives 28 ELRS SMI 181 Neutral setting of bru...

Page 43: ...C with trolley 02 No 10 Baking dynamo meter with test bed 01 No 11 Brazing extractor 02 set 12 Brazing tongs with transformer 01 No 13 Hand operated shearing machine for insulation 01 No 14 Traction motor assembly fixture 01 set 15 Grease guns 02 sets 16 Commutator soldering irons 06 Nos 17 Surge tester 01 No 18 Bearing extractor insertor for TM 01 No 19 Tick welding kit 01 No 20 2 5 KV Megger 02 ...

Page 44: ...embly 03 Nos 37 Rocker assembly locking gear opening tightening spanner 03 Nos 38 Chamfering tool 02 sets 39 Mica under cutting tool 02 sets 40 Nose pliers 05 Nos 41 Spanner 24 27 mm 04 Nos 42 Spanner 30 32 mm 04 Nos 43 Spanner 17 19 mm 04 Nos 44 Box spanner 30 mm 04 Nos 45 Box spanner 22 mm 04 Nos 46 Pliers 05 Nos 47 Screw driver 05 Nos 48 One pound hammer 05 Nos 49 Badi one mtr long Dia 1 inch 0...

Page 45: ...ature connection due to human error a Put reverser in idle position either up or down b Switch on the battery c Put an insulation strip at reverser armature tips in other words cut off H0 side feed from armature side d Put test lamp across commutator side tip and earth point e If lamp does not glow i e connections are correct not to be interchanged Time of checking 5 to 10 minutes Check should be ...

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