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Maintenance Handbook On Hitachi Traction Motor HS-15250A of Electric Locomotive-Eng
Maintenance Handbook On Hitachi Traction Motor HS-15250A of Electric Locomotive-Eng
OF INDIA
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MAINTENANCE HANDBOOK
ON
HITACHI TRACTION MOTOR (HS – 15250A)
OF
ELECTRIC LOCOMOTIVES
TARGET GROUP – TECHNICIANS AND SUPERVISORS OF ELECTRIC LOCO SHEDS/WORKSHOPS
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CAMTECH/E/2005/TM(H)/1.0
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January, 2005
Centre
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MAINTENANCE HANDBOOK
ON
HITACHI TRACTION MOTOR (HS – 15250A)
OF
ELECTRIC LOCOMOTIVES
TARGET GROUP – TECHNICIANS AND SUPERVISORS OF ELECTRIC LOCO SHEDS/ WORKSHOPS
FOREWORD
With increasing freight and passenger traffic, reliability and availability of electric
locomotives have become very important. Proper maintenance of traction motor is vital to ensure
good reliability and availability of electric locomotives in service.
CAMTECH has prepared this handbook to cover all essential aspects of maintenance and
overhauling of Hitachi Traction Motor type HS 15250A. It describes various maintenance schedules,
overhauling procedure and trouble shooting for common failures.
I am sure the book will prove to be very useful for our maintenance staff in electric loco sheds
and workshops.
Traction motor is one of the most important equipment of electric locomotives which
provides driving power to the wheel. Its proper upkeep and maintenance is necessary to ensure good
reliability and availability of electric locomotives in service.
This handbook on maintenance of Hitachi Traction Motor type HS 15250A has been prepared
by CAMTECH with the objective of making our maintenance personnel aware of correct
maintenance and overhaul techniques to be adopted in field.
It is clarified that this handbook does not supersede any existing provisions laid down by
RDSO or Railway Board. The handbook is for guidance only and it is not a statutory document.
I am sincerely thankful to Director, Std./ Elect./ RDSO/ LKO for his valuable comments. I am
also thankful to all field personnel who helped us in preparing this handbook.
Technological upgradation and learning is a continuous process. Hence feel free to write us
for any addition/modification in this handbook. We shall highly appreciate your contribution in this
direction.
Foreword iv
Preface vi
Contents viii
Correction Slip ` xii
1. GENERAL DESCRIPTION 01
1.1 INTRODUCTION 01
1.2 TECHNICAL DATA 01
1.3 CONSTRUCTIONAL FEATURES 04
1.4 POWER SUPPLY ARRANGEMENTS 06
3. OVERHAULING 14
3.1 GENERAL 14
3.2 INCOMING INSPECTION/ TESTING 14
3.3 GENERAL CLEANING 15
3.4 DISMANTLING 16
3.5 CLEANING OF ARMATURE BEARING 23
3.6 CHECKING OF ARMATURE BEARINGS 23
3.7 CLEANING OF ARMATURE, STATOR AND OTHER PARTS 24
3.8 OVERHAULING OF ARMATURE 24
3.9 OVERHAULING OF ROCKER RING (BHRR & BRUSH HOLDERS) 27
3.10 OVERHAULING OF MAGNET FRAME (STATOR) 28
3.11 OVERHAULING OF PE & CE BRACKETS 29
3.12 OVERHAULING OF TERMINAL AND INSPECTION COVERS 29
3.13 OVERHAULING OF EARTHING PLUNGER ASSEMBLY 29
3.14 CHECKING OF PINION 29
3.15 REASSEMBLY OF ARMATURE BEARINGS 30
3.16 REASSEMBLY OF TRACTION MOTOR 32
3.17 FITTING OF CARBON BRUSHES 36
3.18 TEST THE MOTOR ON NO LOAD 36
3.19 FINAL ASSEMBLY CHECKING 36
3.20 INSPECTION AND TESTING PROFORMA FOR OVERHAULING
OF TRACTION MOTOR 37
3.21 SPECIAL TOOLS FOR TRACTION MOTOR OVERHAULING 42
Chapter No. Description Page No.
4. COMMON FAILURES 43
REFERENCES 50
ISSUE OF CORRECTION SLIPS
The correction slips to be issued in future for this handbook will be numbered as follows :
CAMTECH/2004/E/TM(H)/C.S. # XX date---------
Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards).
CHAPTER 1
GENERAL DESCRIPTION
1.1 INTRODUCTION
It is a six pole dc series wound motor with commutating poles. It is of the forced
ventilation system and cooling air is supplied by the separate motor blower. It is
attatched to its respective driving axle of bogie by nose suspension and tractive effort is
transmitted from the traction motor to the axle through gear device with a single
reduction. In this traction motor axle taper roller suspension drive (bearing) is used in
place of sleeve bearings.
1.2.5
Armature bearings Pinion side Commutator side
Type of bearings NU 330 NJ324 + HJ324
Manufacturer NSK/ SKF/ FAG NSK/ SKF/ FAG
Radial clearance of free 0.165/0.210mm 0.155/0.195mm
bearing when new
Fitment between inner race Intf = 0.045/0.086mm Intf = 0.039/0.075mm
and shaft
Fitment between outer race Intf = 0.046mm to Intf = 0.041mm to
and bearing bracket Clr = 0.018mm Clr = 0.016mm
Charge of lubricant (total 925 gm. 864 gm.
volume)
1.2.6 Commutator
Diameter with new : 400mm
Minimum usable diameter : 380mm
Riser width : 20mm
Mica groove depth : Max. 2.5 mm
Min. 1.2mm
Mica groove width : 1.1 mm
Length of working face : 146 mm
Mica thickness : 1.16 mm
The core and commutator are fitted directly onto the armature shaft. The
armature is lap wound with kapton covered
conductors. The armature coil leads are TIG welded
to commutator risers in order to improve the
strength and have low voltage drop. The armature
coils are held down in the core slots by Epoxy glass
wedges and the end windings are secured by Res-I-
glass bands. The wound armature is finally Vacuum
Pressure Impregnated with solventless epoxy resin
insulating varnish.
Figure 1.2 Armature
1.3.2 Commutator
The commutator is of arch bound construction built-up with hard drawn silver
bearings copper segments which are insulated with micanite segments and are
assembled with moulded mica insulation between steel V-rings. After assembly, the
commutator is statically and dynamically seasoned to ensure stability. The complete
armature is dynamically balanced. The commutator outer mica V-ring is protected with
anti-creepage PTFE tape/ring.
1.3.2.1 Commutation
The mmf developed by the interpole must be stronger than the armature mmf in
the neutral zone, because this mmf has to cancel the armature mmf and in addition
induce an emf in short circuit coil which opposes reactance voltage and the voltage drop
at the brushes.
This motor is 6 pole type motor and the brush holders are
mounted on the rocker ring that is fixed to the bearing bracket at
commutator side by four bolts. The brush holders and carbon
brushes can be inspected by rotating the rocker ring until each
brush holder comes to the inspection window. The brush holders
are mounted on the rocker ring by one insulating rod. Brushes
can be changed without dismantling the motor. Flame retardent
modified ETFE(fluonlex) cable is used for brush gear
connections.
Figure 1.4 Rocker Assembly
1.3.5 Arcing Horns
Arcing horns are provided near the brush holders on the rocker ring to minimize
the damage in an event of a flash over.
CHAPTER 2
Following maintenance schedules are to be followed for traction motors (type HS-
15250A).
2.2 IA SCHEDULE
5.5 Check the flexible leads are firmly secured to the brush Secure
holders.
5.6 Check the tightness of rocker lock pin and rocker holding Ok
bolt.
5.7 Check the bellow net & bellow condition. Ok
5.8 Rotate rocker if found necessary. Ok
6. Examine the motor for signs of flashover, overheating, No
loose connections and damaged insulation. abnormality
7. Check the cables of all traction motors visually for any No damage.
rubbing or damages.
8. Check the MP & IP bolts and if required, apply the ‘M’ Ok
seal/RTV compound.
9. Check visually from PE endshield net for any abnormality. No
abnormality
10. Check visually earthing brush connection, terminal covers, No
cables cleats, both ends end shields and overall appearance abnormality
for any abnormality.
2.3 IB SCHEDULE
Carry out the following inspections and fill up the proforma.
S. Inspection & work to be carried out Standard Actual
No. value value
1. Clean inspection covers before removing them and check Clean, ok
their condition.
2. Examine the commutator thoroughly with the help of Clean, well
torchlight or hand lamp for a uniformly coloured, well polished
polished surface, free from bar marked, groove and high
mica.
3. Remove copper beads from the commutator surface with Clean
fine cloth.
4. Check commutator riser for solder run out. No damage
5. Check the following through inspection window up to
possible extent.
5.1 Check the condition of arcing horns and clearance. Ok, 11.5-
13.5 mm
5.2 Check brush holder and positive/ negative lead insulators Clean
for proper glaze and clean them.
5.3 Check the carbon brushes for chipping, mechanical No damage
damages and breakage of pig tails.
5.4 Check the size of carbon brushes and if required, change New-
the brushes which are likely to wear beyond the permissible 64mm
limit before the next maintenance schedule. condemn -
(Exchange limit 30mm) 25mm
5.5 Check the flexible leads are firmly secured to the brush Secure
holders.
5.6 Check the tightness of rocker lock pin and rocker holding Free
bolt.
5.7 Check the bellow net & bellow condition. Ok
5.8 Rotate rocker if found necessary. Ok
6. Examine the motor for signs of flashover, overheating, No
loose connections and damaged insulation. abnormality
7. Check the cables of all traction motors visually for any No damage.
rubbing or damages.
8. Check the MP & IP bolts and if required, apply the ‘M’ Ok
seal/RTV compound.
9. Check visually from PE endshield net for any abnormality. No
abnormality
10. Check visually earthing brush connection, terminal covers, No
cables cleats, both ends end shields and overall appearance abnormality
for any abnormality.
2.4 IC SCHEDULE
Carry out the following inspections and fill up the proforma.
S. Inspection & work to be carried out Standard value Actual
No. value
1. Clean inspection covers before removing them and Clean, ok
check their condition.
2. Blow out the interiors of the motor. Blown
3. Clean commutator with fluff – free cloth, moistened Clean
with a suitable solvent (such spirit).
4. Examine the commutator thoroughly with the help of Clean, well
torchlight or hand lamp for a uniformly coloured, well polished
polished surface, free from bar marked, groove and
high mica.
5. Remove copper beads from the commutator surface Clean, no
with fine cloth and inspect visually commutator end abnormality
banding and risers for abnormality.
6. Check interpole lead for any crack. ok
7. Clean hands with suitable solvents & cloth. Clean.
8. By Rotating the rocker ring , check the following.
8.1 Measure spring tension of each spring and check their 2.82 kg. to 3.44
condition and record in format ‘A’. kg. per brush
8.2 Check up spring pins by hand. ok
8.3 Check the carbon brushes for chipping, mechanical No damage.
damage and breakage of pig tails.
8.4 Measure the length of each carbon brush and record in New – 64 mm
format “A”. Replace them which are likely to wear Condemn 25
beyond the permissible limit before the next mm
maintenance schedule
(Exchange limit 30mm)
8.5 Check the flexible leads are firmly secured to the brush Secure
holders.
8.6 Check each brush is free in its pocket. If it is sticking, Free
wipe the brush with a fluff-free cloth moistened with a
suitable solvent and also clean the brush pocket.
8.7 Check the condition of arcing horns and measure Ok, 11.5 – 13.5
clearance and record in format ‘A’.. mm
8.8 Measure the gap (clearance) between brush holder 2 – 4 mm
bottom and commutator and record in format ‘A’.
8.9 Check brush holder and positive/ negative lead Clean
insulators for proper glaze and clean them.
8.10 Tight the rocker lock pin and rocker holding bolt. Tighten
FORMAT “A”
(i) Size of carbon brushes (in mm) : New – 64mm, Condemn- 25 mm
(Exchange limit – 30 mm)
TM carbon Brush ACTUAL VALUES
holder No. TM1 TM2 TM3 TM4 TM5 TM6
1.
2.
3.
4.
5.
6.
(ii) Brush holder spring tension : 3.44 kgf/ brush ± 10% (with new brush)
2.82 kgf/ brush ± 10%(with condemn brush)
CHAPTER 3
OVERHAULING
3.1 GENERAL
3.3.1.1 Cloth
Cloth used for cleaning of traction motor parts should be non-fluffy, clean and dry,
unless it is moistened with a recommended solvent.
Cotton waste or fluffy cloth should not be used for cleaning brushgear, commutator
etc. since left over flufts or fibres may cause failure.
Warning
As all solvents are toxic to a varying degree, the minimum amount of solvent should
be used and the workshop area should be well ventilated.
Some solvent when heated become more toxic and therefore, the cleaning of hot
surface should be avoided.
Smoking should be prohibited in all areas where solvents are used, since some are
highly inflammable.
When using solvents, the operator should wear plastic gloves and not rubber since
some solvents can be absorbed through the skin with harmful results.
i. For cleaning of electrical winding parts having silicon based, class ‘H’
insulation ORION 77 may be used.
ii. For cleaning of mechanical parts ORION 510 diluted with kerosene oil in
the ratio of 1:6 may be used.
Note: Ensure that oil based cleaning solutions used for general body cleaning are
not allowed to come in contact with windings.
3.4 DISMANTLING
3.4.1 General
Bring the motor from testing place to dismantling place.
Disassembly of the traction motor must be performed at a clean place with no dust,
and the parts must be handled carefully not to damage and rust.
Observe the orders of disassembly correctly.
The conditions on the work (for instance, temperature, pressure, amount of grease
supplied etc.) must be observed strictly.
Inspection cover
Carbon brush
Pinion nut
Pinion
Armature en
End Shield (PE)
The tapped hole in the shaft is sealed with a rubber screwed plug to
prevent gear lubricant from entering and blocking the oil ways. Follow the
procedure mentioned below:
Remove all traces of gear lubricant from the pinion, the shaft end and the
oil injection plug using a solvent, such as white spirit.
Remove the plug which seals the oil injection hole, using the plug driver/
screw driver.
Remove gear lubricant if found its way past the plug.
Assemble the oil pump and injector attachment, fit the high-pressure pipe
and fill the pump reservoir.
Do not fit the pump handle at this stage.
Open the pump relief valve using the fingers.
Operate the pump until air bubbles cease to the expelled with the oil.
Close the relief valve again.
Operate the pump handle socket with the fingers until system is full of oil
and resistance of pumping is felt.
Fit the pump handle and continue pumping raising the pressure gradually
and pausing after each stroke to let the pressure built up at the pinion
seating.
A sudden loss of pressure accompanied by movement of the pinion
indicates its release.
OIL TANK
PISTON
ADAPTER
PINION
PINION NUT
INJECTOR BRACKET
2. Method for removal of pinion when extraction fails due to leakage of oil
Procedure - I
1. Clean the face of the pinion & shaft with petrol or suitable cleaning solvent.
2. Wipe and clean the pinion faces & shaft with dry cloth.
3. Apply thick layer of ‘M’ seal putty on both side faces of the pinion at the mating
points of pinion bore periphery and shaft, to seal the same.
4. Allow the putty to cure at room temperature for 12 hours.
5. After the putty gets cured, heat the pinion slightly with the gas torch.
6. Extract the pinion with oil injection method which is explained earlier.
7. If oil still leaks out through ‘M’ seal putty, repeat the process as per clauses 1 to
6.
Procedure – II
1. Clean the faces of the pinion & shaft with petrol or suitable cleaning solbent.
3. While applying extraction force, pour hot oil (200 deg. C approx.), over the
pinion.
4. If the pinion is not getting extracted, apply oil pressure simultaneously by using
oil injection. For this purpose, a small metallic spacer may be used in between
shaft end and ram of the puller so as to enable fitting of oil injection plug into
the shaft.
NOTE
i. The procedure II of pulling and heating the pinion to be used only after oil
injection with ‘M’ seal fails repeatedly.
ii. The use of excessive pressures may cause the pinion to be ejected violently, it
may then rebound and reseat itself on the shaft.
iii. Excessive pressures may also cause permanent distortion of the pinion bore.
iv. Refit the plug in the oil injection hole immediately after removal of the pinion to
prevent the ingress of foreign material.
v. Protect the pinion bore and shaft extension from damage and corrosion.
Dismount the outer bearing stopper (pinion side) by using the exclusive tools as
shown in fig. 3.2
3.4.5.1 Preparation
The armature is to be dismounted from the stator with the bearing bracket (end
shield) at the pinion side kept fitted. Before dismounting the armature, make preparation
as follows:
Remove all the carbon brushes from the brush holders by disconnecting terminal
bolts of carbon brushes lead wires and rotating rocker ring.
After removing the carbon brushes, wind a press board on the commutator for
preventing the commutator surface from being scratched.
Dismount the bearing cover from the bearing bracket (CE end shield) utilizing the
tapped hole for pulling out.
Dismount the outer bearing stopper (CE) and thrust collar of roller bearing (CE)
from the armature shaft.
3.4.5.2 Disassembly
Remove all bolts tightening the bearing bracket (PE end shield),
screw M24 bolts into three tapped holes in the bearing bracket
(PE end shield) and dismount the bearing bracket (PE end
shield).
Figure 3.3b
Fit the armature lifting hook on the armature shaft end at the
pinion side, lift the armature by crane, screw the bolts in the
tapped holes of bearing bracket (PE end shield) in turn, turn the
armature slowly till the spigot joint of bearing bracket (PE end
shield) and magnet frame comes off, and while checking to see
that the armature is turned smoothly, dismount the armature and
bearing bracket (PE end shield) together from the stator.
Figure 3.3c
Never support the armature with the coil, glass bind part or commutator part.
Figure 3.4
Dismount the CE bearing bracket (end shield) from the magnet frame utilizing the
tapped hole for pulling out.
As the outer ring of roller bearing will come out together with the bearing frame,
pay full attention when handling the bearing bracket. Write the serial number with
white paint to CE end shield.
Remove one special reamer bolt (dowel bolt) that is fixing the rocker ring to the
magnet frame commutator side. (This work is already performed during removal of
carbon brushes for rotating the rocker ring).
Remove the rocker from the magnet frame and write serial number with white paint
to rocker ring and magnet frame.
When the bearing bracket (end shield) at the pinion side is removed from the
armature, the following parts are fitted on the armature shaft pinion side:
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 exclusive tools as shown in the fig.
3.5.
Figure 3.5 Bearing Inner Ring and Inner Bearing Stopper Pulling out (PE)
Figure 3.6 Bearing Inner Ring and Inner Bearing Stopper Pulling Out (CE)
Item no. Description Tool mark Qty.
1 Hook TL-12 2 (1 set)
2 Keeper plate TL-3 1
3 Nut TL-4 1
4 Double end stud TL-14 4
5 Support disk TL-6 1
6 Nut M24 -- 4
7 Ram with oil power pump -- 1
8 Bolt M24 L40 -- 2
Ram
In case where the following conditions are recognised, apply turning to the
commutator surface:
If eccentricity, unequally in diameter, high-bar, low-bar etc are generated in
commutator, cut the commutator as per given table.
When correcting the commutator surface by the lathe, align the armature shaft as
shown below in figure 3.10
Commutator surface
Chuck
Centre
Steady rest
A
Push the shaft end of armature shaft on the commutator side by the centre of
lathe, align the armature shaft by using the bearing fitting portion A, on the pinion side
as reference and chuck the shaft end on the pinion side. Apply a steady rest to the
bearing-fitting portion B, on the commutator side.
When the commutator surface is cut, the slot between the commutator bars
shallows and chamfering of commutator bars, become too small. Therefore after
cutting, under cutting, chamfering should be performed with suitable tool. This is to be
done as per RDSO SMI No. 31. Details of under cutting & chamfering are shown
below in figures 3.11 to 3.14.
A. Correct
B. Excessively large
C. Excessively deep
D. Left unchamfered
E. Left ungiven under cutting
Figure 3.13 Details of under cutting and chamfering Figure 3.14 Example of under cutting
3.8.2.5 Cleaning
The creepage area surface, should be kept in good condition. The area should
be cleaned and painted with anti track varnish or E 233 varnish. The procedure for
painting this surface is as follows:
After keeping the armature at room temperature for 2 hours or longer, dry its
cleaned surface with portable dryer.
Make sure that the carbon brush moves smoothly into the pocket of brush holder.
Check the condition of arcing horns, if found flashed/ damaged, repair/replace the
same.
Check the condition of threads of pig tail fixing holes on brush pocket and tap it if
required.
Apply bectol red varnish on pocket from outside area.
Clean rocker ring (BHRR).
Check the condition of Teflon sleeve of insulating rod assembly, if required
replace it.
Check the tightness of all 06 nos. insulating rod assemblies.
Check the tightness of positive and negative insulating rod and also check their
stud threads, if found damage/slack, replace the insulating rod.
Check the condition of lead wire for flash/ insulation damage, if required replace/
repair.
Check the binding of lead wire with ‘C’ clamp, if found loose/damage, rebind it.
Check IR of each insulator and lead wire by 1 kV meggar, if IR found less, replace
the insulator.
Fit the overhauled brush holders on rocker ring and connect the lead wires.
Carry out HV testing on 3 KV for one minute and measure the leakage current and
record.
Check the condition of gear case mounting lug, bushes if found worn out/ablong
replace it.
Bake the frame for 5 hours at 100 deg.C and varnishing to be done with anti-track
varnish or E 233 red varnish by spraying and again bake the frame for 3 hours at
100 deg.C.
Check IR value by 1 kV meggar and record.
Check the pole bore dia at main pole and commutating pole at centre.
Check the distance of magnet frame between connecting faces of axle suspension
tube as per SMI-207.
Perform H.V. test by applying 2.5 kv a.c. supply for one minute and measure the
leakage current of the stator and record.
Check the condition of lead wire terminal for ovalness and crackness.
Measure distance between lug mounting bush and stator collar and record.
Check the PE & CE side housing end shield bore dia and record.
Check the brazing joints of field coils (MP) by injecting high current and ensure
the temperature rise at joints by hands. This is to be carried out as per RDSO SMI
no. RDSO/ELRS/SMI/ 151 dtd. 08.12.92 and also record the voltage drop.
Check the wire mesh, if found broken/ damage, repair/ replace it.
Apply anti-track varnish or E 233 red varnish on both end brackets from inside.
Check the condition of earthing brush, if found condemn in size, replace it.
3.15.1 Preparation
Reassemble the armature bearings carefully after cleaning and be careful with
ingress of dust, etc. during reassembling process.
When reassembling the bearings do not strike or pressure fit them unduly.
Shell Alvania grease no.3/Servogem RR-3/ Lithon-3 grease to be used and never
mix with grease of other brands.
Fill grease in the bearing bracket and bearing cover at the PE & CE side as shown in
fig.3.15 (PE side 925 gm. and CE side 864 gm.)
Figure 3.16
Shrink fit outer bearing stopper too by the same procedures.
Outer race
Bearing bracket
Piston
Grease
Figure 3.17 Inserting bearing Outer Ring into Bearing Bracket (PE)
Check each bolt and nut for looseness and retighten as required. Each bolt and
nut should be tightened with tightening torque as shown in table below.
Nominal size bolt and nut Tightening torque (in kgf. cm)
Min. value Standard value Max. value
M6 41.0 51.1 61.6
M8 97.4 122.0 146.0
M10 196.0 245.0 295.0
M12 355.0 418.0 503.0
M16 815.0 1020.0 1225.0
M20 1600.0 2000.0 2420.0
M24 2800.0 3500.0 4200.0
M30 5500.0 6900.0 8300.0
M36 9600.0 12100.0 14500.0
Rocker ring
Magnet frame
Brush holder
Armature
Bearing bracket (PE)
Deflector (pinion end)
Pinion
Carbon brushes
Inspection covers
Mount the bearing cover to the bearing bracket and tighten the bearing cover by the
bolts
Insert a round steel bar to the bolt hole of bearing bracket, lift the bearing bracket by
a crane and mount it to the pinion side of armature shaft as shown in fig.3.20
Figure 3.20
Keep the magnet frame up right. Don’t tilt it. If the magnet frame is left tilted, when
inserting the armature into the magnet frame, the commutator and/or armature coil
may contact the brush holder, main pole coil, interpole coil etc. and may damage
them.
Insert the armature into magnet frame kept upright, with the armature lifting hook
installed on the shaft end at pinion side and the armature lifted by crane turning the
commutator side downward.
When inserting the armature, screw guide bolts into bearing bracket clamping built
holes in the magnet frame as the guide for the bearing bracket.
Lower gently the armature keeping lifted by crane. Do not lower suddenly and insert
the armature assembly unduly; otherwise bruise is caused in the bearing inner race
face.
When the bearing bracket has been fitted to the due part of magnet frame, remove
the guide bolt and clamp the bearing bracket with the bolts.
Tighten the bearing bracket bolts while confirming that there is no abnormality,
turning the armature. So long as the armature is assembled correctly, it can be turned
smoothly, but if it fails to turn smoothly, re-tighten the bearing clamping bolts
uniformly.
Turn the armature
slowly
Guide bolts
Armature
Magnet frame
Perform shrink fitting of pinion immediately by putting together the tally marks
on the armature shaft and the pinion. Tighten the pinion nut lightly and allow to
cool naturally.
After the pinion has cooled off completely, release the pinion nut. Measure and
record “l” dimension 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 (advancement)
= 1.92 to 2.00 mm.
where l0 = dimension before shrink fitting
l = dimension after shrink fitting
After making sure that the pinion entering allowance is satisfactory, insert the lock
plate and tighten the pinion nut.
If the pinion entering allowance is not sufficient, remove the pinion and perform
shrink fitting again. This must be done until perfect result have been achieved.
3.17 FITTING OF CARBON BRUSHES
Adjust the clearance between commutator & brush holder. It must be 2 to 4 mm
(standard: 3mm)
Check the gap between brush holder and riser. (4mm minimum)
Fit the new (bedded) carbon brushes of same recommended make & grade in brush
holders.
Check the free movement of carbon brushes in their pocket.
Make the supply connection (armature and field connections in series) and ON the
variable d.c. supply.
Increase voltage gradually till the TM gains the speed 895 rpm, allow it to run and
check for any abnormality such as abnormal noise from bearings, vibration etc.
Run the motor at 895 rpm for two hours (in both directions) and record the
temperature of bearings, the steady state temperature rise should not exceed 35 to 45
deg. C above ambient.
3.19 FINAL ASSEMBLY CHECKING
Check ovality of commutator in assembled traction motor. (0.04 mm max.)
Check the insulation resistance with 1 kv meggar between:
i) Main pole circuit and earth.
ii) Inter pole circuit and earth.
iii) Main pole and inter pole circuit.
It should be 10 Mohm min.
Fit the P.G. clamps , terminal box covers and cleats. Also fit all inspection covers,
grease nipples.
Provide dummy cover on bellow portion.
Provide earthing plunger assembly.
Paint the motor from outside by grey paint.
CAMTECH/E/2005/TM(H)/1.0
Tools Combination of tools
Tool Description Outer Bearing Bearing Bearing Bearing Inserting Inserting Oil injector Common Qty.
No. bearing inner ring inner ring outer ring outer ring bearing outer bearing outer to remove tool (Nos.)
stopper pulling pulling out pulling pulling out ring into ring into pinion
pulling out out (PE) (CE) out (CE) (PE) bearing bearing frame
(PE) bracket (CE)
(PE)
TL-2 Hook 2
TL-3 Keeper plate 1
TL-4 Nut 1
TL-5 Double end stud 4
TL-6 Support disk 1
TL-8 Double end stud 4
TL-9 Distance piece 1
TL-10 Absorber 1
TL-11 Hook 1
TL-12 Hook 2
TL-14 Double end stud 4
TL-15 Puller 1
TL-16 Distance piece 1
TL-17 Absorber 1
TL-18 Puller 1
Spanner for pinion nut 1
Nut M16 4
TL-25 Nut M24 4
Bolt M24L40 2
Stand 1
Pump 1
TL-19 Ram 1
Hose 6
Oil injector 1 set
Adapter 1
TL-115 Grease gun
January, 2005
1
Commutator stone 1
42
Maintenance Handbook on Hitachi Traction Motor(HS-15250A) of Electric Locomotives January, 2005
CAMTECH/E/2005/TM(H)/1.0 43
CHAPTER 4
COMMON FAILURES
vii. Traction motor power Check and attend the damaged cable
cable insulation damaged and secure all the cable properly
due to rubbing with providing the proper rubber gaskets.
metallic body.
ix. Traction motor cable Check the terminal box and attend
connection flashed in the same. Tightness of cable
terminal box due to loose connections to be checked.
connection etc.
iv) Axle box bearing seizure Check the axle box bearing and
or bearing damaged. grease condition for metal contacts &
replace the axle box if required.
CHAPTER 5
1. Add a few drops of mineral oil to the solvent while cleaning the bearings and
their components to protect them from rust.
2. Always use torque wrench for tightening nuts & bolts as recommended tightening
torque value.
3. Always ensure that the modification/ special maintenance instructions are being
followed.
4. Ensure that the new carbon brushes are of the same grade, as the old ones, while
replacing the carbon brushes.
5. Ensure that the cables are secured properly and not rubbing with any metal parts.
6. Ensure that the washers and locking plates are properly provided while
assembling the traction motor parts.
7. Ensure that the oven/ induction heater/ oil bath heater is working at the
recommended temperature.
8. Always use Shock Pulse Meter (SPM) for monitoring the condition of bearings
and keep a record of the bearings.
9. Ensure that the all specified clearances are maintained properly.
10. Ensure that the carbon brushes are removed before application of solvent for
cleaning the traction motor.
11. Always slip a thin clean pressboard between brush holder and the commutator
while replacing a brush holder to prevent damage to the commutator surface.
12. Always check the clearance between the under side of the brush holder and the
commutator when refitting a brush holder.
13. Ensure that the lubricating oil/ compound of approved make are in use.
5.2 DON’TS
1. Don’t use cotton waste or fluffy cloth for cleaning brush gear, commutator since
left over fluffs or fibres may cause electrical or mechanical failures.
2. Don’t reuse used grease or lubricant oil.
3. Don’t carry any alteration or modification without the approval of component
authority.
4. Don’t over tight cable cleats because cable insulation may damage.
5. Don’t use carbon brushes of different grades on same traction motor.
6. Don’t use higher voltage meggar than specified.
7. Don’t use detergent or any other volatile cleaning solvent/ agent, for cleaning
inside the traction motor, junction box, insulator etc.
8. Don’t mix up the greases of same grade but different make.
9. Don’t compromise with clearances of bearings.
10. Don’t carry out the commutator resurfacing/ turning unless grooves or stepped
wear or ovality is found.
11. Don’t allow the wearing of carbon brushes beyond specified condemning size.
12. Don’t soak the carbon brush in solvent as solvent will gradually ooze out,
effecting the commutation and will cause the brush to jam in the pocket.
13. Don’t run motor at high speed under no load condition for long period because
of the possibility of rollers skid, which can cause scuffing of the track and roller
surface and premature bearing failure.
14. Don’t forget to refit the plug into the oil injection hole immediately after
removal of the pinion to prevent the ingress of foreign matter.
15. Don’t strike the commutator surface, the commutator sleeve and riser. (High bar
or low-bar of the commutator may be caused).
16. Don’t strike the glass bind with a hammer or polish with a file. In case that the
armature is set, it shall be supported by the armature core and never with the
commutator or glass bind.
17. Don’t remove the film on the commutator surface, unless there is special reason
such as bad commutation, abnormal wear of carbon brush and so on. (Film
adjustment may get disarranged).
18. Don’t polish the commutator surface with sand paper or a file.
19. Don’t apply stone to the commutator during high speed operation or in vibration.
(Bias wear or deformation of the commutator may be caused).
20. Don’t release the brush spring of brush holder from hand suddenly. (The brush
may be broken or hands injured).
ANNEXURE – A
Special Maintenance Instructions for Traction Motor type HS-15250A.
ANNEXURE ‘B’
REFERENCES
4. Field study and Literature collected from various electric loco sheds/ workshops.
OUR OBJIVECTIVE