06 Maintenance Manual For JD160B Traction Motor

Maintenance Manual For JD160B Traction Motor
JD160B 牵引电动机检修手册
牵引电动机检修手册
Rev.
Rev. 1.0
版本：
版本：第 1.0 版
Doc. Name： Traction Motor Page 1 of 84 Project Name： Ethiopia Freight E-Loco
Date： 2015.09 Rev.： 1.0
Revision history 修改记录
版本
Rev.版本 Date of Reason for modification 更改的 Modified clauses and content 更
号 modification 主要原因改的章节与内容
更改日期
1.0 2015-09-25 Newly established 初始创建 All 全部
Date： 2015.09 Rev.： 1.0
Table of Contents
目录
1 Function and purpose 功能及用途 ·························································································· 5

2 Technical Description 说明 ········································································································ 6
2.1 Technical parameter 技术参数 ······························································································ 6
2.2 Structure and technical description 结构及技术说明······················································ 7
2.3 Work principle 工作原理 ·········································································································· 9
3 Safety description 安全说明 ······································································································11
4 Usage and operation 使用操作 ······························································································· 13
5 Installation and commissioning 安装和调试 ····································································· 13
5.1 Installation 安装 ······················································································································· 13
5.2 Commissioning 调试 ·············································································································· 13
6 Preventive maintenance 预防性维修 ···················································································· 14
6.1 Maintenance levels 维修等级 ······························································································ 14
6.2 Maintenance Plan 维修计划 ································································································ 16
6.3 Maintenance Works 维修工作 ····························································································· 18
6.4 Correction Work 修正工作 ···································································································· 24
7 Corrective maintenacne 修复性维修 ····················································································· 28
7.1 Fault Treatment 故障处理 ····································································································· 28
7.2 Disassembly 拆卸 ··············································································································· 35
7.3 Replacement Principle 更换原则························································································ 37
7.4 Dismantling 拆解 ····················································································································· 39
7.5 Maintenance 维修 ··················································································································· 43
7.6 Assembly 组装 ························································································································· 50
7.7 Reassembly 重新安装 ··········································································································· 58
7.8 Parameter Setting and Limit Table 参数设置与限度表 ············································ 58
7.9 Flaw Detection Range 探伤范围 ························································································ 59
7.10 Coming into Use/Function Test 投入使用/功能试验 ··················································· 60
8 List of Special Tools, Equipment, Consumables and Spare Parts 专用工具及设
备、易损件及备件清单 ························································································································ 60
8.1 Special Tool 专用工具 ············································································································ 61
8.2 Equipment 设备 ······················································································································· 62
8.2.1 Chemical Cleaner 化学清洗剂 ························································································ 62
8.2.2 Coating Composition 涂层成分 ··················································································· 64
8.2.3 Lubricant 润滑剂 ·········································································································· 64
8.2.4 Other Equipment 其它设备 ··························································································· 65
Date： 2015.09 Rev.： 1.0
8.3 Measurement and Test Equipment 测量和试验设备 ···················································· 65
8.4 Wearing Part and Spare Part list 易损件及备件清单 ···················································· 65
8.5 Application Material 运用材料 ····························································································· 67
9 Waste Processing Scheme 废弃物处理方案 ······································································ 67
9.1 General Rules 总则 ··················································································································· 67
9.2 Driving System Performance Relative to Environment:与环境有关的驱动系统性能：
································································································································································ 68
9.3 Recycling Use 循环使用 ·········································································································· 68
9.4 Abandoning 摒弃 ························································································································ 68
10 Transportation and Storage 运输与贮存 ··········································································· 69
10.1 Transportation 运输 ········································································································· 69
10.2 Storage 贮存 ·························································································································· 69
11 Daily Maintenance and Maintenance for Long-term Reservation 日常保养和长
期备用的保养说明 ································································································································· 73
11.1 Description on Daily Maintenance 日常保养说明 ··························································· 73
11.2 for maintenance description on long-term spare parts.长期备用的保养说明 ········ 73
12 Parts Catalogue and Spare Parts Procurement 零件目录及备件采购 ··················· 75
12.1 Parts Catalog, See Table 25 零件目录，见表 25 ························································ 75
12.2 Storage and Purchase of Spare Parts 备件的仓储及采购········································ 77
13 Unpacking and Inspection 开箱及检查 ·············································································· 79
14 Others 其他 ··································································································································· 79
15 缩写和索引 Abbreviation and Index···················································································· 81
Date： 2015.09 Rev.： 1.0
1 Function and purpose 功能及用途
The traction motor is an important component that the locomotive carries out
interconversion between mechanical energy and electrical energy. It is installed on the
bogie of the locomotive, connected with the wheel set by drive device. When the
locomotive is in the traction state, the traction motor converts electrical energy into
mechanical energy to drive the operation of the locomotive. When the locomotive is the
state of electrical braking, the traction motor converts the mechanical energy of the train
into electrical energy to produce the braking force of the train.
牵引电机是机车进行机械能和电能相互转换的重要部件。它安装在机车转向架上，通
过传动装置与轮对相连。机车在牵引状态时，牵引电机将电能转换成机械能，驱动机车运
行。当机车在电气制动状态时，牵引电机将列车的机械能转化为电能，产生列车的制动力。
The traction motor is used for the traction of Ethiopia 7200KW high power AC drive
six-axis locomotive, with the advantages such as small volume, high power, high
efficiency, wide constant power range and small maintenance amount.
本牵引电机用于埃塞俄比亚大功率交流传动 7200KW 六轴机车牵引，具有体积小、功
率大、效率高、恒功范围宽、维护量小等优点。
The operation environment requirements of this traction motor are as follows:

本牵引电机运行环境要求：
a) Altitude: ≤2500m, the power limitation may appear when the altitude is above
1400m, the ambient temperature approaches +40℃ and it carries out continuous
operation at the maximum power condition.
a) 海拔：≤2500m, 在海拔高于 1400m、环境温度接近+40℃且连续在最大功率状态
下运行时可能出现功率限制。
b) Ambient temperature: Maximum ambient temperature is 50℃ (shading position);
minimum ambient is -25℃.
b) 环境温度：最高环境温度为 50℃（遮荫处）；最低环境温度-25℃。
c) Maximum relative humidity: The monthly average maximum relative humidity is
95% at wettest month (the monthly average minimum temperature is 25℃ at this month).
c) 最大相对湿度：最湿月月平均最大相对湿度为 95%（该月月平均最低温度为 25℃）
。
d) The locomotive is affected by rain, snow, wind and sand and occasional
Date： 2015.09 Rev.： 1.0
sandstorms, but the cooling air entering into the motor must be filtered.
d) 机车受雨、雪、风沙和偶有沙尘暴的侵袭，但进入电机内的冷却空气必须过滤。
e) Outline (appearance) drawing.外形（外观）图。
2 Technical Description 说明
2.1 Technical parameter 技术参数
T The technical parameters of the motor are shown in Table 1.

电机技术参数详见表 1
Table 1 Technical Parameter Table of JD160B Asynchronous Traction Motor
表 1 JD160B 异步牵引电机技术参数表
Motor Model 电机型号 JD160B
Continuous power 持续功率 1225KW
Rated voltage (fundamental wave) 1420V
额定电压（基波）
Rated current (fundamental wave) 569A
额定电流（基波）
Rated speed 额定转速 1720r/min
Maximum speed 最大转速 3452 r/min
Rated frequency 额定频 58.1HZ
率
Rated torque 额定转矩 6802Nm
Date： 2015.09 Rev.： 1.0
Starting torque 起动转矩 9717Nm
Maximum current 最大电流 814A
Constant power range 恒功范围 1720r/min～3452r/min
Insulation class 绝缘等级 Class 200 200 级
Cooling mode 冷却方式 Forced ventilation 强迫通风
Driving method 传动方式 Unilateral bevel wheel 单侧斜齿轮
Suspension mode 悬挂方式 Roll journal sticking 滚动抱轴
2.2 Structure and technical description 结构及技术说明
2.2.1 Stator 定子
The stator consists of stator core, stator winding and other components, its structure
is shown in Figure 1.
定子由定子铁芯、定子绕组等零部件组成，其结构如图 1 所示。
1 – Junction box; 2 – Stator core; 3 – Support frame; 4 – End hoop; 5 – Stator

winding; 6 – Slot wedge.
1-接线盒； 2-定子铁芯； 3-支撑架； 4-端箍；5-定子绕组；6-槽楔。
Figure 1 Stator Structure Drawing
图 1 定子结构图
2.2.1.1 The motor base is all-welded composite structure without the enclosure, it
consists of front pressing ring and rear pressing ring of motor base made of cast steel,
lamination, tooth support and rib plate.机座为无机壳全焊接复合结构，由铸钢制成的机座
前压圈和后压圈、冲片、齿压板以及筋板五部分构成。
2.2.1.2 The connecting line of stator coil leads out of the coil directly; the connecting
line overlaps each other and is welded firmly with silver brazing.定子线圈联接线直接由线
圈引出来，联接线相互搭接并用银铜焊焊牢。
Date： 2015.09 Rev.： 1.0
2.2.1.3 The outlet box is overall structure, it is welded on the motor base, the lead
wire is fixed on the wire holder, the lead wire clamp for lead wire fixation of the
locomotive is installed on the outside of the junction box.出线盒为整体结构，焊接在机座
上，引出线固定于接线座上，固定机车引线的引线夹安装在接线盒外面。
2.2.1.4 All the stator coils adopt workblank installation, and are carried out whole
vacuum pressure dipping paint treatment.定子的所有线圈均采用白坯定装，经整体真空压
力浸漆处理。
2.2.2 Rotor 转子
The motor consists of revolving shaft, rotor core, pressing ring, conducting bar, end
ring and inner oil seal, etc., as shown in Figure 2.
转子由转轴、转子铁芯、压圈、导条、端环和内油封等组成，见图 2 所示。
1 2 3 4 5 6 7
1 – Shaft; 2 – End ring; 3 – D end pressing ring; 4- Core; 5- Conducting bar; 6 – End
plate; 7 – N end pressing ring
1-转轴；2-端环；3-D 端压圈；4-铁芯；5-导条；6- 端板；7- N 端压圈。
Figure 2 Rotor Structure Drawing
图 2 转子结构图
2.2.2.1 The rotor core and pressing ring are installed on the shaft directly, the
conducting bars are embedded in the groove of iron core flatly, local position carries out
wedge ramp, the rotor core consists of 0.5mm no-orientation cold rolled electrical steel
sheet. 转子铁芯和压圈直接安装在转轴上，导条平放嵌在铁芯槽内，局部楔紧, 转子铁
芯由 0.5mm 无取向冷轧电工钢片组成。
2.2.2.2 The conducting bar and end ring are welded together by medium-frequency
induction welding. 导条和端环通过中频感应焊接为一整体。
2.2.3 The bearing is insulated bearing imported from foreign country, the driving
end uses roller bearing N332, non driving end uses cylindrical bearing NU320 and four
point contact ball bearing QJ318. The driving end bearing is carried out circulation
lubrication of gear box oil, the lubricating oil is Mobilube SHC gear oil; the non driving
end bearing adopts lubricating grease, the grease grade is lubricating grease UPG#2
Date： 2015.09 Rev.： 1.0
from Royal Purple, the grease replenishing device is provided, it is convenient to
replenish the lubricating grease.轴承是从国外进口的绝缘轴承，传动端使用的是滚柱轴承
N332，非传动端使用的是圆柱轴承 NU320 和四点接触球轴承 QJ318。传动端轴承由齿轮
箱油循环润滑，润滑油为美孚公司的路宝 SHC 齿轮油；非传动端轴承采用润滑脂润滑，
润滑脂牌号为紫皇冠公司的 UPG#2 润滑脂，并设有润滑脂补充装置，方便补充润滑脂。
2.3 Work principle 工作原理
2.3.1 Main Operating Principle of Traction Motor 牵引电机的主要运行原理

After the stator passes three-phase alternating current, a rotating magnetic field is
produced in the air gap, the magnetic field generates induction current in the conducting
bar of the rotor after cutting the conducting bar of the rotor, it will produce electrodynamic
force when the charged conducting bar of the rotor is in the rotating magnetic field of air
gap, to make the rotor rotate in the same direction of rotating magnetic field of the stator.
Because the current in the conducting bar of the rotor is produced by induction that the
conducting bar of the rotor cuts the magnetic field of air gap generated by the stator
winding, the rotor speed can only be lower than the rotating speed of magnetic field of air
gap, they will never be synchronized, otherwise the conducting bar of the rotor carries
out synchronous rotation with the magnetic field of air gap, the conducting bar of the
rotor no longer cuts magnetic field to generate the induction current and generate
electrodynamic force, the rotor could not rotate, therefore the motor which operates
according to this principle is called as asynchronous motor.
定子通上三相交流电后，在气隙中产生旋转的磁场，该磁场切割转子导条后在转子导
条中产生感应电流，带电的转子导条处于气隙旋转磁场中就要产生电动力，使转子朝定子
旋转磁场的同一方向旋转。由于转子导条中的电流是因转子导条切割由定子绕组产生的气
隙磁场才感应产生的，所以转子的转速只能低于气隙旋转磁场的转速，永远不可能与其同
步，否则转子导条与气隙磁场同步旋转，转子导条不再切割磁场产生感应电流和产生电动
力了，转子也不可能旋转了，所以称按这种原理运行的电机为异步电动机。
2.3.2 Speed Governing Principle of Traction Motor 牵引电机的调速原理
At present, the speed governing of asynchronous traction motor for the locomotive
widely uses VVVF technology. The formulas of speed, electromotive force and
electromagnetic torque of asynchronous motor are as follows:
现在机车用异步牵引电机调速普遍采用变频变压调速技术。异步电机转速、电动势和
电磁转矩公式如下：
Speed n=60f/p（1-s）
转速 n=60f/p（1-s）
Electromotive force E1=4K1 f Ns Kdp1φ
电动势 E1=4K1 f Ns Kdp1φ
Electromagnetic torque Tem=CφIrCOS ϕ
电磁转矩 Tem=CφIrCOS ϕ
n: speed; f: stator frequency; s: slip ratio; p: number of pole-pairs of motor; E1：

electromotive force; K1：waveform factor; Ns：number of series turns per phase; Kdp1：
Date： 2015.09 Rev.： 1.0
winding coefficient; φ： magnetic flux; Tem：electromagnetic torque; C: constant; Ir：
rotor current; COS ϕ ：power factor.
n：转速；f：定子频率；s：转差率；p：电机极对数；E1：电动势；K1：波形系数；
Ns：每相串联匝数；Kdp1：绕组系数；φ：磁通；Tem：电磁转矩； C：常数；Ir：
转子电流；COS ϕ ：功率因数。
Changing the stator frequency can change the motor speed, with the increase of
stator frequency, the motor speed increases accordingly, if the voltage does not increase,
which will lead to the field weakening of the motor, the motor torque will reduce, when the
magnetic field of the motor drops to a very low value, the motor cannot output enough
torque, which cannot meet the load requirements; on the other hand, when carrying out
low frequency starting, if the voltage is too high, which will cause the motor saturation.
Therefore, when the asynchronous motor carries out frequency conversion, the voltage
should also maintain a certain proportion of change in a certain range, this speed control
method is called as VVVF. The VVVF of asynchronous traction motor mainly adopts the
speed control methods such as constant torque frequency control (a constant flux
frequency control section, the magnetic flux and current is constant), constant flux
frequency control and constant power frequency control.改变定子频率即可改变电机转
速，随着定子频率的增加，电机转速相应增加，如果电压不增加，将导致电机磁场减弱，
电机转矩将降低，电机磁场降到很低时，电机不能输出足够的转矩，不能满足负载要求；
另一方面，低频起动时，如果电压很高，将导致电机过分饱和。因此异步电机变频时，电
压也应在一定范围内保持一定比例的变化，这种调速方式称之为变频变压调速。异步牵引
电机变频调速主要采用了恒转矩变频调速（恒磁通变频调速的一个区段，磁通和电流不
变）、恒磁通变频调速、恒功率变频调速等调速方式。
The traction and regenerative braking principle of asynchronous motor: Within the
range of 1>s>0, the electromagnetic torque and rotor have the same rotation direction, it
drags the rotor to rotate, the motor converts the electrical energy absorbed form the
inverter into mechanical energy, overcoming the resistance of the locomotive to drive the
operation of the locomotive, it is the operation state of the motor. s=1 is starting operation
state. Within the range of s<0, the rotor and rotating magnetic field of the stator have the
same rotation direction, the rotor speed n is larger than the synchronous speed n1 of the
motor, the electromagnetic torque and rotor have the opposite rotation direction, which
prevents the rotation of the rotor, the motor converts mechanical energy of the
locomotive into electrical energy to transmit to the inverter, which generates brake torque
for the locomotive, the motor is in the operation state of the generator, it is called as
regenerative braking. The equivalent circuit of JD160B asynchronous traction motor is
shown in Figure 3.
异步电机牵引与再生制动原理：在 1>s>0 的范围内，电磁转矩与转子转向相同，它拖
动转子旋转，电机从逆变器吸收电能转换为机械能，克服机车阻力驱动机车运行，处于电
动机运行状态。s=1 为起动运行状态。在 s<0 的范围内，转子转向与定子旋转磁场一致，
转子转速 n 大于电机同步转速 n1，电磁转矩与转子转向相反，它阻碍转子旋转，电机将机
车机械能转换为电能传送给逆变器，对机车产生制动转矩，电机处于发电机运行状态，称
之为再生制动。JD160B 型异步牵引电机等效电路如图 3 所示。
Date： 2015.09 Rev.： 1.0
U1
M
3
I1 R1 L1s L2s' R2'
U1/(√3) R2'/s
Lh
Figure 3 Equivalent Circuit of JD160B Asynchronous Traction Motor

图 3 JD160B 型异步牵引电机等效电路图
3 Safety description 安全说明
The related safety description is shown in Table 2.

相关安全说明详见表 2
Table 2 Danger Warning Signs
表 2 危险警告标识
Danger
In order to prevent possible personal injury, the occupational and industrial
program must be strictly followed！They also include the warning for special
danger when operating the subsystem and equipment！
危险
为防止可能的人身伤害，必须严格遵循的职业和工业程序！它们也包括操作
子系统和设备时，关于特殊危险的警告！
Warning
In order to prevent the damage and destruction of subsystems and
equipment, the occupational and industrial program must be strictly followed！
This refers to daily work and the work which must be performed in special
working pressure, abnormal weather conditions and operation mode！
警告
为了防止子系统和设备损伤和毁坏，必须严格遵循的职业和工业程序！这也
与日常工作、以及在特殊工作压力、异常天气条件和操作模式下必须执行的工作
有关！
Notice
It refers to relevant technical requirements that the users of the subsystem
or equipment must pay special attention to.
注意
指子系统或设备的使用者必须特别注意的有关技术要求。
Notice！The maintenance work must be implemented by professional and technical
personnel trained.
Date： 2015.09 Rev.： 1.0
注意！必须由经过培训的专业技术人员实施维修工作。
Danger！The maintenance work can be implemented only after the traction motor
is confirmed to carry out power failure.
危险！必须确认牵引电动机断电后才能进行维护作业。
Notice！The maintenance work is carried out with specified tools.
注意！使用规定的工具进行维修工作。
Notice！The exhaust port of the motor should be covered before cleaning the
locomotive.
注意！清洁机车前，应将电机排风口盖住。
Notice！It should be determined that the motor and the bogie will not move before
starting the maintenance work, the motor should be placed safely.
注意！开始维修工作前，应确定电机和转向架不会移动，电机安全放置。
Warning！It should be carefully inspected before opening any component of the
motor, to ensure that the motor has been carried out discharge process in accordance
with the requirements.
警告！打开电机任何部件前，应仔细检查，保证电机已按照要求进行放电处理。
Notice！The torque wrench must be used when fastening the nuts and bolts;
other wrenches should not be used. Please refer to Table 3 for tightening torque.
注意！对螺母和螺栓紧固，必须使用扭矩扳手，不得使用其他扳手。拧紧转矩请
参照表 3 进行。
Table 3 Tightening Torque Table of Bolts and nuts (The allowable tolerance of
tightening torque is ±20% )
表 3 螺栓和螺母拧紧转矩表（拧紧转矩的允许公差为±20%）
Nominal
dimension of
thread M6 M8 M10 M12 M16 M24
螺纹公称尺
寸
Tightening
torque (Nm)
8 20 40 70 170 600
拧紧转矩
(Nm)
Date： 2015.09 Rev.： 1.0
1) M10 fastening bolt of observation cover plate, with
tightening torque of 22N.m±20%;
1）观察盖板 M10 紧固螺栓，拧紧转矩 22N.m±20%；
2) Oil cup M10, with tightening torque of 13N.m±20%;
2）油杯 M10 ，拧紧转矩 13N.m±20%；
3) M12 fastening bolt of wire holder, with tightening torque
of 50N.m±10%;
Tightening
3）接线座 M12 紧固螺栓，拧紧转矩 50N.m±10%；
torque of special
4) Magnetic plug M30X1.5-ST-PM, with tightening torque
parts:
of 79N.m±20%.
特殊件拧紧
4）磁性螺塞 M30X1.5-ST-PM，拧紧转矩 79N.m±20%。
转矩：
5) M12 tightening bolt of N-end outer bearing cover(see
No. 6.20 in Fig.8), with tightening torque of 79N.m±20%.
5）N 端外轴承盖（参见图 8 序 6.20）M12 紧固螺栓，拧紧
转矩 57N.m±5%；
6) M12 fastening bolt of N-end outer bearing cover(same
as above), with tightening torque of 60N.m±10%.
6 ） N 端外轴承盖（同上） M12 紧定螺钉，拧紧转矩
60N.m±10%。
4 Usage and operation 使用操作
Refer to related sections of use and operation of the locomotive.

参见机车使用操作相关章节。
5 Installation and commissioning 安装和调试
5.1 Installation 安装
Refer to the installation of traction motor of driving system.

参见驱动系统牵引电机的安装。
5.2 Commissioning 调试
Refer to related sections of the commission of the locomotive.

参见机车调试相关章节。
Date： 2015.09 Rev.： 1.0
6 Preventive maintenance 预防性维修
6.1 Maintenance levels 维修等级
Before causing serious damage, in order to check and eliminate possible errors
operation, the regular, careful maintenance work should be carried out, regular
inspection cycle and its contents are shown in Table 4.
为了在发生严重损害前，检查和排出可能的错误操作，应进行定期的，仔细的检修工
作，定期检查周期及其内容见表 4.
The following sections have detailed instructions for maintenance work which
should be carried out. The final maintenance cycle should be based on the experience of
early operation stage.
下列章节对应进行的检修工作做了详细的说明。最终的检修周期长短应根据初期操作
阶段的经验而定。
Faults or abnormal operating conditions show that the electrical or mechanical parts
of the motor have overload condition, at this point, proper maintenance and testing work
should be immediately carried out.
故障或不正常操作条件表明电机的电气或机械部分有过载的情况，此时，应立刻进行
恰当的维护和试验工作。
Table 4 Maintenance Level
表4 维修等级
Maintenance Operation Interval
Description Main Content 主要内容
Level Mileage Period
说明
维修等级运行里程数间隔期
Visual 1000 km 1000 公
2 weeks Visual inspection
VI inspection 里
2周目视检查
目视检查
Carry out visual
inspection, clean
magnetic bolt. The
magnetic bolt should be
Inspection 6 cleaned after operating
100000 km
level 1 months 15000 km firstly.目视检
I1 100000 公里
检查 1 级 6 个月
查，清洁磁性螺栓。在首
次运行 1.5 万公里后应清
洁磁性螺栓。
Replenish lubricating
grease at motor bearing
Date： 2015.09 Rev.： 1.0
(N-end)
电机轴承（N 端）补充润
滑脂
Carry out visual
inspection, clean
magnetic bolt;
Inspection Replenish lubricating
200000 km 1 year
level 2 grease for the motor
I2 200000 公里· 1年
检查 2 级 bearing (N end)
目视检查，清洁磁性螺栓；
电机轴承（N 端）补充润
滑脂
Clean traction motor,
carry out dismantle
inspection to check
bearing, winding and
insulation conditions of
Inspection traction motor, as well as
400000 km 2 years
level 3 replace rubber pad,
I3 400000 公里 2年
检查 3 级 O-ring and lubricating
grease.清洁牵引电机、解
体检查牵引电机上的轴
承、绕组及绝缘情况，更
换橡胶垫及 O 型密封圈及
润滑脂。。
Clean the traction motor,
replace the bearing,
rubber pad and O ring on
Maintenance the traction motor,
800000 km 4 years
level 1 inspect the winding and
R1 800000 公里 4年
维修 1 级 insulation.清洁牵引电机、
更换牵引电机上的轴承、
橡胶垫及 O 型密封圈，检
查绕组及绝缘
Clean the traction motor,
replace the bearing,
rubber pad and O ring on
Maintenance the traction motor,
1600000 km 8 years
level 2 inspect the winding and
R2 1600000 公里 8年
维修 2 级 insulation.清洁牵引电机、
查绕组及绝缘
Maintenance 16 Clean the traction motor,
3200000 km
level 3 维修 3 years replace the bearing,
R3 3200000 公里
级 16 年 rubber pad and O ring on
the traction m otor,
Date： 2015.09 Rev.： 1.0
inspect the winding and
insulation.清洁牵引电机、
查绕组及绝缘
Unplanned
UM maintenance
计划外维修
Remarks: For the operation mileage and interval period of each maintenance level,
whichever is earlier.
备注：对于每一维修等级下的运行里程数和间隔期，以先到为准
Remarks： Assumes that the locomotive running 200 000 km.
注：假设机车年运行 20 万公里。
6.2 Maintenance Plan 维修计划
The maintenance plan of the motor is shown in Table 5.

电机维修计划详见表 5
Table 5 Maintenance Plan
表 5 维修计划
No. Contents 维修手册
序号/维修手册
序号维修手册检修内容 VI I1 I2 I3 R1 R2 R3 UM Remaks 备注
索引号
1 Appearance inspection of traction motor
牵引电机外观检查
Inspect the outgoiung line, wire clip, terminal sign and √ √√√√ √ √
nameplate of the motor.检查电机出线、引线夹、线端标志
及铭牌
Inspect the installation of cover plate of junction box. √ √ √ √ √ √ √

检查接线盒盖板的安装
Looseness of bolts, spring washers 螺栓的松动、弹簧垫圈 √ √ √ √ √ √ √

Dust and water immersion 灰尘和水的浸入 √ √ √ √ √ √
Leading wire and wire clip state, terminal contact 引线和线 √ √ √ √ √ √
夹状态、端子接触
Oil leakage of bearing 轴承漏油 √ √ √ √ √ √
Cleaning magnetic bolt 清洁磁性螺栓 √ √ √ √ √ √
2 Inspectionbefore disassembling the motor 电机解体前
的检查
Measuring the insulation resistance of the winding against √ √ √
ground 测量绕组对地绝缘电阻
Operation state of bearing 轴承运行状态 √ √ √
Inspect the motor vibration 检查电机振动情况 √ √ √
3 Rotor inspection 转子检查
General inspection 一般检查
Inspect the surface condition of end ring and conducting √ √ √
bar 检查端环、导条表面状况
Date： 2015.09 Rev.： 1.0
序号/维修手册
索引号
Inspect the welding condition between the conducting bar √ √ √
and end ring.检查导条与端环焊接情况
Inspect the fastening state of balance weight.检查平衡块紧 √ √ √
固状态
Carry out cleaning and drying for the rotor.转子进行清洗烘 √ √ √
干
Shaft, bearing 轴、轴承
Diameter of bearing block 轴承挡的直径 √ √ √ √
The runout of conical surface of shaft extension 轴伸端锥面 √ √ √ √
跳动量
Disassembly, cleaning, inspection and oil injection of √ √ √ √
bearing 轴承的拆卸、清洗、检查和注油
Radial clearance of bearing 轴承径向间隙 √ √ √ √
Axial clearance of bearing 轴承轴向间隙 √ √ √ √
The ultrasonic wave and magnetic powder inspection √ √ √ √
should be carried out for the shaft.应对轴进行超声波和磁
粉探伤
Inspect whether there is abnormal noise 检查有无异常声音 √ √ √ √
Inspect whether there is oil leakage 有无漏油 √ √ √ √
Inspect whether the bearing retainer has abnormal wear, √ √ √ √
whether the rivet has looseness.轴承保持架有无异常磨损，
铆钉有无松动
Inspect whether the bearing appears overheating.轴承有无 √ √ √ √
过热
Replenish the lubricating grease for the motor bearing (N √ √ √ √ √
end).电机轴承（N 端）补充润滑脂
Replace the bearing 更换轴承 √ √ √ √
4 Stator 定子
Carry out cleaning and drying for the stator 定子清洗、烘干 √ √ √
The joint state of stator coil 定子线圈接头部位的状态 √ √ √
The exterior insulation state of stator coil 定子线圈外部绝缘 √ √ √
状态
They should be replaced if the insulation and joint of the √ √ √
connecting line appear damage.联接线的绝缘或接头如损
坏则应更换
Measuring the insulation resistance of coil against ground √ √ √
测量线圈对地绝缘电阻
Measuring cold DC resistance of the coil 测量线圈冷态直流 √ √ √
电阻
Carry out whole dipping paint 整体浸漆 √ √ √
Withstand voltage test 耐压试验 √ √ √
New product: 6200V, 1min (power frequency)
新品： 6200V、1min（工频）
Repair product: 4650V, 1min (power frequency)
维修品： 4650V、1min（工频）
5 端盖
End cover:端盖
Date： 2015.09 Rev.： 1.0
序号/维修手册
索引号
Carry out appearance inspection and cleaning.进行外观检 √ √ √
查并清洗
Inspect the state of spigot of end cover, through large pore, √ √ √
bearing cover and seal ring.检查端盖止口、通大气孔、轴承
盖、封环状态
Replace O ring 更换 O 型密封圈 √ √ √
6 Speed sensor 速度传感器
Insulating strength inspection 绝缘强度检查 √ √ √ √
Transmitting pulse count inspection per turn 每转发送脉冲 √ √ √
数检查
7 Temperature sensor 温度传感器
Ground insulation inspection 对地绝缘检查 √ √ √ √
Resistance measurement 电阻值测量 √ √ √
8 Junction box 接线盒
Open the cover to inspect the wire holder, outgoing line, √ √ √ √
and fasten the fixing bolt.
开盖检查接线座、引出线，并紧固固定螺栓。
9 Assembly, test and others 组装、
组装、试验及其它
Withstand voltage test of insulation 绝缘耐压试验 √ √ √ √
New product: 6200 V、1min (power frequency)
新品：6200 V、1min（工频）
Repair product: 4650 V、1min (power frequency)
修理品：4650 V、1min（工频）
Insulation resistance test 绝缘电阻试验 √ √ √ √
DC resistance measurement 直流电阻测量 √ √ √ √
No-load test, inspect abnormal vibration or abnormal noise √ √ √ √
and temperature rising of the bearing 空载试验，检查异常
振动或异音及轴承温升
Measure the assembling play of the bearing 测量轴承装配 √ √ √ √
游隙
Inspect the runout of the shaft extension 检查轴伸径跳 √ √ √ √
6.3 Maintenance Works 维修工作
The maintenance work is carrying out maintenance/repair without disassembly. See

section 6.3.1 and 6.3.2 for basic maintenance. The maintenance work summary is
shown in Table 4 according to maintenance level.
维护工作为不拆卸情况下进行检修维护。基本维护见 6.3.1 和 6.3.2 节。按维修等级
进行的维护工作汇总见表 4。
6.3.1 Appearance Inspection of Motor 电机外观检查
（1）Inspect whether the outgoing line, lead clamp plate, terminal sign and nameplate of
Date： 2015.09 Rev.： 1.0
the motor are complete with good fastening.检查电机出线、引线夹板、线端标志及铭牌是
否齐全、紧固良好。
（2）Inspect whether the installation of cover plate of junction box is in good state.检查
接线盒盖板的安装是否良好。
（3）Inspect the condition of fastening bolt.检查紧固螺栓状况。
6.3.2 Bearing 轴承
Because the bearing is a kind of important rotating parts, it must be kept in good
lubrication condition, the bearing rotation should be flexible without abnormal noise, so
regular maintenance is very important. In the maintenance without disassembly, the
abnormal noise, oil leakage, etc. of the bearing can be inspected.
由于轴承是一种重要旋转部件，因此必须保持良好的润滑状态，轴承转动灵活无异音，
所以日常维护十分重要。在不拆卸检修中，可检查轴承异常声音，漏油情况等。
6.3.2.1 Operation Sound of Bearing 轴承运转声音
Please pay attention to the operation sound of the bearing when operating, if abnormal sound or
vibration is found, the operation should be stopped immediately, and the motor should be removed to
carry out inspection carefully.
运行时，请注意电机运转声音，如果发现有异常声音或振动，应立即停止运行，并拆下电机仔细检
查。
After removing the motor from the locomotive, the no-load operation test should be
carried out, and inspect whether there is abnormal noise. Place the inspection pole
whose two ends are closest to the outside of bearing cover when inspecting the noise;
电机从机车上拆下后，应进行空载运转试验，并检查异常噪音。检查噪音时，将检测
杆放置于两端最靠近轴承的轴承盖外侧；
Inspect whether the bearing appears oil leakage.
检查轴承是否漏油。
Notice！The lubrication system of the bearing adopts non-contact labyrinth seal, the oil
gas can be discharged from the last labyrinth ring clearance. So it does not show oil
leakage when the outside surface of the labyrinth appears slight oil stains.
注意！轴承润滑系统采用无接触迷宫式密封，油气可以从最后一个迷宫环形间隙排出。
因此迷宫外表面出现轻微油迹不表示漏油。
6.3.2.2 Replenishing Lubricating Grease 补充润滑脂
During normal operation, it shall be ensured that bearing at non-driving end is
replenished about 40g every 100000km or every 6 months. It is suggested that user
Date： 2015.09 Rev.： 1.0
continues the inspection, and dismantle motor to check the distribution conditions of
lubricating grease on motor in I3 maintenance. Then, stipulate the time and quantity of
replenishing grease according to specific operation condition and maintenance
experience on locomotive operation; E.g. Replenish 20g lubricating grease at
non-driving end of motor when locomotive runs for 50000km (about 3 months) every
time.
在正常运行时，至少应保证每 10 万 km 或每六个月对非传动端轴承补充润滑脂量 40g，
建议用户持续进行跟踪观察，并于 I3 检时对电机进行解体检查各部件油脂分布情况，最终
根据具体运行情况及对机车的运用维护保养经验制定补脂的时间和重量；如机车每运行 5
万公里（约 3 个月）电机非传动端轴承补充润滑脂 20g。
All grease should be replaced with new grease when carrying out I3，R1, R2, R3
and UM maintenance;
在 I3、R1、R2、R3 修和 UM 修时应全部更换新润滑脂；
For backup motor after long-term (more than half a year) storage and unpredictable
natural disasters, it is considered necessary to replenish lubricating grease as
emergency measures, the amount of replenishing the lubricating grease for non driving
end of the bearing is about 40g;
对于长期（半年以上）保管后的备用电机以及发生不可预测的自然灾害，作为应急措
施而认为需要补充润滑脂时，非传动端轴承补充润滑脂量约 40g；
The replenished grease must be consistent with the grease grade, manufacturer
when assembling.
补充的润滑脂必须和组装时使用的润滑脂牌号、厂家一致。
Notice: It should be strictly ensured that the lubricating grease is clean.
注意：严格保证润滑脂的清洁。
In order to ensure the specified oil change period, it should be assessed whether the
oil change period can be extended, it is suggested to check the oil. The sampling
inspection table is shown in Table 6.
为了保证规定的换油周期，评估是否可以延长换油的周期，建议对油进行检查。抽样
检验表见表 6。
Before operating for 200000km or carrying out annual main inspection at regular
intervals, four used driving systems should be selected from two different locomotives to
carry out oil sample analysis. When carrying out this test, about 100cm3 oil should be
selected from the gear box (take from the hole of drain oil bolt).
Date： 2015.09 Rev.： 1.0
在每跑完 200000km 或每年定期主要检验前，应从两个不同机车上，选取 4 个使用的
驱动系统，做一个油样分析。做此检验，应从齿轮箱中选取大约 100cm3 的油（从排油螺
栓孔取）。
Notice！Before obtaining oil sample, the area around oil drain bolt should be cleaned
firstly.
注意！在取得油样前，先清洁排油螺栓周围的区域。
Table 6 Inspection Feature Table of Lubricating Oil Sample
表 6 润滑油样检验特性表
Character 特性 Analysis Process 分析过程 Allowable Initial Value (Limit Value)
允许的初始值（限界值）
Maximum peak (provided by grease
IR exposure IR 曝光 IR exposure IR 曝光
manufacturer)
最大峰值（由油制造商提供）
Max. 5.5mg KOH/G
(Increase 2.0mg KOH/G for new
Ageing/oxidation 老化/氧化 Neutral quantity 中性数量
grease)
Max. 5.5mg KOH/G
（新油增加 2.0mg KOH/G）
Fixed solid-state object (adopt
1.2µ filtering agent to carry out
Whole pollution 全部污染
filtering) Max 0.4% MA
固定固态物（采用 1.2µ 过滤器
进行过滤）
Iron content (whole pollution
is larger than 0.3%) RFA, AAS Max 0.3% MA
铁含量（全部污染大于 0.3％）
Qualitative analysis (crack Specific data cannot be obtained.
Water 水
inspection)定性（裂缝检查）不能取得具体数据
Water content (if water result Xylene method or K Flescher

is favorable) method 二甲苯法或 K Flescher Max 0.2% MA
水含量（如水的结果有利）法
Kin. Viscidity Viscidity test: according to The deviation of nominal viscidity at
Viscidity index at 100℃ and Ubbelohnde method 40℃: ±15％mm2/s
Date： 2015.09 Rev.： 1.0
40℃ 粘性试验，在 40℃时从标称粘性的偏差；
Kin. 粘性按照 Ubbelohnde 法 ±15％mm2/s
100℃和 40℃粘性指数
SRV test
Frictional wear of vibration **) 2h, 300N, 90℃
(µ) undetermined
friction value 50Hz, 1000µm, 720m
(µ)待定
振动摩擦磨损**)摩擦值 SRV 试验
2h, 300N, 90℃
50Hz, 1000µm, 720m
**）Test after running for 600000km and 1200000km;

**）运行 600000km 和 1200000km 后应进行试验；
The analytical result should be recorded in the motor running log.
分析的结果应被记录在电机的运行履历中。
Warning！In general, the excessive compressed lubricating grease may cause risk,
especially when the storage temperature is lower than 10℃. When system starts under
low temperature, some or all the high-viscosity lubricating grease will hinder the
movement of the ball. If the rotor accelerates rapidly, which will cause the bearing
damage, especially the raceway, as some lubricating grease film surface may crack .
警告！通常油脂压缩会引起危险，特别是储存温度低于 10℃时。低温下系统启动时，
部分或全部高粘度的润滑脂会阻碍滚珠的运动。如转子快速加速，将会引起轴承损害，特
别是滚道，因为润滑油膜面可能部分裂开。
Strong suggestion:
强烈建议：
Adopt the clean grease from original container;
使用原始包装中取出的洁净的润滑脂；
Too much grease should not be replenished, the lubricating grease should be
replenished according to the specified supplementary amount of the grease;
不要过多补充润滑脂，按规定的润滑脂补充量补充润滑脂；
When the bearing is very cold, the replenishing of excessive grease should be
avoided (but when the equipment is still hot, the lubricating grease should be
filled);
Date： 2015.09 Rev.： 1.0
当轴承非常冷时，避免过多加润滑脂（但设备还是热的时候，应将润滑脂注满）；
In any case, after the grease is filled, even if the grease is stored in the condition
above 10℃, the vehicle should be also moved for a few kilometers under the
condition of low speed (such as going to the service interval); this makes the
grease uniform distribution to avoid the injury of the ball or raceway surface. The
maintenance work is shown in Table 7 according to maintenance level.
任何情况下，注满润滑脂后，就算润滑脂存储在高于 10℃的条件下，也应在低速
条件下移动车辆几公里（如开到服务区间去）；这使得润滑脂均匀分布，避免发生
滚珠或滚道面损伤的情况。按维修等级进行的维护工作见表 7。-
Table 7 Maintenance
表7 维护
Maintenance level: I1 (inspection level 1)
维修等级：I1 （检查 1 级）
No. Component Inspection Quoted code
序号部件检查引用代号
The magnetic bolt should be cleaned after operating for
15000km firstly. Inspect the installation condition of
outgoing line, lead clamp, terminal sign and nameplate;
inspect the installation condition of cover plate of junction
box; inspect whether the bolt has looseness; inspect
Traction motor whether there is dust and water immersion in the stator;
1 牵引电动机 inspect whether there is oil leakage in the bearing; clean
the magnetic bolt.
在首次运行 1.5 万公里后应清洁磁性螺栓。检查电机出线、
引线夹、线端标志及铭牌安装情况；检查接线盒盖板的安
装情况；检查螺栓有无松动情况；检查定子内有无灰尘和
水的浸入；检查轴承有无漏油；清洁磁性螺栓。
Maintenance level: I2 (inspection level 2)维修等级：I2 （检查 2 级）
Quoted code
No. Component Inspection
引用代号
序号部件检查
Inspect the installation condition of outgoing line, lead

clamp, terminal sign and nameplate; inspect the installation
condition of cover plate of junction box; inspect whether the
Traction motor bolt has looseness; inspect whether there is dust and water
1 牵引电动机 immersion in the stator; inspect whether there is oil leakage
in the bearing; clean the magnetic bolt. Replenish the
lubricating grease for the motor bearing (N end).检查电机出
线、引线夹、线端标志及铭牌安装情况；检查接线盒盖板的安
装情况；检查螺栓有无松动情况；检查定子内有无灰尘和水的
Date： 2015.09 Rev.： 1.0
浸入；检查轴承有无漏油；清洁磁性螺栓。电机轴承（N 端）
补充润滑脂
Maintenance level: I3 (inspection level 3)维修等级：I3 （检查 3 级）
No.
Component Inspection Quoted code
序号
部件检查引用代号
Inspect the installation condition of outgoing line, lead

clamp, terminal sign and nameplate; inspect the installation
condition of cover plate of junction box; inspect whether the
bolt has looseness; inspect whether there is dust and water
immersion in the stator; inspect whether there is oil leakage
in the bearing; clean the magnetic bolt.
Traction motor Dismantle traction motor to inspect its bearing, winding and
1 牵引电动机 insulation conditions, replace rubber pad, sealing ring and
all the lubricating grease.检查电机出线、引线夹、线端标志
及铭牌安装情况；检查接线盒盖板的安装情况；检查螺栓有
无松动情况；检查定子内有无灰尘和水的浸入；检查轴承有
无漏油；清洁磁性螺栓。
解体检查牵引电机上轴承、绕组及绝缘情况，更换橡胶垫、
密封圈和全部润滑脂。
6.4 Correction Work 修正工作
The correction work is maintenance under the state of disassembly. See section 7.2
for the disassembly; see section 7.5 for the maintenance after disassembly. The
correction work is shown in Table 8 according to maintenance level.
修正工作为在拆卸状态下进行的检修。拆卸见 7.2 节，拆卸后维修件 7.5 节。按维修
等级进行的修正工作见表 8。
Table 8 Correction
表8 修正
Maintenance level: R1 (maintenance level 1)维修等级：R1 （维修 1 级）
Quoted
No.序
Component 部件 Inspection 检查 code 引用
号
代号
Appearance of
traction motor 牵 Clean and disassemble 清洗并解体
1
引电动机外观
Inspection Measure the insulation resistance of winding against

2 before ground, operation state of the bearing, inspect the motor
disassembling vibration.测量绕组对地绝缘电阻、轴承运行状态、检查电机
Date： 2015.09 Rev.： 1.0
the motor 电机解振动情况。
体前检查
Inspect the surface condition of end ring and conducting

bar; inspect the welding condition between the conducting
bar and end ring; inspect the fastening condition of balance
weight; inspect the diameter of bearing block, the runout of
conical surface of shaft extension; carry out ultrasonic wave
Rotor 转子 and magnetic powder inspection for the shaft; carry out the
3
washing and drying for the rotor.检查端环、导条表面状况；
检查导条与端环焊接情况；检查平衡块紧固状态；检查轴承
挡的直径、轴伸端锥面跳动量；对轴进行超声波和磁粉探伤；
转子进行清洗烘干。
Bearing 轴承 Replace the bearing 更换轴承

4
Carry out washing and drying for the stator; the joint state of
stator coil; external insulation state of stator coil; they should
be replaced if the insulation or joint of connecting line is
damaged; measure the insulation resistance of coil against
Stator 定子 ground; measure cold DC resistance of the coil;; withstand
5
voltage test.定子清洗、烘干；定子线圈接头部位的状态；定
子线圈外部绝缘状态；联接线的绝缘或接头如损坏则应更换；
测量线圈对地绝缘电阻；测量线圈冷态直流电阻；耐压试验。
Carry out appearance inspection and washing; inspect the

state of the spigot of end cover, through large pore, bearing
End cover 端盖
6 cover, seal ring. Replace O ring.进行外观检查并清洗；检查端
盖止口、通大气孔、轴承盖、封环状态。更换 O 形密封圈
Speed sensor 速 Carry out insulating strength inspection; carry out

7 度传感器 transmitting pulse count inspection per turn 绝缘强度检查；每
转发送脉冲数检查
Temperature
Carry out ground insulation inspection; measure resistance
sensor 温度传感
8 value 对地绝缘检查；电阻值测量
器
Junction box 接 Open the cover to inspect the wire holder, outgoing wire, and
fasten the fixing bolt.开盖检查接线座、引出线，并紧固固定螺
9 线盒
栓。
Measure DC resistance; insulation resistance test; withstand

voltage test of insulation; no-load test, inspect abnormal
Assembly and vibration or abnormal noise and temperature of the bearing;
measure the assembly play of the bearing; inspect the runout
10 test 组装、试验 of shaft extension.直流电阻测量；绝缘电阻试验；绝缘耐压试
验；空载试验，检查异常振动或异音及轴承温升；测量轴承装
配游隙；检查轴伸径跳。
Maintenance level: R2 (maintenance level 2)维修等级：R2 （维修 2 级）
Date： 2015.09 Rev.： 1.0
Quoted
No.序 Component 部
Inspection 检查 code 引用代
号件
号
Appearance of
traction motor
Clean and disassemble 清洗并解体
1 牵引电动机外
观
Inspection
before Measure the insulation resistance of winding against ground,
disassembling operation state of the bearing, inspect the motor vibration.测
2
the motor 电机量绕组对地绝缘电阻、轴承运行状态、检查电机振动情况。
解体前检查
Inspect the surface condition of end ring and conducting bar;

inspect the welding condition between the conducting bar
and end ring; inspect the fastening condition of balance
3
检查导条与端环焊接情况；检查平衡块紧固状态；检查轴承挡
的直径、轴伸端锥面跳动量；对轴进行超声波和磁粉探伤；转
子进行清洗烘干。

4
damaged; measure the insulation resistance of coil against
Stator 定子 ground; measure cold DC resistance of the coil; withstand
5
voltage test.定子清洗、烘干；定子线圈接头部位的状态；定子
线圈外部绝缘状态；联接线的绝缘或接头如损坏则应更换；测
量线圈对地绝缘电阻；测量线圈冷态直流电阻；耐压试验。

End cover 端盖
Speed sensor Carry out insulating strength inspection; carry out transmitting
pulse count inspection per turn 绝缘强度检查；每转发送脉冲
7 速度传感器
数检查
Temperature Carry out ground insulation inspection; measure resistance

value
8 sensor
对地绝缘检查；电阻值测量
温度传感器
Date： 2015.09 Rev.： 1.0
9 线盒 fasten the fixing bolt.开盖检查接线座、引出线，并紧固固定螺
栓。
measure the assembly play of the bearing; inspect the runout
10 test 组装、试验 of shaft extension.直流电阻测量；绝缘电阻试验；绝缘耐压试
Maintenance level: R3 (maintenance level 3)维修等级：R3（维修 3 级）
Quoted
No.序 Component 部
Inspection 检查 code 引用代
号件
号
Appearance of
traction motor
Clean and disassemble 清洗并解体
1 牵引电动机外
观
Inspection
before Measure the insulation resistance of winding against ground,
disassembling operation state of the bearing, inspect the motor vibration.测
2
the motor 电机量绕组对地绝缘电阻、轴承运行状态、检查电机振动情况。
解体前检查
Inspect the surface condition of end ring and conducting bar;

inspect the welding condition between the conducting bar
and end ring; inspect the fastening condition of balance
3
检查导条与端环焊接情况；检查平衡块紧固状态；检查轴承挡
的直径、轴伸端锥面跳动量；对轴进行超声波和磁粉探伤；转
子进行清洗烘干。

4
Stator 定子
5 damaged; measure the insulation resistance of coil against
ground; measure cold DC resistance of the coil; withstand
voltage test.定子清洗、烘干；定子线圈接头部位的状态；定子
线圈外部绝缘状态；联接线的绝缘或接头如损坏则应更换；测
Date： 2015.09 Rev.： 1.0
量线圈对地绝缘电阻；测量线圈冷态直流电阻；耐压试验。

End cover 端盖
Speed sensor Carry out insulating strength inspection; carry out transmitting
pulse count inspection per turn 绝缘强度检查；每转发送脉冲
7 速度传感器
数检查
Temperature
Carry out ground insulation inspection; measure resistance
sensor 温度传
8 value 对地绝缘检查；电阻值测量
感器
fasten the fixing bolt.开盖检查接线座、引出线，并紧固固定螺
9 线盒
栓。

10 test 组装、试验 measure the assembly play of the bearing; inspect the runout
of shaft extension.直流电阻测量；绝缘电阻试验；绝缘耐压试
7 Corrective maintenacne 修复性维修
7.1 Fault Treatment 故障处理
The fault analysis and treatment is shown in Table 9.

故障分析与处理见表 9
Table 9 Fault Analysis and Treatment
表 9 故障分析与处理
Fault
Fault Cause Inspection Method Treatment method Remarks 备注
Phenomenon
故障原因检查方法处理方法
故障现象
There is no
reliable
Inspect whether the
connection Remove and wash
Ground fault earthing holder has
between earthing cable joint 拆去并清洗
接地故障 holder and shell. rust.检查接地座是否
电缆接线头
接地座与外壳没生锈
有可靠连接
Date： 2015.09 Rev.： 1.0
Fault
Phenomenon
故障现象
The earthing
Inspect whether the
fault causes the
Inspect the lead wire has sharp
damage of Replace the lead wire.
connecting wire.检查 edge and damage.检
connecting wire. 更换导线
接地故障造成连连接导线查导线是否有锐边和
损伤
接导线损坏
The winding Carry out repair after

Inspect the insulation
insulation is inquiring the
resistance.检查绝缘
damaged.绕组绝 manufacturer 询问制
电阻
缘损坏造商后再进行维修
The locomotive load

The winding The motor Decrease the load,
is too large, each
temperature appears determine the fault
motor load is
is too high.绕 overload.电机过 position and eliminate.
uniform.机车负载过
组温度过高载降低负载，确定故障位
大
置，并清除
各电机负载不均匀
Replace
The temperature
resistance-type
detection unit
temperature detector.
The has fault.温度检
更换电阻式温度检测
temperature 测单元出现故障
indication 器
does not
accord with Use the required
reality or has fastening torque to
Open terminal tighten the terminal,
error.温度指 The connector is connection box to and replace the cable Inspect the damaged
示不符合实 loose.连接端子 inspect the terminal.
joint when necessary. thread 检查损坏螺纹
际或出错松动打开端子连接盒，检
使用要求的紧固转矩
查端子
来上紧端子，必要时，
更换电缆接头
Inspect the winding

The winding resistance, insulation Carry out repair after
Local resistance, measure
insulation is inquiring the
overhearting
damaged.绕组绝 the impedance 检查 manufacturer 询问制
局部过热
缘损坏绕组电阻、绝缘电阻，造商后进行维修
测量阻抗
Replace the bearing,

The bearing Inspect the bearing
only carry out
grease includes Remove the bearing seal, replace when
relubrication at N end.
impurity 轴承润滑 cover.拆去轴承盖 necessary.检查轴承
更换轴承，只在 N 端进
脂含杂质密封，必要时更换
行再润滑
.
Date： 2015.09 Rev.： 1.0
Fault
Phenomenon
故障现象
Lift the shaft, and use Install the bearing with
Determine the
The bearing play the dial indicator to correct play, inspect
change reason of
has error.轴承游 measure the play.吊 the related parts.以正
bearing play.确定轴
隙错误起轴，并用千分表测确的游隙安装轴承，检
承游隙变化的原因
量游隙查相关部件
Inquiring the
Bearing failure 轴 Remove the bearing Replace the bearing
manufacturer 询问制
承损坏 cover 拆去轴承盖更换轴承
造商
Remove the bearing

cover, the bearing Determine the stuck
changes color or has Replace the part reason, the
Bearing is stuck. deformation, the oil which changes color lubrication failure,
轴承卡位 seal has or has deformation.更 too much load 确定卡
deformation.拆去轴换变色或变形零件住原因，润滑失效，
承盖，轴承变色或变负载过多
形，油封变形
Excessive or too Faulty lubrication will

less lubrication reduce the service
Correctly lubricate the
of the bearing 轴 life of the bearing.润
bearing 正确润滑轴承
承润滑过量或过滑不当将降低轴承使
少用寿命
Friction of oil Find fault reasons

Inquiring the
sealing or interior Test after dismantle and the damage
dirty 油封摩擦或在拆下后进行检测 range 查找故障原因
造商
内部不干净及损坏范围
The cooling air
duct in the motor Clean the air duct.清
is blocked.电机洁风道
内冷却风道堵塞
Determine the
damage reason: Dirt
Inspect the winding
inside the motor, the
The winding resistance, insulation Carry out repair after
bar breakage of
Smoking 冒 insulation is resistance, measure inquiring the motor rotor, too large
烟 damaged.绕组绝 the impedance 检查 manufacturer 询问制 current 确定损坏原
缘损坏绕组电阻、绝缘电阻，造商后进行维修因：电机内污物，电
测量阻抗
机转子断条，电流过
大
Date： 2015.09 Rev.： 1.0
Fault
Phenomenon
故障现象
The bearing changes
Find whether it is
color or has
Replace the bearing, stuck, the lubrication
deformation, the
Bearing is stuck inquire the is insufficient or
bearing cover
轴承卡位 manufacturer 更换轴 excessive.查找是否
changes color.轴承变
. 承，询问制造商卡位、润滑不足或者
色或变形，轴承盖变
过量
色
Carry out inspection Find the fault reason

Inquire the
The shaft is bent. only after removing and damage range.
轴弯曲只能在拆下后进行检查找故障原因及损坏
造商
测范围
The cable
connection has Inspect the cable Repair the cable
fault or appears connection 检查电缆 connection.修复电缆
breakage.电缆连连接连接
接故障或者断裂
Scorching Inspect the winding

smell 烧焦味 resistance, insulation
The terminal resistance and Carry out repair after
installation is measure the inquiring the
loose.端子安装 insulation manufacturer 询问制
松动 impedance.检查绕组造商后进行修复
电阻，绝缘电阻和测
量绝缘阻抗
There is Inspect the bend or

abuzz noise. Cable breakage Inspect the cable.检 Replace the cable.更 broken position of
有嗡嗡的噪电缆断裂查电缆换电缆 the cable.检查电缆弯
音曲处或磨破处

Determine the
change reason of
There is 隙错误起轴，用指千分表测确的间隙安装轴承，检
singing 承游隙变化的原因
量游隙查相关部件
noise.有振鸣
噪音 Carry out inspection Find the fault reason
Inquiring the
The shaft is bent. only after removing and damage range.
轴弯曲只能在拆下后进行检查找故障原因及损坏
造商
测范围
Find the current

There is the reason and carry out
There is Carry out visual
current flowing Inquiring the
impacting inspection for suitable
through the manufacturer 询问制
noise.有撞击 bearing surface 视觉 measurement.查找有
bearing.有电流从造商
的噪音检查轴承表面电流的原因并进行适
轴承流过
当测量
Date： 2015.09 Rev.： 1.0
Fault
Phenomenon
故障现象
Find the reason of
Bearing fault 轴 Remove the bearing Replace the bearing
bearing fault 查找轴
承故障 cover 拆掉轴承盖更换轴承
承故障原因
Remove the speed

The speed measurement gear Restore the speed
measurement disk, inspect the measurement gear
gear disk of related parts and disk of speed sensor
speed sensor is
installation state 拆掉恢复速度传感器的测
loose 速度传感器
测速齿盘，检查相关速齿盘
的测速齿盘松动
零件及安装状态
.
Find the fault: The
The suspension bearing assembly of
device of the Inspect the Inquire the journal sticking box,
motor has crack suspension device. manufacturer 询问制 the interface of gear
电机悬挂装置开检查悬挂装置造商 and motor 查找故障：
裂抱轴箱轴承组装，齿
. 轮与电机的接口
Fasten the
Inspect the fastening
The suspension corresponding
position, inspect the
device of the fastener according to
bearing assembly 检
motor is loose.电 specified torque 按规
查紧固位置，检查轴
机悬挂装置松动定扭矩紧固相应紧固
承组装
件
Inspect whether the

sealing device has
damage, carry out
the replacement if
Fasten the there is damage;
Inspect the fastening corresponding
The motor replace the bolt with
position, carry out fastener according to
fastener is loose larger strength after
visual inspection for
or has crack.电 specified torque.按规 inquiring the
crack position.检查紧
机紧固件松动或定扭矩紧固响应紧固 manufacturer if the
固位置，视觉检查裂
者有裂纹件；或者更换相应紧固 fastener has crack.检
纹位置
件查密封装置是否有
损，如有损则进行更
换；如果紧固件有裂
纹则询问制造商后更
换强度稍大的螺栓
There is Determine the
sharp noise. change reason of
有尖锐的噪 bearing play.确定轴
隙错误起轴，并用千分表测确的游隙安装轴承，检
音承游隙变化的原因
量游隙查相关零件
Date： 2015.09 Rev.： 1.0
Fault
Phenomenon
故障现象
Determine the
damage reason: The
dirt inside the motor,
the rotor core
Bearing failure 轴 Remove the bearing Replace the bearing contacts with the
承损坏 cover 拆去轴承盖更换轴承 stator core.确定损坏
原因：电机内的污物，
转子铁芯与定子铁芯
接触
Lift the shaft, and use

The bearing play the dial indicator to Install the bearing with
Determine the
is too large 轴承 measure the play.提 correct play 以正确的
reason 确定原因
游隙过大起轴，用千分表测量游隙安装轴承
游隙
Determine the
damage reason: The
Bearing failure 轴 Remove the bearing Replace the bearing the rotor core
承损坏 cover 拆去轴承盖更换轴承 contacts with the
stator core.确定损坏
接触
Small parts inside
The balance
Radial Inquire the the motor (screw,
weight is loose or Visual inspection 目
vibration 径向 manufacturer 询问制 balance weight, etc.)
lost.平衡块松动测
振动造商电机内的小部件（螺
或丢失
钉、平衡块等）
The motor
Inquire the
suspension is Inspect the
damaged.电机悬 suspension 检查悬挂
造商
挂损坏 .
Inspect the screw

Tighten the screw with
The motor joint, bearing position
specified fastening
suspension is and damping
torque, replace the
loose.电机悬挂 element.检查螺钉接
damping element.以
松动头、轴承装置和阻尼
规定紧固转矩上紧螺
元件
钉，更换阻尼元件
目测，平衡清洁转子，再平衡转子
转子不平衡
Visual inspection, Clean the rotor,
Rotor imbalance
balance rebalance the rotor
Lift the shaft, and use
Determine the
Axial The bearing play the dial indicator to Install the bearing with
change reason of
vibration 轴向 has error.轴承游 measure the play.提 correct play 以正确的
振动隙错误起轴，用千分表测量游隙安装轴承
承游隙变化的原因
游隙
Date： 2015.09 Rev.： 1.0
Fault
Phenomenon
故障现象
Determine the
damage reason: The
Bearing failure 轴 Remove the bearing Replace the bearing. the rotor core
承损坏 cover.拆去轴承盖更换轴承 contacts with the
stator core.确定损坏
接触
The motor
Inquire the
suspension is Inspect the
damaged.电机悬 suspension.检查悬挂
造商
挂损坏
The motor Inspect the screw Tighten the screw with

suspension is joint and bearing specified fastening
loose.电机悬挂 device.检查螺钉接头 torque.以规定的紧固
松动和轴承装置转矩上紧螺钉
Inspect whether the

The machine
The lead wire is Inspect the lead wire has sharp
torque has Replace the lead wire.
damaged.导线损 connecting wire.检查 edge and damage.检
damage.机器更换导线
坏连接导线查导线是否有锐边和
转矩损失
损伤
Connection of Replace the lead wire,

Inspect the lead wire,
speed sensor is repair the plug
plug connection 检查
interrupted.速度 connection 更换导线，
导线、插头连接
传感器连接中断修理插头连接
传感器探头松动
检查紧固件固定速度传感器检查密封
Probe of speed
Inspect the fastener Fix the speed sensor Inspect the seal
The speed sensor is loose.
signal has The speed
Replace the speed
change.速度 sensor has fault.
sensor 更换速度传感
信号变化速度传感器有故
器
障
The driving
Remove the cover,
wheel of speed
inspect the base and Fix the speed sensor
sensor is loose.
gland.拆去盖，检查底固定速度传感器
速度传感器的传
座和压盖
动轮松动
油/ The grease at N
Remove the bearing Remove overmuch
Oil/grease end bearing is
too much.N 端轴 cover.拆去轴承盖 grease 除去过多油脂
leakage 油脂
泄漏承油脂过多
Date： 2015.09 Rev.： 1.0
Fault
Phenomenon
故障现象
Determine the
It can be seen only Inquire the reason of generated
Current on the
after removing the manufacturer 询问制 current, and adopt
Grease bearing 轴承上的 suitable measures.确
bearing.拆卸轴承后造商
pollution or 电流
才能看到定电流产生的原因，
early aging
油脂污染或并采取恰当措施
Determine the
过早老化 Impact or Inquire the
impact and vibration
vibration 冲击或 manufacturer 询问制
reason.确定冲击和振
振动造商
动的原因
7.2 Disassembly 拆卸
The disassembly of traction motor must be carried out in a clean and dust-free place,
it must be careful to contact the parts, don’t make them damage and rusting. Please
carry out disassembly according to the order of Table 10, if the work order is not correct,
it cannot be fully disassembled and reassembled correctly. The work conditions must be
strictly followed.牵引电机的拆卸必须在干净无灰尘的地方进行，必须小心接触部件，勿使
其损坏和生锈。请按表 10 顺序进行拆卸，如果工作顺序不正确，则不能正确完整地拆卸
和重新组装。必须严格遵守工作条件。
Danger！All of the following inspection and maintenance work must be carried out under
the conditions of power off and stop operation of the motor.
危险！以下所有的检查和维修工作必须在断开电源，电机停止运转的情况下进行。
Table 10 Disassembly
表 10 拆卸
Cross Reference
No.序 Component 部件 Method 方法
交叉引用
号
Disassembly of suspension
Wrench 扳手
1 seat /
悬挂座的拆卸
Disassembly of pinion 小齿轮的 Figure 4
2 Hydraulic device 液压装置
拆卸图4
3 Disassembly of speed sensor Wrench, process bolt 扳手、 /
Date： 2015.09 Rev.： 1.0
速度传感器拆卸工艺螺栓
Disassembly of sensor cover 传 Wrench 扳手
4 /
感器盖拆卸
Disassembly of speed
Wrench 扳手
5 measurement gear disk 测速齿 /
盘的拆卸
Disassembly of outer bearing
Wrench 扳手
6 cover at N end N 端外轴承盖拆 /
卸
Disassembly of inner bearing
Wrench, process bolt 扳手、
cover at N end N 端内轴承盖松
7 工艺螺栓 /
卸
Wrench, rotor fixture of

horizontal installation, lifting
Remove the rotor 取出转子 Figure 5 图 5
8 appliance 扳手、转子卧装工
装、吊具
Disassembly of D end cover D Wrench, process bolt 扳手、

9 /
端端盖的拆卸工艺螺栓
Disassembly of outer ring of D
Pulling device, hydraulic Figure 6 图 6
10 end bearing D 端轴承外环的拆
device 拔出装置、液压装置
卸
Disassembly of D end check
ring and inner race of D end Three-jaw puller 三爪拔出器 Figure 7 图 7

11
bearing D 端挡圈和 D 端轴承内
圈拆卸
Disassembly of inner bearing

Hydraulic device 液压装置
12 cover at N end (with bearing)N /
端内轴承盖(带轴承)拆卸
/
Disassembly of N end bearing Hydraulic device 液压装置
13
N 端轴承拆卸
14 Three-jaw puller 三爪拔出器 /
Disassembly of inner oil seal at
Date： 2015.09 Rev.： 1.0
N end N 端内油封拆卸
Disassembly of N end cover N Wrench, process bolt

15 /
扳手、工艺螺栓
端端盖的拆卸
7.3 Replacement Principle 更换原则
7.3.1 Replacement of Stator Coil 定子线圈的更换

Local repair is allowable when the upper edge insulation of stator coil appears local
damage; please replace all the coils according to the following order when the stator coil
appears abnormal and serious burning loss:
定子线圈上层边绝缘局部损伤时，允许局部修理；当定子线圈出现异常和烧损严重情
况时请按下列顺序更换全部线圈：
a) Clean up the stator.将定子清扫干净。
b) Cut off two-terminal binding tape of stator coil and take out of the binding tape.切
断定子线圈两端绑扎带并取出绑扎带。
c) Put the stator into the baking oven to carry out heating, with heating temperature
of 130℃ for 8 hours.将定子放进烘箱进行加热，加温至 130℃时间 8 小时
d) Take the stator out of the baking oven, remove the slot wedge with special tool
and pull out the stator coil from the core groove rapidly.定子从烘箱中取出，用专用工
具打出槽楔并迅速将定子线圈从铁芯槽中拔出。
e) Clean up the core groove and the inside.清扫铁芯槽、内部。
f) Insert new stator coil into replaced core groove.将新的定子线圈嵌进所更换的铁
芯槽中。
g) Insert the slot wedge of the stator into the groove with special tool.定子槽楔用专
用工具打入槽内。
h) Carry out the binding for two terminals of stator coil.对定子线圈两端进行绑扎。
i) Carry out vacuum pressure dipping paint for the stator.对定子进行真空压力浸漆。
j) Carry out drying and baking for the stator.对定子进行干燥烘焙。
k) Carry out interturn withstand voltage inspection and withstand voltage inspection
over the ground 匝间耐压检查和对地耐压检查。
7.3.2 Replacement of Bearing 轴承的更换
a) Disassemble the motor according to the requirement and order of section 7.4.按
Date： 2015.09 Rev.： 1.0
照第 7.4 节要求和顺序将电机解体。
b) Pull out the inner race of the bearing from the shaft according to the method of
section 7.4.按照第 7.4 节方法将轴承内圈从转轴上拔出。
c) Pull out the outer ring of the bearing from the end cover according to the method
of section 7.4.
d) 按照第 7.4 节方法将轴承外圈从端盖上拔出。
e) Inspect the model, size of new bearing, and clean up it, fill the lubricating grease
according to the requirement.检查新轴承的型号、尺寸，并将其清洗干净，按要求填
充润滑脂。
f) Wash the related parts such as the shaft, oil seal and end cover, fill the
lubricating grease according to the requirement.清洗转轴、油封、端盖等相关部件，
按要求填充润滑脂。
g) Press N end bearing into the inner bearing cover at N end with hydraulic device,
and press the bearing and inner bearing cover at N end into the shaft together.用液
压装置将 N 端轴承压入 N 端内轴承盖，再将轴承与 N 端内轴承盖一起压入转轴。
h) Install the outer ring of D end bearing into the corresponding position in the
bearing housing of end cover with hydraulic device; push the inner ring of D end
bearing into the shaft by hand.用液压装置将 D 轴承外圈安装到端盖轴承室内相应
部位，将 D 端轴承内圈用手推入转轴。
i) Assemble the motor according to the requirement, inspect the assembly play of
the bearing and axial displacement of the rotor.按照要求将电机组装好，检查轴承装
配游隙和转子轴向窜动量。
j) The motor carries out idling for 30min, inspect the motor vibration and the
heating situation of the bearing.电机空转 30min，检查电机振动和轴承发热情况。
7.3.3 Replacement of Temperature Sensor 温度传感器的更换
Screw out the fastening bolt of temperature sensor, and then remove the probe of
temperature sensor. Carry out the inspection for temperature sensor according to the
requirements. Install the probe of new temperature sensor into mounting hole, it should
pay attention to install in place, tighten the fastening bolt. Install the wire clamp, tighten
the fastening bolt. Inspect the ground insulation resistance according to the requirement.
将温度传感器紧固螺栓拧出，然后取出温度传感器探头。按要求对温度传感器进行检
Date： 2015.09 Rev.： 1.0
测。将新温度传感器探头装入安装孔，注意安装到位，拧紧紧固螺栓。装好线卡，拧紧
紧固螺栓。按要求检测对地绝缘电阻。
7.4 Dismantling 拆解
7.4.1 Disassembly of Suspension Seat 悬挂座的拆卸

Screw out the bolts which fix the motor on the suspension seat of the bogie.
拧出电机固定于转向架悬挂座上的螺栓。
7.4.2 Disassembly of Pinion 小齿轮的拆卸
Install the hydraulic device into two G1/4 thread holes on the pinion (D end); press
the hydraulic device until the pinion ejects.
将液压装置装入小齿轮（D 端）上两个 G1/4 螺纹孔内；使液压装置加压，直至小齿

轮弹出。
Warning！Increase the pressure step by step with the amplification of about 200 bar
every time from 600 bar, the pause between each pressurizing is 2 min at least, the
pause time allows the liquid to flow into different areas uniformly, the maximum oil
pressure is 1900 bar.
警告！从 600bar 开始以每次约 200bar 的增幅逐步增压，每次增压之间停顿至

少 2 分钟，停顿时间是让液体均匀流入不同区域，最大油压 1900 bar。
Danger！Because the gear has the conicity of 1:20, strong oil pressure can appear
axial pressure to eject the gear. At that time, there is a risk of personal injury！The
operators do not stand near the ejecting direction of the gear.
危险！因为齿轮有 1:20 的锥度，很强的油压会产生轴向压出力，将齿轮弹出。

此时，有人员伤害的风险！操作人员切勿站在齿轮弹出方向附近。
Date： 2015.09 Rev.： 1.0
Figure 4 Disassembly Schematic Diagram of Pinion
图4 小齿轮拆卸示意图
7.4.3 Disassembly of Speed Sensor, Sensor Cover, Speed Measurement Gear Disk,
Outer Bearing Cover at N end 速度传感器、传感器盖、测速齿盘、N 端外轴承盖的拆卸
Remove the wire clamp and fastening bolt, and take out of speed sensor. Loosen
the bolt M12 on the sensor cover at non driving end, eject the sensor cover with the
process bolt. Loosen the bolt M16 on the speed measurement gear disk, eject the speed
measurement gear disk with the process bolt. Remove the bolt of outer bearing cover at
N end, and take down the outer bearing cover at N end.
将线卡与紧固螺栓拆下，取出速度传感器。松开非传动端传感器盖上的螺栓 M12，用
工艺螺栓将传感器盖顶出。松开测速齿盘上的螺栓 M16，用工艺螺栓将测速齿盘顶出。退
出 N 端外轴承盖螺栓，取下 N 端外轴承盖。
7.4.4 Disassembly of Inner Bearing Cover at N End N 端内轴承盖松卸
Extrude the inner bearing cover at N end from N end cover with three M16 process
bolts.
用 3 个 M16 的工艺螺栓将 N 端内轴承盖从 N 端端盖上压出。
7.4.5 Taking Out of Rotor 取出转子
Screw out the fastening bolt of end cover at driving end (D end), install the rotor
fixture of horizontal installation on the conical section of rotor shaft, lift the balance
position of the fixture of horizontal installation with the overhead crane, hoist out the rotor
slowly and smoothly. It should be ensured never damage any position of the stator and
rotor. The suitable method should be adopted to place the rotor, guaranteeing its safety.
拧出传动端（D 端）端盖紧固螺栓，将转子卧装工装安装在转子的轴锥部，用天车吊
Date： 2015.09 Rev.： 1.0
住卧装工装的平衡部位，将转子缓慢地平稳地吊出。注意千万不要损伤定、转子的任何部
位。采用合适的方法将转子安置好，确保其安全。
1 2 3
1- Fixture of horizontal installation; 2- Rotor; 3 - Stator
1-卧装工装；2-转子；3-定子
Figure 5 Removing Schematic Diagram of Rotor
图5 转子取出示意图
Notice！Because the position of suspension point (considering center of gravity of rotor, D
end cover, bearing and lifting hook, etc.) cannot be determined when disassembling
firstly, the rotor must add the corresponding support and protection to avoid the damage
during movement.
注意！因首次拆卸时并不能准确确定悬挂点位置（考虑转子重心，D 端端盖，轴承和
起重钩等），转子必须加相应的支撑和保护以避免移动过程中出现损伤。
Notice！After removing the rotor, the correct position of suspension point should be
determined, and the position sign should be made on the equipment.
注意！移出转子后，应确定悬挂点正确位置，并在设备上做出位置记号。
7.4.6 Disassembly of D End Cover D 端端盖的拆卸
Place the rotor on the storage platform, remove the fastening bolt M10 of outer
bearing cover at D end, then the end cover and outer bearing cover at D end can be
removed.
Date： 2015.09 Rev.： 1.0
将转子放置在转子存放台上，退出 D 端外轴承盖的紧固螺栓 M10，即可将端盖与 D
端外轴承盖退出。
7.4.7 Disassembly of Outer Ring of D End Bearing D 端轴承外圈的拆卸
Extrude the outer ring of the bearing from the bearing cage with the pulling device
and hydraulic device.
用拔出装置和液压装置从轴承罩内压出轴承外圈。
Figure 6 Disassembly Schematic Diagram of Outer Ring of D End Bearing

图6 D 端轴承外环的拆卸示意图
7.4.8 Disassembly of Check Ring at D End and Inner Ring of D End Bearing 拆卸 D 端挡
圈和 D 端轴承内圈
Remove the check ring at D end and inner ring of D end bearing from the shaft with
three-jaw puller and fixing plate shown in Figure 7.
用图 7 所示的三爪拔出器和固定板从轴上拆下 D 端挡圈和 D 端轴承内圈。
1 – Three-jaw puller; 2 – Check ring at D end; 3 – Inner ring of D end bearing

1-三爪拔出器；2- D 端挡圈；3- D 端轴承内圈
Figure 7 Disassembly Schematic Diagram of Check Ring at D End and Inner Ring of D End Bearing
Date： 2015.09 Rev.： 1.0
图7 D 端挡圈和 D 端轴承内圈拆卸示意图
7.4.9 Disassembly of Inner Bearing Cover at N End (With Bearing)
N 端内轴承盖(带轴承)拆卸
Pull out inner bearing cover at N end with the drawing device, at the moment, the
half inner ring of ball bearing is pulled out at the same time. The outer ring of ball
bearing can also be pulled out at the same time.
用拉拔器拉出 N 端内轴承盖，此时球轴承的半个内圈将同时被拉出。球轴承的外圈也
同时可取出。
Pull out the outer ring of the bearing and inner oil seal at non driving end with pulling
fixture for upper outer ring of the bearing.
使用拉轴承外圈工装，将轴承外圈和非传动端内油封上拉出。
Remove the inner rings of two bearings and lower inner oil seal at non driving end
form the shaft with the pulling device.
使用拉拔器将二个轴承内圈和非传动端内油封下从轴上拆下。
Notice: The three bearings of the motor are the bearing with outer ring insulation, the
insulation layer is ceramics, it is very crisp, it should be very careful when pulling to
prevent the damage of insulation layer. After pulling out the bearing, the sign should
be made in order to assemble according to the number.
注意：电机的三个轴承均为外圈绝缘轴承，绝缘层为陶瓷，很脆，拉拔时要十分小心，
严防损伤绝缘层。轴承拉出后，要作好标记，以便对号组装。
7.4.10 Disassembly of N End Cover N 端端盖的拆卸
Install the bolt in the auxiliary hole of the end cover, apply the force at the symmetric
position to remove the end cover slowly.
在端盖的工艺孔中装上螺栓，在对称位置均匀施力缓慢地将端盖退出。
7.5 Maintenance 维修
7.5.1 Cleaner and Cleaning Work 清洁剂与清洁工作

It is recommended to use the following cleaner, but it also depends on the dirt
property.
推荐使用以下清洁剂，但还应取决于污物性质：
Mechanical cleaning device: Brush or stick.
Date： 2015.09 Rev.： 1.0
机械清洁物：刷子或木棍。
Compressed air: Its maximum pressure is 5 bar.
压缩空气：其最大压力为 5bar。
Notice！When the compressed air is used to carry out cleaning, it should be ensured to
adopt appropriate protective measures (protective glasses, breathing filter or similar
equipment).
注意！当使用压缩空气进行清洁时，请确保采用适当的保护措施（防护眼睛，呼吸过
滤器或者相似设备）。
Notice ！ When using these cleaners, the characteristic value of applicable safety
information related to the cleaner should be noted.
注意！使用这些清洁剂时，务必注意与清洁剂相关适用的安全资料的特征值。
Cleaning work:
清洁工作：
If the pollution is series, the cooling air duct of the stator and rotor must be cleaned
with appropriate flexible shaft and brush, then purge with compressed air. If it is just
dirty slightly, the dirt can be blown off.
如果污染严重，定子和转子冷却风道必须用适当的软轴和刷子清洁，然后用压缩空气
吹洗。如果仅仅轻度弄脏，可以将脏物吹出。
One of above cleaners is used to clean the grease layer on the surface of the
component. Then the drying in the air is allowed.
用上述清洗剂的一种来清洗部件表面的油脂层。然后允许在空气中干燥。
Clean the dirty coil with (H2.1), then dry for 8 hours in the air with about 100℃.
用（H2.1）清洁脏线圈，然后在约为 100℃的空气中干燥 8 小时。
7.5.2 Maintenance and Inspection of Rotor 转子的维护检查
The following inspection should be carried out after disassembling the rotor from the
stator:
转子从定子中拆卸后应进行如下检查：
a) Inspect the rotor appearance, especially for all the welding joints, inspect
whether they change color, because changing color means overheating (short
circuit).检查转子外观，特别是所有焊接接头，检查其是否变色，因为变色意味着
产生过热（短路）。
Date： 2015.09 Rev.： 1.0
b) Clean up the dust on the rotor surface and in the vent hole of iron core with dry
compressed air, and wipe out the grease dirt with the cleaning cloth dipped with
kerosene.用干燥压缩空气清除转子表面及铁芯通风孔内的灰尘，用浸过煤油的抹
布将润滑脂等油污擦净。
c) Inspect whether the conducting bar, end ring of the rotor have the phenomenon
such as crack, overheating, otherwise they should be replaced.检查转子导条、端
环是否有裂纹、过热等现象，否则应进行更换。
d) Inspect whether the shaft, core assembly and squirrel-cage type winding have
mechanical damage.检查轴，铁心组装以及鼠笼式绕组有无机械损伤。
e) Recalibrate dynamic balance for the rotor.转子重新校准动平衡。
7.5.3 Inspection of Bearing 轴承的检查
7.5.3.1 Inspection of Bearing 轴承检查
The normal service life of the bearing is 800000 km or 4 years, in general, the
disassembled bearing should be replaced, unless it is determined that the bearing can
operate until the next repair process through detection. For the disassembled bearing or
the bearing stored for a long time, they should be inspected carefully before reassembly,
to confirm whether they can be used normally.
轴承正常使用寿命为 80 万公里或 4 年，一般情况对于拆卸过的轴承应该更换，除非
经过检测确定该轴承能够运行到下一修程。对于拆卸过的轴承或长时间存放过的轴承，在
重新组装之前要仔细检查，以确认它们是否可以正常使用。
a) Remove the inner sleeve; carry out visual inspection for scratch, bruise, fade and
rust, etc. of inner sleeve.取下内套，目视检查内套的、刮伤、碰伤、退色、生锈等。
b) For the outer ring, inspect whether all the rollers have rough position, scratch,
bruise, fade and rust, etc. while rotating them. The insulating property of
insulated bearing must be inspected.对于外环要边旋转所有滚柱边检查是否有粗
糙部位、刮伤、碰伤、褪色、生锈等。对绝缘轴承必须检查绝缘性能。
c) Turn the roller, inspect abnormal phenomena such as abrasion of roller and
holder, holder damage.转动滚柱，检查滚柱和保持架的磨耗、保持架有无损伤等异常
现象。
d) If the inner sleeve or outer ring is found abnormity, two rings should be replaced
at the same time.如发现内套或外环有异常，应同时更换两环。
Date： 2015.09 Rev.： 1.0
e) The fitting surface between inner and outer sleeve ring of the bearing, rolling
body, working surface and collar must be smooth and clean. The crack, abrasion, pit,
corrosion, peeling, fatigue layer and other defects are not allowed, the parts with the
defect should be scrapped.轴承内外套圈、滚动体、工作表面及套圈的配合面，必须
光洁。不许有裂纹、磨伤、压坑、锈蚀、剥离、疲劳起层等缺陷，有缺陷的应报废。
f) The crack, overlap and deformation of bearing holder are not allowed. The
fracture and looseness of rivet or screw are not allowed, damping part should have
good function. 轴承保持架不许有裂纹、飞边、变形。铆钉或螺钉不许有折断、松动，
防缓件应作用良好。
g) The direct hammering is strictly prohibited when disassembling the bearing. The
heating temperature shall not exceed 120℃.轴承拆装时，严禁直接锤击。加热温度不
得超过 120℃。
The bearing should be replaced in whole set, the installation date should be marked
on the inner and outer rings, the outer ring should turn 90°~120° when carrying out
maintenance at the next time.轴承更换要成套，并分别在内、外圈上标明安装日期，
下次检修时外圈要转动 90°～120°。
Notice: The scoring is strictly prohibited on the outer ring of insulated bearing.
注意：绝缘轴承外圈上严禁使用刻划。
h) When replacing the bearing, the fit dimension between inner ring of the bearing
and shaft diameter, matching interference should accord with technical requirements
and limit requirements. 更换轴承时，必须检查轴承内圈与轴径的配合尺寸，选配过
盈量应符合技术要求和限度的要求。
7.5.3.2 Precautions of Using Bearing:使用轴承时的注意事项:
a) Mixture use of bearing grease with different specification is not allowed 请勿混合
使用不同规格的轴承润滑脂。
b) The inner sleeve and outer ring of roller bearing must be matched use, the
correct number between mutual parts should be confirmed.滚柱轴承的内套和外环必
须配套使用，要确认相互间的编号正确；
c) When assembling the bearing and lubricating grease, the cleaning of
environment and tool must be maintained, to prevent the impurity such as dust
and water entering into the shaft and grease;装配轴承和润滑脂时，必须保持环
Date： 2015.09 Rev.： 1.0
境和工具的清洁，以防灰尘、水等杂质进入轴承和润滑脂；
d) When cleaning the bearing by hand contact, wipe the hand with the degreasing
agent such as alcohol to prevent the rust of the bearing.用手接触清洁轴承时，请
用诸如酒精等脱脂剂擦拭手，以防轴承生锈。
7.5.4 Storage of Bearing 轴承的存放
When storing the disassembled bearing for a long time, wrap it with water proof
paper or plastic cloth, and place it at the cool and dry position. When storing the bearing,
the lubricating grease should be applied on the bearing to prevent rust. Inspect the
bearing grease, replace the grease when aging or abnormity is found. When the deposit
period exceeds one year, the lubricating grease must be replaced before using.
长时间存放拆下的轴承时，请用防潮纸或塑料布将其包起来，并放置于阴凉干燥处。
存放轴承时，应在轴承上涂抹润滑脂，以防生锈。检查轴承润滑脂，发现有老化或异常时，
请更换润滑脂。保管期超过一年时，使用前必须更换润滑脂。
7.5.5 Washing of Bearing 轴承的清洗
The washing of bearing should adopt the cleaning agent can leave the grease on the
bearing surface.
轴承的清洗，应采用能在轴承表面留下油脂的清洗剂。
Notice！The washing area should be located at the dry place without flying sand and
scrap iron where is close to assembly site, and the fire extinguisher and other equipment
are required to provide.
注意！轴承清洗区域应设在干燥，无飞砂、无铁屑进入和离装配工作地较近的地方，
并需设有灭火机等设备。
Notice！Smoking or other igniting material is strictly prohibited in the washing district.
注意！在清洗区域，严禁吸烟或燃点其他起火材料。
Notice ！ Cleaning the bearing with any product including fluorosilicate or chlorate
composition or sodium silicate product is prohibited.
注意！禁止使用任何含有氟酸盐或氯酸盐成分或钠硅酸盐产品清洗轴承。
Notice！It is not allowed that the staple is used to wipe the washed bearing, to prevent the
fiber entering into the bearing.
Date： 2015.09 Rev.： 1.0
注意！在清洗过的轴承上，不得用棉丝揩拭，以免纤维进入轴承。
Notice！The cleaning fluid should be stored well, the filtration or replacement should be
carried out frequently according to the condition, littering the cleaning fluid is prohibited.
注意！清洗液应存放好，并视情况应经常给予过滤或更换, 禁止乱倒清洗液。
a) When washing and removing the bearing, firstly place in the bucket with
non-defatted kerosene which is heated to about 60℃, soak for 10 min, wash
slightly, take out of the bucket, blow off the adhesive grease with compressed air
(pressure of 5kg/cm2).清洗拆下的轴承时，先将它放入装有加热至大约 60℃且无
脱脂的煤油桶中，浸泡 10 分钟，略微清洗一下，从桶中取出，并用压缩空气（5kg/cm2
的压力）吹去粘着的油脂。
b) After repeating the above steps twice, wash once with clean kerosene at normal
temperature, and then fully blow off the adhesive grease with compressed air.重
复上述步骤两次以上后，应用常温下的清洁煤油清洗一次，再用压缩空气完全吹
去粘着的油脂。
c) When carrying out final washing, the kerosene without serious oxidation and
pollution is required to use. When carrying out final washing, blow off the grease
with compressed air.最后清洗时，请使用清洁无严重氧化、无污染的煤油。将轴
承最后清洗后，用压缩空气吹净油脂。
7.5.6 Maintenance and Inspection of Stator 定子维护与检查
a) Inspect external mechanical damage of the stator.检查定子外部机械损伤。
b) Wash the stator.清洗定子。
c) Repair the depainting part.修整掉了油漆的部分。
d) Inspect whether the connecting wire has damage, replace it if necessary.检查连
接引线是否损坏，如有必要，进行更换。
e) Inspect the connection condition in the stator housing 检查定子壳内的连接情况。
f) Inspect the working condition of temperature sensor.检查温度传感器工作情况。
g) Inspect mechanical or electrical damage of the stator winding including the
connecting components of stator circuit. 检查定子绕组，包括定子电路连接部件是否
有机械或电气损伤。
Date： 2015.09 Rev.： 1.0
h) Measure the winding resistance (it is carried out when the fault appears.)测量绕
组电阻（仅在有故障时进行）
Measure the winding resistance between the set of terminals with 10A DC power
supply. Apply the testing voltage between the terminals U-V or U-W or V-W. The
resistance measured must be 0.02486Ω±5% at 20℃. Clean up the internal and external
surface of the stator. Whole vacuum pressure dipping paint treatment must be carried
out after overhaul.
使用 10A 直流电源，测量端子组间的绕组电阻值。在端子 U－V 或 U－W 或 V－W
间加测试电压。20℃时测得的电阻必须为 0.02486Ω±5％。将定子内外表面清理干净。
大修后须经整体真空压力浸漆处理。
7.5.7 Insulation Inspection 绝缘检查
Notice！When carrying out insulation test and within certain period after testing, there is
dangerous high voltage on the terminal, the personnel cannot touch it. This work is
completed by professional personnel, the safety regulations should be strictly followed,
and the motor base shall be discharged firstly through ground connection. Don’t touch
the winding and connecting wire before discharging.
注意！绝缘试验时以及之后的一段时间内，线端上有危险性的高压，人员不可触摸。
此项工作需要专业人员完成，并严格遵守安全条规，先将机座接地放电。在没有放电之前，
请不要触摸绕组与连线。
7.5.7.1 Insulation Resistance Inspection of Stator Winding after Cooling the Motor 电机冷
却后检查定子绕组的绝缘电阻
Apply 1000V DC power supply between each terminal U, V and W and stator base
successively, measure the insulation resistance. Hot insulation resistance of the winding
is larger than 1.8MΩ, the cold insulation resistance is larger than 18MΩ. Then the
withstand voltage test can be carried out after the insulation resistance is qualified.
依次在每一个接线端子 U、V 和 W 间以及定子机座施加 1000V DC 电源，测量绝缘
电阻。绕组热态绝缘电阻大于 1.8MΩ，冷态大于 18MΩ。绝缘电阻检查合格后方可进行
耐压试验
Notice！The insulation resistance of the winding is much influenced by the temperature;
when the temperature increases 10k each time, the resistance decreases to the half of
original value, that is: if the temperature increases 50K, (for example, increase from 25℃
Date： 2015.09 Rev.： 1.0
to 75℃), the resistance value decreases to 1/30 of original value.
注意！绕组的绝缘电阻受温度影响较大；温度每升高 10K，电阻降至原来值的一半，
即：如果温度升高 50K（例如，从 25℃升至 75℃），电阻值降到原来值的 1/30。
7.5.7.2 Carrying out Withstand Voltage Test:进行耐压试验：
For repaired winding, gradually apply the testing voltage of 50Hz 4650V AC for 1 min
on the winding and housing; for new winding, i.e. the replaced winding, gradually apply
the testing voltage of 50Hz 6200V AC for 1 min on the winding and housing.
对检修绕组，在绕组和机壳上逐步施加 50Hz 的交流测试电压 4650V，持续 1 分钟。
对新绕组，即更换了的绕组，在绕组和机壳上逐步施加 50Hz 的交流测试电压 6200V，持
续 1 分钟。
7.6 Assembly 组装
Carry out the disassembling steps conversely, then reassembly is relatively easy, all
the components and tools are required to prepare before reassembling.
将拆卸的步骤反过来实施，会使重新装配较为容易进行，在重新组装之前，请准备所
需的所有部件和工具。
7.6.1 Preparation before Reassembly 重新装配前准备
7.6.1.1 Sweeping:清扫：
Sweep all the components with high-pressure air before reassembly.
在重新装配之前，用高压风清扫所有的部件。
7.6.1.2 Replacement of Consumables:消耗品的更换：
Replace the spring washer which cannot be used due to abrasion.
首先将磨耗无法使用的弹簧垫圈加以更换。
7.6.1.3 Preparation of Stator Base 定子机座准备:
Clean and inspect the installation surface and two-end spigots of stator base;
清洁并检查定子机座的安装表面与两端止口；
Clean the thread hole and carry out tapping again to ensure good fastening thread.
清洁螺纹孔并再次攻丝保证螺纹紧固良好。
7.6.1.4 Preparation of Two-end Covers:两端端盖准备：
Clean and inspect the installation surface of end cover;
清洁并检查端盖的安装面；
Clean the thread hole and carry out tapping again to ensure good fastening thread;
Date： 2015.09 Rev.： 1.0
清洁螺纹孔并再次攻丝保证螺纹紧固良好；
Clean and inspect the bearing housing, oil chamber and oil filler hole.
清洁并检查轴承室、储油室和注油孔。
7.6.1.5 Preparation of Rotor and Pinion 转子及小齿轮准备
Clean and inspect the rotor;
清洁并检查转子；
Clean and inspect the pinion.
清洁并检查小齿轮。
7.6.2 Reassembly of Motor 电机的重新装配
7.6.2.1 Overview 概述
The reassembly of traction motor must be carried out at the clean place without
dust, it must be careful to touch the component, which should have no damage and rust.
Please carry out assembly according to the order, see Table 11 for the assembly order. If
the working order is not correct, the reassembly cannot be carried out correctly and fully.
牵引电机的重新装配必须在干净无灰尘的地方进行，必须小心接触部件，勿使其损坏
和生锈。请按照顺序进行装配，装配顺序见表 11。如果工作顺序不正确，则不能正确完整
地重新组装。
表 11 电机组装
Table 11 Motor Assembly
No. Cross reference 交
Component 部件 Method 方法
序号叉引用
Installation of N end cover Lifting appliance, torque

1 /
N 端端盖的安装 wrench 吊具、扭矩扳手
Installation of inner oil seal at N end
2 Baking oven 烘箱 /
N 端内油封安装
Installation of N end nearing Hydraulic device 液压装置
3 /
N 端轴承安装
Installation of inner ring and inner oil seal
4 of D end bearing / /
D 端轴承内圈及内油封安装
5 Installation of check ring at D end Baking oven 烘箱 /
Date： 2015.09 Rev.： 1.0
D 端挡圈安装
Lifting appliance,
Installation of outer ring of D end bearing
6 hydraulic device 吊具、液 /
D 端轴承外圈安装
压装置
转子卧装工装、吊具
Lifting the rotor 吊入转子 Rotor fixture of horizontal
7 /
installation, lifting
appliance
吊具、扭矩扳手
Installation of D end cover
8 Lifting appliance, torque /
D 端端盖的安装
wrench
测速齿盘及两端外轴承盖安装
9 Installation of speed measurement gear Torque wrench 扭矩扳手 /
disk and outer bearing cover at two ends
液压装置
10 Press fitting of pinion 小齿轮压装 /
Hydraulic device
Installation of speed sensor, temperature

Torque wrench 扭矩扳手
11 sensor, junction box /
速度传感器、温度传感器、接线盒安装
7.6.2.2 Installation of N End Cover N 端端盖安装
Remove the nozzle cap, press the grease into oil nipple until the inside of end cover
outflows 5cm new grease, clear up the outflowed grease, and cover the nozzle cap.
Apply Loctite activator on the thread of fastening screw of end cover, and carry out air
drying in the air. Apply the thread locking glue in the thread hole of stator base. Then
install the screws and washers and tighten, see Table 3-2 for tightening torque.
取下注油嘴帽，将润滑脂压入注油嘴直到端盖内侧有 5cm 新润滑脂流出，清除流出的

润滑脂，盖上注油嘴帽。将端盖吊装到定子机座上。在端盖紧固螺钉的螺纹上涂乐泰活化
剂，并在空气中风干。在定子机座的螺纹孔内涂螺纹锁固胶。然后装上螺钉和垫圈并紧固，
紧固力矩参见表 3-2。
7.6.2.3 Assembly of Non Driving End of Rotor 转子非传动端的组装
7.6.2.3.1 Heat the lower inner oil seal, isolating ring of the bearing and inner ring of the
Date： 2015.09 Rev.： 1.0
bearing with baking oven (only heat inner surface of inner ring I for ball bearing), install
them on the shaft according to the order, the bearing sign faces outside. The heating
temperature of inner ring of the bearing is 90~110℃, the heating temperature of other
components is 140~160℃.
7.6.2.3.1 用烘箱加热内油封下、轴承隔离环和轴承内圈（球轴承仅需加热内圈 I（inner）

面），将他们按顺序套在轴上，轴承标记朝外。轴承内圈加热温度为 90~110℃，其他件加
热温度为 140～160℃。
7.6.2.3.2 Apply the grease on the outer ring of upper oil seal slightly, add 115g grease in
the oil groove, and place the oil groove upwards as standby; apply the grease on the
outer ring of roller bearing slightly, the sign faces outside as standby.
7.6.2.3.2 内油封上外圈上稍抹点润滑脂，油槽内加 115g 润滑脂，油槽朝上放置待用；滚

柱轴承外圈上稍抹点润滑脂标记朝外放置待用。
7.6.2.3.3 Place inner bearing cover of N-end on the platform horizontally, and press
upper inner oil sealing into inner bearing cover of N-end. . Place the outer ring of roller
bearing into inner bearing cover at N end, exert the force to press it in place, later apply
the grease in the bearing, the grease amount is 70g (apply 10g between the roller and
inner ring), squeeze the grease into the position between the rollers of the bearing with
finger or appropriate tool when applying.
7.6.2.3.3 将 N 端内轴承盖水平放在一平台上，将内油封上压入 N 端内轴承盖内。将滚柱

轴承外圈放入 N 端内轴承盖内，用力顶压使其到位，稍后在轴承内抹上润滑脂，加脂量为
70g（滚柱与内圈之间抹 10g），加时应用手指或合适的工具使润滑脂挤入轴承的滚柱间。
Notice: Hammering the outer ring of the bearing is prohibited.
注意：禁止锤击轴承外圈。
7.6.2.3.4 Add 75g grease in the inner oil groove of spacer sleeve of the bearing, add 45g
grease in the outer oil groove, apply the grease on the outer ring of ball bearing slightly,
then place it in the spacer sleeve of the bearing, apply the grease in the bearing, the
grease amount is 45g (apply 5g between the roller and inner ring), squeeze the grease
into the position between the balls with finger or appropriate tool when applying. Place
the spacer sleeve of the bearing and outer ring of ball bearing into inner bearing cover at
Date： 2015.09 Rev.： 1.0
N end together, it should be noted that the notch on the spacer sleeve of the bearing
aligns the notch of inner bearing cover at N end when placing, it is the best to press with
uniform pressure when placing, the copper bar can be used to touch the spacer sleeve
symmetrically and uniformly when the condition is limited really, to make it in place.
7.6.2.3.4 在轴承隔离套内油槽加 75g 润滑脂，外油槽加 45g 润滑脂，将球轴承外圈上稍

抹点润滑脂放入轴承隔离套内，轴承内抹上润滑脂，加脂量为 45g（滚子与内圈之间抹 5g），
加时应用手指或合适的工具使润滑脂挤入轴承的球间。将轴承隔离套联同球轴承外圈一起
放入 N 端内轴承盖内，放时注意轴承隔离套上的缺口对正 N 端内轴承盖缺口，放入时最好
用均匀的压力压入，确实条件受限时可用铜棒对称均匀地轻击隔套，使其到位。
Notice: Hammering the outer ring of the bearing is prohibited.
注意：禁止锤击轴承外圈。
7.6.2.3.5 Wholly install the inner bearing cover at N end on the shaft at non driving end;
detect the insulation resistance (between inner bearing cover at N end and outer ring of
the bearing) of the bearing with insulation resistance measuring instrument: The
insulation resistance is larger than 10MΩ. DC test voltage U=250V.
7.6.2.3.5 将 N 端内轴承盖整体套在非传动端轴上；用绝缘电阻测量仪检测轴承的绝缘电阻
（N 端内轴承盖与轴承外圈之间）：绝缘电阻大于 10MΩ。直流试验电压 U = 250 V。
7.6.2.3.6 Heat the O outer surface of inner ring of ball bearing and install it on the shaft at
non driving end; detect the insulation resistance (between inner bearing cover at N end
and outer ring of the bearing) of the bearing with insulation resistance measuring
instrument: The insulation resistance is larger than 10MΩ. DC test voltage U=250V.
7.6.2.3.6 将球轴承内圈 O（outer）面加热套在非传动端轴上；用绝缘电阻测量仪检测轴承

的绝缘电阻（N 端内轴承盖与轴承外圈之间）：绝缘电阻大于 10MΩ。直流试验电压 U = 250
V。
7.6.2.3.7 Install the locating key on the notches which align two parts such as the spacer
sleeve of the bearing and inner bearing cover at N end, replace new sealing gasket. Add
140g grease for four outer grooves of outer bearing cover at N end, and add 70g grease
for inner groove, screw on the inner bearing cover at N end with the bolt;
7.6.2.3.7 在轴承隔离套和 N 端内轴承盖两件对正的缺口上装上定位键，密封垫换新。N 端
Date： 2015.09 Rev.： 1.0
外轴承盖的四个外槽内加 140g 润滑脂，内槽内加 70g 润滑脂，用螺栓将其拧在 N 端内轴
承盖上；
7.6.2.4 Installation of Inner Ring and Inner Oil Seal of D End Bearing D 端轴承内圈
及内油封安装
Push the inner oil sealing at D end into the shaft until it cannot be moved, install O
ring in place. Push the inner ring of D end bearing on the shaft with hand until it stops.
将 D 端内油封推进转轴直到再也不能移动,将 O 形密封圈安装到位。用手将 D 端轴承

内圈推到轴上，直到停止。
Notice！The installation position should be noted (at the side of steel seal, it can
be seen from the outside).
注意！注意安装位置（钢印侧，在外部可以看见）。
7.6.2.5 Installation of Check Ring at D End D 端挡圈安装
Heat the check ring to 110℃ in the baking oven, then install it on the shaft, and
maintain a bit of time at the final position. Pressurize 50KN after cooling.
将挡圈在烘箱内加热到 110 °C，然后热套到轴上，并在最终位置保持一小段时间。冷
却后加压 50 KN。
Notice！The installation direction should be noted (the slotting inclines towards

the bearing side).
注意！注意安装方向（开槽倾斜向轴承侧）。
Warning！Use the heat insulating gloves when assembling！

警告！装配时使用隔热手套!
7.6.2.6 Installation of Outer Ring of D End Bearing D 端轴承外圈安装
Apply a tiny layer of grease evenly in the bearing housing of D end cover. Press the
outer ring of the bearing in the bearing housing of D end cover with hydraulic device, the
maximum pressure is 100 bars.
均匀地在 D 端端盖轴承室内薄薄涂一层润滑脂。用液压装置将轴承外圈压入 D 端端盖

轴承室，最大压力 100 bar。
Date： 2015.09 Rev.： 1.0
Detect the insulation resistance of the bearing (between D end cover and outer circle of
the bearing) with insulation resistance test instrument:
使用绝缘电阻测试仪检测轴承绝缘电阻（D 端端盖与轴承外圈之间）：
The insulation resistance is larger than 10MΩ; DC test voltage U=250V.
绝缘电阻大于 10MΩ；直流试验电压 U = 250 V。
Hoist the D end cover with outer ring of the bearing on the inner ring of D end
bearing. Install two assembling bolts in the thread hole of inner oil seal at D end, fix the
inner oil seal at D end on the D end cover.
将带轴承外圈的 D 端端盖吊装到 D 端轴承内圈上。将两个装配螺栓装入 D 端内油封

螺纹孔中，将 D 端内油封固定到 D 端端盖上。-
7.6.2.7 Lifting the Rotor 吊入转子
Install the rotor fixture of horizontal installation, lift the rotor carefully with the lifting
appliance, the winding, iron core and bearing should not be damaged.
安装转子卧装工装，用吊具小心地将转子吊入，不要损坏绕组、铁心和轴承。
Notice！The installation position of inner bearing cover at N end should be

noted when lifting the rotor, the oil filler hole of inner bearing cover at N end must align
with that of N end cover, it is suggested that the guide rod is used to carry out
installation and location.
注意！在吊装转子时要注意 N 端内轴承盖的的安装位置，N 端内轴承盖的注油孔必须

和 N 端端盖的注油孔对齐，建议使用导杆进行安装定位。
7.6.2.8 Installation of D End Cover D 端端盖的安装
Apply Loctite activator on the thread of tightening screw of D end cover, carry out air
drying in the air. Apply thread locking glue in the thread hole of stator base. Then install
the screw and gasket and fasten, see Table 3 for fastening torque.
在 D 端端盖紧固螺钉的螺纹上涂乐泰活化剂，在空气中风干。在定子机座的螺纹孔内
涂螺纹锁固胶。然后装上螺钉和垫圈并紧固，紧固力矩参见表 3。
7.6.2.9 Installation of Outer Bearing Cover at D End, Speed Measurement Gear Disk and
Sensor Cover D 端外轴承盖、测速齿盘及传感器盖安装
D end: Remove two assembling bolts for fixing inner oil seal at D end and D end
Date： 2015.09 Rev.： 1.0
cover, install outer bearing cover at D end, apply Loctite activator on the thread of
tightening screw, and carry out air drying in the air. Apply thread locking glue in the thread
hole. Then install the screw and gasket and fasten, see Table 3 for fastening torque.
D 端：取下固定 D 端内油封和 D 端端盖的两个装配螺栓，装入 D 端外轴承盖，在紧

固螺钉的螺纹上涂乐泰活化剂，在空气中风干。在螺纹孔内涂螺纹锁固胶。然后装上螺钉
和垫圈并紧固，紧固力矩参见表 3。
N end: Install the speed measurement gear disk on the shaft and fasten it with the
screws; install the sensor cover and fasten it with the screw.
N 端：将测速齿盘套入转轴并用螺钉紧固；装上传感器盖并用螺钉紧固。
Fastening process is: Apply Loctite activator on the thread of tightening screw, and
carry out air drying in the air. Apply thread locking glue in the thread hole. Then install the
screw and gasket and fasten, see Table 3 for fastening torque.
紧固程序为：在紧固螺钉的螺纹上涂乐泰活化剂，在空气中风干。在螺纹孔内涂螺纹
锁固胶。然后装上螺钉和垫圈并紧固，紧固力矩参见表 3。
7.6.2.10 Installation of Pinion 小齿轮压装
Connect the hydraulic device with G1/4”thread hole of shaft (N end), start the
hydraulic device to press the pinion into the inner hole of the shaft, see the disassembly
process of the pinion for press fitting process. Inspect the pressing amount of the pinion
(measurement accuracy is 0.1mm), minimum allowable pressing amount is 4.4mm,
maximum allowable pressing amount is 4.6mm.
将液压装置与转轴（N 端）的 G1/4"螺纹孔连接，启动液压装置将小齿轮压入转轴内孔，

压装工艺参照小齿轮拆卸工艺。检查小齿轮压入量（测量精度 0.1mm），最小允许压入量
4.4mm，最大 4.6mm。
Notice！ Use the glycerine to carry out press fitting.

注意！使用甘油压装。
Warning！Too fast pressure can lead to permanent deformation of motor shaft or

pinion, thus lead to the scrapping of the pinion or rotor.
警告！压力太快会导致电机转轴或小齿轮的永久变形，从而导致小齿轮或转子报废。
7.6.2.11 Installation of Speed Sensor, Temperature Sensor and Junction Box 速度、温度
Date： 2015.09 Rev.： 1.0
传感器安装、接线盒安装
Install the probe of speed sensor on the sehsor cover at N end and fasten with the
screw; install the probe of temperature sensor on the motor base and fasten with the
screw; then install the cable clamps of various sensors and fasten with the screws; press
the cable joint and fasten with the screws; install the cover plate of junction box and
fasten with the screws after applying the sealant evenly on the fitting surface of the
junction box.
在 N 端传感器盖上安装速度传感器探头并用螺钉紧固；在机座上安装温度传感器探
头并用螺钉紧固；再安装各个传感器电缆紧固夹并用螺钉紧固；压平安装电缆线接头并用
螺钉紧固；在接线盒安装面均匀涂抹密封剂后安装接线盒盖板并用螺钉紧固。
Fastening process: Apply Loctite activator on the thread of tightening screw, and
carry out air drying in the air. Apply thread locking glue in the thread hole. Then install
the screw and gasket and fasten, see Table 3 for fastening torque.
紧固程序：在紧固螺钉的螺纹上涂乐泰活化剂，在空气中风干。在螺纹孔内涂螺纹
锁固胶。然后装上螺钉和垫圈并紧固，紧固力矩参见表 3。
Notice！Measure the clearance between the probe of speed sensor and speed
measurement gear disk; the minimum allowable clearance is 0.4mm, the maximum
allowable clearance is 1.4mm.
注意！测量速度传感器探头和测速齿盘之间的间隙；最小允许间隙 0.4 mm，最大间隙

1.4mm。
7.7 Reassembly 重新安装
See the traction motor installation of driving system.

参见驱动系统的牵引电机安装。
7.8 Parameter Setting and Limit Table 参数设置与限度表
“Original” refers to original design size, allowable manufacture tolerance or

allowable clearance when assembling. “Forbidden limit” refers to minimum requirement
of maintenance limit of the locomotive and component, see Table 12 for the limit table.
When the size and fit clearance of various parts of the motor exceed this limit, they
Date： 2015.09 Rev.： 1.0
cannot be used continually without repair or replacement.
“原形”系指设计的原始尺寸、制造允许公差或组装时的允许间隙。“禁用限度”系指机
车或部件检修限度中最低要求的限度，限度表见表 12。电机各零部件尺寸和配合间隙超过
此限度时，不经修理或更换不准继续使用。
Table 12 Limit Table of Traction Motor
表 12 牵引电机限度表
No. Name Original Limit

序号名称原形限度
Bearing assembly play (driving
1 end/radial direction) 0.190～0.300 mm 0.190～0.360 mm
轴承装配游隙（传动端/径向）
Bearing assembly play
2 (non-driving end/radial direction) 0.061～0.12 mm 0.061～0.12mm
轴承装配游隙（非传动端/径向）
Bearing assembly play (non
driving end/axial direction)
3 0.134～0.203 mm 0.134～0.203mm
轴承装配游隙（非传动端/轴向）
Cold CD resistance of stator

winding (20℃)
4 0.01646Ω±5% 0.01646Ω±5%
定子绕组冷态直流电阻值
（20℃）：
The insulation resistance value
of stator winding against ground is 18MΩ (Cold, clean
100MΩ (Cold)
not less than (1000V megameter) and stoving)
5 100 MΩ（冷态）
(MΩ) 18 MΩ（冷态清洁
定子绕组对地绝缘电阻值不小于烘干）
（1000V 兆欧表）（MΩ）
7.9 Flaw Detection Range 探伤范围
Table 13 Flaw detection Range of Traction Motor

表 13 牵引电机探伤范围
No. Name Flaw Detection
Flaw Detection Period
序号名称 Category
探伤周期
探伤类别
Date： 2015.09 Rev.： 1.0
1 Magnetic powder inspection of base Magnetic
suspension and journal sticking powder I3 (inspection level 3)
position inspection I3(检查 3 级)
机座悬挂和抱轴部位磁粉探伤磁探
2 Inner cone shaft 内锥轴 Penetration or
magnetic
I3 (inspection level 3)
powder
I3(检查 3 级)
inspection 渗透
或磁探
7.10 Coming into Use/Function Test 投入使用/功能试验

投入使用功能试验
See the related sections of the locomotive.

参见机车相关章节。
8 List of Special Tools, Equipment, Consumables and Spare Parts 专用工
具及设备、易损件及备件清单
In order to simplifying purpose, this use and maintenance instructions stipulate the
following abbreviations, see Table 14.
为了简化起见，规定本使用维护说明书使用下列缩写，见表 14。
Table 14
表 14
No. Name Code
序号名称代号
Special tool
1. W
专用工具
Equipment
2. H
设备
Measurement and test equipment

3. M
测量和试验设备
4. Wearing part V
Date： 2015.09 Rev.： 1.0
No. Name Code
序号名称代号
磨损件
Lubricating grease
5. S
润滑油脂
Chemical cleaner
6. R
化学清洗剂
Coating
7. F
涂层
Application material
8. B
运行材料
8.1 Special Tool 专用工具
See Table 15 for special tool list used for the maintenance.
维护所需使用的专用工具清单见表 15。
Table 15 Special Tool
表 15 专用工具
Quoted
Special Tool Use Manufacturer
Code
专用工具用途制造厂家
引用代号
CSR Zhuzhou Electric
Hydraulic device Used for taking out the
W001 Co., Ltd.
液压装置 pinion 用于取小齿轮
南车株洲电机有限公司
Used for pulling out inner
sleeve, inner seal ring, CSR Zhuzhou Electric
Three-jaw puller check ring of the bearing
W002 Co., Ltd.
三爪拔出器
用于拉出轴承内套、内封环、南车株洲电机有限公司
档圈
Used for the assembly of
CSR Zhuzhou Electric
Baking oven seal ring and check ring
W003 Co., Ltd.
烘箱用于封环、挡圈的装配
南车株洲电机有限公司
Motor fixture of CSR Zhuzhou Electric
Used for motor assembly
W004 horizontal installation 电 Co., Ltd.
用于电机装配
机卧装工装南车株洲电机有限公司
Date： 2015.09 Rev.： 1.0
8.2 Equipment 设备
8.2.1 Chemical Cleaner 化学清洗剂
See Table 16 for chemical cleaner list used for the maintenance.
维护所需使用的化学清洗剂清单见表 16。
1) Generally accepted cleaner:
1)普遍认可的清洁剂：
Petroleum solvent 155/185
石油溶剂 155 / 185
Kerosene
煤油
Methylated alcohol (ethanol)
甲基化酒精（乙醇）
Notice ！ During using the cleaner, the related chemical cleaner information
provided in the safety information sheet should be observed constantly. The safety
information sheet should be delivered together with the cleaner.
注意! 在清洁剂的使用过程中，应时刻遵守安全信息单中提供的有关化学清洁剂的信息。
安全信息单应和清洁剂一同出库。
2) Chemical cleaner used for outdoor and cleaning mechanical components
2)用于户外和清洁机械部件的化学清洁剂
Solvent type cleaner:
溶剂型清洁剂：
Alcohol (methylated alcohol, propyl alcohol, butyl alcohol)
酒精（甲基化酒精、丙醇、丁醇）
Acetone
丙酮
石油溶剂 155/185
Water-based cleaner used together with positive ion and anionic surfactant in the
open air:
在户外与阳离子和阴离子表面活性剂一同使用的水基清洁剂：
Date： 2015.09 Rev.： 1.0
Low-surface-tension water (for example, 1…2% cleaner)
低表面张力水（如 1…2%清洁剂）
Outdoor alkaline cleaner, which is not suitable for washing the motor whose surface
is not protected:
用于户外的碱性清洁剂，不适用于清洗未加保护表面的电机：
When applied to the insulation system, pH value cannot be higher than 9, and the usage
time cannot exceed 30 min. Then the clear water must be used to rinse.
当应用于绝缘系统时，pH 值不可高于 9，且使用时间不能超过 30 分钟。随后必须用清水
漂洗。
Outdoor hydrochloric acid cleaner, which is not suitable for washing the motor
whose surface is not protected:
用于户外的盐酸清洁剂，不适用于清洗未加保护表面的电机：
When applied to the insulation system, pH value cannot be higher than 2, and the
usage time cannot exceed 30 min. Then the clear water must be used to rinse.
当应用于绝缘系统时，pH 值不可高于 2，且使用时间不可超过 30 分钟。随后必须用
清水漂洗。
3) Chemical cleaner of winding
3) 绕组的化学清洁剂
石油溶剂 155/185
Methylated alcohol
甲基化酒精
Notice！When applied to the insulation system, pH value cannot be higher than 9,

and the usage time (of winding) cannot exceed 30 min, the usage time is 2 ~ 3 hours if
the winding has thicker dirt. Then the clear water must be used to rinse, and the winding
should be dried in the baking oven for 12 hours at 110~120℃.
注意!当应用于绝缘系统时，pH 值不可高于 9，且使用时间（绕组）不可超过 30 分钟，若
绕组有较厚污垢时使用时间为 2 到 3 小时。随后必须用清水漂洗，随后绕组应在 110 至
120℃的烘箱中干燥 12 个小时。
Table 16 Chemical Cleaner
表 16 化学清洗剂
Date： 2015.09 Rev.： 1.0
Quoted Code Chemical Cleaner Manufacturer Hazard Kind
引用代号化学清洗剂制造厂家危害种类
R001 Methylated alcohol Jiuhua Coating
甲基化酒精九华涂料
R002 Petroleum solvent Jiuhua Coating

155/185 石油溶剂九华涂料
155/185
R003 Kerosene Jiuhua Coating
煤油九华涂料
R004 Acetone Jiuhua Coating
丙酮九华涂料
8.2.2 Coating Composition 涂层成分
If carrying out paint repair, firstly eliminate all loose, damaged original paint coating,
the paint repair surface must have no ash, dust and oil, and the sand paper is used to
grind. See Table 17 for coating composition list used for the maintenance.
如果补漆，首先清除所有松动、损坏的原油漆涂层，补漆表面必须无灰、无尘和无油，
并用砂纸打磨。维护所需使用的涂层成分清单见表 17。
表 17 涂层组成
Table 17 Coating Composition
Quoted Code Coating Composition Manufacturer Order No.
引用代号涂层成分制造厂家订货号
F001 Jiuhua Coating RAL 3012
Double-component primer of
九华涂料
epoxy resin
环氧树脂双组份底漆
Finish Jiuhua Coating RAL 7039
面漆九华涂料
Thinner 稀释剂 Jiuhua Coating 九华涂料
8.2.3 Lubricant 润滑剂
See Table 18 for lubricant list used for the maintenance.

维护所需使用的润滑剂清单见表 18。
Table 18 Lubricant
表 18 润滑剂
Quoted Lubricant Manufacturer Dosage Replacement Cycle Remarks
Date： 2015.09 Rev.： 1.0
Code Name 制造厂家 (each motor) 更换周期备注
引用代号润滑剂名称用量
每台电机）
（每台电机）
Grease
40g (fill
UPG#2 Each 100000km 每 10
grease) (Fill grease) （补
S002 润滑脂万公里
40g（补油脂）油脂）
UPG#2
8.2.4 Other Equipment 其它设备
See Table 19 for other equipment list used for the maintenance.
维护所需使用的其它设备清单见表 19。
Table 19 Other Equipment
表 19 其它设备
Quoted Code Other Equipment Manufacturer Order No.
引用代号其他设备制造厂家订货号
H001 Assembly glue ALTEMP Q Fa. Klüber Lubrication NB 50
组装胶 ALTEMP Q D 81310 München
8.3 Measurement and Test Equipment 测量和试验设备
See Table 20 for measurement and test equipment list used for the maintenance.
维护所需使用的测量和试验设备清单见表 20。
Table 20 Measurement and Test Equipment
表 20 测量和试验设备
Measurement and Test
Quoted Code Manufacturer Order No.
Equipment
引用代号制造厂家订货号
测量和试验设备
M001 High-frequency pulse
tester 高频脉冲试验机
M002 TY type insulation
dielectric loss tester
TY 型绝缘介损测试仪
M003 1000V magameter
1000V 兆欧表
M004 Motor Idle Test Stand
电机空转试验台
8.4 Wearing Part and Spare Part list 易损件及备件清单
See Table 21 for wearing part and spare part list used for the maintenance.
Date： 2015.09 Rev.： 1.0
维修中需更换的易损件及备件清单见表 21。
Table 21 Wearing Part and Spare Part List
表 21 易损件及备件清单
Secti Maintenance Level
Quoted on Supplier/Order 维修等级
Material No.
Code Name No. No.
材料号
引用代名称章节供应商/订货号
号号
VI I1 I2 I3 R1 R2 R3 UM
V001 UPG#2 13170041 Royal Purple x x x x x

紫皇冠公司
V002 Sealant 16006320 E. Zollern x x x x
密封剂 GmbH & Co.
Loctite x x x x
activator
1
V003 7471
6005802
乐泰活化剂
7471
Heat x x x x
conduction
grease
6
V004 without
3130070
silicon
不含硅的导
热脂
Oil cup x x x x
V005 M10x1 16460100
油杯 M10×1
Oil nipple x x x x
cap
V006 09514060
注油嘴帽
Note: 1. The wearing part to be replaced is marked with “x” in the corresponding maintenance level; 2.
The maintenance level accords with the stipulations of 6.1.
注：1. 需更换的易损件在相应的维修等级中用“x”标记；2. 维修等级按 6.1 的规定。
Date： 2015.09 Rev.： 1.0
8.5 Application Material 运用材料
See Table 22 for application material list used for the maintenance. The glycerinum is
used as hydraulic medium, the waterproof glycerinum with ultrapurity can absorb water
strongly and prevent entering of air, the hydraulic device maintains high seal all the time.
Carry out regular inspection for glycerinum performance through reaction paper.维修所
需运用材料清单见表 22。使用甘油来做液压介质，防水和超纯度的甘油能强烈的吸水并能
防止空气的进入，液压装置一直保持高度的密封。通过反作用纸来定期的对甘油的性能进
行检查。
Notice！When the temperature is lower than 18℃, the glycerinum has the risk of
largening viscosity even concretion！
注意!当温度低于 18°C 时，甘油有黏度变大甚至凝固的的险发生！
Table 22 Application Material
表 22 运用材料
No. System / Component Application Material Model Volume/Weight
序号系统/部件运用材料型号体积/重量
Pinion Hydraulic medium Glycerinum

B001
小齿轮液压介质甘油
9 Waste Processing Scheme 废弃物处理方案
9.1 General Rules 总则
The development, manufacturing and abandoning process of our products have

been fully considered environmental protection. It is the best to meet the development
requirements of ecology and economy.
我们产品的发展，制造和摒弃过程已充分考虑环境保护。能最好的满足生态和经济的
发展要求。
Date： 2015.09 Rev.： 1.0
与环境有关的驱动系统性
9.2 Driving System Performance Relative to Environment:与环境有关的驱动系统性
能：
Low abrasion, three-phase AC asynchronous traction motor guarantees low

maintainability.
低磨耗，3 相交流异步牵引电机保证了低维护性。
High traction efficiency and low weight structure save energy effectively.
高牵引效率和低重量结构有效节约能源。
World class non-contact sealing system guarantees oil tightness, to protect environment
from pollution.
一流的无接触密封系统保证了油密性，保护环境不受污染。
9.3 Recycling Use 循环使用
Our traction driving system is a product in harmony with the environment:

我们的牵引驱动系统是与环境相协调的产品：
98% products are all recycled.
98％的产品都是可循环使用的。
9.4 Abandoning 摒弃
The oil and grease must be cleared away wholly and disposed separately. See Table 23
for handling method.
油和油脂必须全部被清除掉并单独处理。处理方法见表 23。
It should be avoided to dispose rubber products by incineration mode.
应避免采用焚烧方式处理橡胶产品。
Table 23 Waste Disposal Method

表 23 废弃物处理方法
No. System/Component Raw Material Dimension Waste Disposal
序号系统/部件原料尺寸废弃物处理
1 Steel product Iron Waste
钢铁制品铁废料
2 Wire Copper Waste
导线铜废料
Date： 2015.09 Rev.： 1.0
3 Rubber parts N-NBR70 Hazardous
橡胶件 waste 危险废弃
物
3 Insulating material Phenolic resin, polyester Hazardous
绝缘材料 compound waste 危险废弃
酚醛类、聚酰类化合物物
10 Transportation and Storage 运输与贮存
10.1 Transportation 运输
When transporting the motor, the transportation safety device should be adopted to
protect axle hung part of the motor, special transportation equipment should be adopted
to protect the rotor and bearing at two sides.
搬运电机时，应采用运输安全装置对电机抱轴部位进行保护，两侧采用专用的运输设
备来保护电机的转子和轴承。
Notice！When transporting the motor, fix the pinion and install anti-rotation bolt on
the N end shaft to prevent damage during transportation, and guarantee that the rotor
has no radial and axial movement.
注意！电机运输时需固定小齿轮并在 N 端轴上安装防转螺栓以防止运输过程中出现损伤，
并保证转子不会有径向和轴向的移动。
Notice！It should be confirmed that the transportation locking bolts on the N end
shaft have been removed before the system is put into use officially.
注意！系统正式投入运用前应确认去掉电机 N 端轴上的运输锁紧螺栓。
10.2 Storage 贮存
After the manufacturer carries out the system test on the test stand, the gear box oil
for operation should be applied, so that all internal gear parts such as gear and bearing
can obtain sufficient lubrication without corrosion in six months. The motor bearing (N
end) must also be protected by grease.
在制造商试验台上做完系统试验后，应加上运行使用的齿轮箱油，使得在 6 个月内所
有内部的齿轮部件，如齿轮和轴承，都得到充分润滑而不会腐蚀。电机轴承（N 端）也必
须采用油脂进行保护。
The motor should be filled with lubricating oil for official operation, then wholly wrap
the whole motor and drying agent with packaging file in the sealing mode.
电机应装入正式运行使用的的润滑油，然后用包装膜将整个电机与干燥剂整体密封包
Date： 2015.09 Rev.： 1.0
裹起来。
After about 6 months, the packaging film and transportation support should be
removed according to the need, and the motor rotor is rotated for several turns so that
various parts of the bearing have oil film protection, and guarantee that the outer ring of
the bearing has the grease used for lubrication track and roller. After rotation, the motor
rotor should be at different circumference points prior to 6 months.
大约 6 个月后，根据需要应去掉包装膜和运输支架，并转动电机转子几圈，使轴承各
部分都有油膜保护，保证轴承外环有用于润滑轨道和滚子的油脂。在旋转之后，电机转子
应处在与 6 个月前不同的圆周点上。
If necessary, the transportation support can be reinstalled, the motor should be
sealed again, this process repeats once every 6 months, with three times at most,
therefore the motor can be stored for 2 years at most.
如需要，可以重新装上运输支架，电机应重新密封，此过程每 6 个月重复一次，最多
3 次，因此电机最多可以储存 2 年。
Then oil change should be carried out, the motor should rotate for several minutes
at the speed of 1000r/min so that the bearing can obtain fresh oil, the above process
repeats once every 6 months, the equipment can store for another 2 years, if possible,
this process can repeat fro several times according to the need. Before the motor
bearing (N end) is put into operation, carry out lubrication once every 2 years, then carry
out package and seal for the motor again.
然后就应换油，电机应以 1000r/min 的速度旋转几分钟以使轴承内得到新鲜的油，以
上程序每 6 个月重复一次，则设备可以多储存 2 年，如有可能，此程序可以根据需要多重
复几次。电机轴承（N 端）在投入操作前，每 2 年润滑 1 次，然后可以重新将电机包装密
封。
New motor:
新电机：
If the motor is not used, it should be stored in the dry environment without vibration.
如电机未被使用过，则应保持在干燥无振动的环境中。
If the equipment needs longer storage time, special corrosion prevention, storage,
package and dry method should be adopted, for example, drying motor, carrying out seal
with plastic film and silica gel, etc., see the description of overall requirements of CSR
Zhuzhou Electric Locomotive Co., Ltd. for details.
Date： 2015.09 Rev.： 1.0
如设备需要储存更长的时间，则应采用特殊的防腐，保持，包装和干燥方法，如将电
机干燥，使用塑料膜和硅胶进行密封等，细节见株洲电力机车有限公司工作的总体要求内
的描述。
Notice ！ If the storage environment has vibration, fix the pinion and install
anti-rotation bolt on the N end shaft.
注意！如储存环境有振动，则必须固定小齿轮并在 N 端轴上安装防转螺栓。
For the used motor:
对使用过的电机：
If the equipment will be not used for a period of time, special corrosion prevention,
storage, package and dry method should be adopted, for example, drying motor,
carrying out seal with plastic film and silica gel, etc., see the description of overall
requirements of CSR Zhuzhou Electric Locomotive Co., Ltd. for details.
如设备将有一段时间不被使用，则应采用则应采用特殊的防腐，保持，包装和干燥方
法，如将电机干燥，使用塑料膜和硅胶进行密封等，细节见株洲电力机车有限公司工作的
总体要求内的描述。
10.2.1 Storage Rules of Rubber and Metal Parts 橡胶金属件的储存规则
10.2.1.1 Storage Area:储存区域：
The storage area should be cool, dry and have suitable ventilation.
储存区域应凉爽，干燥和适当通风。
The storage area should be not affected by wind and rain.
储存区域应不受风雨的影响。
10.2.1.2 Temperature:温度：
The storage temperature of rubber and metal parts is within -10℃ and 25℃.
橡胶金属件储存温度在-10℃到 25℃之间。
The higher temperature is only allowed for short time.
更高的温度只允许短时出现。
10.2.1.3 Humidity:湿度：
The parts should not be stored in the humid environment.
部件不应储存在潮湿的环境内。
It should be guaranteed that there is condensation water, the best condition is that the
Date： 2015.09 Rev.： 1.0
relative humidity is less than 65%.
保证不会出现凝结水，最好的条件是相对湿度小于 65％。
10.2.1.4 Sunlight:日照：
The equipment should avoid direct sunlight, especially sunlight including high ultraviolet.
设备应避免阳光直射，特别是含有高紫外线的光照。
10.2.1.5 Oxygen and Ozone:氧和臭氧：
The equipment should avoid the influence of air change, it should be packed well and
stored in the airtight box.
设备应避免受到空气变化的影响，应将其包装好，储存在密闭箱体内等。
The ozone has special hazard, the storage area has no the equipment which can generate the ozone,
for example, motor or other equipment which can generate discharging.
臭氧特别具有危害形，储存区域不得有能产生臭氧的设备，如电动机或其它可以产生放电的设备。
10.2.1.6 Chemicals 化学：

The solvent, fuel, lubricant, chemicals, acid, sanitizer and similar material cannot be
stored in the same storage room.
溶剂，燃料，润滑剂，化学物品，酸，消毒剂和类似材料都不能与设备储存在同一间
储存室。
The packing –case material and covering material shall not include the ingredients
which may damage the parts, for example, copper or copper alloy, petroleum, oil and
other similar ingredients.
包装箱的材料和覆盖物的材料不得含有可能损害部件得成分，如铜或铜合金，石油，
油或其它类似成分。
The packing film shall not include plasticizer.
用于包装的膜不得含有可塑剂。
Any protective layer for the equipment shall not damage rubber and rubber metal.
任何用于设备的保护层不得对橡胶和橡胶金属产生损害。
It should be guaranteed that the equipment is stored in the environment without
stress, for example, there is no tension, pressure or other tensile force, because the
stress can lead to permanent deformation and crack.
应保证设备储存在无应力的环境中，如无张力，压力或其它拉力，因为应力会导致永
久性的变形和裂纹。
The position between the rubber and metal should adopt the mixed solution of
glycerinum and ethyl alcohol (1:10) to carry out washing, the wax on the protective layer
Date： 2015.09 Rev.： 1.0
of ozone should not be wiped off when washing.
橡胶金属间应采用甘油和普通酒精（1：10）的混合溶液来进行清洗，清洗时不要擦
掉臭氧保护层上的蜡。
When storing in the outdoor and stress condition, which can harm the rubber and
metal, so it should be avoided. The service life of metal and rubber will shorten with the
storage time, specific lifespan involves concrete storage condition.
储存在露天或有应力的条件下，会对橡胶金属产生伤害，所以应该避免。金属橡胶的
使用寿命随储存时间而缩短，具体寿命跟具体储存条件有关。
11 Daily Maintenance and Maintenance for Long-term Reservation 日常保
养和长期备用的保养说明
11.1 Description on Daily Maintenance 日常保养说明
Conduct daily inspection on the appearance, inspect motor appearance, and confirm
the integrity of motor components.外观日常检查，检查电机外观，对电机部件完好性进
行确认。
长期备用的保养说明
11.2 for maintenance description on long-term spare parts.长期备用的保养说明
Table 24 Maintenance Description 表 24 保养说明
Component
No.序 Spare part state
Description 部件 Maintenance description 保养说明
号备用状态
名称
Installed in the
locomotive, as
long-term spare Pay attention to the
1 Motor 电机 parts to the
locomotive 装在 anti-corrosion 注意防腐。
机车上，机车长期
备用
Date： 2015.09 Rev.： 1.0
Installed in the
locomotive, put
into operation Before put into the line, check
after as motor appearance, and confirm that
long-term spare speed sensor and temperature
2
parts of the sensor are in good conditions.上线前
locomotive 装在检查电机外观，确认转速传感器与温度
机车上，机车长期传感器是否完好。
备用后即将投入
适用
Roller bearing
Paint anti-rust oil, pack it well,
N332EMR/HB3L3
Spare parts and then place it into a dry
3 BVA841 滚柱轴承
备品 environment. 涂抹防锈油并包装好，
N332EMR/HB3L3
置于干燥环境中。
BVA841
Four point contact

ball
bearing2TS2-7M Paint anti-rust oil, pack it well,
C3-QJ318LIBC4P Spare parts and then place it into a dry
4
6S20 四点接触球备品 environment.涂抹防锈油并包装好，置
轴承于干燥环境中。
2TS2-7MC3-QJ3
18LIBC4P6S20
Cylindrical roller
bearing
Paint anti-rust oil, pack it well,
2TS2-7MC3-NU3
Spare parts and then place it into a dry
5 20EHSP6V3S20
备品 environment.涂抹防锈油并包装好，置
圆柱滚子轴承
于干燥环境中。
2TS2-7MC3-NU3
20EHSP6V3S20
Temperature Pack it well, and then place it

6 sensor 温度传感 Spare parts into a dry environment.
备品
器包装好置于干燥环境中。
7 Speed sensor 转 Spare parts Pack it well, and then place it

备品
Date： 2015.09 Rev.： 1.0
速传感器 into a dry environment.
包装好置于干燥环境中。
12 Parts Catalogue and Spare Parts Procurement 零件目录及备件采购
12.1 Parts Catalog, See Table 25 零件目录，

零件目录，见表 25
Table 25 Parts List of Traction Motors

表 25 牵引电机零件清单
Part Drawing No. Part Name Quantity Adoption Manufacturer
No. 图号零件名称数量 Standard 生产厂家
零件采用标准
编号
1 JD160B general 1 IEC60349-2 CSR Zhuzhou
assembly drawing Electric Co., Ltd.
JD160B 总装配图南车株洲电机
2 JD160B profile 1 IEC60349-2 CSR Zhuzhou
drawing Electric Co., Ltd.
JD160B 外形图南车株洲电机
3 Cable installation 1 IEC60349-2 CSR Zhuzhou
instructions Electric Co., Ltd.
电缆安装说明南车株洲电机
4 Wire holder 1 JT-2006-044D Taihu
接线座太湖
5 Connecting line V1 1 GB/T5584.2 CSR Zhuzhou
联接线 V1 Electric Co., Ltd.
南车株洲电机
6 Connecting line 1 GB/T5584.2 CSR Zhuzhou
W1 联接线 W1 Electric Co., Ltd.
南车株洲电机
7 Connecting line 1 GB/T5584.2 CSR Zhuzhou
U1 联接线 U1 Electric Co., Ltd.
南车株洲电机
8 Balance weight 10 GB4425 CSR Zhuzhou
平衡块 Electric Co., Ltd.
南车株洲电机
9 Speed sensor 1 JT-2006-041D Zhuzhou
速度传感器 Electric
Locomotive
Motor
Manufacture &
Date： 2015.09 Rev.： 1.0
Repair Co., Ltd.,
Zhuzhou Tianli
株洲电机修造、
株洲天利
10 Temperature 1 JT-2006-038D Zhuzhou
sensor 温度传感器 Electric
Locomotive
Motor
Manufacture &
Repair Co., Ltd.,
Zhuzhou Tianli
株洲电机修造、
株洲天利
11 Copper washer 1 GB2040 CSR Zhuzhou
铜垫圈 Electric Co., Ltd.
南车株洲电机
12 Cover plate 1 GB/T 700 CSR Zhuzhou
盖板 Electric Co., Ltd.
南车株洲电机
13 Epoxy laminated 1 JB 5822 Zhuzhou
board 环氧层压板 Guangyuan
株洲广缘
14 Terminal box lid 1 GB/T 700 CSR Zhuzhou
接线盒盖 Electric Co., Ltd.
南车株洲电机
15 Wiring clamp 1 JB 5822 Zhuzhou
导线夹 Guangyuan
株洲广缘
16 Jointing clamp 1 JB 5822 Zhuzhou
plate 接线夹夹板 Guangyuan
株洲广缘
17 Earthing mark 1 GB/T 2041 CSR Zhuzhou
接地标志 Electric Co., Ltd.
南车株洲电机
Date： 2015.09 Rev.： 1.0
Figure 8 Exploded drawing of Traction Motor
图 8 牵引电机爆炸图
12.2 Storage and Purchase of Spare Parts 备件的仓储及采购
Table 26 Storage and Purchase of Components and Spare Parts of Traction Motor
表 26 牵引电机部件备件的仓储及采购
Recomm
Part
• Sended equi
Category
crap Number red
Min. Kg (R=
Delive proce of Soft
N Order Part Maintena
Component ry Delivery ssing Vehicle war
o. Order No. Quan Weight, nce
Name Time Terms Size opini Spare e
序订货号 tity kg Spare
部件名称交货交货条款尺寸 on Parts of 4 所
号最少零件重 Parts)
时间报废Years 需
订货量零件类别
处理(Set) 4 年软
数量（R=维修
建议推荐的台件
备件，C=
车备件数
易耗件）
量(套)
Delivery
30 against Scrap Non
80000951420 Oil cup M10X
1 days the 1 0.1 R 报废 6 e
0 M10X1 油杯 1
30 天 payment 无
M10X1
款到发货
Delivery
30
against Scrap Non
80000951405 GPN days
2 the 1 0.1 R 报废 6 e
0 985/0201 30 天
payment 无
款到发货
Date： 2015.09 Rev.： 1.0
Delivery
φ2 pure cotton 20day
against Scrap Non
80001710201 braided rope s 20
3 the 1 Φ2 0.01 R 报废 1.6m e
0 Φ2 纯棉编织天
payment 无
绳
款到发货
Roller bearing
Delivery
N332EMR/HB 60 Recy
against Non
80005023067 3L3BVA841 滚 days cled
4 the 1 33 R 6 e
0 柱轴承 60 天可回
payment 无
N332EMR/HB 收
款到发货
3L3BVA841
Four-point
contact ball Delivery
60day Recy
bearing 四点接 against Non
80005000000 s 60 cled
5 触球轴承 the 1 17.5 R 6 e
6 天可回
2TS2-7MC3- payment 无
收
QJ318LIBC4P 款到发货
6S20
Cylindrical
Roller Bearing
2TS2-7MC3-N
U320EHSP6V
80005000000
6 3S20
5
圆柱滚子轴承
2TS2-7MC3-N
U320EHSP6V
3S20
Delivery
O ring 30
against Scrap Non
80009999953 265x4 days
7 the 1 265x4 0.01 R 报废 6 e
0 O 型密封圈 30 天
payment 无
265x4
款到发货
Delivery
O ring 30day
against Scrap Non
80009999956 450x8 s 30
8 the 1 450x8 0.01 R 报废 6 e
0 O 型密封圈天
payment 无
450x8
款到发货
Delivery
O ring 30day
against Scrap Non
80009999955 415x5 s 30
9 the 1 415x5 0.01 R 报废 6 e
0 O 型密封圈天
payment 无
415x5
款到发货
80009999951 O ring 30day Delivery Scrap Non
10 1 19x3 0.01 R 6
0 19x3 s 30 against 报废 e
Date： 2015.09 Rev.： 1.0
O 型密封圈天 the 无
19x3 payment
款到发货
45
Delivery
da Non
Grease against Scrap
80001317004 ys e
11 UPG#2 the 0 0 0 C 报废 3kg
1 45 无
润滑脂 UPG#2 payment
天
款到发货
13 Unpacking and Inspection 开箱及检查
When using the standby motor which has been stored for a long time, carry out
careful inspection and adjustment for it before operation according to the following items:
在起用长时间存放后的备用电机时，要在运行之前按照下列各项对其进行仔细的检查
和调整:
a) High pressure air must be used to sweep the inside of the motor.
电机内部必须用高压风加以清扫。
b) The megameter must be used to inspect the insulation resistance.
必须用兆欧表检查绝缘电阻。
c) The bearing grease must be inspected, replace all the grease if the lubricating
grease has deterioration or there is other abnormity.
必须检查轴承润滑脂，如果润滑脂变质或发生其他异常应全部换新。
d) The motor operates for about 1 hour at low voltage alternating current (about
150V), inspect whether there is abnormal phenomena.
用低压交流电（大约 150V）使电机运转约 1 小时，检查有无异常现象。
14 Others 其他
Before using this motor, the user must carefully read this instruction, understand
and master the structure characteristics, related maintenance data and maintenance
points skillfully in detail.用户在使用该电机之前，必须仔细阅读本说明书，详细了解和
熟练掌握该电机的结构特点、有关维护数据以及维护要点。
The user should use and maintain this asynchronous traction motor in strict
Date： 2015.09 Rev.： 1.0
accordance with the stipulations of this instruction, which has very important role to
guarantee reliable operation of this motor.
用户严格地按本说明书的规定使用和维护本异步牵引电动机，对保证该电机的可
靠运行起着十分重要的作用。
This instruction is the essential information of drivers, staffs, maintenance
personnel, management personnel, etc., they should be carried out training, and
they are required to correctly use and maintain this motor in strict accordance with
the stipulations of this instruction
该说明书是司乘、维护、管理等相关人员的必备资料，应当对其进行培训，并要
求其严格按照本说明书之规定正确地使用和维护该电机。
Besides the manufacturer, the repair of this motor should be carried out by the unit which possesses
specialized technology strength and obtains qualification authentication of related departments (it refers to
repair qualification of asynchronous traction motor), any other unit without quality assurance ability shall not
repair this motor.
除制造厂外，该电机的修理应由具备专门的技术力量并取得有关部门资格认证（指异步牵引电机修理资格）
的单位才能进行，其他任何无质量保证能力的单位不得承担该型电机的修理。
If the user needs to replace the material or parts, it is suggested to use the brand
or supplier recommended by our company and use original spare parts of our company.
Please see Chapter 9 of this instruction for the purchase of related spare parts,
including related spare parts list, supplier name and related description.
如果用户需要更换材料或零部件，建议使用我公司推荐的品牌或供货商以及使用我
公司原产备件。有关备件的采购，请参阅本说明书第 9 章，其中包含了有关备件的清单
和供货商名称及有关的说明。
Please contact our company timely and provide detailed conditions if there is
unclear question or any difficulty during operation, when maintaining or there is fault.
If the motor has damaged, in order to assess damaged degree accurately, you
should clarify the damaged degree so that effective repair can be carried out timely.
如果在运行期间、维护时或出现故障时有不清楚的地方或有什么困难，请及时与我
公司联系,并提供详细情况。如果电机已损坏，为准确评估损坏的程度，以便及时实施
有效的修理，还请阐明损坏程度。
When you encounter the above conditions, please provide the following
Date： 2015.09 Rev.： 1.0
information:
遇到以上情况时，请提供以下信息：
—— relative locomotive no.;
——有关的机车编号；
—— travel mileage of locomotive or bogie where the motor locates;

——电机所在机车或转向架的走行公里数；
—— locomotive no., bogie no. and axle no. where the motor locates;
——有关电机所在机车、转向架和车轴的编号；
—— motor production no. corresponding to the nameplate.
——对应于铭牌的电机生产序号。
The motor model, year of manufacture and production no. can be found on its
nameplate. If the nameplate is lost or cannot be recognized, please provide the
product no. printed on the stator and shaft, we will do our best to find out relative
information.
电机型号、制造年份和生产序号可在其铭牌上查到。如果铭牌丢失或不能辨认，
请提供印在定子和转轴上的生产序号，我们将尽最大努力找到有关资料。
We will reply in time according to specific conditions.
我们将根据具体情况及时答复。
This instruction is only used as reference for the user when carrying out
operation, maintenance and repair, the date shall not be copied to disclose.
本说明书仅供用户在运行、维护、检修时参考使用，不得将资料复制外流。
15 缩写和索引 Abbreviation and Index
Table 27 Index Summary Sheet of Quoted Drawing

表 27 引用图纸索引汇总表
No.序号 Description 名称
1.10 Stator base 定子机座
1.20 Stator 定子
2.10 Shaft 转轴
2.20 Rotor assembly 转子装配
Rotor pressing ring at D end
2.21
D 端转子压圈
2.22 Rotor pressing ring at N end N 端转子压圈
Date： 2015.09 Rev.： 1.0
2.30 Squirrel cage rotor 鼠笼转子
2.40 Inner oil sealing at N end N 端内油封
2.50 Tachometer disc 测速盘
3.10 Roller bearing at N end N 端滚柱轴承
3.20 Bearing cover at D end D 端轴承盖
3.30 Inner oil sealing at D end D 端内油封
3.40 Roller bearing at D end D 端滚柱轴承
3.50 Retainer ring 挡圈
4.10 D-end end cover D 端端盖
5.10 Four-point contact ball bearing at N end N 端四点接触球轴承
5.20 Inner bearing cover at N end N 端内轴承盖
6.10 N-end end cover N 端端盖
6.20 Exterior bearing cover at N end N 端外轴承盖
7.10 Junction box 接线盒
8.10 Sensor cover 传感器盖
Date： 2015.09 Rev.： 1.0

06 Maintenance Manual For JD160B Traction Motor

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06 Maintenance Manual For JD160B Traction Motor

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Maintenance Manual For JD160B Traction Motor

1 Function and purpose 功能及用途 ·························································································· 5

The operation environment requirements of this traction motor are as follows:

2.1 Technical parameter 技术参数

T The technical parameters of the motor are shown in Table 1.

2.2 Structure and technical description 结构及技术说明

1 – Junction box; 2 – Stator core; 3 – Support frame; 4 – End hoop; 5 – Stator

2.3 Work principle 工作原理

2.3.1 Main Operating Principle of Traction Motor 牵引电机的主要运行原理

n: speed; f: stator frequency; s: slip ratio; p: number of pole-pairs of motor; E1：

I1 R1 L1s L2s' R2'

Figure 3 Equivalent Circuit of JD160B Asynchronous Traction Motor

3 Safety description 安全说明

The related safety description is shown in Table 2.

4 Usage and operation 使用操作

Refer to related sections of use and operation of the locomotive.

5 Installation and commissioning 安装和调试

Refer to the installation of traction motor of driving system.

Refer to related sections of the commission of the locomotive.

6.1 Maintenance levels 维修等级

6.2 Maintenance Plan 维修计划

The maintenance plan of the motor is shown in Table 5.

Inspect the installation of cover plate of junction box. √ √ √ √ √ √ √

Looseness of bolts, spring washers 螺栓的松动、弹簧垫圈 √ √ √ √ √ √ √

6.3 Maintenance Works 维修工作

The maintenance work is carrying out maintenance/repair without disassembly. See

Water content (if water result Xylene method or K Flescher

**）Test after running for 600000km and 1200000km;

Maintenance level: I2 (inspection level 2)维修等级：I2 （检查 2 级）

Inspect the installation condition of outgoing line, lead

Maintenance level: I3 (inspection level 3)维修等级：I3 （检查 3 级）

Inspect the installation condition of outgoing line, lead

6.4 Correction Work 修正工作

Maintenance level: R1 (maintenance level 1)维修等级：R1 （维修 1 级）

Inspection Measure the insulation resistance of winding against

Inspect the surface condition of end ring and conducting

Bearing 轴承 Replace the bearing 更换轴承

Carry out appearance inspection and washing; inspect the

Speed sensor 速 Carry out insulating strength inspection; carry out

Measure DC resistance; insulation resistance test; withstand

Maintenance level: R2 (maintenance level 2)维修等级：R2 （维修 2 级）

Inspect the surface condition of end ring and conducting bar;

Bearing 轴承 Replace the bearing 更换轴承

Carry out appearance inspection and washing; inspect the

Temperature Carry out ground insulation inspection; measure resistance

Maintenance level: R3 (maintenance level 3)维修等级：R3（维修 3 级）

Inspect the surface condition of end ring and conducting bar;

Bearing 轴承 Replace the bearing 更换轴承

Carry out appearance inspection and washing; inspect the

Measure DC resistance; insulation resistance test; withstand

7 Corrective maintenacne 修复性维修

7.1 Fault Treatment 故障处理

The fault analysis and treatment is shown in Table 9.

The winding Carry out repair after

The locomotive load

Inspect the winding

Replace the bearing,

Remove the bearing

Excessive or too Faulty lubrication will

Friction of oil Find fault reasons

Carry out inspection Find the fault reason

Scorching Inspect the winding

There is Inspect the bend or

危险！因为齿轮有 1:20 的锥度，很强的油压会产生轴向压出力，将齿轮弹出。

注意！测量速度传感器探头和测速齿盘之间的间隙；最小允许间隙 0.4 mm，最大间隙