M.R.

16004
J. Jensen
Rev. B

MODERNIZATION RECOMMENDATION

Steel Slip Ring Retrofit

TABLE OF CONTENTS

PURPOSE ........................................................................................................ 2
APPLICATION............................................................................................... 4
TOOLS REQUIRED ...................................................................................... 4
MATERIAL REQUIRED .............................................................................. 5
PROCEDURE ............................................................................................ 6-13
 PURPOSE

In an effort to improve the long term reliability and service interval of the alternator, EMD
has developed a steel slip ring assembly, brushes and brush holders. EMD has traditionally
used a tin bronze alloy material for the slip ring material on the traction and companion
alternators. The service interval for the tin bronze slip ring brushes has historically been 6
Rev B
months but can be extended to 1 year with steel slip rings. However, the steel slip ring
assemblies should be cleaned during the 6-month inspection interval, to avoid excess dust
gathering between the slip ring assemblies, and creating electrical arc paths. Refer to Service
Advisory 015-062 Rev B for details on the proper 6-month service interval cleaning
procedure.

A Steel slip ring assembly offers the following benefits:

1. Harder material with a higher melting point will increase wear life and decrease
damage from arcs.
2. Alignment, although important, is not as critical with steel and the steel brush
material.
3. Film is not needed and the steel brush application material is polishing rather than
filming.
4. The new slip ring assembly has a smaller outer diameter, which should reduce brush
wear for the same amount of rotations.
5. Larger brush cross section allows for lower current density through the brush which
will decrease wear.
6. New brush holders have 2 points of contact on holder which should allow for easier
and more repeatable installation in the field.

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 APPLICATION

Rev B

Rev B

TOOLS REQUIRED

TOOLS
REQUIRED:
 8-10 Ft-lb. Torque Wrench
 50-55 Ft-lb Torque Wrench
 110-120 Ft-lb. Torque Wrench
 3/8”-16x24” threaded rod all thread (2 pieces)with 4 nuts
 5/8”-11x24” threaded rod all thread (2 pieces) with 4 nuts
 3/8” wrench
 1/2” wrench
 9/16” wrench
 5/8” wrench

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 MATERIAL REQUIRED

SHORT HUB 40274295 SLIP RING ASSEMBLY APPLICATION

PART NUMBER DESCRIPTION QUANTITY
SLIP RING ASSEMBLY KIT – SHORT HUB

KIT CONTENTS
180083 BOLT-5/16-18 HEX(QTY=-6)
40274312 CLAMP(QTY=6)
40274306 BRUSH HOLDERASSEMBLY(QTY=6)
40274295 120214 WASHER(QTY=12) 1
8418959 GASKET(QTY=1)
40274263 CARBON BRUSH(QTY=6)
40274298 CABLE ASSEMBLY(QTY=1)
180075 BOLT-5/16-18 HEX(QTY=6)
40274296 SLIP RING ASSEMBLY(QTY=1)
40274297 COVER ASSEMBLY-BEARING(QTY=1)
9442069
BEARING ASSEMBLY 1 (optional)
9507146 (35 lb 2.1 lbs (optional)
pail) 9507147 GREASE - BEARING
(120 lb drum)
Rev B 8405527 SEAL - OUTER 1

LONG HUB 40274203 SLIP RING ASSEMBLY APPLICATION

PART NUMBER DESCRIPTION QUANTITY
SLIP RING ASSEMBLY KIT – LONG HUB

KIT CONTENTS
180083 BOLT-5/16-18 HEX(QTY=-6)
40274312 CLAMP(QTY=6)
40274306 BRUSH HOLDERASSEMBLY(QTY=6)
40274203 120214 WASHER(QTY=12) 1
8418959 GASKET(QTY=1)
40274263 CARBON BRUSH(QTY=6)
40155245 CABLE ASSEMBLY(QTY=1)
180075 BOLT-5/16-18 HEX(QTY=6)
40274314 SLIP RING ASSEMBLY(QTY=1)
40274343 COVER ASSEMBLY-BEARING(QTY=1)
9442069
BEARING ASSEMBLY 1 (optional)
9507146 (35 lb 2.1 lbs
pail) 9507147 GREASE - BEARING (optional)
(120 lb drum)
Rev B 8405527 SEAL - OUTER 1

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 CAUTION
Please refer to the EMD Safety Precautions section in the applicable Locomotive
Running Maintenance Manual or Locomotive Service Manual whenever routine service
or maintenance work is to be performed.

All shop safety rules and practices must be followed at all times during this procedure.

***SAFETY ITEMS TO WATCH FOR***

 HAVE WORK AREA WASHED IF NEEDED

 INSPECT TOOLS FOR DEFECTS AND WEAR
 BE AWARE OF YOUR SURROUNDINGS
 MAINTAIN GOOD HOUSE KEEPING
 ON ALL TASKS BELOW BE AWARE OF BODY POSITIONING
 ON ALL TASKS BELOW BE AWARE OF OVEREXERTION TAKE
BREAKS AND STRETCH WHEN WORKING IN AWKWARD BODY
POSITIONING, SAME POSITION, OR CONFINED SPACES FOR
LONG PERIODS OF TIME

For any tasks that require additional safety risks beyond those listed above, please
note the safety risk within the specific step.

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PROCEDURE

1. Verify and/or perform the following actions prior starting the procedure steps:
a. Ensure reverser is centered.
b. Locomotive is isolated.
c. Parking brake is applied.
d. Engine is shutdown (Shut down locomotive engine using the EFCO switch. This
action disables the Auto Start system).

2. Remove all existing top and bottom brush holders from the studs. Also remove
cables from brush holders. Take note of which cable went to which holder as these
will be reinstalled at a later point. A new cable assembly 40155245 or 40274298 has
been added to the BOM to ensure that there are no issues with bent or damaged
cables. Replace this cable assembly if the cables or lugs are bent or damaged. Refer
to the figure below for nomenclature.

Figure 1 - Slip Ring Parts Diagram

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 3. Remove the two main and two companion alternator cable lugs, and remove the front
plate, shown below, that holds the slip ring assembly on the main generator shaft.
Remove the front plate, taking care not to damage the cables.

Figure 2 - Removal of Front End Plate

Rev B 4. Remove slip ring assembly per instructions in Maintenance Instruction MI3317-1. If
the hydraulic puller tool in Maintenance Instruction MI3317-1 is not available,
remove two (2) slip ring assembly clamping bolts and insert 3/8”-16x24” threaded
rod (with 2 3/8”-16 nuts on the end of each rod), the purpose of this is to push the slip
ring assembly outwards as illustrated in the photo below. Tighten each side equally to
push the slip ring assembly off of the main generator shaft.

Figure 3 - Slip Ring Assembly Removal

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Rev B 5. Remove outer seal per instructions in MI3317-1.

6. Remove existing Bearing cover assembly. At this time a bearing change out is
Rev B recommended. For bearing replacement procedures refer to MI3317-1. If a bearing
change out is not completed, a bearing regrease and inspection needs to take place.
Rev B For inspection and regrease procedure, refer to MI3317-1. Replace gasket part
number 8418959, with the fresh gasket included in the retrofit kit.

7. After bearing replacement or regrease has been completed, carefully weigh 10 oz of

grease for the new bearing cover assembly part number 40274343 or 40274297.
Distribute grease in cavity of bearing cover assembly as shown below in Figure 4.
Fill inner labyrinth grooves with grease as well. Ensure that the bearing cover
assembly is positioned correctly. The bearing cover assembly has two holes that are
used to secure cables on the left side (when looking at the slip ring) of the bearing
cover, ensure these are on the correct side before continuing. Bolt the new bearing
cover assembly in place with 6 bolts that were removed. Torque the bolts to 50-55 ft-
lbs.

Figure 4 - Bearing Grease Application

8. Heat the outer seal using an oven, oil bath or induction heater to 220°F. Install the
outer seal on the rotor shaft until the seal bottoms out on the bearing. When the
heated seal is in position, allow the seal to cool to room temperature.

9. Clean the alternator shaft with an emory cloth and cleaner to remove any small
material or high spots that will hinder easy install. Place the slip ring assembly, part
number 40274296 (Short Hub version) or 40274314 (Long Hub Version), on the
main generator shaft as far as it will go by hand. Install the front plate by using the
two 5/8-11x24” threaded rods, and push the slip ring assembly all the way down the
main generator shaft by tightening each rod equally. Make sure all four cables are
pulled through the hole in the front plate. Once the slip ring assembly is fully installed
on the shaft, remove the threaded rods and install the 4 existing bolts on the front
plate. Torque these bolts to 110-120 ft-lbs.

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 10. OPTIONAL SLIP RING ASSEMBLY INSTALLATION PROCEDURE – The
slip ring assembly can be heated in an oven or using an induction heater to 220
degree F to install on the alternator shaft. DO NOT OVERHEAT THE
ASSEMBLY.

11. Measure the Total Indicated Runout of the slip rings to confirm that the maximum
Rev B .006” out of round requirement is satisfied.

12. Reconnect the four(4) leads that are numbered 1-4 to the associated terminal post.
The numbers are stamped on the slip ring assembly, as shown highlighted in Figure 5
below. These nuts should be torqued to 7-8 Ft-lbs once the cable leads are in place.
The clamp bolts, shown in Figure 6, should be already tight with a torque of 24 Ft-
lbs.

Terminal post nuts

should have 7-8
FT-LBS of Torque.

Figure 5 - Cable Terminal Post Installation

NOTE – The lug should be placed in between the two brass washers and tightened
down 7-8 Ft-lbs so each post looks like what is shown below.

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 Clamp bolts should
have 24 FT-LBS of
Torque.

Figure 6 - Steel Slip Ring Assembly

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 13. Apply 6 brush holders, part number 40274306, on bearing cover posts. 4 brush
holders are located on the top set of posts and 2 brush holders are on the bottom.
Ensure that the brush holders are centered on the slip ring width. Use clamp, part
number 40274312, bolt part number 180083, and washer part number 120214, to
secure brush holders in place. Apply new cable assembly part number 40155245 or
40274298, included in the kit, using terminal bolt part number 180075. Ensure that
the cables are going to the correct ring terminal. Torque the bolts on the clamp and
lugs to 10 ft-lbs. See Figures 6 and 7 below.

Figure 6 - Torque Values on Brush Holders

Figure 7 - Bottom Brush Holders and Cables for Slip Rings 3 and 4

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 14. Apply one brush, part number 40274263, per ring. Use spring 40274310 that came
with the brush holder. Verify the brushes have a green colored shunt insulator as
shown below in Figure 8.

Correct
Green Shunt
Insulators

Figure 8 - Brushes Showing Green Shunt Insulators

15. Tighten pigtail bolt after brush is installed. Ensure brush face sits flush on slip ring
face as shown below. New arrangement with 2 brush holder posts limits changing
this alignment, however a check should still be done to ensure the brush is sitting on
the rings properly. Any brush that is not sitting relatively in line with the slip ring
surface indicates some issue with the brush holder post dimensions and it should be
brought to Progress Rail Engineering’s attention. Lock spring clips into place.
Check for free movement of the brushes. If brush drags, replace brush and/or brush
holder to resolve.
NOTE: DO NOT REUSE ANY OLD BRUSHES OR SPRING CLIPS

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 Figure 9 - Correct Brush Holder Setting

16. Reapply the slip ring enclosure cover.

17. Load test and stall test locomotive.

18. END OF PROCEDURE

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 CAUTION
Please refer to the EMD Safety Precautions section in the applicable Locomotive
Running Maintenance Manual or Locomotive Service Manual whenever routine service
or maintenance work is to be preformed.

All shop safety rules and practices must be followed at all times during this procedure.

(D-L)

Progress Rail
La Grange, Illinois 60525 USA
Telephone: 708-387-6000
Website: [Link]

©2020
Progress Rail Locomotive. All rights reserved. Neither this document,
nor any part thereof, may be reprinted without the expressed written
consent of Progress Rail Locomotive. Contact PRL Customer
Publications Office.

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