esr 0602 - overhaul of 48 class locomotive traction generators · traction generators which shall...

Engi

neer

ing

Stan

dard

Engineering Standard Rolling Stock

ESR 0602

OVERHAUL OF 48 CLASS LOCOMOTIVE TRACTION

GENERATORS

Version 1.0

Issued June 2010

Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.

Owner: Chief Engineer Rolling Stock Approved by:

Stephen White, Technical Specialist Rolling Stock Performance Standards, Rolling Stock Access Integrity

Authorised by:

Michael Uhlig, Manager, Rolling Stock Access Integrity

UNCONTROLLED WHEN PRINTED of 24

RailCorp Engineering Standard — Rolling Stock Overhaul of 48 class locomotive traction generators ESR 0602

© Rail Corporation of 24 Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1.0

Document control

Revision Date Summary of change (RSS 0602) 1.0 August 2007 Based on TRS 1333 (ESR 0602) 1.0 June 2010 Reformatted and renumbered ESR 0602

Summary of changes from previous version

Summary of change Section NOTE – If the final document is small enough for the ‘Contents’ and ‘Document control’ to fit on one page remove the page break between the existing pages 2 and 3. HOWEVER if the ‘Document control’ page carries over to a second page separate pages must be used for ‘Contents’ and ‘Document control’



Contents

1 Scope..................................................................................................................................................6 2 General ...............................................................................................................................................6

2.1 Torque settings .........................................................................................................................6 3 Pre-service/overhaul inspection......................................................................................................6

3.1 Armature, fields and interpoles .................................................................................................6 3.1.1 Pre cleaning activity .....................................................................................................6

3.2 Post cleaning activity.................................................................................................................7 4 Service procedures ...........................................................................................................................7

4.1 Armature and commutator ........................................................................................................7 4.2 Brushgear..................................................................................................................................7 4.3 Stator/generator frame..............................................................................................................8 4.4 Bearings ....................................................................................................................................8 4.5 Fan ............................................................................................................................................8 4.6 Bull gear ....................................................................................................................................8 4.7 Bull gear case ...........................................................................................................................9 4.8 Generator painting ....................................................................................................................9

5 Post service test................................................................................................................................9 5.1 General......................................................................................................................................9

5.1.1 Continuous rating .........................................................................................................9 5.1.2 Rated voltage ...............................................................................................................9 5.1.3 Rated speed .................................................................................................................9 5.1.4 Maximum speed of the traction generator....................................................................9 5.1.5 Direction of rotation ....................................................................................................10 5.1.6 Runout of commutator................................................................................................10 5.1.7 Eccentricity of commutator .........................................................................................10

5.2 Summary of tests to be performed on the traction generator .................................................10 5.2.1 Resistance measurement ..........................................................................................10 5.2.2 Insulation resistance test 1.........................................................................................10 5.2.3 Direction of rotation test .............................................................................................10 5.2.4 Bearing temperature measurement ...........................................................................10 5.2.5 Neutral point setting ...................................................................................................11 5.2.6 Commutator temperature measurement ....................................................................11 5.2.7 Insulation resistance test 2.........................................................................................11 5.2.8 Commutator roundness..............................................................................................11 5.2.9 Brush pressure ...........................................................................................................11

5.3 Instrumentation .......................................................................................................................11 5.4 Documentation ........................................................................................................................11

6 Overhaul/rewind procedure............................................................................................................11 6.1 General....................................................................................................................................11 6.2 Armature overhaul...................................................................................................................12 6.3 Summary of tests to be performed on the traction generator .................................................13 6.4 Stator/generator frame............................................................................................................13 6.5 Bearings ..................................................................................................................................14



6.6 Fan ..........................................................................................................................................14 6.7 Bull gear ..................................................................................................................................14 6.8 Bull gear case .........................................................................................................................14 6.9 Generator painting ..................................................................................................................14

7 Post overhaul/rewind test...............................................................................................................15 7.1 General....................................................................................................................................15

7.1.1 Continuous rating .......................................................................................................15 7.1.2 Rated voltage .............................................................................................................15 7.1.3 Rated speed ...............................................................................................................15 7.1.4 Maximum speed of the traction generator..................................................................15 7.1.5 Direction of rotation ....................................................................................................15 7.1.6 Runout of commutator................................................................................................15 7.1.7 Eccentricity of commutator .........................................................................................15

7.2 Summary of tests to be performed on the traction generator .................................................15 7.2.1 Resistance measurement ..........................................................................................15 7.2.2 Insulation resistance test 1.........................................................................................16 7.2.3 Direction of rotation test .............................................................................................16 7.2.4 Temperature rise test .................................................................................................16 7.2.5 Neutral point setting ...................................................................................................16 7.2.6 Commutator roundness..............................................................................................16 7.2.7 Brush pressure ...........................................................................................................16

7.3 Instrumentation .......................................................................................................................16 7.4 Documentation ........................................................................................................................16

8 Technical specification for GE 586 traction generator................................................................17 8.1 Pre service/overhaul inspection specification .........................................................................17

8.1.1 Armature.....................................................................................................................17 8.1.2 Fields and interpoles ..................................................................................................17

8.2 Service specifications..............................................................................................................17 8.2.1 Armature and commutator .........................................................................................17 8.2.2 Brushgear...................................................................................................................17 8.2.3 Bearings (approved)...................................................................................................17

8.3 Post service testing specifications ..........................................................................................17 8.3.1 Resistance measurement (at 25 o C) ........................................................................17 8.3.2 Insulation resistance...................................................................................................17 8.3.3 Temperature rise test .................................................................................................18

9 Technical specifications - GE 584 D3 traction generator............................................................18 9.1 Pre service/overhaul inspection specifications .......................................................................18

9.1.1 Armature.....................................................................................................................18 9.1.2 Fields and interpoles ..................................................................................................18

9.2 Service specifications..............................................................................................................18 9.2.1 Armature and commutator .........................................................................................18 9.2.2 Brushgear...................................................................................................................18 9.2.3 Bearings (approved)...................................................................................................18

9.3 Post service testing specifications ..........................................................................................18 9.3.1 Resistance measurement (at 25 o C) ........................................................................18



9.3.2 Insulation resistance...................................................................................................19 9.3.3 Temperature rise test .................................................................................................19

10 Reference standards.......................................................................................................................19 10.1 RailCorp standards .................................................................................................................19 10.2 RailCorp drawings...................................................................................................................19 10.3 Australian/British standards ....................................................................................................19 10.4 Other standards ......................................................................................................................19

Appendix A – Drawing 004-463 Traction Generator Flow Chart......................................................20 Appendix B – Torque Settings ............................................................................................................23



1 Scope This standard sets out the minimum requirements, procedures and tests for the overhaul of the traction generator used on 48 class locomotives.

2 General This standard is to be used in conjunction with the Manufacturer's Maintenance Instructions, drawings and technical information, listed herein, for the respective generator types and with Drawing 004-643, Traction Generator Service Flow Chart. (See Appendix A)

The overhaul and testing Information and maintenance manuals referred to in this specification are the minimum standard acceptable. These manuals and information shall be used by the Repairer in the development of procedures to effect the overhauls.

The goal of this specification is to provide inspected, serviced, overhauled and tested traction generators which shall operate at the specified performance levels for a period of not less than eight (8) years. However with new insulation, commutators and bearings, the generators shall be required to operate at specified performance levels for a period of not less than twelve (12) years, supported only by scheduled maintenance programs.

2.1 Torque settings The following applications in traction generator assemblies are critical in relation to the tightness of the fastening:

• Mounting of brush holders in frame.

• Inter-field connections (where not brazed).

• Connection of field circuit leads onto brush holders.

• Mounting of main fields in frame.

• Mounting of interpoles in frame.

The checking of the fastening tightness or their installation during assembly must be effected by torque values being appropriate for the size and grade of the fastenings (see Appendix B for torque charts).

3 Pre-service/overhaul inspection

3.1 Armature, fields and interpoles If it is not visually obvious that a rewind is required the following checks shall be carried out and the results recorded. Any non-conformance to specifications shall be reported to the Engineer to determine further action.

3.1.1 Pre cleaning activity The following inspection is to be carried out prior to the generator being dismantled, cleaned of all dirt and grease.

• Measure the position of the brush holders relative to the commutator riser and face.



3.2 Post cleaning activity The following inspections are to be carried out after the generator has been dismantled, cleaned of all dirt and grease, immersion rinsed (only if required to achieve two volt and PI test standards) and oven dried.

• Visually check commutator for any bar pattern, grooving, high bars, high mica or physical damage.

• Examine the armature insulation for charring, cracking and physical damage.

• Examine glass banding for physical damage.

• Measure diameter of commutator to ensure it is above condemning size.

• Measure commutator for eccentricity.

• Measure armature resistance.

• Measure the resistance of the generator fields.

• Measure resistance of the interpole coils.

• Measure insulation resistance as per traction generator service flowchart, drawing 004-643 (see Appendix A).

• Apply surge test and bar-to-bar comparison test to commutator to check for open or short circuited coils.

• Check armature shaft for straightness, size (including 4 points on each bearing seat for ovality or taper, length of shaft, overall and critical sections) and surface integrity.

• Examine the armature for any physical damage.

4 Service procedures Service work shall generally be in accordance with Manufacturer's Maintenance Manuals and SRA drawing 004-643 with particular attention being given to the following:

4.1 Armature and commutator • Inspect for indication of high or loose bars and take corrective action as necessary.

• Inspect V-ring band and riser bars for any flashover damage and correct.

• Resurface the commutator with the minimum cut required to ensure surface integrity and roundness.

• Undercut commutator micas to width and depth shown in relevant generator manual.

• Chamfer the commutator bar edges (45o , 0.2 - 0.4mm across face).

• Dip armature in varnish or VPI (compatible with existing insulation) where generators have been recovered by rinsing or there has been visible damage to the insulation.

• Dynamically balance armature. Balance quality grade 2.5 (AS 3709; ISO 1940/1).

• Apply red air drying insulating varnish to armature (shaft and commutator to be suitably masked) excluding bands which are to retain the epoxy resin or Teflon surface finish.

4.2 Brushgear • Remove brush holders and check insulators for any visible damage (cracks or chips).

Replace any defective insulators.



• Inspect for any flashover deposits on brush holders and correct.

• Inspect arc horns and replace any damaged.

• Ensure brush boxes are not deformed.

• Sand blast brush holders. Brushways and insulators to be suitably masked.

• Set brush spring pressure. Refer to technical specification.

• Ensure mounting screws and clamps are sound and correctly torqued (see clause 2.1).

• Ensure brushgear alignment is parallel to commutator centre line.

• Ensure spacing of brush holders is correct.

• Fit new brushes. Refer to technical specification.

• Inspect braiding of brushes and ensure tightness of brush terminal connections. (Braiding must be positioned to allow free movement of hammers.)

4.3 Stator/generator frame • Inspect for any flashover damage and correct.

• Ensure connections are sound and correctly torqued (see clause 2.1).

• Ensure all mounting bolts and nuts are correctly torqued (see clause 2.1).

• Inspect general condition of main field and interpole insulation and correct as required. Apply red air drying insulation varnish to inside of assembly.

• Inspect cables, crimp lugs and markers for any signs of mechanical or electrical damage and replace any defective parts.

• Internal field leads must be securely bound to the bracing staples. Replace any loose or defective binding. (Cable ties are not permitted for this purpose.)

• Ensure that flash rings or arc horns are clean and free of paint. Replace if damaged.

• Inspect bearing housings and seals for excess wear as indicated in relevant traction generator data and restore where necessary.

• Inspect condition of cable cleats. Replace any damaged.

• Ensure inspection cover components including locating lugs, latching mechanisms, springs, bolts, cover and felts will provide correct securing of covers and sealing.

4.4 Bearings New bearings shall be provided and fitted by the Repairer. Acceptable bearings are listed in the individual generator specifications.

4.5 Fan • Inspect fan and blades for evidence of physical damage, cracks or excessive wear.

Restore to serviceable condition.

• Inspect mounting holes for deformation or physical damage and correct.

4.6 Bull gear • Inspect gear teeth for excessive wear, physical damage or cracking. Refer any non-

compliance with specification to the engineer.



• Ensure gear bore is within tolerance.

4.7 Bull gear case • Inspect bull gear case for physical damage. Refer details of any major damage to the

Engineer.

• Ensure mating surfaces are clear of any physical damage or distortion.

4.8 Generator painting After stripping off old paint work all generators shall be painted with 1 coat of suitable primer and 1 coat of enamel paint - which shall be approved under GPC-E-24. The colour will be nominated by the Engineer and shall comply with AS 2700.

Note: Areas to be masked:

• Manufacturer's data plate

• Leads

• Coupling flange

• End of armature shaft

• Commutator inspection hatches.

5 Post service test

5.1 General This procedure covers the performance testing of direct current traction generators used for propulsion on diesel locomotives.

The definitions applicable to this standard are:

5.1.1 Continuous rating The rating that corresponds to a load that the D.C. traction generator can withstand on the test for an unlimited period, without exceeding the limits of temperature rise as given in BS 173, Clause 31, the test being started with the machine cold (see BS 173, Clause 34).

5.1.2 Rated voltage The specified value of the voltage at the terminals of the machine.

5.1.3 Rated speed The speed corresponding to the manufacturer's specification.

5.1.4 Maximum speed of the traction generator The maximum rotational speed of the traction generator corresponding to the maximum speed of the diesel engine.



5.1.5 Direction of rotation The direction of rotation of the armature when facing the commutator end of the generator.

5.1.6 Runout of commutator Maximum out of round measured over twelve (12) segments.

5.1.7 Eccentricity of commutator Out of round measured over the full circumference of the commutator.

5.2 Summary of tests to be performed on the traction generator The test programme shall, in principle, be carried out in accordance with the requirements of BS 173.1980.

5.2.1 Resistance measurement Measure the resistance value of the main field, the interpoles and the armature windings.

If the ammeter and voltmeter method is used for the measurement of resistance, the current used shall be of a value such as to obtain a suitable accuracy of measurement, whilst being low enough to neither cause the armature to start through the effect of residual flux nor influence the temperature rise.

5.2.2 Insulation resistance test 1 Prior to the overspeed test, the generator shall be subjected to a high potential test as detailed below:

60 Sec high New winding Used winding potential testing

Test volts 2,500 AC & DC 2,500 DC

Pass criteria less than 2.5uA DC and no less than 25uA and no disruptive disruptive discharge AC discharge

5.2.3 Direction of rotation test Connect lead "AA" and "Y" together. Connect "A" to the positive side and lead "YY" to the negative side of a suitably rated power supply. Increase the voltage until the armature rotates. Rotation should be counter-clockwise as viewed from the commutator end of the generator.

5.2.4 Bearing temperature measurement Run the generator for sixty minutes at the speed referred to in the individual generator specifications in the counter-clockwise direction.

Record temperature of the bearing every ten (10) minutes. Listen for any abnormal bearing noise during rotation.

Measure and record vibration of the generator running. This shall not exceed range classification 1.12 table 1 AS 2625.



5.2.5 Neutral point setting Ensure neutral point setting is correct.

5.2.6 Commutator temperature measurement Measure and record the temperature of the commutator at the end of the two (2) hour test.

5.2.7 Insulation resistance test 2 After the overspeed test, the generator shall be subjected to a high potential test as below:

60 Sec high New winding Used winding potential testing

Test volts 2,500 AC & DC 2,500 DC

Pass criteria less than 2.5uA DC and no less than 25uA and no disruptive disruptive discharge AC discharge

Compare results with insulation resistance test 1 (5.2.2).

5.2.8 Commutator roundness Position dial gauge to touch the commutator surface. Rotate armature slowly by hand and measure the commutator runout and eccentricity. Record values on test sheet.

5.2.9 Brush pressure Use a suitable instrument to test the brush spring pressure of all brush springs.

5.3 Instrumentation The serial numbers of all instruments and meters used to perform the tests outlined in section 5.2 shall be recorded, together with the date of their most recent calibration check.

5.4 Documentation The recorded measurements shall be entered in dated test report sheets and returned with the machine.

6 Overhaul/rewind procedure

6.1 General This part of the specification covers the rewind/overhaul of the traction generators. The work shall incorporate rewinding the armature, correcting generator frame and fields and installation of the following new components:

• Commutator (new or rebuilt)

• Armature bearings

• Brushes



The following shall be inspected for suitability for further duty and restored to service specifications. If beyond repair they shall be replaced with new components:

• Armature shaft

• Brush holders

• Commutator inspection covers

• Generator leads and cleats

• Fan

• Bull gear

• Bull gear cases

The commutators, fields, bearings removed from generators and replaced shall be returned to the Purchaser.

6.2 Armature overhaul Remove bearings and commutator.

Strip the armature of coils and insulation.

Shafts suitable for resizing may be repaired by Gas Metal Arc Welding - GMAW and machined to specified dimensions. The welding procedure shall be strictly in accordance with AS 1554.1, the electrodes shall be type ESD2 to AS 2717.1 and the gas shall be Argoshield 51. This procedure may be utilised for restoration requiring weld deposits to 6 mm. Repairs exceeding 6 mm deposit shall be referred to the Engineer. All welding shall comply with Australian Standards.

Fit new shaft, where required, in accordance with the relevant drawing.

Flux test the core to ensure no shorts or damage exist in the laminations. Defective cores are to be referred to the Engineer.

Fit new or rebuilt fully seasoned commutator.

Rewind armature with new main and equaliser coils insulated to Classification 180 of AS 2768.

TIG weld/resistance braze coil ends to riser bars.

VPI the armature with Isonel 772 varnish or compatible equivalent.

Oven dry.

Resurface the commutator with the minimum cut required to ensure surface integrity and roundness.

Undercut commutator mica, width and depth of cut as specified in the individual generator manuals.

Chamfer commutator bar edges (450, 0.2 to 0.4 mm across face).

Dynamically balance the armature. Balance quality grade 2.5 (AS 3709; ISO 1940/1).

Apply red air drying insulation varnish to armature (shaft and commutator to be suitably masked before applying varnish).



Cleaning, drying, rewinding, testing and banding throughout the process shall be in accordance with the Manufacturer's Maintenance Manuals for original equipment or previously approved replacement eg glass band.

Fit new armature shaft bearings, as approved in the relevant generator specification.

Fit qualified fan.

6.3 Summary of tests to be performed on the traction generator Remove brush holders and check insulators for any visible damage (cracks, chips, or tracking etc). Replace any damaged insulators.

Inspect for any flashover deposits on brush holders and correct.

Sand blast brush holders. (Brushways and insulators to be suitably masked.)

Inspect arc horns and replace any damaged.

Replace any deformed brush holders.

Set brush spring pressure. Refer technical specification.

Ensure mounting screws and clamps are sound and correctly torqued (see clause 2.1).

Ensure brushgear alignment is parallel to commutator centre line.

Ensure spacing of brush holders is correct.

Fit new brushes. Refer technical specification.

Inspect braiding of brushes and ensure tightness of brush terminal connections. (Braiding must be positioned to allow free movement of hammers.)

6.4 Stator/generator frame Thoroughly clean the stator inside and outside, preferably by an ultrasonic process that does not utilise a detergent. Alternatively a spray wash may be used in conjunction with a detergent incorporating a non-ionic surfactant wetting agent and such detergent shall have the Engineer's written approval. Generators so cleaned shall have all traces of detergent removed by a clean water/steam rinse.

Remove main and interpole coils and pole pieces.

Inspect insulation quality. Where required reinsulate to ensure suitability for nominated duty requirements. Reinsulation shall be with an approved asbestos-free system incorporating B stage epoxy rich materials to classification 180 of AS 2768.

Pot the coils onto the pole pieces.

Fit all coils into the frame. Ensure correct torque of all mounting bolts and nuts (see clause 2.1).

Check cables, crimp lugs and markers, correct any signs of mechanical or electrical damage and replace any defective parts.

Interconnect the fields. Ensure correct torque of all bolted connections (see clause 2.1).

Internal field leads must be securely bound to the bracing staples. Replace any loose or defective binding. (Cable ties are not permitted for this purpose.)



Ensure that flash rings or arcing horns are clean and free of paint. Replace if damaged.

Inspect bearing housing and seals for excess wear as indicated in relevant Traction Generator data and restore where necessary.

Inspect condition of cable cleats. Replace any damaged.

Spray the interior of the machine with red air drying insulating varnish.

Ensure inspection cover components including locating lugs, latching mechanisms, springs, bolts, cover and felts will provide security of covers and sealing.

6.5 Bearings New bearings shall be provided and fitted by the Repairer. Acceptable bearings are listed in the individual generator specifications.

6.6 Fan Inspect fan and blades for evidence of physical damage, cracks or excessive wear. Restore to serviceable condition.

Inspect mounting holes for deformation or physical damage and correct.

6.7 Bull gear Inspect gear teeth for excessive wear, physical damage or cracking. Refer any non-compliance with specification to the Engineer.

Ensure gear bore is within tolerance.

6.8 Bull gear case Inspect bull gear case for physical damage. Refer details of any major damage to the Engineer.

Ensure mating surfaces are clear of any physical damage or distortion.

6.9 Generator painting After stripping of old paintwork all generators shall be painted with 1 coat of suitable primer and 1 coat of enamel paint - which shall be approved under GPC-E-24. The colour will be nominated by the Engineer and shall comply with AS 2700.

Note: Areas to be masked:

• Manufacturer's data plate

• Leads

• Coupling flange

• End of armature shaft

• Commutator inspection hatches



7 Post overhaul/rewind test

7.1 General This procedure covers the performance testing of direct current traction generators used for propulsion on rail vehicles.

The definitions applicable to this standard are:

7.1.1 Continuous rating The rating that corresponds to a load that the D.C. traction generator can withstand on the test for an unlimited period, without exceeding the limits of temperature rise as given in BS 173, Clause 31, the test being started with the machine cold (see BS 173, Clause 34).

7.1.2 Rated voltage The specified value of the voltage at the terminals of the machine.

7.1.3 Rated speed The speed corresponding to the manufacturer's specification.

7.1.4 Maximum speed of the traction generator The maximum rotational speed of the traction generator corresponding to the maximum service speed of the vehicle.

7.1.5 Direction of rotation The direction of rotation of the armature when facing the commutator end of the generator.

7.1.6 Runout of commutator Maximum out of round measured over twelve (12) segments.

7.1.7 Eccentricity of commutator Out of round measured over the full circumference of the commutator.

7.2 Summary of tests to be performed on the traction generator The test programme shall, in principle, be carried out in accordance with the requirements of BS 173.1980.

7.2.1 Resistance measurement Measure the resistance value of the main field, the interpoles and the armature windings.

If the ammeter and voltmeter method is used for the measurement of resistance, the current used shall be of a value such as to obtain a suitable accuracy of measurement, whilst being low enough to neither cause the armature to start through the effect of residual flux nor influence the temperature rise.



7.2.2 Insulation resistance test 1 Prior to the rotational tests, the generator shall be subjected to a high potential test as detailed below:

60 Sec high potential testing New winding

Test volts 2,500 AC & DC

Pass criteria less than 2.5uA DC and no disruptive discharge AC

7.2.3 Direction of rotation test Connect lead "AA" and "Y" together. Connect "A" to the positive side and lead "YY" to the negative side of a suitably rated power supply. Increase the voltage until the armature rotates. Rotation should be counter clockwise as viewed from the commutator end of the generator.

7.2.4 Temperature rise test A temperature rise test, generally in accordance with clause 29.1 of BS 173, but of two (2) hours duration and test conditions specified herein and utilising state of the art instrumentation. During this test the main and interpole temperatures and bearing temperatures shall be logged and the armature winding temperature and commutator temperature shall be measured immediately upon shutdown.

A Pyrometer shall be used to measure the commutator surface temperature.

Measure and record vibration of the generator running. This shall not exceed range classification 1.12 table 1 AS 2625.

7.2.5 Neutral point setting Ensure neutral point is set correctly.

7.2.6 Commutator roundness Position dial gauge to touch the commutator surface. Rotate armature slowly by hand and measure the commutator runout and eccentricity. Record values on test sheet.

7.2.7 Brush pressure Use a suitable instrument to test the brush spring pressure of all brush springs.

7.3 Instrumentation The serial numbers of all instruments and meters used to perform the tests outlined in 7.2 shall be recorded, together with the date of their most recent calibration check.

7.4 Documentation The recorded measurements shall be entered in dated test report sheets and returned with the machine.



8 Technical specification for GE 586 traction generator

8.1 Pre service/overhaul inspection specification

8.1.1 Armature - Insulation resistance 20 M ohms 25 o C (min)

- Armature resistance 0.0017 ohms +/- 2% @ 25 o C

- Commutator diameter 584 mm (min)

8.1.2 Fields and interpoles - Shunt field resistance 0.928 ohms +/- 2% @ 25 o C

- Commutating field resistance 0.00120 ohms +/- 2% @ 25 o C

- Starting field resistance 0.00119 ohms +/- 2% @ 25 o C

8.2 Service specifications

8.2.1 Armature and commutator - Commutator runout 0.01 mm (max)

- Commutator eccentricity 0.025 mm (max)

8.2.2 Brushgear - Spring tension 1.5 kg +/- 0.1 kg

- Replacement brushes

8.2.3 Bearings (approved) - Pinion end SKF NU 330EM6/C4-VA301

8.3 Post service testing specifications

8.3.1 Resistance measurement (at 25 o C) - Armature ..........Ohms

- Shunt field ..........Ohms

- Commutating field ..........Ohms

- Starting field ..........Ohmx

8.3.2 Insulation resistance - 20 M ohms @ 25 o C (min)



8.3.3 Temperature rise test - Generator speed 900 rpm

- Vibration 0.1 mm/sec (max)

9 Technical specifications - GE 584 D3 traction generator

9.1 Pre service/overhaul inspection specifications

9.1.1 Armature - Insulation resistance 20 M ohms 25 o C (min)

- Armature resistance 0.0061 ohms +/- 2% @ 25 o C

- Commutator diameter 584 mm (min)

9.1.2 Fields and interpoles - Shunt field resistance 1.35 ohms +/- 2% @ 25 o C

- Commutating field resistance 0.00335 ohms +/- 2% @ 25 o C

- Starting field resistance 0.00385 ohms +/- 2% @ 25 o C

9.2 Service specifications

9.2.1 Armature and commutator - Commutator runout 0.01 mm (max)

- Commutator eccentricity 0.025 mm (max)

9.2.2 Brushgear - Spring tension 1.5 kg +/- 0.1 kg

- Replacement brushes Refer Drawing. 303-007

9.2.3 Bearings (approved) - Pinion end SKF NU 322 EC-C4M-VA301

9.3 Post service testing specifications

9.3.1 Resistance measurement (at 25 o C) - Shunt field .........Ohms

- Commutating field ..........Ohms

- Starting field ..........Ohms



9.3.2 Insulation resistance - 20 M ohms @ 25 o C (min)

9.3.3 Temperature rise test - Generator speed 900 rpm

- Vibration 0.1 mm/sec (max)

10 Reference standards

10.1 RailCorp standards ESR 0550 Overhaul of 48 class locomotive engine assembly

10.2 RailCorp drawings 102-804 Diesel electric locomotives cast crimp lugs.

004-643 Traction generator service flow chart.

303-007 Standard grade brush for 43, 44 and 48 class type 584 generator.

10.3 Australian/British standards AS1554.1 SAA structural steel welding code - welding of steel structures.

AS 2625 Rotating & reciprocating machinery – mechanical vibration

AS 2700 Colour standards for general purpose

AS 2717.1 Welding electrodes - gas metal arc ferritic steel electrodes.

AS 2768 Electrical Insulating materials, evaluation and classification based on thermal endurance

AS 3709/ISO 1940 Vibration & shock – balance quality of rotating rigid bodies.

BS173 Methods of specifying performance of rotating electrical machines for rail and road vehicles.

10.4 Other standards MI-20014 Traction generator, type GT 584

MI-200084 General maintenance of electric rotating equipment.

MI-2004A Traction generator maintenance - Alco

GPC-E-24 Full gloss oil and petrol resistant enamel.


Appendix A – Drawing 004-463 Traction Generator Flow Chart



Appendix A (Continued)


esr 0602 - overhaul of 48 class locomotive traction generators · traction generators which shall...

Documents