SECTION CONTENTS GENERAL. LL Specifications CONSTRUCTION So Aum Jd Armature hearivgs Main joes 6 Motor suspension unit 2.8 Fart brash and earth brush hoides 2.9 Terminal box MAINTENANCE 3.1 Maintensmee dats 3.2.“ Inspection OVERHAUL AND REPAIR 4) Disussen bly 4.2 Maintensnee wf armature be: 4.3. Maimtenance af commuiates sustaee 44 Removal of commutator'complete 45 Removal of amature coils 4. Replacement of armature shaft 4.7 Gear ease MBLY OF TRACTION MOTOR S.A Preparation far reassembly 5.2 -Reassembly 5.3 Precaution for maintenance 5.4 Installation of the traction Motor... Page 8 18 ” a 93| : i i i SECTION. 6, TEST ‘ ot ju resistance tes! 6.2 Dieloetie test Polarity test a Volt 7. pRy.our TA Day-aut eandition 72 Mor aw method 7.3. Peete method 24 nsutation resistance and dry-out tins S. MATERIAL“ FSR: REMEDs AND SPARE PARIS, SL Preparation oo rate K.2 Inspection of spare motor lof spare posts o TROUBLS: PHENOMENA AND REMEDIES 10, INSPLETION ITEMS Th ATTACHED DRAWING 12. PARTS'LIST OF FRACTION MOTOR APPENDIX-A ASSEMBLY & DISASSEMBLY INSTRUCTIONS FOR MOTOR sUoreNStON-UNIT ge drop test for commutator segments or remedy and spare parts. 7 7 98 9 98 ” 100 106 100 10 101 tor 107 102 102 1s 136 138 59095 AAA AAO? AA1. GENERAL 1.1 Specifications Number 6/Lecomotive Modet HS15250A, ‘TWpe Fosced vemtiiation Field Series etd with commutating poles Fld strength 40x " Class 1 ae ous ating 630KW, 750V, YOO, 895 cpm (95% field) Single reduction (64/18) Clearange hotween year ease aund Lop of rail with, wew tyre 140 ma (1) Six Gaction metors ate mounted on eget mean: Ech one is attached to its respeetive deving axle of hoyie iy nose suspension, 2) The cractive ) provides intermediate grease refilling is employed. At the commutator side, Type NJ324AMCG17SEPGA 15324 roller bearing isused and at the pinion side, Typre NU330ZAMCGIBBEPGA is used, These armatur* bearings can be operated for 4 years without dismounting, by refilling the bearing grease intermedi 23° Main Potes _ © The pole cores and coils are potted with a solventless varnish. C 24 Commutating Poles The comm ing pole core and coil are potted with solventess vassish 2.9. Brush Holders and Carbon Brushes bearing bracket at commutater side by four Solts, The "brush holders and carbon nsshes can be inspect F rotating the se:ker ring until each Nrush holder comes to the inspection :vinduw. TI.: brush noldese 9° ‘mounted on the rocker ting by ©» insulating rod. ‘This motor is,G-pole t pe motor snd the brush holvers are mounted on the rocker ring iat is fixed tw the C> C 2.6 Motor Suspension Unit ¢ ‘This item is shown in instructions for motor suspension unit, 27 Gear Case ‘ ‘Tlie gear compound is filled from the inspection cover installed on the lower gear case 28 Earth Brush and Earth Brush Holder The earth brush holder is installed on the axle section of the magnet frame. ‘metallic carbon and pressed to the axle by the coil spring. he carth brush is made 0 29° Terminal Box ‘The terminal boxes have been provided at the commutator side ana pinion side. The crossover line i fixes to the insulating rod and lead supporter is wats! =. ii outlet of lead wites.on the fitting-out side. On the reverse of the terminal cover, the packing is stuck to prevent dusts from coming into the terminal box. 3. “MAINTENANCE 7 For ensuring the safety continuous operation of rolling stock over long time periods, the daily maintenan and periodical checks are essential. This traction motor is made to maintenance-free as much as possible by” + ducting the up-tovdate techniques. However, the mainienance cycle and procedure should be determinés according to the materials construction and working standard. In this item, the fundamental mainienan. procedures which are required at the minimum are given. : z e9 € b. Type-form ¢, Numnber of pales : 4, Insulation windings 7 ¢. Continuous rating £, Dielectric tsi voltage & Air vo hi Ar pressure Might Approx.) Complete r (inctudin Armature gent case and must sus Pinion (3). Resistance values Armature winding Series feld winding Commutating pole winding (4) Anmatuse details Core diameter Cor: Tength Distance between bearing abutment faces Overall length of armature (5) Armature permanent banding Material Tums on PE winding Tums on CE winding (6) Armatusé bearings ‘Type of bearings Manufacturer Radial clearance of free bearing when new Fittment between inter race and shaft 2 80mm? /m tors with reference to the following data. 2 HS1S250A EFFZOH Enclosed, force? ventilated iype. Series excitation with commutating poles. 6 Class 630kW, 750V, 900A, 895 spr New: 5720V, A.C. for 1 min. Periodical checking: 3432V, AC. for | min 150 ming, 3489 hs ion unit) 1010 kg, 2 ks AL LISS 0.01283 viums +10% 0.01184 ohms #10% 0.00907 chins +10% 500 mm . 5 480 mmm 990 Av28°C 0.00953 ohms *10% 0.00880 ots #10% 0.00674 olvms 10% BASTIM 1306 TAM 0.3K » 2Fwide (Glas Binding Tape) 70 nos. 2 86nos. : Pinion side + NU330EAMCG188EP6A : NSK + 0.165/0.210mm Intf = 0.045/0.086 mm ) ‘Commutator side 1NJ324AMCG17SEP6A+115324 NSK 0.155/0.195 men Int = 0.039/0.075 mmi | i oO ‘s) o (10) ay a2 Fitment between outer race and bearing bracket ‘Charge of lubricant (total volume): Conunutator Diameter with new Minimum usable diameter Riser width Mica groove depth Mica groove width Length of working face Mica thickness Carbon brushes Number per brush holder Brush grade Brush ype Brush size Brush soring pressure Brush wear limit Brush holders Number per motor Clearance-bottom of rush holde: to commutator Poe bore: faverage) Main pote (at centre) Commutating pole (at centre) Liner at back of pole M: pole ‘ommutating pole ‘Axle suspension tube Roller bearing details Manufeturer ‘Type of bearing Charge of lubricant (total volume): 5 Intf= 0.046 mm to 0.041 mn to Clr = 0.016 mien 804g + 400 mm 380 mm 20mm Max. 2.5 mm Min. 1 sna 1d mm 146 mm 1.16 mm 3 EG105S oF EG1 16 (Moran) 2 split 2G mmm x 40 mm x 4 nn split Max. 3.44 ke/Omsh 210% Min, 2.8? kg/brush 240% eush Tength is 25 mm 6 2~4mm 512.7 mm (Nominal air gap = 6.35 mmy 520 mm (Nominal ai gap = 10.0 mp Nil 2 49mm Gear end Non gearend TIMKE TIMKEN Taper roller Taper roller Cone 31349547 Cone M249747 ‘Cup M349510 Cup M249710 12508 300g 5 eooa0oc no LAA3 (13) Gear case Initial charge of lubricant 2 85 liters Lubricant levet Refer to Fig, EL1-7, EL1-132 (24) Atternative lubricant Acmature bearing, 1 SHELL ALVANIA GREASE NO. 3/SERVOGEM 3 ‘Axle suspension bearing, 1 SHELL ALVANIA GREASE NO. 3/SERVOGEM 3 Gear ease compoand 1 Sliv'LLCCARDIUM COMPOUND D Inspection installed nthe etch, Those clicehs ate tu be performed in the condition where the main motor his be 2. ELIA sows the flow el 1 Brush lwsbters snd carbon brushes: : I have a great effect fe brust holder and earhon brush are éaportant components in particular aways correct mainte vee for obtaining no commntation. 1 is therefore necessary to perf 0 ‘operasion, ween the holder case packet and ea:pon brush (1} IF dust, worm powders of cathon brush, ete. en ‘sud the motor is operated in the sticking state of carbon brush. poor contact with the commutat surface is caused and results in poor commutation and/or flash-over from time to lime. Therefore, in Ihe cheek af brush holder, blow out the holder ease packet with sir and wipe with a dry cloth care Tally. (2) Contamination of surfice of insulating rod may cause a creeping short-circuit. So it should be cleaned by white gasoline infiltrated rag as frequently as needed. ocroet with emery (3) {3 case that the surface of insulating rod has been roughened by flash-over, et paper (No. 400) and clean. If the surface is so heavily damaged as not to correct by emery paper and also, erack or seizure is four: in the insulating rod, replace with new one forthwith. n Fig, ELI-2 as clearance between holder check to see as required that the pocket (2) The carbon brush in the iraction motor is filed a6 shos ‘ease pocket an cashon brush increases in the evolution, So acnsion of heush holler case and. carbon beush dimension areas specified. Ifthe pocket is found ‘worn beyond the maximum wear limit given in Table EL-1, replace it with new one. a Pa eRi ; 5 4 ii g t 3 7 { 3 Cc L [Motor suspension unit Meee [Bion utr rane cena ‘Measurement wath megger ' ithstend vortage A.C. 2.4920 i Gtreeessary « a © ¢ ¢ Prag 0) Delivery Fig. EL1-1 Flow chart for daity choek and monthly check + ‘ F : 1 ! ‘ ne i i ' ‘ r t Fal larger the gn Ws, 7 Aheheerier the attccnired oearece sun of carbon brush. a Fig. EL1.2.‘Table ELI-1 shows the cleuranee between carbon brush and holder ease, | TH 5 eSERR | (CSSA ELEC > : Table EL-1 ~ Dimensions Symbols new | wear tiie] B 20 0-1 | 20.3 ‘ uw [®t [ 3 See ee { we a 0 s0.5 f (8). The austity (materia) and shape oF carbon brush have a very great efTect on gomumtation, therefore the specinned one niust be uscd without fail If any carbon brash of different msterial is used. in particu ‘unusual wear, damage oF commutator surface, ete, Se ‘bom brush made of diferent material from thal it may cause 9 poor commutat sro sen Moov any other carbon brush than that spes 1d-can not be used, (©) Cheek if the carts Ineash has such length that it can be used sul ciently Fig, ELI-120 shows the shape and dimensions of carbon brush, the next cheek. (2) Cheek for etaek in the carbon brush - (@) There shoulda’ 1 break of the pig tail (lead wite of earbon brush), (9) There shouldn't he. ay loaseness, drop-off, etc. in the tamped part of pig tal (10) The carbon brush shouldn't be left setzed in the holder case pocket, (11) Contact of the earbon brush and inmutator should be proper condition. (12) 1F the carbon brush con ni longer be used tll the next check hecnose of wear, replace it with new we. Hf the dimension “I fs found equal to 2Suim in the check of earbon.brush. it may wear down 2 30nor, wea init efor the next check comes round, Such carbon bros should all be replace Inne replacement work of carom brash observe the following strictly. (2) After inserting the carbon brush into the pocket of brush liolder, try Lo move the earben brush upand down, and make sure that it moves smoothly.el 1 _-— Beuth older ce Try to move the cxxboos “ carbon brush pn a wrbae 3 ~N a Fig. EL13 c € {) Won setting the bs spring afer igri the esos int the brie bee, so thatthe ad wie gta of ean brash sno caught by the spin € {e) Whow the wou carbon brash has een repeed wil mow ine, ke aid -tittng se tat 0 6 wn vas eats the commutator surface coset : 7 UF the cnbom_ brah, rate emery pap abo a emulators’ ofthe enery paper »poied to the Gch, and eat ch proccdive a few ~ us song Le catonbuth 7 ‘Move emery paper To dre right and ett _= Commutetor surface Fig. EL1-4 Stide-fitting of carbon brush Note: Handie gently in making stidefitting. to avoid commutator surface damage, {4) After completion os sve sini-flting blow away brush powder with compress a. 7 (@) Tighten the terminal bots of carbon brush lead wires securely. (13) Do not release the brush spring of brush holder from hand suddenly or do not drop the spring off, spring support; otherwise. the carbon brush may break or the brush spring may be damage : place the brush spring on the carbon brush gently. (14) The brush holders are fitted on the rocker ring and the brush holders and carbon brushes can tb. spected by rotating the rocker ring until the brush holders come to the inspection window of the =i.» net frame, The inspection proceduse for the brush holders and carbon brushes is showa in the ino == chart in Fig, ELIS.“Taking off inspection cover | Take off the inspection cover. 1 Pull out dowel bolt [}-————— Pull out the dowel bolt from T ‘commutator side magnet frame, ‘Taking off tight-ning [bolts of rocker ring “Taking off tightening bolts ‘of connection lead wire-—} = 4 ‘Turning of rocker ring, |-———-— Pll the lever and tuen the roeke: ring Inspection of carbon brushes ro 1 f= “1 Change eavbon brushes. | = _ Bete Measurement orbasik 4 Insulating rod. Putting brash springs ae eee ‘Check the bolts for brushes teemsinals, Repeat about each brush holder Rotate roclar ring in order to meet “V" slot and “U" slot + [Tightening dowel bot. Tightening rocker ring in bearing bracket by special bolts ut ‘Setting of connection wo lead wire with nut. Fig. EL1-5 Flow chart for checking the brush holder and carbon brushMagnes frome (9.3) i are Fig. EL1-6 Method of carbon brush holding ring rotating & measuring brush wear QO800004 aA ARAL PS AAAAD ONnutator So long ss commutator is operated in guod commutation state, a chestnut colour Iuster is formed on the consmutator sutface. However. if a brush made of different material is used oF dust gets on the surface, ideal film won't possibly be obtained. Unless otherwise wear ofthe brush, rough surface of the commutator, stepped wear of the commutator, etc, are caused, thers is no need to be ron- cerned about the film on the commutator. Morecrer, if such abnormalities ocowr, perform the maintenan- ce of commutator. (Refer section 4.3.) av with a cestain : 3.2.3 Gear case and lubrication ‘The maintenance checks of gear case and gear lubrivaticn oll should be made placing imporance on the following respects. PHRRERERE Se (OIL LEVEL OF CEAR CASE Fig. EL1.7 (@ When checking the gear ol level, i it is checked immediately after stop ofthe train, it will be felt as ifthe gear oil is short. So, check the level afte: 20 to 30 minutes have clapsed, (b} When supplying the gear oil heat itt» 60 t0 80°C so that it ean flow smoothly. ures with the motor Het in its fe) After the gear oil has been supplied, keep 1 1a 20 10 30 ‘Stationary status, ind then, check the oil level. @) Chéck to see that there is no much leak of the gear oil. If much leak of the gear oil is discovered or ‘consumption of the oil is considerably heavy, the felt sealing of gear case might have worn off. So, ‘check for drop-off of the sealing by remmving the gear ease. (3) Check for obstructions af the breather. If iis discovered clogged with something. wash it with Kerosene and blow out it with air. (4) Check for loseness of the gest ease saunting bolts and for crackscL 4 3.24 Armature bearings Since the armature bearing is an important mechanical part, it must always be kept in good lubicated state, For this, the dally maint ® the routine check, check for unusual sound. vii leak, etc, during rotation of the bearing, and re-supply grease every year. At the time of overhaul, ex- change the whole grease. (As for grease filling prowedure in the case of overhunt, refer to the section 4.2.7 oF it.) (1) Sound of hearing (a) tn the operation, always jay attention Yo the working sound of the Uuetion metor, stud: any ‘unusual sound and/or vibration are observed, stop the operation immediately, dismount the ‘motor and look for the real cause carefully. ight (hy When the traction motor ix left removed from the truck. he sure te perfirmn ths test oF the motor snd cheek for unusuat ie detevtor bar to the outside of side cover ncusest the beating des: cr few mators. check for noise, When comparing tl forbe judged casily whether th g wohl heal wtliog, i wil be sfease sscimbly 1 he refilled intecinediately should be the sumye kind as tinat used Js and the amount of grease sefillad are ay shown in Tiling. i€ © AR A e Table ELV-2 Seetnon Incersal Amount Pinion side 110 gr : Yeuly - Commutator sid Be 4 OVERHAUL AND REPAIR Iv the disassembly of the traction motor, cheek each part carctully following the maintenance chant Fig, ELE, Soe the Following drawis . Description jon motat J Engin section of 620KW traction motor | Cross section pf 030KW traction motor Antu bewingasenbly of 630A tal Terminal box assembly of 630KW traction metor Rocker assembly of (30KW traction motor Tnpetion are aby of 63OKW tacton ator Gear ene msenbly of GOKW caction motor | Assembling of mot suspension wi “Conecion dam 630KW tection mole Assembly of earth brush at Disasemb!y Disassembly and reassembly of the traction motor must be performed at a clean place with no dust, and the parts must be handled carefully not to damage and rust. Observe the orders of disassembly and re assembly correctly following the maintenance chart Fig. FI‘. If the working order i incorrect, proper somplete reassembly wor he aelnived, The vanditions 1 the cone, amount af grease supplied. mast he observed sity i. far isiance, temperature, pre For disassembly and reasscubly. the tools given my Table ELI-3, Teed ist of nation nator, ase Disconnection of external iead-out wires ‘The extermai wires are connected 10 the connection terminals in the terminal box of the traction motor by bolts. Before removing the traction motor from the truck, remove the terminal box cover and remove the bolt en connection terminal. Then, loosen the lead supporter of the terminal box, and remove the exter: nal wires. SS[Yiauat inspection) ee elaeeeeaael : _ arma fumalureveving Euipmut ol okey ia ea “ 2 Tamla ja Cerca 37 — geese tearing by Gledeing ee compressed air Rock: ‘Bevth rolger “compressed air Ht |p] a laminunce es | serene ud inpseion “SEP i ae spose ee tenvaaria ees ay 7 . wget iho a E | Resonee ere year a $n | (ema P Be eonteH | i L r saa 1 i | I tor 4 eee i ? Iesectin of ; i i L a | i mon 3 aca Bimvernin || Sees sschse Ved Ener || Leer i | TRepaie Measurement =a (les Devig i meena a on 1 Washing fee — " Poliing Ceongty Reeds Sema i 4 Measur spring -Tiioaiang —} / Sl Uncer cursing, 1 |iocens™ i |e : ; (Fauna bear need EE !ea Oe ~ Tools Table ELIS Too! list for tuaction motor Combi sion 1196! Too! 12°} Description a, EL1-12) Fig. CL T ma S ese g stopper culling out (Ginton sds) Bearing snort pulling bat inion sae) | Commun Fig, ELI-18 | Fig, E19 | Bearing Taner 99 | patting oot outer nny "ie de tpearng ostornng Sacket Iroweon | ineneg Bearing 3 | IBinion sie) | ino bewringFinto bea aittiay |e civsa rg eblarjeg teiae |r Boon To 3 Keeper sale Toa Nat ‘The 8 Doubivand wi (To 8 "Support dink TB Dewbieand si TUS Distance pice 10 Absorber Ti Hook 12 Hook T 1a TBeabieand mwah = 1S [Puller 16 Distance pees TAT Ataerke [rove Pots " See Ti 25 Spanner Tor pinion wut Nore Teo Siond | Pump Mote 7S, Asae a it ipa t ‘Grease pi [7 T commutator rone u L 2 RAEeL1 0 8 ‘Ouisr bearing stopper (pinion end) et] Bearing bracket si Brush holder | poraslsietspineinaaagaions peoniniasaasaninteseacesnissoasasaaiatoOtn DM OSOMADREASZAABHDO Fig, EL1-9 Flow chart for disassembly 442 Disassembly se c Daan a Ax the gear oil Hoes ont af the gear ease aa time ab dvassembly of the eave, te of vl Ae ‘drained by opening the oil filler cap (150) fixed onto the lower half gear case (127). @ 42) Disassembly of gear ca Remove the bolts (131) and (149) tightening the upper half gear cace (126) and lower one (127), Next, remove the bolls (65), fixing the gear case on the magnet frame (18), and demount the lower half gear case (127) and upper one (126) im this order. In this ease, be careful not to drop the gwar eases carelessly, 4.1.3 ,Detachment of motor suspension unit « (1) Remove the bolt (70) tightening the suspension tube (159). : Next dismount the traction motor from the suspension tube utilizing the tapped hole for pulling out. ~~dia ae ghew sown tian the truck, Blew aut cL 4 Doth entering gnu unter vith_ fren Pinion aut nea Va Euity Oi jee or teem epi an om sch vm oe PAR AA EAA A: a3 e4 4.15. Disassembly of pinion from armature shaft Prior to disassembling the pinion, loosen the pinion nut so that clearance of 3 10 4 mm is made between the nut and pinion, as shown in Fig. EL1-11, then operate the oil injector. 4.1.6 Disassembly of outer bearing stopper <58) Dismount the outer bearing stopper (58) hy using the exclusive tools a shown in Fig. ELI-17. 4.1.7 "Dissssombly of armature (Two procedures of disassembly are described.) (A. (1) Piepatation fer disassembly of armatur, ‘The armatire is tobe diamounted from the stator with the beating Bracke (10) atthe pinion side kept sted. LWefore dismounting the armature, make preparation as follows. fa). Remove the eariven orushes (26) from the brush holders (27), Refer to section 3.2.) (15) and Fig. LI 13. tb) After removing th bon iusives (26), wind a press board on the commutator for preventing the commutator surface from being seratehed. (e) Dismount the bearing cover(38)from the bearing bracket (33) utilizing the tapped hole for pulling (@) Dismount the ou‘er hearing sinpper(44)and thrust collar of roller bearing (41) from the armature shaft, (©) Aqshown in Fig. ELI-12, mount the lifting tool of armature to the pinion side of armature shaft (0) Remove the bolts (1) which are fixing the bearing bracket (10) to the magnet frame. (2) Preassembly of armature @) Lift the lifting tool of armature by a crane and hold it in the state that detrimental force will not be applied to the armature bear esserea Wes cone = Searing bracket removing bolts aaa 4 Fa Encl Di sem ye im ate ELIE KT OO ONTO O98 99.0900 0 6-0-6 -D*BL () Usiizing the three tapped holes for pulling out provided to the bearing bracket (10). By these bolts, as first loosen the bearing bracket slightly and, then, pull the bearing bracket slightly. Repeat ‘these steps by tums until the spigot joint of magnet frame is disconnected, vg the armature balanced by the handle of lif W the armature. tool of armature, move the erane and (0) Place the dismounted armature om a wooden support sw that the armature rests on it by the -ciccumferential surface of armature core, Never fet the armature rest on the woolen support by the glass bi coil or by the commutator, wing po ton of arma B. (1) Preparation for disassembly of armature The armature is to be demounted from the stato: with the bearing bracket (10) at the pinion side kept fitted, Before dismounting the armatu.*, make preparation as follows. (a) Remove the earbon brush (36) from the biush holde: (27). Refer the section 3.2.1 (15) and Fig, BLI-43. (b) After removing the carvon. brush (26), wind « press board cin the commutator.for preventing’the ‘commutator surface from being seracthed. (©) Dismount the bearing cover(38)from the bearing bracket (33) utilizing the tapped hole for pulling out, (}) Dismount *he outer bearing stopper(44)and thrust collar of roller bearing (41) from the armature shat (2) Disasscsibly of armature (2) After completion of the preparation for disassembling the armutuiz, keep the motor upright with the commutator side dcwnside. Refer to Fig, ELI-13. (b) Remove all bolts (11) tightening the bearing bracket (10), screw M24 bolts into three tapped ‘holes in the bearing bracket (10), and demount the bearing brackel.t. Refer to Fig. BLI-14. (©) Fitting *he armature lifting hook on the armature sisft end at the pinion side, life the armature by ctano, serew the bolts in the tapped holes of bearing bracket (10) in turn, turn the armature slowly till the spigot joint of bearing bracket (10) and magnet frame (18) comes off, and while oalig’ 10 $60 that the armature is turned smoothly, demount the armature and bearing bracket (10) together from the stator. As shown in Fig. ELI-14. (@) Blace the armature demounted from the stator on the table with laid down. “Lay the armature on a wooden table with it supported by the core face. [Never support the armature with the coil, glass bind part or commutator par. Handle the armature by using the armature handling too! as shown i Fig. ELI-15. sirenty ak em ee SHASTA HOOBBONNANFh ELA ROE SCRE ae Pee Fig, EL1A3 Method of transportation & arm jure take out Fig, EL1-14 Method of transportation & armature take out aE a CINE A Ser Er mtg| | = ® ! ~ 5 TOOL MARK | / To ‘SUPPORT Fost Tis | ec 752 i Pes is NSS Z FLL Armature handlin 1901 ror set Pa. Be oe ee Fin ELIAS Armature hondliny 190: sor aetie mer a A eile Mea hbo. hts Bo db NN t : OVP OOMAAM AR AR Ael 4 bly wf bearing bracket, the amature dismounted from the stator contains the be: brucket (10), insert a steel bar (20 to 24 mom in dia.) A AL Disspses \ entrat the bearing mare divecvon Fig. EL1-16 ‘Armature handling too! for traction motor 4.1.9 Dissssembly of commutator side hearing bracket () Dismount the bearing bracket (33) from the magnet frame (18) utilizing the tapped hole for pulling out. Fig, ELIS (2) As the outer ring of roller bearing will come out together with the bearing frame, pay full altcation ‘when handling the bearing bracket. (3) Preparation for disassembly of bearing bracket : May install a guide plate to the rocker ring for purposes of safety before dismounting the commutator side bearing bracket. Pore remem ep4.11G Disassembly of rocker ring 1 disassembling of the rover ving is necessary, it can be done accosding to the fallowing procedure: the rucker ring tr the magnet fran we one special seamer bolt (dowel bolt (61)} that ate fi putatar side. (This work is performed in 4.1.7(1}a), Disassembly of Armature, since the remove the carbon brash.) i (2) Install the exclvsive 100! to the rocker ring, After that, zemove the guide plate fe GY Rey ing is tal J sacker ring, eo CSNAAHS SOAEL i (3) Remove the rocker ring from the magnet frame. (4) Write serial number with white paint to rocker ring and magnet frame. 4.1.11 Disassembly of brush holder : If necessuy 10 remove it inevitably, remove ouly the brush holders (27) without removing the insulating rod (116) from the rocker ring, (1) Removal of brush holders (27). - ‘The brush holders (27) can be removed by Joosening the bolt (113). (@) Removal of insulating rod (105) When removing insulating rod for replacement, chip’ the welded part for locking the nut (110) by and then, slacken the nut. 41.12 Mn oe disisetubling the atasatu ¢ bearing, Follow the procedures giver in the sevtion 4.2 on the sueccedi 4.2. Maintenance of Armawure Bearings both sides of the caller bearing, ringed grease holding-cliambers are arranged sideways, and on the cascdholling-chambe: of the outside bearing cover. a waste grease chamber is prt periphery 0 Yor the arnaiure bearing, 9 cylindrical roller hearing is use mt buy commutator and pinion ses. At | nat the used erease in the roller beating is forved toward the waste grease i mediate grease eotling The srmata rotary unit, therefore, it nnust be handed with 4.21 Cautioins when handling arossture bearings (1) Do pot mix the heating stease of different specifications. 7 _ (2) The inner race’and outer race of roller bearing should be used always in combination with those hav : {ng the same serial numbers with each other, Never combine the races having differen serizl numbers with each other for use, 3 (3) When hanetinw the hearings and grease. always keep the handling ple and tovtz clean fe preventing ingress of dust owater, ete. inte the hearings and grease, (41 Wher! Isindling the cleaned hearings hy hare hands, wipe Singess hy such degreasing agent as ethyl ‘cohol For preventing the bearings from getting rusty. 7 Storage of bearings (1) When storing the demounted bearings over fong time periods, wrap them in a volatile rust preventive pauper and store thems in a eokd dark place with litte humidity. wt rust preven: - (2) Whien storing these bearings applying grease (or lubrication to them, pay Full utte€L 423 424 Tools for disassembling and reassembling the bearings ings should be disassembled aud ceassembled dy using thé exclusive twols, And, these fouls The of work to be sure that the alhould be checked up fallowing the tools Uist prior to initia inissing and defective cae. ate ne Disassembly of armature bearing. (1) Disassembly of rallee bearing inner ring at pinion side 1, the Following parts is removed fom the arm ner bearing stopper (56), be bracket (10) at the pit wn sides Whew the bear ave fitted on the armature shalt pin bearing stopper (58). ig the outer Searing stopycs ($8), dismount the inner bearing stopper (56) and hear: sly by sising the exclusive tools are shown in the appended Bes. we inner ving and outer ise ring simulta (2) Disassembly a heamg mney ong at eonomnttor side si frame the wearing cmmiutatt. side Disneys seu Fig, EL."-19. wed Yom the eacket (33) af the commutator side ie ring s-npper (63) ure ‘Fixed ow tie atumawure shafte fools as shown in the apy: When -ive we og and inner bs these parts at the same tine by using ze excl 2) Extaction of beveng outer tngat pinion side re. the roller bearing outer sing is Fitted bracket (10) removed trom the armat pended Fig. ELI-20, On the beatin ic esetusive tena as shown in the Dignan it By asi ator side (4) Estiactiow of beasing 1 roller bearing outer rings fitted: On the bearing bracket (33) cemoved from the armature, ELL.3 ones Too! asombling procedure set nooks tpt oe) D sin stop02 2. Fix hooks @ by newer plate @) Serew dovbeand sts @ in ook Set gp ci @) on a. nor s Bego” outed sue ‘nd nuts (6) 6, Press piston with handling ol power Bump, Fig, EL1-17 Outer bearing stopper pulling out ‘pinion side) Stopper 2 AT PRES NRTA TI IR IS Ie: 8 NuMIs 4 = & el "[ seni ot sone el =| 1] 7 Aumatuee Cutline of root arrangiment TS REARS era 13Ram inte beac Description Hoot = Kugoer ple Teele |= & (Unubieand sud { Supp0rt dis Toe nea “oat ssembing procedure Seto typ type! @ on inne Dearing stopper Fn nooks Q) by Kaan oate @) Serew double-end studs @ in tooks Ser waport ak Qn tar, et out @) on paton, 3 Fiesmpeyt 3) ty deste de ind Puts © 6, Press piaton with andl oi Bower pump. Ram with oil power pura] Bolt 24 LAO. Armature sae Outline 2° tools arrangement, OI TS OEY HOWOOO0ON) a~ =f 4 [ser nial pone! ony = Sreuaaas t 2 Toa sn ting orate Seton tt pe) CO) ong eine tooper Fie hooks (by kero pate Screw doblewnd suas @ sn nook. @ setnspport dah @) onren,set ut (3) on pston Fexnpuey.gnx @ bv dougewrasnat @ 6, Press piston with handling ol power pump. Onn woken, uitine of teat arrangement a Fig. EL1-19 Bearing inner ring ard inner bearing stopper putling out (commutator side} = 2 LL OATES ART TES» SAAS me seatBearing bracket “oats aembing procedure 1. setram nto wand @) 2. Scr tupport die. @ oncam. 3, Pursbuorber ) and dwiance piese @ on support dak 4 serpuler @ on cute: ne Ipevekae (pus together outer race and Sun ditance piece, £8. Pras piston down werd with handling eit power pum. Fig. EL1-20 Be: ceghinets “28 el ae ° POI © ng outer ring pulling out (pin‘on side) Outing 2 ote arrangement, aPOE OT MO t ce : “Tools sesembling procedure seven 1 Sora G evan (3), onpeeonee rene seer © |. Puraboroer @) and support disk 4, teat Hae Gu oper Ove ree ime Oo 5, Set puter @) on over et € seat © onviton. 9, mre ptondovn ward ith hain i ower pump. uttine of took areangerent Fig EL1-21, Bearing outer ring pulling out (eortmutstor side} aa4 425 Cleaning of armature bearings ‘When cleaning the dismounted armature bearings, put them into vessel containing kerosene heated up to QO about 60°C without degreasing and leave them as they are in Kerosene for more than 10 minutes. After that, wash them roughly and take them out of the vessel, Then, blow away sticking grease with compres: © sed. i Repeat the procedures more than twice, and then, wash the bearings finally with a clean kerosene having. © ordinary temperature, and blow away adhering Kerosene completely with air. For the final washing. always use new kerosene and do not heavily.oxidized or foul one § Also, when handling the beating from which oil content has been blown away with alt after the final Q washing. wash hands’ with such degreasing 2gent 2s ethyl alcobol carefully for preventing the bearings G from getting rustly. 3 © ioe Geta oon eaee € ‘When resulting the dismounted bearigs or bratings lett stored fora long period, check them hefore fiting, © to make suce that they are usable normstly. a (1) Removing thé inner ring nom the outer ring of bearingvcheck visually for roughness, scrateh, rus, iscolouiation, rust ec. on the incr eae. & (2) As for the outer race, too, check while turning the rovers {all rollers) if there is any roughness, me scratch, bruise, discoluration, rust. ot. as with the inner race. : gy (3) Check while moving the rollers for wear of retainer, looseness of rivets. wear or roles and retainers, ‘And. make sure that there is no abnormality. (4) IF abnormality is discovered in cither of inner or outer ring, replace both rings with new anes tor ether. (5) Outer ring and inner ring of same serial number should be assembled. 4.2.7 Reassembly of armature bearings Reassemble the armature besrings carefully by using the exclusive tools after cleaning, and be careful wit Ingress of dust, ete. during reassembling process. Also, when reassembling the bearings, do not strike or pressure-it them unduly. (1) Grease to be used Use SHELL ALVANIA GREASE NO. 3 and never mix with grease of other brands. {25 Filling grease and arwount of grease filled = (2) Amount of grease to be filled Fill the grease as specified fullowing the procedure below. (b) Grease filling Fill grease in the bearing bracket and bearing cover at the pinion side, and bearing bracket and bearing cover at the commutator side as shown in Figs. EL.1-22, EL1-23, EL-24 aid EL1-25, séeeia taEL Fig. £1.25, (3) Reassembly of roller bearing ines ing at pinion side Wipe carefully the bearing inner ring sssembliig part of the armature shaft. and fi the inner bearing stopper (36) and inner ving ia place in this order, Put the ier beating stopper (36) and bearing inne rng into theo bath contain up to 110. 120°C for heating them and shrnk-fit on the armature shaft. kerosene heated ‘When shrink-fitting them on the armature shaft, press them by hand {ill they cool so that gap is not produced at the stopped pari of inner bearing stoprr (36) and shaft, and betwe: stopper (36) and bearing inner ring, nner hearing Sheink-(it the outer bearing stopper (38) loo by the same procedures. OO ©eu 4 However, outer bearing stopper (58) must be fitted to after assembly of armature as shown in Section 5.2.5. ~ i ‘Atzarble the part without producing | SS f Fig. EL1-26 = + After cach part thas been Fitted on the shaft, apply grease thinly to the surface for rust prevention, purpose (4) Reassemibly of roller bearing outer ring at pinion side Pressures the outer ring to the bearing bracket (10) by using the exclusive tools. For the pressure-fiting procedure of the outer fing, refer to the app ide Fig, ELI-27, 2 Prioe to reassembling the outer sing, fll the interiors of grease holding chamber of bearing bracket ca (10) and hearing outer ri specified amount of grease following Fig, ELI-22 and EL1-23, Providing for'the subsequent reassemb!y. Ne be with fit the outer sing while striking by hammer without using the exclusive took: otherwi fs damaged.Greate C Outer ace Bearing backet ‘oo! enembling roieeare j Se samiavo tans @ seit tupport ai @) 00 am, Puttenring becker on wpperi dite: @ outer race on bering back srihook @ ov outer race seit @ on piston, Press p ston down ward with hanging oi Outer race Bewiceorcnet tine of toots arrangement into bar-ing tnucket Uginion side) ne decane we ey te Oey SA AMR = Lan aeu 1 tted to after assembly of armature as However, outer bearing stopper (58) must be fit shown in Section 5.2.5. im Atsambie the parts without producing , ‘op at thre sac oe opt li f Fig, EL1-26 After each part been fitted on the shaft, apply grease thinly 10 the sui for rust prevention papas (4) Reasembly of rollr bearing outer ving 34 pinion side Pressure the outer rng tothe bearing bracket (10) by using the exclusive tots For te pressuresiting pravedre of the outer ring. refer to the appended Fig. EL1-27 Prioe 10 reassembling (erring. fll the imteriors of grease holding chamber of bearing bracket (QO) and bearing outer ring with the specified amount of grease following Fig. EL1-22 and EL1-23, 2 providing for'the subsedjuent reasseutbly. Never fit the outer ring wi Desring is damaged, ¢ striking by hammer without using the exclusive tool: ty ssPiston ue race Beating bracket 700 enembing procedct Sx somo ard © Secow wpe die @) on am. Puntearg bracket on wear dik @) > outer ‘ac on bearing bracket. serm00k @ on outer rae Setmut @) on . Press piston down wad with hansting ait ‘ower Bum. aa eo he et EL 1 428 Storage of grease When grease is stored for a long period, the oil content of grease decomposes oF oxidizes. Handle the reas let stored fora long period following the suggestions, below. (1) Donor use grease made more than one year and a half ago. (2) Although the storage period is less than one year and half after mumufueture, when more than 3 rnwoths elipses alter the grease can las been opened. do not use the grease, 4.3. Maintenance of Commutator Surface Applying # grindstone to. the commutator is iatended (o remove the rough filo on the surface, and turn ang i for the purpose of eliminating the rough film and at the same time, correcting the surface uneven- ness sich at stepped ear and eccentricity. th scver, the necessity of reworking the commntator surface is determined depending on various conditions, and it is hard to judge it unconditionally. It must be judged observing the condition of commutator surface carefully. ‘The commutator exhibiting the follow- ‘ons must be reworked by applying 2 grindstone or (wining. ing e 43d Appl indstone ty commutator surface Applying 3 grindstone in the following cases. (1) Where the commutator surface is heavily giackened. (2) Where thee (or surface i tough owing to minor Mash-over. 43.2 Grindstone applying procedu:es to commutator Apply a grindstone to the commutator in the condition where the armature has been assembled in the ‘We recommend doing the work with the armature put on a lathe as shown in Fig. ELI-30since there is possibilty of eecentiriciy or snevenness heing caused in the commutator. Fig, L130 oo nama SRE esiMoreover, after completion of applying a grindstone, blow away the stone powders wiih air, and check ‘carefully the groove inside between commutator bars to be sure that there is no abnormality, 43.3. Turing the commutator surface f {In case where the Following conditions are recognized, apply (urning to the commutator surface. 40 (1) If eccentricity, inequality in diameter. high-bar, low-bar, ctc. are generated in the commutator, cut the commutator following Tale ELL. A Tetde ELLA Corrective limits Aer turning i Eceewisiity | Not more than 0.1 mm 0.03 mm é Inequality in diameter 10.005 mm ue Fighsbar, Low-har [Not more than 0.003 mm | 0 © € (2) In ease that stepped wear is exused in comnurtator surface:” : ie ‘The brush con!» face of commutator surface wears stepwise is coustant year-round usige- . ie C ‘Therefore, the stepped purt should be corrected flat by turning, Standard for yurning: +m Corton Brush : Fig. E131, 7 When “So/"exeseds 0.1 yam at the maximum. i requires cutting work. (3) In case where\it is impossible to rework by a grindstone because the commutator surface is heavily rough: tet . “ 4 (4) When rousing the'traction motor after a long-lerm storage: When the operation of motor is suspended over long time periods (more than 6 months). oxide film is produced on the commutator surface. If the motor is reused in that condition it causes 2 poor * heeld fenmmutation, As for the nature of the traction moter feft stored far a long period, measwre the cesistance by megger and at the same time, prior to reusing stone tw the commutator surface to eliminate oxide film, and thes ingulati wri be sure to apply turning or a 4.3.4 Turning procedures of commutator surface The degree of turning of commutator surface should be judged according to the condi tor surfass, and if mus! be cut at mi required ns of commuta- (1) Under cutting and chamferi'g : ‘When the commutator surface is cut, the slot betw-en the’ commutator bars shallows and the cham- feving of conunutator bars, too, become small Therefore, after cutting, under-cutt ing should be performed, : yg and chamfer. fa) Curry out the undercutting following the exaniples in Fig, BL1-32, ELI-33 and ELI-34, Fig, EL192 Fig. E1133 Fig, €11-36Fig, EL135, Fig, £11.36 Gor Goiess otlior ans she under euteing 2 Ayo) musta! hhrasivn in sie dbo perficnved cataectly in eo nity with the exampres in Kips, ELI-S7 and ELL ator hats, eattous twos ane awatlable, ake the suas suite say an a the essenples in Fig, ELAI-35 and EL1-36, c bee wrgetly ron buash, so theve pus edics 9049 c Fig, EL137 Detuils of under-cutting and chamfering = : A: Correct undercutting ad cramnt 9 1B: Excesively tnge undercuts “+ Excess dep under eutieg D+ Leftunchamtived G . Fig. EL192 Exampte of undercutting Let ungiven vader-euttingeu. 1 ae 2) bathing (a) The onrimutator surface is 40 be corrected by lathe with the armature put on the lathe as svat Feeotuvon of york: 120 16 150 10m (0.08 10.0.4 mwnieew Fig. £11.39 the commutator surface by the lathe-slon the armature shaft as shown in Push the shaft ‘of armature shaft on the ccmmmutator side by the center of lathe, align the armature shalt hy using the be chuck the shalt @ne en thy pinion sid ing fing portion” Aon the pinion sice as the reference and Portion 1 Apply a steady est to the besving ttn fh the commutator side commutator curlact : : 2 ® . comer = 7 + Steady res ©} es Fig. EL140 rE (ed Cleaning On the completion of cutting the eemmiutator surface, elean by blowing ai direetty to iay 4.3.5 The creepage area surface ‘The ereepage area surface, shown in Fig, ELJ-41, should be kept in good condition, Tie areas shoud be cleaned frequently and repainted whenever necessary with arc resistance camel paint. The proceaure for repainting this surface is a8 follows: C € : € 2) Clean suefaces thoroughly with alcohol. Remove any uace o! carbon, € Cc (2) Using a clean brush, apply the insulation paint carefully to the ersepage surfaces, Make as thin a coat as possible applying the insulation paint evently leaving no dehs or overlappins areas. (G) Take care to avoid getting paint into commutator slots or the relief at the bottom of commutator Cc neck. ic (4) Wait until paint is dry before running motor. Note: © Bo wot apply paint aver carbonized or charred insulation. If the insulation can nut be eleaned up satisfactorily as outtined above, the m:-tor should be remove! for sn performent eepaits € c € Teflon “na . N | 7 Commurstor : ee | ata eae c 7 UV ‘Bo not pint Bae these face Fig, EL1-41 Care of commutator sreepage> 43.6 Replacement of the Teflon-ring on the Vee-ring Insulation 5 If the Teflonsting is found loose, distorted or damaged, replace with new one following the procedures . suggested below. (A) Preparation for tasertion of Teflon-ing To protect the c::amutator surface from injuring under reinsertion of the Teflon ring, you should wind pressboard and polyester tape round it as shown in Fig, EL?-42. Polyester tape 0.18 x 25 ‘90m ip 1 ayer Pressboae -08 x1 layer Fig. L142 rAOTECTINC COVER FOR COMBIUTATOR elo o ©) Cutting the Glass Tape Face Remove old Teflon ring insulation, cut the face of glass tape wound on Veessing and semove thoroughly the calings of old adhesive by cutting in alae only if necessary. Next, remove the varnish stuck on the surface of epoxy glass tape with No. 80 sandpaper. (3) Degreasing Work CAUTION: ALWAYS WEAR RUBBER GLOVES WHEN DEGREASING WITH AN ACETONE-SOAKED CLOTH TO AVOID INSUFFICIENT DEGREAS:NG THROUGH HANDLING BY BARE HANDS, Check the glass binding face carefully after cutting in aIathe, and degrease by wiping with acetone soaked cloth. Also, degrease the inner and outer faces of new Teflon ring. (4) Cleaning ofthe Surface of Glass Tape (Refer Fig, EL1-43) Clean the surface of glass bind and the si acetone, After keeping the armature at room temperature for 2 hours or longer, dry its cleaned surface with portable dryer. commutator bar by wiping with clean cloth containingel 1 Fig, ELI43. CLEANING SURFACE OF SLASS BIND (5) Application of Adhesive Vasnish Coat the seli-deyng amd hardening adlsive (€X. LHEVIO2N) on the spony glase tape staf. tit ty Adhesive "HEWSO2N" should be mixed completely ie, main resin and har?=yer, Mixture rai is as follows. HEWSO2NA : HEWSO2NB : HEWSO2NC= 100 : $0 -2 (6) Tosertion of Teflon Ring (Toke off Teflon sing thon. the polyester cylindrical jig. (Refer Pig, L144) Tetten ring [— Poiyesereytinariea ig for sotage and transportation Fig, L140 . NOTE: To prevent irom deformation of Teflon ring, Teflss: ring is installed on polyester jg. If Teflon ring is ta’en off from polyester jg, insert it to commutator Vee-ring within 10 {) Clean the surface of Tefion ing by wiping with clean cloth containing acetone. ogosgsdoo0086 2 AanEL 4 {li tnsert the Teflon ring onto commutator Vee-ring insulation, Push the Tefln ing fo the commutator bar end not tc make a clearance between Teflon rag and com. mutator bar eid as shown in Fig. EL1-45. Do not make » clearance Push the Tetlon cing Fin. EL145 INSERTION OF TEFLON RING 7) Daying and Heating ~ Diy and heat around the Teflon ring by a handy type hot air dryer, pushing it to direction of arrow ®), Until the Teflon ring shrinks perfectly on the Vee-ting insulation as shown in Fig, EL-1046, NOTE: This Teflon cing has the praperty of shrinkage by heating. Heat uniformly around the Teflon, ring. E OG. TAMIRel 1 a 9 DARA O00 Commutator Vee-ing Fig. EL1.46 DRYING AND HEATING OF TEFLON RING (8) Finishing of Teflon Ring Surface @ Coat the seli-drying and hardening varnish (ex. WSY-190R) on both ends of Teflon ring by suitable brushes as shown in Fig. BL1.47. a CConing area of fnsing varity x J 7 od i =e 2 i Tellon ig | oe e Fig. EL1-47 APPLYING OF FINISHING VARNISH ees Renee ® (i) Cleaning of surfaces of commutator and Teflon ring Remove the protection cover for commutator surface. Check whether varnish, finishing varnish or any other article does not remain in grooves, and ifyou find them, you should clear them away.el 1 3 3 44 Removal of Commutator Complete Oo When it is necessary to replace the commutator complete, remove it from the amature following the 5 procedures below. 44,1 Cutting off the Armature Coils from the Commutator Risers © ‘The armature coils and commutator risers are connected by TG. welding (Tungsten Inert Gas Welding), © For removal of the armature coils, cut off the connected part ina lathe and remove from the commutator ° tise, (Refer Fig, BL1-48) : ‘ * NOTE: Cut off the commutator riser at minimum required. i Cc Armawre coils 2mm apron) * x sponta eee eeneee Pe } {aparax.) to remove the armature coils. i € Be poua Le Be eee ee = a ate a : Aumeree sal ic ms +— BE Hen | € Rommutator sider Fig. L148 CUTTING OF THE COMMUTATOR RISER 44.2. Removat of Commutator . 7 For removing the commutator spider, arrange the support and split support as shown in Fig. EL1-49 S and apply pressure to the end face of armature shaft by means of a round pressing device. ck aes e k § ry i € i ne on SCEL 4 i sri emai att 2nd SSN k { : | Anti : conor itr Camm sameln : = > eae support ' i ' ' i Gin v 1 as Poca ' : omasresns | ‘ ff 1 : 1 i : ' i 4 ' 1 1 I i ' : : . : 4 1 : ' ' ' . Rubber | romero for armature shaft | g Is t i i x T wens Fig. EL1-49. Removing method of commutator complete ICAUTION: AS FOR THE COMMUTATOR COMPLETE REMOVING SUPPORT AND PRESSING DEVICE, KEEP DIMENSION L1 AND L2 MORE THAN 200 mm.et 45 Removal of Armatire Coils 45.1 Protection of Commutatcr (Q) To protect the commutator surface from injuring under reparation, wind press board and polyester tape round it. Polyester tape -0,18 x 19mm oondap 1 layer 7\ Press boad'- 0.8mm thick 1 layer Dt On On On - 0-09.60 9.0 Commursror surtsce Fig. EL1-50 PROTECTION OF COMMUTATOR € é a (2) Removal of glass band é Cut the lass oands of both sides by using a portable grinder and a knute as shown in Fig ; remove the glass bands Re & Giess cand Aoptox. 150mm c Cursing area (Cutting ares jeune Armature coit Fig, EL151 REMOVAL OF GLASS BAND @) Cutting of armature coils and commutator riser end face. (Refer Figs. ELI-S2and ELI-53) Cut the coil ends at the distance of 10 mm from core end at pinion side with a lathe, then removed + those coil ends. Gi) Cut the coll ends at the distance of 30 min from commutator riser back with a lathe.EL Coil ands aaeeae {commutator side) : : \ Coli ers 7 {pinion se) 5. \ Jj hal Commutnor riser Cutting position of coil ende Fig. EL162 CUTTING OF COIL ENDS Gusting depth is 2mm Welded bead = + Commurator segment bart Equalizer coils —— Fig. EL153 MACHINING OF COMMUTATOR RISER END FACE (li) Machine the commutator riser end face to the depth of 2 mm, to disconnect the cols from commuta- tor sepment bars. ie NOTE: Not included welded bead height, + 452 Removalot Wedges « Wedge Upper coils Bottom coils Fin FI.8& MACHINING NE WENGE (1) Make a clit of 5 mm depth and $ mm widtis on center of each wedge in axisl direction with =illing | \ | | \el (2) ‘Then remove the wedges with chisel or other suitable tools, € 45.3 Removal of Armature Coils (1) Drive a chiesel between upper coils and bottom coils from pinion side, then remove the upper coils, (2) Remove the bottom coils by driving a chisel between the bottom coils and the bottom of the slot. —4$4. Removal of Equalizer Coils, + Cut the equalizer coil at a distance of 30:mm from commutator rise-back with a lathe, then take off iuose equalizer coils. (Refer Fig. EL1-55) NOTE: If the equalizer coils have not breten down, itis not necessary to dismantle the equalizer coils, | = Commutator tiser Z of equalizer coils : (Custing pos Fig EL1-55 CUTTING OF EQUALIZER COILS 48.8 Removal of the Coil Lends from Commutator Riser Slits (1) Insert the chisel between riser and coils leads, then take off the col leads by means of lever action with a { suitable tools. : NOTE: Width of chiesel: Approx. 20 mm ‘Thickness of chisel with sharp edge: Approx. 1 mm ‘ Length of chisel: ‘Approx. 100 mm : Fig, L156. EXAMPLE OF CHISEL i & Gea F E 45.6. Cleaning of the Armature Core Slots r Completely remove remains of the insulation material and resin from inside of core slots with a file or senife. ' 5 45.7 Cleaning of Commutator Riser Stits £ Remove remains of the vamish and brazing filler from inside of riser slits with-a-suitable-file-or-kalfe ¥ completely. 458 Remove the Insulation of Rotor Clamp SRR he Kemove the insulation or rotor clamp fram both sides with knife :el 1 4,6 Replacement of Armature Shaft 1 camages (such as scratching, wearing or bending and 50 on) is caused in the armature shaft. Replace the shaft by following the procedures below. 4.6.1. Cleaning of the armature Completely remove the remains of grease and dirts from the armature by blowing with air and sweeping with Tags. Especially take cate of commutator area such as uicapage on ving and grooving to's between bars. ae 4.6.2. Measure and confirm the following items. (1) Meggering 2) Barto bar check 8) High voltage test ) Resistance 4.6.3. Prior to initiation of the replacing work of th armature shaft Frepare the tools shown in Fig. EL1-62. Then remove beating and collars from bath side, 5.644 Installation of armature shaft replacing jigs (1) Set the annature into body (1) after fixing the centering collar (3) to body (1). (2) Set the fastening plate (2) to body (1), after fixing the centering collar (4) t fastening plate (2). (3) Tighten bolts (5) in tum uniformly, watching the gap between body (1) and fastening plate (2). (Tightening torque : 4950 kg-em) : : Note: Purpose of centering collar (3) and (4) is to keep concentriity for both armature shaft ends, There- foi, both collars should be removed after final tightening with bolts (5). 46.5. Cutting and boring the armature shaft —58-a1 465. Cutting and boring the armature shaft (2) Cutting the armature shaft end at pinion side ‘Cutting the armature shaft end at the pinion side by a boring machine square with the armature shaft as shown in Fig. EL1-57. Cut the armature shaft at the position nearest-the body (1). Fig, EL1S7. Cutting of shatt end FLAY RENN RNR EE AeEL 1 f (2) Drilling the armature shaft Make a through hole of 30 mm dia, parallel withthe center of shaft from both sides of pinion and com- mutator. Further, make a through hole of SO mm dia. in the shaft based on the previously made 30 mm dia, hole. (2) Boring the armatuce shaft ‘After 50 mam dia, hole has been made, bore the armature shaft by a boring machine from the pinion side, as shown ia Fig, EL1-58. if the shaft is eccentric when boring it, the armature core may be cut. So, be sufficicnily careful with eccentricity. Tien take out core key by hand tool. =e 6 MASBKRBOO00DS yA A erst eS a. YF (Frame cutting is ot recommendabie) #13, Boring inner diameter Section AA Section BB Section ¢C Fig. EL1-58 Boring of armature shaftel 1 >: és 46.6 Extraction of armature shaft After boring the armature shaft, place the armattire into a drying oven complete and heat it to 130°C for more than 3 hours. Then, use rags to block the hc!s at the pinion side immediately and place the assembly pes table in an upright postion with the pinion side down. Next, pour dry ice into the hole of armature shaft from dhe commutator side and pac rags to block the hole at the commutator side. At Gis point, put a pressing device on the shaft end at the commutator side and apply pressure to extract the armature shaft, Fig. EL1-59 Extraction of armature shaftea. 4.6.7 Insertion of new armature shaft é * (1) Cleaning ¢ After extracting the shaft, clean the inside diameter face of armature core, and rotor cow clamp and é commutator spider inside diameter faces. é e 4m particular, carefully clean so that epoxy varnish powders, protuberance of cave, etc, are not left in the inside diameter faces. (2) Measurement of dimensivas : he Prior to inserting the new armature shaft, measure the inside diameters of armature core, rotor core GS clamp and commutator spider, and the ovlside diameter of new armature shaft, and verify that corsets interferencs is ensured. te For the dimensions of each part refer to Fig. ELI-60. 1c Armature core Rotor etre Fig. EL1-60 Armature without the shaft (3) Setting the key and ant-friction powder oll coating (@) ‘Setting the armature core key to the aratature core and shalt key slot. Check the dimensions, and fit + the key into the key slot in the armature shaft while tapping the key. (©) Apply antifrietion powder oil such as Molybdenum disulphite uniformly to the new shaft to which, the key has been fitted. (4) Heating the armature Potting the armature into a drying furnace with the arriature left fixed with a jig, retain Bhours at 150 to 160°C for heating. .Removal of jig ‘After confirming that tire shaft has been Gtted to the core completely, check from the exterior and de- Dimensional check and test F (4) Measure that dimensions of each part of armature complete of which shaft replacement has been finish- ed, and be sure that there is no abnormality found in the core, col, glass binding part and commutator surface, : "AS co) Measurement of dflection of commutator and core faces Setting the armature on a lathe, measure the deflection of'the outside diameter part of core and com- j ‘mutator surface bazed on the installing faces of bearsgs at pinion v4 commutator sides. (3) Conection of commutator surface Couect the deflection of commutator surface. 47° Testing Perform the test of the aimatuss complete with new shaft. (See item 6 “Testing") a a wa aR k(5) Fitting the new shaft Place the heated annature stably on.a press table with the commutator side downward lit the shaft by crane with the lifting hook on the shaft end a pinion slde, and presswre-It the shaft Into zhe armature from the pinion side, as shown in Fig, ELI-61. Pressure-fit the shaft while applying pressure progressively at more than 15 tons before the armature cools down, and even after the shaft has been inserted completely, keep pressure applying for about 20 minutes Q oo eS rere VON OA ROR Ae Fig. EL161 Press.inserting method of armature shaft‘ Ue lDBS > P OOD © ORO OrrFig. EL1-64 Fastening plateaE) 2HOLES-¢ 12 2HOLES-M10 (6315S. FASE). Fig. EL1.65 Center FTO EES EE IRFBok nif get 2HOLES-M10 2HOLES-$ 12 (931.5 S.FASE) Fig, EL1-66 Centering collar te ee150, Fig, EL1-67 Clamp i ren ow ae OO Oe Oe yO SEBS aE ceeFig, EL1-68 Stuc boltRAF yey jel 1 "ALA Maintenance of gear case Prior to assembling the gear case, check the following, (1) Check for eracks, damage, etc in each part of gear case, especally in the support arm which sustains the gear case. Where necessary, perform colour check for locating cracks, (2) Chselett the packing (147), (48, (152) of ol sealing ate worn or off, @) Check for loading of the steet woo! (138) of breathsr with gear oil, ete. by removing the coves (135) of breather. : (4) Check for condition ofthe ol fer cap (150). (5) Check for damage in the gaskets of breather (140) ad oil filer cap (150). 4.7.2 Replacement if packing for gear case (4) A packing is In we which provents dil leakage from the gear case and witeel axle. Ifthe rocking is ‘and worn or damayed, replace it wath new one its desicable to keep the spare packing at hand. (Make or purchase the packing in advance following the appended! Figs. ELI-115, BLI-116, ELI-116-). (2) The packing fitted 10 the jointing part of the upper and lower gear cases shouid be cut conforming to the slot of the upper gear case and put with a suitable bonding agent. 4.7.3 Reassembly of goat case : ‘The gear cascs are 10 be assembled after mounted on the truck of traction motor. ‘The upper and lower gear cases are formed as a set and the serial numbers are put on the respective ones. ‘When assembling the cases. do it conforming to the serial numbers to cach other. (2) Oi the felt packings (147), (148) for improving the sliding characteristics before assembling ‘The location of the felt packings applied is showm in Fig. EL1-70-1. [Use muck oil for preventing seizure of felt. Kind of the off; machine ofl or turbine ofl (2) Coat grease to the sliding surface of the felt packings (147), (148), when assembling gear case > Applying portion is shown in Fig, EL1-70-2, Kind Of the grease: Grease LTT A MERE OTE SRE MRIS ARMMEL 5 L ZR _ r # Me a agra he sigma ff ig Me x Fig. BLI-702 {3} When assembling the gear case, first install the lower case and make sure that there isno gap between. the gear caso packing and wheel axle, Then, install the upper case. 41.4. Supply of gear oil ‘fier completion of the reassembly of the gear case, pour the gear oil through the oll ler cap (150). For =~’ = the gear oil level, refer to the proceding section 3.2.3. oa oxEL REASSEMBLY OF TRACTION: MOTOR Reassembly can be made easily hy rewrsing the procedures of disassembly. ‘Party and fools necessary for reassembly correctly. or tw reassembly, prepare aii lean all parts hy blowing, 1 of consumables 54.2 Replacem (1) Packings Replace beforehand’ such consumable as packings (for gear case, ete.), gaskets (for inspection beut | ings. carbon brudies etc.) replacing the worn ones | 2) Particutzily, she lock washers wed so Car eannot be reused, Mike them hefevehwad. 5.1.2 Picparation of armature bearing * Profit armature bearing to the armmuture shaft, bearing bracket and bearing frame with the mner wwe, > \ bearing stopper and outer race follawing the preceding section 4.2 t 3.14 Preparation of commutator Wind a press board-on the surtace of commutator checked following the section 4.3 for protection of the surface and make preparation for reassembly. - Ans gn OS om le> D SAS Tightening torque of each bolt and nut Check each bolt nut for looseness, and retighten as required. Each bolt und aut should be tightened? with tightening torque as shown in Table ELIS, Oo Table EL © 6 Won rb _Tamenetorne | © and nut Mis. value | Stands:d value’ | Max, value a 41.0 kfm O16 keen a 974 | 140.0 G 196.0 Ee EECaSs OLE € nee e f peo [Bee “Ma | 380007 | “sson0 | wo Cc mo. | ss000 | omwoo | ase : t = M36 9600.0, I 2100.0 1800.0 Note: The desizabis tightening torque was follows. Yj Stainless steel bolts: Minimuin value should be applied. 2) Steel bolts: Maximum value should be applied. Magnet frome Deflector (pinion end) Pinion j= (Carbon brush Ingpection cover ‘Mount troction motor on work Gear case Fig. EL1-71 Follow chart for assembly -16 -rN Aes EL o7 5.2 Reassembly m Reassemble the armature and stator following Fig. ELI-74. : 5.2 Installation of brush holders Brush holders (27) are installed to the insulating rod (165) by bolt (113). The insulating vud is fixed to the socker ring by nut (110), and nut (110) is welded to he JockedWhen installing the brush holder and insulat- ing tod, use the pulling jig for the brush holder to caste the accurate brush holder pitch. Reassemble the brush holders (27) and insulating rod (146) by using the jig so that gap (clea dard: 3 mm), following Fig, ELI-72. nee) with the ommutator surface becomes 2 to 4 mm oe Brush holder toauleting rod Rocka rng i ig [ é | i : Foc be rock rng ung the 0 Sia veating hla= Fig, ELIZ 5.22 Reassembly of rocker ring ‘The neutral point mark and serial number are carved on rocker ring (30) and magnet frame (18). When instal ling the rocker ring to the magnet frame, combine one$ that have the same number. Refer to Fig- EL1-6. And then tighten reamer bolt (61) to fix position of the rocker ring after mounting the bearing bracket (33) according to next stage. 5.2.3. Reassembly of commutator side bearing bracket (1) To the commutator side of magnet frame, mount the bearing bracket (33) to which the outer ring of roller bearing is force-fitted ‘according to Section 4.2.7. 5.24 Reassembly of pinion side bearing bracket i) To the heating bracket (10) 10 which the outer sing of roller beating is force-itted according to ‘Section 4.2.7, mount the bearing cover (6) to whith the specified amount of grease is filled into the rease holding chamber and tighten the hearing cover by the bolts (7). t (2) Insert 4 round steet har tthe holt hole of bearing bracket. lift the bearing bracket hy a erane and ott 16 the pinion side of armature shalt,EL assemble the armature and ‘bearing bracket while keeping the busting bracket lite by Bearing bracket DE trates | Fig. EL-73 5.25 Reasscmbly of amature (Two procedures of Reassembly are Aeseribed.) A. (1) Preparation fo sembly of armature ‘The arinature is to be assembled into the magnet frame in the state the bearing bracket (10) Ga the pinion side, Before reassembling the armature, make preparation as follows, {@) To the pinion side of armature shat, mount the liftin of anmatise as shown in Fig. ELI-74, QY Reassembly of armature (a) Lift the lifting toot of armature by a erame, keep the armature balanced and gently insert it to the magnet frame. (b) When the fitting portion of bearing bracket slightly projects to the commutator sido cf magnet frame, uniformly tighten the mounting bolts (31) for the’ bearing bracket (33) and push the amature in (c) Conflem that the armature rotates smoothly. (4) Mount the thrust collor (41) and the outer bearing stopper (44) to the shaft end on the commuta- tor side, and tighten the bolt (42). Lock the bolt by bending the lock washer (43).fae ee Jaen, l a, Wire rope o. 0 Sli Hanger Fig. ELE:74 Lifting of armature m 22 O-D-< O DODO n0¢ SAOAAA € eS Becsaiarias G Fig. EL1-76 Reassomoly of roller beating inner ring and inner bearing stopper [commutator side) -Fig. EL1-78 Heassembly of roller beating inner ring and inner bearing stopper (pinion side) Et Fig. ELI-79 Bearing bracket (pinion side) e REE Rape VEpeenBMARET: eI STEFig, EL1.63 Magnetic frame (pinion side) DOTA A AAMARAGSO.0.9 Se er ar ‘ak Cy a “Oy oni S % x xsesame EOE ERR RTE EAR EC saryRO&9.8.0 096 Fig, ELI-BR Reassembiy of armature Fig. L189. Runssembly of armatuteer aeEOS OPK KIS Fig, EL1-93 Sot the bearing stopper and tock washer € Cc € c 9.6. Cot a cane Fig. EL1.95 Look the bolt of bearing :isapee veB Reassembly of armature (Reassembly of pinion-side bearing bracket and armature) (1) Pave to reassembling the armature, fit the pinion. a us bearing bracket onto the armature shaft, ant assemble the armature and tearing bracket together into the magnet frame. For fitting the bearing bracket onto the armature shaft, lay the armature and lift the bearing bracket by eraie assivown in Fig, ELI-73. wert the armature into the magnet frame kept upright, with the armature lifting hook installed on the on side and the armature lifted by crane turning the commutator side downward ove eforchand the carbon brush. Also, be sue to Us sure to keep the magnet fame upright. Don't UIC it. IF the magnet frame is lett tiled, whew ingorting the amature into the monet frame, the commutator andjor amature coil contact the and results in them from brush holder, osin pole coil, interpate coil, et damaged fom tine When inserung the armature, sevew guide bolts into the bearing bracket clamping built holes in the magn frame as the guide for the bearing bracket. Lower gently the armature keeping lifted by crate. Do not lower suidenly and inser ih sassemibly unduly: otherwise bruise is caused in the bearing inner race face, When the bearing bracket las been fitted 10 the due part of magnet Frame, remove the clamp the bearing bracket with the bolts. (Refer to Fig. EL1-98-1.) Ti bearing, bracket bolts while confirming that there is no abnormality, turning the armature So fong as the armature is assembled correctly, it ean be turned smoothly, but if it fails to sinoothly.se-tighten the bearing brackei ctmping bolts uniformly. (Refer to Fig, EL1.98.2.) ide bolt and eassembly of beating stopper (44) at comnuutator side Atter the amature has been asembled in place, lay the motor, install the thrust ring for cylindrical roller bearing of roller bearing inner race at dhe commutator side and bearing stopper (44), tighten the bolt MIOL3S (42) and bend the lock washer (43) for fixing, RE RRR IRE RESgece ooeoowueys ww EL196 Set the beatin aode Wes Fi,et 5.26 Reassombly of comer Wt sie bearing cover ai pinion side outer heating stopper (1) To the bearing bracket (32), filled into the g bolts (9) jount the bearing cover (38) bo which the specified pe hokting ch setion 4.2.7 and tighten the bs mount of en cover hy the (2) Mount the outer bearing stopper ($8) on the pinion side by sh 120°) Kft ting tne jst ¢ HE heating temperate 10 ~ (clean the pinion watl Kerosene 4 Whe, Oy portend ioe tally auth ant the Ho the heae str sce a fot, ance BE thei sion shown tie ig. ELI, HW micasaseuient as povtonned wale dept Vip, ELI-100 it ean ie easily Ws elitly val the Shalt, Een mcasing an essa eX des a dwn (2) Newt, renee i pinion and check dhe stute of cutact heaween the Hhegsstyt 9 bio that MOS of the Heamens rent let sepa the howe safe tite panna. (3) im Je snd hea he vin for abou oa har kre a Rese to a ep eo TOP ee te room temperate. 1s he most portant tke Temperature a oil bi accurate. Be sure, therefore, 10 control acvurately tne temiperature of the kerosene (4) Alter the heating work me bee completed. temuce the pinion froun the ail bt rom he pinion suk ce hy air hlowing as fest ax possible ind remove the-ail Perform shrink ftting of the pinion cunfieming that the temperature uf pinion is 10° danse the foo temper, ptng oe he als hse ait saad te pie, Ten int a igh ond ol 1S) Alter the pi 7 cs ie a wt ee i i, HLS) : Mae se shat albicance vote hat on is = eotemg to 1.92 mm 0 00 mm ¢ "i € be dimer betne rik ¢ e {ten sink € hig, are the : igen the pinion st C peeing slik fi he punion catering allowance 1s satisfactory, insert AE the pinion en allowance wit sabsftcteny 1 4 ws must he denne anit jcatoet tevalt eave bea attaned, When c the sok of weassemiting ite beet eompleted, a thoravgh chieek: mast he nile ot all ysis Ho sake sure that not of the parts or procedures have been omitted and shat packing of th U ‘been neglected. erease Ins not inspection aid test in aceudanice withOE COO OCOD DOG GW OR URE Ie PFT o Te nema eee diamnatt Fig. €L1-98.153 elo Prmon L199 Measurement dimension. between pinion and shart end Fig, EL1-100 Measurement of dimension, between pinion and shaft end Precaution for Maintenance Fhe following stems shall be psoisibeted sm aggutar inspection and ther eecasions tase Furious tenes niay be eausst snot 11) Never strike tlhe comnts suifice, the commutator sleeve and rier. {High-har or fow-nar of the ‘commutator may be caused.» lever stuke with LL Incase that the 98 phan hit ae ro eit polish with a file, the glass shall ne suppstes fy the sonst Pheretine. a shall he heures prepare a special stand for the armature, (No oil shall be theve on the commutator surface ar the carbon brush. (Bad commutation or abnorinal ‘wear of carbon brusit may be caused.) roy fee shall never be somaved, emf the: ss yee agen satel os or ust ane se on. (ihn aus of cranamuatation may geket (5) The commutator surface shall never be polished with sand-paper ora file, (Bias-wear or defurmation ¢ commutator surface may be exused.) 46) Never apply stone to the commutator during highspeed operation or in vibyation. (Biaswear on deformation of the commutator may be caused.) 17) Never tet fali the brush spring upon t uyured.y s brush head quickly. (The brush tay be Before inspection «r replacement of carbon Brush, the brush sping shall be hug onthe supp the brush holder, the brash spring shall never be feft up but set downafterinspectinn or repiteemes + carbon brush (the fifted brusl may eause flash over). (5) Neyer conduct clectric curre the armature. (The « bar caused.) (ino Tess than 60% of cated current) ts the auanature eiteurt, lod act surfaces of the commutator and the brush y get overheated and high: +) when highs-bar or low.bar of the commutator is mere than 3/100 mon, ren it soon by machin. “ fone, haul commutation late: lay be promoted and wearing of Srush hastened), n Ft by machin: i of the brush shall be checked s0 as nui ti use it over w: ang it ewes apply the bush of different grade or of diftezent form, (Bad commutation may be caused.) (EL) Other precaution (a) When the tract motor is to be sent to.Us for repair, fitting for transportation shall be attached se that the arcsatuce may not move, IFUL is transportation without fittings for (ransportat 1h) When the disassembled traction motor isto be sent fe is, be carefull in packing o transport nethod s0 35 aot 10 Uamage or loss any par of it fo) Whe wher paint. the name af the +ypatates (AW), same ture number marked on the name plate and {rouble condition shall be fully informed. you reter ba us Tor troubles or anel 5A Installation of the Traction Motor The motor suspension unit is mounted to the wheel axle. Fit the traction motor to the motor suspension, ‘unit with reference made to Fig. ELI-132, $4.1 Clean carefully the connecting face of axle suspension tube with a dry clean rag as well. the surface on the magnet frame. $4.2 _Lift the-tractiow motor with a crane andline-the mounting face at ante side of tie motor upwith the con- neeting face of suspension unit at an inclination of about 30° 54.3 Lower the traction motor gradually toward the suspension vinit and fine up the axial pe:ition so that magnet frame can get in between both side faces of suspension bearing housings. 544. After the action motor has been pt on the suspension unit lower the traétion motor gently intl the keyway surface of contacts the surface of suspension unit mownting fang: correctly with the weight of traction motor. SA.5 Tempoarily mount the motor suspension unit (159} to the magnet frame using hex head bolts M36x 110 (70): Refer :0 Fig. Fig. EL1-101 Mounting the traction motor caution: ‘When mounting the traction motor, the earth brush holder should be removed from magnet frame not to {injure the earth brush and whesl axle during mounting the traction motor. RUE eR:EL 4 a 5.4.6 Hex. head bolt (70) tightening torque ve 12100 ~ 14500 kgf-cn G oS (1) Tighten hex, head bolts (70) equally not fully tighten cach bolt in a stroke. the order shown in Fig. EL1-102 by 2 minor extent ata time, Do ©” Motor suspension unit On Me Sa, So Oe 2 ~ Op ran ELI-102 Hex, head bolts tightening sequence Oe (2) After hex. head bolts (70) were suitably tightened, lock these bolts usiag locking wite.as shown in Fig, ELI-103, a Si Bolt loosening direction Frm fsten at this point ee “, EL1-103 Locking bolts with wire NOTE: Exercise care in the wire stringing method in order not to allow the bolts to become loose.pena VOT = RELA 9 eu oy (3) Afier the traction motor was fitted, apply sealant (ex. silicone rubber compound KE4S-RTV) to portions {A and B showa in Fig, BLI-104 for preventing cutry of water and dust > onl | HT 1 Li ‘Apply seatant in the as roboth portions Ana Fig, EL.1-104 Treatment for water and dust protectionUl : | Pt in 7 a I a | |eu 4 vel, 1000V wneypet. The insula oF moisture and thevetore its very difficult tu determine the 5 seatstanee ts greatly influenced we al by the a is hes thon L megolim, this vale she be considered amdesinable for service fesistance I exiiennely fa, cic eating mast be investigated. Ay carbon dist apound the ne, ou the crnimatos surhge averages the spparcnd insulation resistance, the final cheek of Hie msulation resistarice Soil be dene fo the cleaned wiacline:EL 63 64 Db 3 IF the msulation resistance dvap is due 1o the absogption of marsture, hy So Dielectric Test ‘The machine passed the dielectric test can be supposed ty continue the safely operation Fara without electric breakdown, The test voltage shall be supplied with testing aust le ELIS. pe The test voltage for the machine windings is shown, Table EL1.6, Test voltage (V) Kind of winding FST ance oO & OF Or O © 0 Ail windltigs 5,720 | 3,432 ~, Dusan: of test = F minute The test voltage fur sed nding. 605 of the vuitage for the new winding, - = the high voltage deter nv deterinn thon Into aeewant for the wld latiess materia, we must take especially this ins Polarity Test ‘The polarity test must he done in ease the field poles or the lead wites haw been replaced, N polarity aud S polarity must be distributed sltermately in rexular urder, When cheeking the polstities, suitahl> direct OR corrent is supped to the wing accordance with connection gram ee The pole. which aitricts the S polarity of the magnetic needte. is N pol and the pole, which attracts ae the N polaiity of the magnetic acedie. is § polarity. & » 4 Voltage Drop Test for Conunutator Segments x i Fg. ELL1467 dveot currents applied 1 he armature wi ye tor seyments, Thr voltape dip between the commutation segments 1 ¢ & D.C. millivotimeter (SOmV), “The variations in the w less. than #84 of the mean value.” If there are extrer ceither that the joint on the conmuutator riser hiss come ie drop between commutator segtents must be ly arg tions in the voltage drop. This means we oF thal there is.2 show circu winding Therefore. in such cases thorough search snust be made for the eause. and Jn making these tests, please ante that it an ‘nested. For this reason, the current applied du of the machine. rouble must be repatted -eewsively large current is applica the winding will be were js {esting should he about 20 ~ 30°% of the rated current Preewutlons: fn case wf cary be given to the fet that sot voltage chop tests the commutator sano xd on and wif by mieans ut the elect ast with the commutaton, Thos 1 because the commutator segment will he damage by arcingit the RE ‘and ff. oe this rea, iis abnoluely necessary ta use the knife switch the rent- myst not be ste electrodes are switched ‘current on and off. Electrodes tar eusrent supply ure eatbon brushes af copper bars, Copper bars as the electrodes shall be contacted on the commut brush way. jor surface witich is emt of the carbonel 4 oe Voltene source Fig. EL1-106 Voltage Drop Test Applying direct eugent to the winding, measure the currentand voltage drop with DC ammeter and DC wtinete Resistance of the winding (R )is Jeterinmed by the following formula, whew é Vo Voltage drop ” 1+ Curent w no Wis ng temperature eo The suitable current is abe 20 ~ 30°F of te rated current, Excessively large current heats the winding sind decreases the measuring accuracy In order te the resistance Rey at "tne Fellewing fo wed. Temperarane Tis 110°C. ‘Contiany tha vale of th eu resistance eoineides the value in the inspection report ee LIEWhen the measured value is either exeesuvely large or excessively sinall in conypirison with the value a may be Fault on conmections of leads and in the latter cas the inspection repurt, in former ease, ee there may be short-cueuits inthe wi a 7. DRY.OUT ‘The dielectrie stron OF the insulating ‘machines is appreciably reduced by e absinpe tio of moisture, Wiica a mashing is put inte operation for the first time or when it has been ot af eperation fie Sem time. reasurcd before pulting the machine into operation, and dry- med if ce is found eut,to be extremely low. 1 is particularly essential 1» perforin diya + the machine has been immersed in flood waters ar has covered with seu water. !F thew Monod with dirty water, dey-out is carried out after the mud and dirt hus been completely fold water or with warm water. Atics the machine has en inmmeved in sea water, water with a tsmperanare of 70 ~ 80°C. and then dried afterall of the sa lation resistance is mn resi ust he uncrse ls be ee 4 TO Ce Oe Qe B 7.1 Dry-out Condition fag dynes oe te eget the om tion mate re inside the ine fal “The Iry-oat time is deter at by ae satel he 5 a6 the amount of bunsslity insile the insulation snatesial, the temperature ant the at elociny a Ce rererre rr eee ee eee aera rae the danage om the insaation moter. During dry-ont the sureunding sir should be wep! stat & tines the sitale aed. antes the ait absorbed the muistre evaporated fon the auton mieisl unl the exehange af the moisture fiom the insulation Hevial to the aie will be disturbed The ait webveity i O.2mviséea Insee is suatable. a a 7.2 Hot Air Method This is miethod of hea the machine fiom outside, The machine is placed « heater of shout 1 ~ 2 AW is placed shout 1a ‘Suitable covering oF suitable pit. and et below the machine. The mac mvas ot the Hihe, ani heating is performed taking cave th ot stnpass 80°C. nd the in suirontnded by a the temperate of Sunable holes are provided on the top of the euvering so that the bet sit it is citcalated, Care must be taken euncerning the position af the heater vs as or pethiog.detaele 4 elay is the most efficient anal reliable hea When separa sleying bythe hot aie 1.3 Electric Method sng by tarang the ‘ciaper wisting Wen th fue andes te Loop i wa edd without rotating the mach the wi eaten te pe Ht ing. he cucient applied to each of the windings she ated cunient ot ay wt ang. Particaar care Show be taken wet te apple at escessny,|sine this will overheat the machine and cause deterioration of the insulation and bue As long as the insulation resistance has dropped extremely low (.c..28 long as itis higher th: A will also be possible to restore the insulation resistance te a certain extent by perfacn ‘uniming oF lightload sunning. o1M), wg norload 7.4 Insulation Resistance and Dry-out Time —- The relation between insulation resistance and dry-out time is shown in Fig, EL1-107. Generally speaking, the insulation vesistance deops tetuporarily due U6 the extremely high humidity expelled fons the insu ling temperature rise, material ann the wi Attet the winding temperature has $3 wisture is expalied gradu J. the sasulation sexist eases gradually and then levels if because the ind earsied away by the surrounding ait, Was sesirable fo etd) angulation resistance te be restored over IM wf the het state, Atte ot, i esate oaypletion UR, OF RE IGE: EN temperature, takes about more than 24 hooes fur sie complete dry -om resistance aud the During the process af dry-out, I he measur at the suitable intervals in orde: rE aeemate tnt 1 at dry-ut condition, Wong emperstore oe ‘naulation sistance Devout ne P Fig, EL1-107 € . © MATERIAL FOR REMEDY AND SPARE PARTS © Preparation of Matesial for Remedy and Spare Farts the arcing bolts worsening af the packing oF ally wnexpected aecalents causes lass of ct shall be repatest oe esphaced with 9p pie aol eratertals foe seamecly’ cot able BLD, natertals shall always be prepsred shove antes ate sted mp anEL a2 83 The number of quantity of stored purts and materials shall be ghusen accord mn motors and service cond because it varies with the number of tra Inspection of Spare Motor When the spire motor stored Toes longi befure operation acearding tw the following is to be used. it shall be carefully mspected and adjusted (1) The inside of the motor chall be cleaned by using compressed air; and che commutator surface and the Carbon inush shall be inspectee 7 (2) Insulation shall be checked with a Megger. (2) The bearing gr-nse shall he checked. I the grease becomes wouse or has any abnormality, renew the grease. (4), Drive it about az hour at rated spec with D.C., low voltage (approx. 100 ~ 1SOV) end checked abnornalit, Caution to Storage of Spore Parts Du ‘time, he caretul ubout the lollowing items, r spars parts are stared for a ton (1) They shall never be placod at a place of high-tempecature or high-humidity anki never directiy on ste o ground, bul ong suitable (2) They shall be kept ia damp proof bay ig silicage’ so us not to become damp. (3) Anticorrosive paint shall he applied to the area which easily gathers rust, (4) The wolder, oF ke Wound around the camautator susfage, (The hugh shall never be ke} commutator surface, Otherwise, a brush mark is made on the commutator sw Zice by Hong.tecm pressure of the brush and various troubles may be cyused.) vuntact with paper b diver contact with the ° ° © © é é é € ¢ é ey : & Oe Or ar aC. x Foam at ee geTable EL1-7 Consumed mater et list for maintenance aryiet | Fig to, | Ret. Remarks 1 | eus08 Pinion 1 | eirs0 | outer bearing stoppe: 2 | eu | Neto ae nit 5 1 | euete Inspection cover of magnet (me 6 1 Cover of mageet frame 2 8 ' \"o tt 2 Rubber plug Amature shaft 1 | eommutator ie [| eure Pinion side 18 t EL1-120 | eur Earth brah __ eta tec | evs | Each brush SHELL ALVANIA No. wm: RO OMEFig CL3-108 Lock washer for pinion Cote sted earn si lls G 31011 9 ORO Oe Oe OO Or O OO * we ¥ & ‘ ¥ uFig, EL1-110 Lock wasner for ou Fig. ELI-AT1 Gasket for not of air inter wosSestion A A, = 901 Fig. ELI-112 Gasket for inspection cover of magnet frame ‘ these Oe Ow OOO OO Oe Oe OO O.0.0.0 0 < al tna oh gh od ak Daa eas Or a On Da Oy. ee, Pa, Desee ead) tee eeovte ayia LES 424 | i i i ! | 7 \ 4 i | le 287 al Fig. ELI-113 Gasket for cover of magnat frrme CHLOROPRENE RUBBER. (WISK1380)100 ae es 43 Polyeniovoorene nara 40 + 5 ' | | | roreorere ubber (1883801 POLE OO OOOO FOTO SE fae 4 noteso12 Fig EL1-114 Gasket fur breather of gear cateIS G3141)_ GUIDE PLA“E (SPCC-1.61; JIS 63141) is (3201) \ ovine iro Two PARTS Fig, EL1-195 Packing for gear case “oS enn es } WOOL PRESS ern “A AA Dory CROSS-RECESSED HEAD MACHINE _\, AD MACHINE | SCREWS (SWRMIO; JIS G3506)_ SIZE, M36; JIS 81111) SECTION AA a3SIFT POSITION ONLY ONE FLACE PLAIN WASHER (SPCC.0.8T; JIS G3141) 81266) \ GUIDE PLATE (SPCC-1.6T; JIS G3141) Serer Na LOCK THE SCREW BY_ kK PUNCHING AFTER _ SETTING 6 \ os | \ «| est & ‘e258 bee) , LA) es WOOL PRESS FELTAT,” 1.6 (NS L3201)) -SEOSS-RECESSED HEAD MACHINE SCREWS (SWRMIO; JIS G3505) (SIZE, M3L6; JIS B1111) SECTION AA DIVIDE INTO TWO PARTS Fig, €L1-116 Packing for avar caro a i a RRR SVN OAOFABOeoseoo000005uaa yam ey EL a A ( / < He es me ores ot eos fais 3200 f Fig, ELI-116-4 Packing for gear case : Potvehtoroprene hardness 60 ~ 60" Fig. EL1-117 Rubber plug for arinature shaft° 9280 6.025 21385 t | ~ 9.002 1 A 0120 “pure i : | 9 i | : . [Rosina cearce | 0168~ 003 r Asi lent searnee 2 ‘ ‘Basie dy rnc load rating € | 44,000 KT : ai aad ating © | 38.500 Tolwance claw TiS dé Fume stale 3 ing, NSRHANCSTTEEDsy + ¥ 1 12007 Fis. EL1-10 Roar bes ~ ee Beare mu. Godt Geer a a 5 * 6 Te ah pe ok Ca Ge OOS OL L-TAORaagads .f | C el ee ate Se aoaige | RR Se swe mae Tse a 7 : ier i ! |" Sane mEmTaRaTaaA e i ! els i 2 |g a : 813 E \os be |e Fig. ELII19 Rotler beiring of commutator side ERR PERSE En ! BET2) ys z rurnot 24 k nusseng # ay § QOB X37x3xX7-4 149 Material EG-A16S oF €C.105. s7 WEAR LIN (BOTH FACES) €L1-120 Carbon brush ye en) Oracee oOgs EO CRU COR OC OLCED 1aMOOVODOVD0G; 3 3| (= ot ” ae An al 9 a ig HU HH sccm. por ict th ["(eanes ¢3002 + HzO) | Chins Tr SOUR Febeee came a Soret ao ATH BRUSH __ (rETAL GRAPHITE) L743 Fig, 11-121 Ear'h brush |17a Spring pre:sure at assembly Brush height 64: 3.44 kof/Brush £ 10% Fig. EL1-122 Assombly of brush holder Brush height 25: 2.82 kat/Brush ¢ 10% PTC te COROTeeu Fig. EL1-123 Assembly of earth brush holder * seo aE rape MRE Tee wwe we nineteen ni te poreatisay pur arascond 903 (F ete ane PaNOM 9 HEE UN lowe) fe osiig gO acl bs peo eB oH ee Ney ARSENE Fe sone IAC AP ono ct eos opts 1 os ps syst snag ” yelp “pana Secon seaas aes, aes org qu wee oad JF pre 81 pe fev amneensy Spoor pave seas sab ainssond ands sdandery ¢y Auypene sodouduey (2 Ses ugar 30 ere | ARN JO ROK ws 7 soupy je fares ae wo sunrag td ae mld ows : igs feuay a8 apes, 1 woqeey oy evra sae sata: pojgnony ONY VNAWONTHE4. Other parts 1. Bearing, Trovble Troubled Possible i prenseecd ih phan Inspection and remedy Trouble of 3. Commutator "| 1) High-bar, 1) Color change. unequal oxygenated film ‘commutation low-bar, abnormal wear of brush may be caused | deformation, the fash over. Polish commutator i omality surface with lathe. 2) Joggle wear 2) Weis er brash. and roughening | Polish commutator surface with Jathe | of surface 3) Bad chamfering or bad under cutting 4) Shorting the bars by dust and foreignes between bars 6) Black bar 7) Vibration | 1) inadequate 3) Reform, 4) Inspect and cleaned. 5) Cotes would be change at abnormally high temperature, Examine ventilation and load and adjust 6) Adjust commutation, 7) Examine radial clearance and lateral clearance of besting, vibration of truck, and unbalance of atasature. Abnormality shall be adjusted according to the maintenance data 1) Color of commutator surface may be condition of riser, layer shori of armature coil. j 3) Slip or skid of wheel | 4) Over voltage, ‘Over current, 1) Bruise, scratch, rust changed (ex. black). Adjust. i { 2) Roughening of commutator surface. |” Machining commutator Prevent the invasion of water, 3) Change limit current. 4) Examine safety relay. 1) Replace it with 2 new one. = 119 Sperm eC I Ee RRR ENTERSTrouble Troubled Possible phenomena part cuia Inspection and remedy Over heat 2) Improper 2) Replenish with new grease. quantity Apply proper grease. degradation or improper quality of 3) Improper 3) Check attaching and adjust it. attaching, Cheek clearance and replace it with ‘itting or ‘g00d one. clearance of beating 2. Coils 1) Layer short, 1) Find trouble part 2nd repair it. \eakdown, | ! pie alle wll) eed 1) ape CT | { insotasson inguleton of ponent shall ie systematicslly | i ceil,commu- | examine, Soa to find trovbled pat i tat, lead ie 2umaged part acconting wir, inner to lnslation. | connection, i ' brush holder Oilleskags | 1. Armature | I) Improper | 1) Check the queatty of pease iearing quantly grea exe 2. Gear case 1) Excess charge of gear oil. 1) Check the oil level, 2) Bad packing and oil sealing 2) Replace the new packings and oll sealings, = 190- SOME OO 0% A058 Oe Og Oa aed, Staeataacerale ‘eine Salt th hathPas eu 10. INSPECTION ITEMS Tobie U9 3 Inspection interval | Remini z Inspection itemsand standard! or pera slasizs| s Note | tee 8 | He llega £28 | 88/88/28) 68128 esis eB eelesles SzlSE|ma1CE BH eels T, Trieion motor on ner (4) Appearance on generat olojofojojolo (2) Attaching: O};C/Olo;olol|o pa | (3) Louse | ojo}lolo dana | 14) tnvasion of Just and olsfolo Condition oF tad wie, cfolojo (6) Gil leakage of bearing olojojo (7) Grease adding to 0 | 0 fm armeture bearin; aoa (8) Grease adding to motor © | Oj 0 |Z Baers ‘suspension bearing Sle Eglo 2. Armature j 2.1 Glass bind (1) When damage is great by, Ee ° are, varnish i discolored or as be s down, renew it. 22 Commutater (1) Diameter: 400mm (1) 380mm ° (2) Bceéntricity 2) O.lmm ojo (3) Inequality in diameter (3) 0.0Smm ° (4) High or ow bar (4) 0,005mim olo {) Under cutting olo dep: 1 2mm (69 Chamiceing sharp colo cae toftng: 0.20Inspection items and standard Repair lit ‘operation Inspection interval Trip. Inspection Month inspection ‘Intermediate (yeas) L Note Overhaul (years) G7) Width of riser: 20snm Ta 4mm (exclude TAG. welding) (8) Difference of voltage drop betwees bars within 5% (9) Diclecisic test newly manufactured £5,720Y/1 niin repaired 3,432 VA min 2.5 Armatur (1) Cleaning (2) Layer insutation test (When winding is renewed, ‘vacuum impzegnation of solventless epoxy varnish stall be applied for insulation. During inspection or ir, be careful sas + ‘ot to damage coils.) Dismeter of shaft bearing fon commutator side: 120mm (2) Wrap of shaft (Deflection of shaft end.) ‘Taking off, cleaning, inspection and olling of bearing Jntesference fit shall be applied to inlay of Snner ring of roller beating and shaft of Binion side, Temperature of heating 110~120°C. Interference on the pinion side. . @) 1) 150+0.068 +0.043, 120+ 0.059 +0037 | ey bess than 0.03mm | | ry \ ° OOO Om mw me ehe1 : Inspection interval Repaic limit ‘or operation range Inspection items and stondard ‘Intermediate Byer) Overhaul inspection inspection monthly inspection Yearly inspection (4 years) | smonitly Monthly | (5) Interference fit shalt be applied to inlay of iancr | ting of roller bearing and shaft of commutator | side, Temperature of heating 110~120°C, 1 Interference on the { ! | | It J ° Ti inspection ‘commutator side. (6) Radial clearance of the caller bearing on pinion side. (7) Radial Gearance of the roller beating on ‘commutator side. Interference fit shall be © 6 applied to inlay of i | Piston. ! . Interference Heating : { ‘Temperature t 125~130 deg. | (9) Contact degree of 1 semature shaft and taper | : % of pinion shall be more! \ i than 90% 90% | j ! 1 Jf (10) ts sonic and magnetic particle testing shall be carried out about shaft. 3. Stator ‘ } ) 3.1 Magnet fame (1) Dimensions of mounting | parts. (as shown in the Arawing of right) i He 40.2 B = 4623 105 403° c= 105 *3 p= nan 19.052 E = 30520.75et Inspection items and standard Repaic limit range ‘on operation Inspection inspection Monthly Trip 3 monthly inspection inspection 6 monthly inspection Intermediate (years) Overhaul years) Note (2) Dent of pole retaining ‘bolt shall be filled ‘with compound. (3) Width of key way of suspension bearing. 44) Renewing of packing of inspection cover, 4.2 Stator evil, lead wire and connector (0) Lead view snd connertor shal! be place mote than Smmnv away from magnet frame and brush holder (2) Lead wire with damaged covering or damaged terminal shail be eplaced. 3) Damage of core of ead wire and con- rector may be used “3.3. Brash bolder and carbon brush (1) Cleaning and check (2) Spring pressure {at assembly) at brush height 64mm, 34k fforush at brush height 25mm 282kg‘]bcush (3) Dimension of brush « holder pocket ‘Thickness 20 +0.1 mm 0 Width 40.15 baat) to. 400 sbvery 4 years ° ° + Less than 10%, 3.10~3.78 Agffbrush 20.3 mm i i | | 403mm | MA KOA A LAAs me CAAAEL 1 Inspection items and standard Inspection interval ‘or operation range Mouhly inspection 3 monthly = spectinn in 6 fcpection Yearly. Intermediate @years) Overhaul (4 years) inspection Note a) © @ M Clearance holder cease and commutator surface Gap: 3 mer Inequa'y in gap Distance between ‘brush end face and ‘commutator end face 4 mis Length of carbon daush 64mm Chipping of carbon brush Breaking of pig tal of carbon brush Service limit 25 zim Exchange limi: 30mm Loss than 10% Loss than 10% ° ° a) 6) @) @, 13.4 Gear case Check the gear oil level. Check the packings of gear ease. Worn packings should be replaced. Gear oil eakage. Inspect the breather clean the sigel wool in breather. a) @ 8) (4) 4, Assembly test and others Bedding of carbon brush Delete est ‘Newly manufactured 5,720 V/1 min. Repaired 3,432 V/I min. Insulation resistance test No-load test amine abnormal vibra: tion o abnormal noise. (5) Load test ‘Watch commutating 3,432 V/I min, More than 1.0MQ [At exchange ommmege ere —11: ATTACHED DRAWING Explanation drawings are shown as fotlows Table EL1-10. Tele EL1-10 Attaches drawings lst ae Fig. Nv. Desctiption EL1-124 | Outline drawing of 630KW traction motor EL1-125 | Longitudinal section of 630KW traction motor EL1-126 | Cross section of 630KW traction motor £L1-127 | Armature bearing assembly of 630KW traction motor ‘Terminal box assembly of 630KW traction motor ELI-128 ELI-129 | Rocker assembly of 630KW traction motor Inspection cover assembly of 630:.w tcaction niwtor ELI-I31 | Gear cas: assembly of 630KW traction motor EL1-132_|. Assembly of motor suspension unit EL1133- | Connection diagram 630KW traction motor EL1-134 | Assembly of earth brush LD.O0 OD faite! KROL th Cathe9 12 93,18- 15,18,17 18 19,20 20,21 22,232.28 28 27 a8 29 30 : : _ alee Dey hee t ; f e - 33 z 435 Fig. EL1-125 Longin oe Pe a a RE CO Oe MeO, Be Be Oe O- Oe On On > 6jetion of 630 KW traction moter Fig. EL1-126 Cross se RL IL ETT PSOE OE TET RN“le ce 11,12 3132 | ie 10 ears aa NX mare fel : —— ry ies | 233 8 V f/f os \y a) 4 : Fig. £L1427 Armati 9 assembly of 830 KW tractor. moter Oe OY na -~ ein Ai at i le 8s ae a. Me. as, Na ee Os Te Se he OOOO Bo= Rp. 78, 79,80 78,79,80 Fig, EL1-128 Tetminal box assembly of 630 KW traction motor _e-EER ES RRR VsNRRERNRIMRAINZSETS Is RN Peer agemf 107,108,109 a i ~ 102,103,104 1 SECTIONBB | 110 101 ‘ secriowaa | | 34,35,36 itl 7 he» i 73 7478 6182 - —— 61.62 SECTION CC Fig £L1-129. Rector va op E12, Recker a CARO ae mo OD Oe Oe MD. O-O OD: OD © PO a Ni abs al a aSEMEINRR STREET TS RRR EFITOOSOSFOOAOTOIO:vu VIEW AT COMMUTATOR SIDE VIEW AT PINION SIDE. AA 4 E fF sage Lc Fig. EL1-133 Connection diagram 6301: traction motor SARE RNR Pees So TS ae LeFla, ELI-I32 Ansimbly of motor scspendion nit | POSE ES SOLS ORIW OREN OT OOO ANS OOAaGSSOSa9 05elt 12. PARTS LIST OF TRACTION MOTOR 630KW Traction Motor (Fig. EL1-124 ~ €L1-133) if Description Ory ier Remarks 1 Rubber plug 1 2 Pinion nut 1 oS NE seer Magnet frame Ta L [pei 30 ced ‘Spring lock washer E 2i_ | Bok M2010 22 | Commutating pol 23 Commutating pole i : 24 | Commutating poie 25__|__ Commutating pole ' a 26 | Carbon bruh 2 Brush holder assembly 28 : 29_| Roller bearing fe 30 Rocker ring * : _ [[a [Bok 20 v7 c 32_| Spring lock washer M20 ¢ [ae] Bowing beastot : 3a | ‘Special bolt M2476 4 3 Spring tock washer M4 4 | f -1aR =a nes ensnncnnaanatiehinineetittiaimaldtan tle BE ae Cale / ” / eo ye : 476,177,178 eae 172 167,168,169,170 a S. c A ™ | \\ Motor suspension tube ~~ toa Fig, EL1-134 Assembly of earth brush SPC a ee ee Oe FONE OOOO OOO AOE OCO VONe Description Orty/set Remarks, m B ~ cca 38 a 7 1 7 73 Bow Miz 125 oo ; 79 | __ Spring lock washer M12 8 ef 80 Washer, M112. aaa et | BoRMiZE 8 82_| __ Soving lock washer M12 a 3 |" Washer Miz 3 I 92 | Spring lock washer M12 [4 [83 | Washer Miz a) ‘94 | BoleMi2i6s 8 eee 95 | ~ Spring tock washer M12 8 [96 Washer M12 @ 7 97 Lead wire a 4 (ALINE) 98 Lead wire 1 (AA LINE) 99 Lead wire 1 (F LINED 100 | Cead win 1 (FF LIne) | 108 Handie 7 (Turning iever) | 102 Bott M12 L25 6 103 | __ Spring lock washer M112 6 ~ 6 6 12 107 Nut Mi6 te 2 108 | __ Spring lock washer M16 iL_2 108 ‘Special washer M16, ea ‘ 110 | Lock nut 24 6 111 | __ tnsutating rod 2 TT a a. SLT TEREST: 70 APRN HO ogISN INSANE onmaeeRfee Description areyiset Semarks 36 37 Washer M24 4 [33 | Bearingcover 1 29 | Bole MIO Las 42 _| Spring lock washer M16 [4 lounszancstreereal— aa Roller bearing 1 42_| Bok MiG 136 3 1 7 7 1 7 7 wit tet Tet 7 7 : dl Ter bearing stopper 7 Roiter bearing 7 |INOS20EANCGTBBEPGAT Outer biearing stopper 1 |(Deflector} Special reaner bolt M20 1 [fOowel bart Spring lock washer M20 1 Tnner bearing stopper 5 Earth brush enembly 7 ‘Specie! bolt M36 L90 = _ Spring lock wosher M36 2 i Bolt M36L110 a ‘Spring lock washer M36 8 7 7 ao OO OO & ete eam me OKO ORO *eL 1 Description O'ty/set Remarks 150 Oil fitter cap 152 ‘Taper rotier bearing 7 11349547, 345510 k ; 153_| Tope vole bearing 1 | zasra7 wzasrio | é fee 154 1 155 7 ae ae ‘ 156 | __Beoring housing 7 aa 1 : 2 : | 161 | Socket HD-CAP screw M10L30 | 6 eee y 162 | Endcover eased aaveaeecevPee oa al Z 163 | Socket HO.CAP serew M1? L90 a! a } : 164 | Socket HD-CAP serew S12L70 eT. = eee f | 165 | Insulating pate 7 ER 166 | Brush case ee 1 : oe ; i 168 |__ Plain washer, M10 3 i 168 | Spring washer, M10 3 i il 770_| __tesuting bolt 3 a7 | Eerth brush 1 : 12 Compression spring 7 “| . 173 | Cow 1 = 174 ‘Spring washer, M10 3 175 | _ Bolt, M1025 Ba 3 “176 | __ Plain washer, M12 1 177_| __ Soring washer, M12 1 [170 | Nowataa 7 2 = 142 =EL 1 4 be Description | oryiet Remarks & WZ ae [Tis sonra eso &__|(Heiaht dimension 10) 6 is ‘Spring lode washer M20 6 cere | é a5 ‘Special washer : 6 = ! | Bolt MI2Lza eset Sprine ook washer MT2 I jscsesaeaceeneaaa é "Gear cee upper ‘ Gear case (ower sds) € “428 | Splitpin 8160 ce : &é 729 | Slotted nut M30 % [130 | Spring lock washer WOO fa | © 131 Bolt M30'L190° eae C [132 | tnapscton cover en Le ee ® Bolt M10 L22 i i Spengioak washer MIO r & Gover x Gott WTO LES a ea x Spring lock washer Mi0 ¢ ‘Stee! wool poet & Bresther box % Rubber packing ‘e ae R : 4 Bont M12 130 a Bs Reamer bolt M12 L30_ a 4 EEE a Packing Tset | (Fete seal) ee Packing Zsows [ (Felt seal) af Bolt M30 L150 210 20 3.0 4G 5 6 6 CONTENTS a DESCRIPTION AND OPERATION . & , FAULT FINDING i rs MAINTENANCE PRACTICES - € 3A Removalfinstallation .. 0.0. cee eeeeeeeeeeecee ce eevee Ce 32, Servicing... 3.3 Aujusting/Checki a. OVERHAUL FROCIDURES «2... eee ee eee & € 4.8 Diewsenbly ey 42 Cleaning c 43° Checking. i 4.4 Reassembling we é é je G “ $ oy ~ So %2.0 FAULT FINDING 21 Cracked Suspension Bearing Housing 2.1.1 During wheel changes, suspension bearing housing should be carefully checked visually for cracks and if found replaced. 2.2 Loose Securing Bolts 2.2.4 Securing bolts should be checked to ensure that Wer tightness conforms fo the requied torque value Refer Table 200), 2.3. Failure of Bearings (Seized) 23.1 [isnot possible to check bearings in condition of assembly. > 23.2 Touch the hand to outside of suspension tube, and check temperature of bearing, just behind operating | the locomotive. If und abnormal vemperature, change out it's suspension unit. sim Smee EA1.0 DESCRIPTION AND OPERATION (REFER FIGS. 1 and 2.) 1. The axle suspension tube (Iraction motor suspension bearine) (3) is made from east steel, of one integral part, and atthe both ends cylindrical beating housings are formed. 1.2. At the opening side of the U-type section of the suspension tube (3), there is a machined flange which ‘orves as the mounting suface to the magnet fcame (Refer Fig. 1). 1.3 The upper Naige of suspension tube (3) is mourited to the magnet frame with’ hex. head bolis (14). 14° The lower hex, head bolts (14). ange of suspen tube is mounted in a slot provided in the magnet frame, is secuved with 4 1.5 The hex. head bolts (14) are tightened with sping wash.s (13), and the Reads ofthe bolts (14) are lockea with we, 1:6 Tapered roller bearings (T!3:SEN) (1) (2) ae used at both sides of tube ‘The outer sace of year side bearing (2) is ited viscetly into the bearing housing or suzpens:on tub, where 4s the outer race of he opposite-side bearmg (I) is fitted into + separate cartsidge bearing housing (4) for Adjusting the axial distance 1.8 The inner races i both gear and oppositeside bearings are fitted to the axle 1.9 Adjustment of axial distance'is accomplised by varying the thickness of spi: ‘ype adjestment washer (5). 1.10: The splittype adjustment washer (5) are locked between the flange of suspension tube and beating housing @). LIL The suspeesion bearings (1) (2) are lubricated with grease. 1.12 Grease is supplied through a grease nipple (3) fitted 10 the suspensi be by a grease pump. 1.13. Bearing tnformat ‘Axle suspension tube Roller bearings: Non-gear wheel side Gear wheel side Manufacturer: TIMKEN TIMKEN Type: ‘Tapered roller Tapered roller cone M349547 cone | M245747 cup M349S10 cup M245710 & & ROR RO WOR OR “a wl € 1¢3.0 MAINTENANCE PRACTICES . 3.1 Removal/Instalation 3.1.1 Removalfinstallation of suspension bearing unit can only be undertaken during dismantling/assembling of whee! pairs. 3.2 Sewicing = __ 3.2.1 Lubrication ieformation for akle suspension bearings Non-gear wheel side Gear whee! side First fill” lubeicant: Shell Alvania No. 3 Shell Alvania No. 3 ‘Manufacturer: Shell 02 Co. Shell OW Co. Quantity used for first fl: 900 gr 1250 gr Replenishment period: Annual Annizal Replenishment quantity: 150¢ 250 3.3 Adjustment/Checking 3.3.1. in the maintenance checking of suspension bearingy and unit, listen for any abnormal noise {rom the unit 3.3:2 Check the bearing tensperatine, in accordance (0 touch the outside of bearing housing of suspension tubs, 33.3. Also eheck for loose securing bolts to prevent unnecessary problems. + 3.3.3.1 The suspension unitis secured to the magnet frame with bolts, The bolts may slacken from.time to tims, Reguiscly reighten these bolts: 3.34. Perform the following checks. 3.34.1 Check the eghiness of the suspension tube and cotter mounting bolts with using the torque arercis. if Found loose, zetighien t eorteet torque value, (Refer Table 200) ‘Check suspension be for eracks. ‘Check tive condition of bolts, wife Locking and washers, replace the damnaged belts and waste's, owing table is to be worked to for the correct torque vales: Torque value ken ‘Standard4.0 OVERHAUL PROCEDURES 4.1 Disassembly 0 ‘Aude suspersion bearings are disassembled after dismantled the road wheel of non gear side. ° 4 Disassembly procedures ae shown in Fig. 3. oS B11 Withdeawal of abutment piece © r 3.12 ___ Removal ofcover (Road wheel end) Cc eee eee eer Removal of adjusting washers ce ee CG 2.14 Removal al securing bolts r | 3.15 __Dismanuing the suspension tbe c 3.16 __ Removal of gear wheel end bearing cove c € Fig. 3. Disassembling procedure © € c 4cL1 Withdrawal of Abutment Piece * C 4...1 Towithdrawal the abutment piece (7), use the spectal tools as shown in Fig. 4. c 4.1.1.2. Remove the abutment piece (7) by special tool. € 401.1:1 , To withdraval the abutment piece (7), use the special tool as shown in Fig 4 < “41.4.2 Remove the'abutment pecs (7 by special tool e 4.12 Removal of Cover (Road wheel end) Z 4.1.24 Remove all seuting bolt (12) and cover (6 from end of suspension tube (3). c 4.1.3, Removal of Adjusting Washer (5) 4.1.4.1 Remove the sealant on the outer surface of suspension tube and co: washer could be found out. and two joints of adjusting ” 4.4.3.2 Insert the chisel into clearances of joints and draw out the adjusting washers (5). 4.1.4 Removal All Securing Botts 4.14.1 Remove all securing bolts (11) of caver (8). 4.1.5 Dismmautfing the Suspension TubeWhaat oe ern fo Oerpion Taawe [Ow a Fuse | a [aes rsa 3] Sawer Toso |r aT] oe m8 eicalce [fam wim nraeestenums | =f TOOLS ASSEMBLING PROCEDURE Set doubleend stud 1, on the abutment piece, set port 3, oF ram, and pin plate 2, an whee! axle ena, suimport 3, by doubln-end stud 1, and nut M16. Press piston with operating hydraulic pump. 1 2 3 A Fig, CL1-4 Puller for abuunent piece Abutment piacevdraw the suspension tube (3) {com axte by withdrawal equipment as shown in Fig. 5, Road whect end bearing inner race (cone) can be pulled out with the suspension tube (3) 45.1 CAUTION: THE ADJUSTING WASHERS (5) SHOULD DE REMOVED FROM SUSPENSION TUBE (3), € BEFORE WITHDRAWAL OF SUSPENSION TUBE. IF THE SUSPENSION TUBE (3) WAS WITHDRAWN AS ASSEMBLING THE ADJUSTING € WASHER (5), THE BEARING WILL MAKE ANY DAMAGES. € —si:1.6- Removal of Gear Wheel End Bearing Cone ‘ © 4.1.6.1. Remove the bearing coné (2) by bearing pullers shown in Fig. é 41.7 Pull out the bearing cup (2) fcom the suspension tube (3) by bearing puiler as shown in Fig 7. © 4.18, Dismantle the bearing housing (4) from the suspension tube (3) as shown in Fig. 8. c 4.19 Pull out the bearing cvp (1) from the bearing housing (4) as shown in Fig. 9. c € a € 6 oCDia): ‘Approx. 101 ane TOOLS ASSEMBLING PROCEDURE 4. Serew eight double-end studs into thread holes of cover, ‘Set support 4, on ram, and fix the supsort by double-ond studs 1. Put plate 2, on whad! axle endl. Press piston with operating hydrautie pump, Fig, 6 Removing bearing cone.at gear wheel efid TN, | Deerption [TeotNe. + | aubiewne stud L807 | @ 2 [rise Tse 2 | Her. autre 3 4 [supper 7803 [1 5_| Ranwith Ryarautiepump |_| 1Remove the adlusting washer; before ‘wlthdroning the susBenion tube { psi } | I Denton Tein Faw] 1 + Clamp. Tiss [gf a Distant piece [se Ps %, Bane sa Tee a iC _ a. e “Pinte Teso2 | 1} =I ‘Support, | resort 1S ge ead oa EP rer eto esate Ram with hydraulic pump - it Q ce) SECTION AA. TOOLS ASSEMBLING PROCEDURE 1. dastall the clamp 1, and distant piece’2, by hox. bolts and hex. nut M36 on the flange of suspension tube, 2, Set support 5, on cam, and secew double-end studs 3, into thread holes of etamp 1 3. Fox the support 8, by doublo-and studs 3, and hex, head nat M36, 4. Put plate 4, on whact axte end. Press piston with operating lydeaulic pump. Fig. 5 Withdrawal of suspension tube‘TOOLS ASSEMBLING PROCEDURE Set support 2, on ram and set plate 1, on piston of ram. Insert hook 4, ints suspension tube end face and béaring housing flange. Install support 2 on bearing housing with hex, head bolts as shown in figure, Remove bearing housing by operating the hydrautie pump, Tem No. Descioton iY [ Poe Tes [a ee esos | 4 a [Mecnedvomess | - [4 = [Hook Tess | 2 5 | Remwit hvarouticpeme | — | t Fig. B Removing bearing housiegnm Teno, [__ Gannon [Toots TS, 1 | Gamo ruses | 2 [ost rose} 2 [supper TSO PS 4 [nue west yt S_[Hennadeounmnas [=] € fi [Socket nena bon wiansa | =| > : 7 [Ram win hycaate gomof —— ‘TOOLS ASSEMBLING PROCEDURE 1. Assemble clamp 1, and hooks 2, in the suspension tube, 2. Set support 3, on ram, and install support 3, on end face of suspension tube by socket head bolts M112x90. 3. Set nut 4, on piston of ram. 4. Pull out the bearing cap by operating the hydraulic pump. . Fig. 7 Pulling out of bearing cap42 Cleaning 4.2.1. Cleaning axle suspension bearings ‘Whea cleaning the‘axle suspension bearings, put them into a container with kerosene heated up to about 60°C, without degreasing, and leave them for more than 10 minutes, to remove excess grease. Then, blow away sticking grease with compressed ai. Repeat this procedurs a few tives, after which the bearings are fieally washed with clean kerosene at normal temperature. Dry with compressed air, When handling the beating after the final washing, make sure hands are cleaned with such degressing agent-as ethyl alcohol to pfevent the bearing from getting rusty, 4.2.2 Cleaning of other parts Soak the dismantled parts such as the suspension tube, covers and bearing housing in kerosene for more than 30 fninutes to remove grease. Wash out remaining grease by brushing in it. Then, take these parts from the kerosene container and blow away kerosene with compressed 42.3 Wiping Wipe insulating bolts and inslaingwather with waste oth kerosene soaked, 43° Checking: q 4.3.1 inspect visually appearances of the axle suspension tube, the covers and so on for damages or rust or ens. 42.2. Chek thease sumpenson tube by guid pean chee or aks 4.3.3, Measurement of dimensions 433.1 Axle suspension tube 4.2.3.1. Inner diameter Of installation portions for bearing. Non-gearend? Min. 375.000 ~ Max. $375,057 mm Gearend: Min, 358.775 ~Max. $358.825 min 433.2 Bearing housing (ZC141003) of nongearend Outer diameter: Min. @375,004 ~ Max. $375,040 mm : Innerdiameter: Min: $342,895 ~ Max. #342.900 mm 4.3.33 Tapered roller bearings (Timken type bearing) 4.3.3.3.1 Non-gear end bearing Inner diameter of cone (Cone No. M349547) Min. $255,600 ~ Max. 255.625 mm Outerdiameter of cup (Cup No, M349510) Mia. $342,900 ~ Max. 9342.951 mm Overall bearing width: 63.$ mm + intent aney 2o00 o AAA AB : c them No. Depron ToatNe. [ow : 7 [Piste jose pa | {2 [Seppo Teste | [327 [Ramwintrabeatiepemef = fa ‘ ‘TOOLS ASSEMBLING PROCEDURE : a 1. Set stipport 2 on ram, and instal the Bearing housing on support 2 2. Stretch piston sultbly and screw plate 1 on piston. 3. Remove bearing cup from bearing housing by operating hydraulic pump. Fig. 9 Removal of bearing cup (road whee! end)44 Reassembling 44.1 General information w @ @ Heating beatings and components far assembly Electric ovens or electrically heated oil baths can be used but these should have thermostatic control, ‘Where oil is heated in a pan or metal container over an open flame, there should bea screen on which the bearings will rest which is raised Z5 Ri or so from the'bottom of the pan. The bearings should not rest on the bottom of the pan as the heat will be transferred directly fromthe flame through the pan to the bearing, This temperature.will be very high and will draw the bearing. IF am induction heater is used, eare should be exercised to prevent residual ueaynetism afTeetiny: the bearing anateria. ' Assembly methods Drivers and sleeves will asmure casies assombly and prevent damage to be ing components If drivers are not available, mild steel bars can be used. Use only mild steel, not hardened duifis or brass bars. The hardened bars will Uamage the bearing and brass will chip casily. On no account should a copper or bfass-faved haynuner be used during assembly of bearing parts. ld st Storage Completed wheelsets must be protected against-the entry of water of foreign matter into the bs housings. ring For short-term storage the wheelsets should Be kept in a covered building. Machined suifaces should be coated with a sultablé rust proventative If the wheelsets are stored outside, the tube should be tuned so that the open portion is ox the lower side and wedged in position. The sssembly’should be cavered with waterproof shests for further pro: tgction and again, the machined surfaces should be coated with a suitable rust preventative 4.4.2. Assembling procedure of motor suspension unit ~ a a it tho gear wheel in the correct position on the axie, Check that the'Tace of the gear whect is square 10 the axle within 0,05 mim on the face adjacent to the sear wheel end bearing, This can be done by pulting hte axle in a lathe between centres atid checking cun-ovt with a dial indicator. If the fee runs out more than the presesibed 0.05 mm, correct this by 10). sachininga 4333.2 Gear end bearing Inner diameter of cone (Cone No. M249747) Min, $257,175 ~ Max. #257.200 mm Outer diameter af cup (Cup No. M249710) Min, $358,826 ~ Max, 6958.775 eam Overall bearing width: 76.2. am. 43.34 Abutment piece nner diameter: Mir 6253957 Max. 9254 mm — Width: Mi 40.8 ~Max. 48.2 mm 4.3.3. Dimensions of mounting flanges of axle suspension tube ‘Symbol Dimension A= 246710952 gym 40.020 40.1 i= 35°01 om 5 OO oo © eo aAAs AAD= biiver Fig. 12 (2) Stand the tube on end, gear wheel end uppermost-and fit cup M249710 into its housing. The cup is a {ight fit in the housing arid should be fitted as follows: (@) Coat the bearing housing bore with a light mineral oil. (®) Place the cup in the housing, back-face (broad-face) down. (©) Using a dzver sitar to that shown in Fig. 3, tap the outer ede at opposite sides to get the cup to center squarely into its housing and continue until the cup is seated. [suitable divers are not avail able, soft stel bars may be used agninst the outer edge of the cup See Fig. 13). (@ Check that the cup is fully seated against its abutment using a fecler gauge of 0.05 mm thickness. The gauge must not enter between the faces of the cup and abutment of the tube (See Fig. 14), (8) Fit cup M349Si0 into tne up holder (Item 4) ina similar mannes, (©) Thrcad the cover (Item 8) over the axle and place in position. NOTE: Ensure that the cover is correetly oriontated to form the labyrinth seals6) “ @) ) (ungut of thie face must not exceed 0.08 mem) eo Fig. 10 oe Fig. The axle should now be placed in a vertical position with the gear wheel at the bottom with the en- closure (Item 9) in position raking sure that all enclosure grooves are free from diet and swarf (Fig. (1) Clean'thoroughly the suspension tube, makiag sure that all holes are free from dirt and swaef ard fighton the-bolt (Item 11) to the gear whkel. Apply “THREE BOND screwlock super No. 1303" 19 bolt (luem 11). ftem numbers referred to in the following notes are those on TIMKEN drawing £36798. Clean thoroughly covers (Item 8 and 6), abutment piece (Item 7), Spacer ([tem 5) arid eup holder (iter 4). Unwrap one bearing M249747 ~ 4249710 and die beating M349547 ~ 349510, Place ths two bearing cone assemblies in a tank of vil or dry oven! heated to 120°C. NOTE: Cone assembly M249747 will be required first for assembly and should he suitably positioned Jnutes andl dusing this time in the heating tank or even, The mininuim heating time is ten operations 7, 8 and 9 can be carried out, T se (ie a” 5 € aFig. 15 (10) Remove cone assembly M249747 from th heater and emter squarely over tlie axle and into position ‘against the gearwheel Face. ; : NOTE: Ensure-thai the back-fae sleeve t0 (broad-tace} of the cone is against the gearwheel face Uses clea: «cools, ensuring that the cone is properly is fully cewlod (Fig. 15), Dimensions of a suitable sleeve ave indicated od TIMKEN drawing C37974, down-the ted. Reamer the sleeve what the «ecooeoooeust we Uwe Oe vu Fig. 14Fig, 17 (13) Remove cone assembly M349547 from the heater and fit in 1! immediately with the sleeve (Fig. 17) as used previously. Do not tap down we the sleeve coriect position on the axle, Fe Ke the (ube as the soo, allow to fully cool and ren (16) Phe the sbutaent piece (Iteny 7) inte position against che back face of cone assembly M349S47Fig. 16 (11) With suitable lifting twekle, thread the suspension tube over the axle and position on the cone assembly ‘engaging the cover (Item 8) on the whe (Fig. 16). (12) Fit tho ght cover bots ( ane collectly seated 3 1 TF) and torque (0 40 Nav. Rojate the tube to ensure tat bearing rollers and also to encure that thee is no fouling of the caver ‘and yeawwhect (13) Fit the cup Holder (Item 4) with Greed cup M349510 inte the tube and HE the split maste? spacer. (This deawing (0 follow) (14) Fit the cover (Hem 4) and cover bolts (Hen 12) and tighten: clamp the cup holder, master spacer, cever aud tube together. Check tht na rap exists herween the faces hy ase af a 0.05 mm ga soe enoogaodgo:s >aay ay Fig, 19 Completed motor suspension unit Purp grease into the rosdwheel snd bearing housing unt 2 Gin of grease is visible around the encio- sure (approximately 9009) ae Fill the georwhee! end bearing housing with approximately 1.25 kg of grease, ‘The tube should be rotated whilst filing with grease to ensure an even distribution around the bearing. The lubticant used should be zm approved No. 3 consistency lithium soap based plo The assembly procedure is mow c 24(17) Remove cover bolts (Item 12) and with draw the two halves of the split master spacer es 16 necesiry se two M0 x SO mum jacking off screws in hoes provided in the tube to loosen te by applying thrust on cup holder Mange remove jacking off serews (18) Pi ronlwicel an to the axle. Whon complete the wheel should now make positive conract with the abutment piece (Item 12). ‘The cone may move sightly an tie axle which will be acceptable. (19) Now measire width af gap at thice positions between cup holder lange (Hem 4) Taking an average of the theee messurcntents and grind the adjustox yt washer (tenn $) size tk hae requited fitted end play. (This should be between 0.05 & U.25 mm split and chanye a syacer after fis eo the two bales of ad int washer (Item 5) refit cover bolts (Item 12) snd once again tigtes p the eup holder. she split adjust washer, cover & the tube together (21) (1s possible that, dusing the previous operations, the roadwheel end cone 3 moved! out of position and thereby disturbecl the tateral clearance in the beats by slinplacing, the tbe faterally in both diveecins. The laters als Jkness of the adjustment washer should be modified where lateral clesramee within specified limits, snbly aay have bee This eat be checks yovement should be checked by nie indicator The (22) Grease nipples (them 13) may be fitted if standard push-on grease co tut it is easier for the initia filling to be by an adaptor screwed inte setors are used for luli tapped holes with the gress: ipples ited afterwards 2B See oo Ooo aia Van os443. Disossemly and withdrawal procedure : S tem number feat ate those on Tien drawing number £36798 uales otherwise stated.) 444 Roadwheet end bearing removal Cc (1) Remove the journal axcbox from the non ear whee! end of the axe, o 2) Remove the roadwhiel from the axl at fhe non gear wheel end. 6 (8) Reni sits tems 11 and 12) fovea en ofthe ae c (1) Remove roadwhveel end cover (Hem 6). Cc (S)_ Remove split adjustment spacer (tein 5) € © To withdraw the abutment piece (Item. 7) and the roadwheel end bearing, fit withdrawal blocksg-9 1. " Should the géarwhecl‘end bearing cone (inner race) require removiig, it may be achieved by removing — ‘oarwheel, This boaring cen then be pushed off the axle. ‘ rods to the flange of the tube and cross Block. Fi the axle end protector and apply pressure thre the hydraulic ram: The Timken Company drawing number E3684] details the arrangement and cox nents roquitéa. : <moment sein ce T0003 | ; + (psu — | + jersseaa —— vase 5 [paaaceen = was9cco (i joanie— pend 5 )evibcs —— waawe? tfoncra tate | [a |uaeenes —— cnaesece | [e |ivaasoe9, = wazegce + fancy ae [ae fonmeanene = error [ir lracas = airacco te fonericy = atte a [13 jascesc7 NTT | a 1 2 WAROLES ~ 912 « 1£0 LONo- Pees ceeesaesteseeeeeeeeeee NOTE» REMOVE ALL SHARP CORNERS POSITION DAMETRICALLY OPPOSITE om MATERIAL > STEEL TUBE ANO BAR. EACH OTHER AS SHOWA WELD ALL f ASSEMBLY S FOR i : TIMKEN’ MOTOR SUSPENSHMANS SAA NOMA AN ODEO O DOOD OD: