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SECTION 10
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MK1500D Locomotive Section 10 - Rotating Electrical System
TABLE OF CONTENTS
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Section 10 - Rotating Electrical System MK1500D Locomotive
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MK1500D Locomotive Section 10 - Rotating Electrical System
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Section 10 - Rotating Electrical System MK1500D Locomotive
LIST OF ILLUSTRATIONS
LIST OF TABLES
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MK1500D Locomotive Section 10 - Rotating Electrical System
10.2 COMPONENT DESCRIPTION The generator stator core is built of laminated electri-
cal grade steel. Laminations are secured under pressure
The following paragraphs describe the rotating electri- and clamped to steel end rings. The generator frame is
cal equipment and major subassemblies used on the MK fabricated of heavy steel members welded to the end
1500D locomotive. rings. The feet are welded to the frame to simplify in-
stallation and alignment with the engine. Lifting eyes
10.2.1 Traction Alternator are welded to the frame to enable lifting of the entire
generator. Windings are inserted into the stator slots
The brushless AC-rectified, DC traction alternator (Figure and the entire assembly is vacuum pressure impregnated
10-2) is a special flange-mounted, two-bearing, eight- with 100% epoxy resin. The phase leads are brought
pole, synchronous generator, complete with brushless out to standard connection lugs which are fastened to
exciter. The traction alternator is rated to provide 1,250 the main AC-to-DC rectifier assembly.
VDC, 4,400 ampere continuous output when driven at
1,800 RPM.
DC TRACTION
MOTORS
TRACTION
ALTERNATOR
DIRECT AIR COMPRESSOR
COUPLED MOTOR
ENGINE
THREE PHASE AC COOLING FAN
COMPANION MOTORS
GEAR
ALTERNATOR
ASSEMBLY
FILTER BLOWER
AUXILIARY
MOTOR
GENERATOR
UNREGULATED DC
LOCOMOTIVE ELECTRICAL
ACCESSORY LOAD
VOLTAGE REGULATED DC
REGULATOR
BATTERY
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Section 10 - Rotating Electrical System MK1500D Locomotive
WARNING
A snubber circuit, consisting of six capacitors and six
resistors, mounted between phases, suppresses voltage
transients caused by diode commutation.
as engine speed varies. Alternator output voltage var- holder for the inboard slipring, one holder for the out-
ies directly with field excitation. Supplying constant board slipring, and two holders on the center slipring.
field excitation to the alternator’s rotating field wind- Each side of a holder has a coiled spring to apply the
ing causes the voltage to vary directly with RPM. The proper pressure directly to the top of the brush in that
source of constant field excitation is the 74 volt out- pocket.
put of the DC portion of the dual auxiliary generator.
To aid in motor starting, a boost circuit is incorporated The brush shunt lead connects to a screw on the
which adds an incremental amount to the field excita- brushholder. The face of the brush must be fully seated
tion in response to high load currents through a spe- to the slipring surface before operating.
cial current transformer and boost module.
10.2.2.6 DC Rectifier and Boost Assembly
The dual auxiliary generator consists of stators, rotors,
bearing bracket drive end, endbell opposite drive end, The DC rectifier and boost assembly are described in
brushes and brushholders, DC rectifier, and boost as- the following paragraphs.
sembly.
10.2.2.6.1 DC Rectifier
10.2.2.1 Stators
A rectifier assembly converts the 3-phase AC output of
The generator stators are constructed with two stator cores, the battery charging alternator to DC. It is located in
heavily insulated, and wound with high quality copper the sheet metal box on top of the dual auxiliary genera-
magnet wire. tor frame. Three dual diode blocks are mounted on top
of the finned heatsink to form the 3-phase rectifier bridge.
10.2.2.2 Rotors Copper strap interconnections extend to form the posi-
tive (+) and negative (-) terminals. The battery charg-
The rotor’s generator field poles are mounted on a large ing positive (+) output passes through an additional di-
diameter shaft. The poles are made of one piece elec- ode block and a current limiting resistor assembly. The
trical steel laminations that are assembled under pres- resistor assembly is mounted on standoffs on the sloped
sure. Field coils of high quality copper magnet wire are sheet metal housing panel and consists of two resistors
machine-wound directly onto heavily insulated poles. in parallel. The diode block, located on top of the heatsink,
prevents battery discharge.
10.2.2.3 Bearing Bracket, Drive End
Fuses are provided for each generator lead to protect
The drive end of the dual auxiliary generator rotor is the windings in case of a shorted diode block. The fuses
supported within the generator frame by a cast iron bracket. are mounted to the top flange of an insulating channel
The bearing fits into a machined bore in the bracket. and bolt directly to the diode blocks. A snubber network
The drive end bracket also acts as the fan housing and of resistors and capacitors is connected across the AC
air exhaust port. input to the rectifier and mounted on the vertical web
of the insulating channel.
10.2.2.4 Endbell, Opposite Drive End
10.2.2.6.2 Boost Assembly
The endbell is located on the outboard or “opposite drive”
end. It houses a regreasable, cartridge type ball bearing An excitation boost assembly is provided for the AC
to carry the rotor. It provides the mounting for the generator element which supplies the air compressor motor,
brushholder assemblies for both generators. Access covers cooling fan motors and the filter blower motor. The boost
for servicing the brushes and sliprings are provided on assembly components are located in the sheet metal box
the face of the fabricated endbell. on top of the auxiliary generator frame and consist of a
current transformer (CT) and a boost module.
10.2.2.5 Brushes/Brushholders
The output of the CT is fed to the boost module, where
The brushholders are mounted on insulated offset studs. it is converted to an incremental DC potential. This DC
Four holders are equally spaced on the bracket with one potential is applied to the generator excitation circuit
to give improved response to high load demands such
as motor starting.
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Section 10 - Rotating Electrical System MK1500D Locomotive
10.2.3.4 Fan, Baffle, and Frame Adapter The cooling fan consists of an induction motor with di-
rectional blades bolted to a hub, mounted on the shaft
The fan is a split aluminum casting assembly, easily extension of the motor. Heavy duty shielded ball bear-
removed for maintenance purposes. The removable fan ings, factory lubricated, support the fan assembly.
is separately balanced. Care must be taken not to alter
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MK1500D Locomotive Section 10 - Rotating Electrical System
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Section 10 - Rotating Electrical System MK1500D Locomotive
ENGINE RUNS
BLOWER FAN
PUSHES AIR FROM
AIR IS PULLED AIR COMPRESSOR INERTIAL AIR
THROUGH RADIATORS RUNS PROVIDING COMPARTMENT
TO COOL ENGINE COMPRESSED AIR THROUGH DUCTS
COOLANT TO RESERVOIRS TO COOL EACH
TRACTION MOTOR
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MK1500D Locomotive Section 10 - Rotating Electrical System
Maintenance Schedule
Procedure Daily 92-Day Yearly 2-Year 6-Year
Traction Alternator
Inspect Operation 10.5.1.1
Inspect Traction Alternator 10.5.1.2
Clean Traction Alternator 10.5.1.3
Replace Filter 10.5.1.4
Check Bearing Temperature 10.5.1.5
Check Vibration Amplitude 10.5.1.6
Check Insulation Resistance 10.5.1.7
Test Winding Resistance 10.5.1.8
Replace Bearing 10.5.1.9
Replace Rotating Rectifier 10.5.1.10
Companion Alternator/Auxiliary Generator
Inspect Operation 10.5.2.1
Clean Companion Alternator/Auxiliary Generator 10.5.2.2
Inspect/Replace Brush and Brushholder 10.5.2.3
Inspect Bearing 10.5.2.4
Inspect Companion Alternator/Auxiliary Generator 10.5.2.5
Check Vibration Amplitude 10.5.2.6
Check Winding and Insulation Resistance 10.5.2.7
Test Exciter Field Saturation 10.5.2.8
Check Coupling Alignment 10.5.2.9
Replace Bearing 10.5.2.10
Air Compressor Motor
Inspect Operation 10.5.3.1
Clean Air Compressor Motor 10.5.3.2
Check Bearing Temperature 10.5.3.3
Inspect Air Compressor Motor 10.5.3.4
Check Vibration Amplitude 10.5.3.5
Check Winding and Insulation Resistance 10.5.3.6
Replace Bearing 10.5.3.7
Cooling Fan Assembly
Inspect Cooling Fan Assembly 10.5.4.1
Check Insulation Resistance 10.5.4.2
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Section 10 - Rotating Electrical System MK1500D Locomotive
10.4.2 Tools and Test Equipment, Table 10-3 lists consumables required to perform scheduled
Consumables, Supplies, and Lubrication maintenance tasks listed in paragraph 10.5.
Table 10-2 lists specialized tools and test equipment Table 10-4 lists supplies required to perform scheduled
needed to perform scheduled maintenance tasks in para- maintenance tasks listed in paragraph 10.5.
graph 10.5. Standard tools, which are found in a typi-
cal tool kit (such as wrenches, screwdrivers, etc.) are Table 10-5 lists lubrication required to perform sched-
not included in this specialized tool listing. uled maintenance tasks listed in paragraph 10.5.
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MK1500D Locomotive Section 10 - Rotating Electrical System
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Section 10 - Rotating Electrical System MK1500D Locomotive
WARNING WARNING
Exercise extreme caution and manufacturers’ safety Shut the engine off before performing the fol-
rules relating to the use of tools, materials, equip- lowing procedure. Failure to observe this warn-
ment, and personal safety in the performance of ing can result in serious injury.
these procedures.
10.5.1.2 Inspect Traction Alternator b. If necessary, use a lint-free cloth moistened with
a nonflammable cleaning solvent to remove hard-
(92-DAY MAINTENANCE) ened deposits of grease, oil, and other substances.
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MK1500D Locomotive Section 10 - Rotating Electrical System
10.5.1.5 Inspect Traction Alternator Bearing 10.5.1.7.1 Traction Alternator Exciter Field Test
Temperature
1. Verify the engine is shut off.
(YEARLY MAINTENANCE)
2. Open access door.
1. Using a pyrometer, check bearing temperature dur-
ing operation. Bearing housing temperature should 3. Disconnect the exciter leads from the terminal strip.
not exceed ambient air temperature by 63 °F. Bear-
ings can operate at 200 °F, but once overheating 4. Connect exciter field leads from the traction alter-
occurs, this limit may be exceeded rather quickly nator to one clamp of 500 volt megger. Connect the
and the problem should be identified and remedied other clamp to alternator frame.
immediately.
Example:
100 megohms measured at 15 oC.
Find megohms at 40 oC.
Conversion factor at 15 oC is .27,
so megohms at 40 oC is 27 (.27 x 100).
Example:
100 megohms measured at 50 oC.
Find megohms at 40 oC.
Conversion factor at 50 oC is 1.7,
so megohms at 40 oC is 170 (1.7 x 100).
11018.DRW
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MK1500D Locomotive Section 10 - Rotating Electrical System
than 1.0 megohm, dry out the alternator and make 4. Apply 500 volts DC from the megger and measure
another resistance check. The traction alternator may resistance after one minute record the resistance.
be dried out by moving the locomotive to a heated If resistance is less than 1.0 megohm, dry out the
building, using heat lamps or torpedo heaters. alternator and make another megger check. The trac-
tion alternator may be dried out by moving the lo-
5. If the generator stator resistance is less than 1.0 me- comotive to a heated building, using heat lamps or
gohm after it has been dried out, the traction alter- torpedo heaters.
nator must be replaced.
5. If the alternator rotor winding resistance is less than
6. Reconnect alternator leads to rectifier assembly. 1.0 megohm after it has been dried out, the traction
alternator must be replaced.
10.5.1.7.3 Traction Alternator Exciter Armature
Test 6. Reconnect alternator field leads to rotating recti-
fier.
1. Verify the engine is shut off.
10.5.1.8 Test Traction Alternator Winding
2. Disconnect the exciter armature leads from the ro- Resistance
tating rectifiers.
(YEARLY MAINTENANCE)
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Section 10 - Rotating Electrical System MK1500D Locomotive
10.5.1.10 Replace Traction Alternator Rotating 4. Remove 12 screws holding clamping ring to fan hub.
Rectifier
5. Remove fan clamping ring.
(2-YEAR MAINTENANCE)
6. Slide the fan out of the traction alternator.
1. Shut off engine. 12. Install cover plate and secure to air duct with 16
screws.
2. Remove 16 screws holding the cover plate to the
air duct. Refer to Figure 10-4. 13. Start engine and verify traction alternator opera-
tion.
3. Remove the cover plate.
HOUSING
WASHER
SCREW
FAN
HUB
RETAINER
WASHER
SCREW
SCREW WASHER
WASHER
SCREW
COVER
WASHER
SCREW
11728.DRW
Figure 10-4: Traction Alternator Rotating Rectifier Replacement
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MK1500D Locomotive Section 10 - Rotating Electrical System
(DAILY MAINTENANCE)
WARNING
1. Inspect the companion alternator/auxiliary genera- Shut the engine off before performing the fol-
tor for abnormal running conditions. Check for bearing lowing procedure. Failure to observe this warn-
vibration or machine noise. Investigate any over- ing can result in serious injury.
heating conditions (unusual radiant heat, discoloration,
or smoke). Refer to troubleshooting charts.
1. Remove generator cover. Brushes are located on the
10.5.2.2 Clean Companion Alternator/Auxiliary front side of the endbell.
Generator
2. Remove brushes from holders.
(92-DAY MAINTENANCE)
3. Inspect brushholders for damage, cleanliness, proper
height, and bolt tightness. If required, clean hold-
WARNING ers, verify carbonways are smooth, adjust holders,
Shut the engine off before performing the fol- and tighten bolts.
lowing procedure. Failure to observe this warn-
ing can result in serious injury. 4. Ensure spring fingers are not broken and have spring
tension.
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Section 10 - Rotating Electrical System MK1500D Locomotive
10.5.2.5 Inspect Companion Alternator/Auxiliary All insulation resistance checks, using a 500 volt megger,
Generator should be made several times during the first year of
operation and annually thereafter. If the generator is
(YEARLY MAINTENANCE) subjected to a dirty or wet environment, the interval be-
tween checks should be shortened. Log all winding test
and maintenance data, temperature, humidity, and a brief
WARNING description of the winding conditions at the time of the
Shut the engine off before performing the following check. If the data shows any large changes, a careful
procedure. Failure to observe this warning can winding inspection should be made.
result in serious injury.
The companion alternator/auxiliary generator has four
separate windings. Check the winding resistance and
1. Shut the engine off. the insulation resistance as outlined in the following
paragraphs.
2. Inspect the generator for dirt buildup and cracks.
Check for loose or damaged wires, signs of rub-
bing, and other indications of damage. Examine the WARNING
rotor shaft next to the bearing for signs of exces- Shut the engine off before performing the following
sive grease leakage. procedure. Failure to observe this warning can
result in serious injury.
3. Check the bearings for visual signs of damage or
deterioration.
Verify the engine is shut off before performing the fol-
4. Report bearing damage or grease leakage to super- lowing procedures.
vision.
10.5.2.7.1 Companion Alternator/Auxiliary
10.5.2.6 Check Companion Alternator/Auxiliary Generator AC Generator Stator
Generator Vibration Amplitude
1. Remove the top access cover.
(YEARLY MAINTENANCE)
Normal vibration readings should be 0.003 inches (peak 2. Disconnect the three AC generator stator leads from
to peak). Maximum vibration limit is 0.006 inches (peak the terminal block.
to peak). The vibration readings taken at start-up can
be used as the standard of comparison for future read- 3. Measure the resistance between each pair of stator
ings. Any significant change in vibration from previ- leads (1-2, 2-3, 3-1).
ous readings should be investigated.
4. The three readings should be within 10 percent of
10.5.2.7 Check Companion Alternator/Auxiliary one another. The average of the three readings should
Generator Winding and Insulation be between 0.0036 and 0.0044 ohms.
Resistance
5. If the resistance is not as specified in step 4, the
(YEARLY MAINTENANCE) companion alternator/auxiliary generator must be
replaced.
The generator winding resistance should not change during
its life except for minor variations due to temperature. 6. Tie the three battery charging generator stator leads
If winding resistance changes, troubleshoot and take cor- together and clamp to one lead of the megger. Connect
rective action. Before checking winding resistance, en- other clamp to frame. Apply 500 VDC to the leads.
sure the generator is at room temperature and the meter Record the resistance reading. Disconnect the megger.
used is suitable for the range of resistance.
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MK1500D Locomotive Section 10 - Rotating Electrical System
5. Tie the three battery charging generator stator leads 7. Ground leads to frame.
together and clamp to one lead of the megger. Connect
other clamp to frame. Apply 500 VDC DC to the
8. The minimum insulation resistance at 104 °F (40
leads. Record the resistance reading. Disconnect
°C) should not be less than 1 megohm. For megger
megger.
conversion to 40 °C, refer to Figure 10-3.
6. Ground leads to frame.
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Section 10 - Rotating Electrical System MK1500D Locomotive
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MK1500D Locomotive Section 10 - Rotating Electrical System
4. With no load on the generator, the output voltage ance at all points and a straightedge lies squarely
at the terminal block (+, -) should be between 98 across the rims at any point.
and 108 VDC.
Nonparallel faces are indicated by a variation in sepa-
5. Shut the engine off. ration of the coupling halves as they are rotated. A dif-
ference on height of the coupling halves will be indi-
6. If the generator output voltage is not as specified, cated by the straightedge and feeler gauge test.
the companion alternator/auxiliary generator must
Angular and parallel tolerances are 0.002" when both
be removed and replaced.
units are cold. Due to thermal expansion, the generator
shaft should be offset high when the units are cold. Adjust
7. Connect all leads to their original terminals. Re-
coupler alignment as required.
place access cover.
10.5.2.10 Replace Companion Alternator/
10.5.2.9 Check Companion Alternator/Auxiliary Auxiliary Generator Bearing
Generator Coupling Alignment
(6-YEAR MAINTENANCE)
(YEARLY MAINTENANCE)
Replace the companion alternator/auxiliary generator
1. Check coupling alignment to prevent high vibra- bearings every six years.
tions and increase operating life of the generator.
10.5.3 Air Compressor Motor
(DAILY MAINTENANCE)
(92-DAY MAINTENANCE)
NOTE
If equipment is subjected to excessive moisture,
11033.DRW
heat, or dust, the schedule for cleaning and main-
tenance should be shortened.
Figure 10-5: A Straightedge and Feeler Gauge
Method of Coupling Alignment
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Section 10 - Rotating Electrical System MK1500D Locomotive
1. Verify the engine is shut off. 10.5.3.5 Check Air Compressor Motor Vibration
Amplitude
2. Make a visual check for excessive dirt buildup or
grease leakage. Remove grease and dirt as follows: (YEARLY MAINTENANCE)
b. Use a lint-free wiping cloth moistened with a 4. While observing the analyzer meter, energize the
nonflammable cleaning solvent to remove hardened air compressor motor.
deposits of grease, oil, and other substances.
5. Record the vibration amplitude indications observed
on the analyzer meter.
c. Vacuum the interior of the motor assembly.
6. De-energize the air compressor motor.
10.5.3.3 Check Air Compressor Motor Bearing
Temperature 7. Move the vibration analyzer probe to a vertical po-
sition on the air compressor motor bearing housing.
(YEARLY MAINTENANCE)
8. While observing the analyzer meter, energize the
1. Check bearing temperature during operation. Bearing air compressor motor.
housing temperature should not exceed ambient air
9. Record the vibration amplitude indications observed
temperature by 63 °F. Bearing can operate at 200
on the analyzer meter.
°F, but once overheating occurs, this limit may be
exceeded rather quickly and the problem should be 10. De-energize the air compressor motor.
identified and remedied immediately.
11. Move the vibration analyzer probe to an axial posi-
10.5.3.4 Inspect Air Compressor Motor tion on the air compressor motor bearing housing.
(YEARLY MAINTENANCE) 12. While observing the analyzer meter, energize the
air compressor motor.
1. Inspect motor for dirt buildup and cracks. Check
for loose or damaged lead wires, signs of rubbing, 13. Record the vibration amplitude indications observed
and other indications of damage. Examine the ro- on the analyzer meter.
tor shaft adjacent to the bearing for signs of exces-
sive grease leakage. 14. Return the air compressor motor to desired opera-
tion.
2. Check the bearings for visual signs of damage or
deterioration. 15. Normal vibration amplitudes are 0.003 inches (peak-
to-peak). Maximum vibration amplitudes are 0.006
inches (peak-to-peak).
tion amplitudes from previous readings should be 8. If insulation fails to meet the minimum test stan-
investigated. dard, the unit may be dried out and the test repeated.
If the insulation fails to meet the minimum test stan-
10.5.3.6 Check Air Compressor Motor Winding dard after dry out, the air compressor motor must
and Insulation Resistance be replaced. Refer to Section 7, Compressed Air
for air compressor motor removal and installation.
(YEARLY MAINTENANCE)
9. Reconnect leads.
The motor winding resistance should not change dur-
ing its life except for minor variations due to tempera-
ture. If winding resistance changes, troubleshoot and CAUTION
take corrective action. Before checking winding resis- Drying temperatures must not exceed 167 °F. Equip-
tance, ensure the motor is at room temperature and the ment damage may result if this caution is not ad-
meter used is suitable for the range of resistance.
hered to.
The insulation resistance check using a 500-volt megger
should be made several times during the first year of 10.5.3.7 Replace Air Compressor Motor Bearing
operation and annually thereafter. If the motor is sub-
jected to a dirty or wet environment, the interval be- (6-YEAR MAINTENANCE)
tween checks should be shortened. Log all winding test
and maintenance data, temperature, humidity, and a brief
1. Replace the air compressor motor bearing every six
description of the winding conditions at the time of the
years.
check. If the data shows any large changes, a careful
winding inspection should be made.
10.5.4 Cooling Fan Assembly
Check air compressor motor winding resistance and in-
sulation resistance as outlined in the following steps. The following paragraphs provide instructions for main-
taining the cooling fan assembly. They include inspec-
tion instructions and instructions for checking insula-
NOTE tion resistance.
The air compressor drive motor has three leads.
Each lead consists of two cables in parallel.
WARNING
Turn off electrical power to the cooling fan mo-
1. Verify engine is shut off. tor before performing work on the motor fan as-
sembly. Failure to comply with this warning may
2. Remove access cover. result in serious injury.
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Section 10 - Rotating Electrical System MK1500D Locomotive
5. Start engine.
NOTE
Common symptoms, probable causes and remedies
are listed in the troubleshooting charts.
(YEARLY MAINTENANCE)
NOTE
If the cooling fan motor has been subjected to
long term high humidity, check motor winding
insulation resistance.
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MK1500D Locomotive Section 10 - Rotating Electrical System
Excitation lead open, shorted, Wiring continuity, check F1 and F2 for 1. Repair or replace damaged lead.
or grounded to frame. insulation resistance.
Short circuit on output. Disconnect leads from +/- terminals of the 1. Remove short or ground.
output rectifier assembly. If voltage is normal, 2. Replace diodes.
check for short or ground in the load. If no
voltage, disconnect the generator leads from
the rectifier assembly and check for short or
ground in generator leads. If generator
windings are normal, check the rectifier
assembly for shorted diodes or connections.
Field coils shorted or open. Check for short or open circuit in the 1. Replace the traction motor
generator field. Refer to paragraph 10.5.1.10 alternator.
to access the rotating rectifier assembly.
Disconnect the generator field leads from the
rotating rectifier assembly to check the
generator field winding.
No excitation to generator. Check output of the exciter module at F1 1. Replace exciter module. Refer to
and F2. Section 11, Electrical System
Weak field due to high temperature. Insufficient amount of cool air supplied to 1. Improve ventilation or provide
cool alternator. cooler air to bring field resistance
down to normal values. Inspect
generator for cleanliness and
blower operation.
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Section 10 - Rotating Electrical System MK1500D Locomotive
High ambient temperatures. Generator cleanliness and blower operation. 1. Improve circulation to lower heat
buildup.
Rotor out of balance due to winding Check for alternator overspeed condition. 1. Replace traction alternator.
failure.
No brush contact at slipring. Brush condition and position. 1. Clean, adjust, or replace brushes.
2. Clean sliprings.
Excitation lead open, shorted, or Check for continuity. Check insulation 1. Replace damaged lead if
grounded to frame. resistance. necessary.
Field coils shorted or open. Check for shorted or open field coils. 1. Replace companion alternator/-
auxiliary generator if field coils
are found to be opened or shorted.
Shorted or grounded sliprings. Disconnect lead wires and check slipring 1. Repair or replace slipring
insulation with megger. assembly.
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MK1500D Locomotive Section 10 - Rotating Electrical System
High resistance connections. Check for heating at connection and 1. Replace or tighten faulty
connection integrity. connection.
Brushes dirty or not properly seated. Worn or dirty brushes. 1. Clean or replace brushes.
Sliprings dirty or in need of repair. Inspect for dirty or worn sliprings. 1. Clean sliprings or replace
companion alternator.
Weak field due to high temperature. Improper ventilation. 1. Improve ventilation or provide
cooler air to bring field resistance
down to normal values.
Poor brush contact. Using a spring gauge, check brush pressure 1. Clean, adjust, or replace brushes
spring force (10 oz. minimum). or repair brush holder as required.
Loose terminal or load connection. Loose terminal or load connection. 1. Tighten or replace defective
connectors.
Initial operation in very cold Cold ambient temperature. 1. Voltage should return to normal as
temperatures. generator field windings heat up
and field current drops.
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Section 10 - Rotating Electrical System MK1500D Locomotive
Diode modules failed to open in Check for load faults. 1. Correct load fault as required and
rectifier assembly. replace faulty diode modules in
rectifier assembly.
No brush contact at sliprings. Check brush pressure spring force, 1. Clean, adjust, or replace brushes
10 oz. minimum. or repair brushholder as required.
2. Clean sliprings.
Excitation lead open, shorted, or Check for continuity. Check for insulation 1. Replace damaged lead if required.
grounded to frame. resistance.
Field coils shorted or open. Check for short or open circuit. 1. Replace dual auxiliary generator.
Shorted or grounded sliprings. Disconnect lead wires and check slipring 1. Replace dual auxiliary generator.
insulation with megger.
Poor brush contact at sliprings. Check brush pressure spring force, 1. Clean, adjust, or replace brushes
10 oz. minimum. or repair brush holder as required.
2. Clean sliprings.
High resistance connections. Check for heating condition at connection and 1. Replace or tighten faulty
connection integrity. connection.
One fuse blown in rectifier assembly. Check for shorted diode module. 1. Correct fault as required and
Check for load faults. replace fuse.
One diode module failed to open in Check for load faults. 1. Correct load fault as required and
rectifier assembly. replace faulty diode module in
rectifier assembly.
Positive lead from generator to voltage Check for continuity. 1. Repair lead as required.
regulator open.
High ambient temperatures. Generator cleanliness and blower operation. 1. Improve circulation to lower heat
buildup.
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MK1500D Locomotive Section 10 - Rotating Electrical System
Rotor out of balance after repair. Rotor balance with cooling fan in place. 1. Replace companion alternator/
auxiliary generator.
Rotor out of balance due to winding Check for dual auxiliary generator overspeed 1. Replace companion alternator/
failure. condition. auxiliary generator.
Improper input voltage. Perform paragraph 10.5.2.8.1 maintenance. 1. Replace companion alternator/
auxiliary generator.
Dirt in motor. Inspect for plugged vent ports. 1. Clean ventilating ports and
remove buildup from winding.
Winding failure Check for open or shorted grounded winding. 1. Replace air compressor. Refer to
Section 7, Compressed Air
System.
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Section 10 - Rotating Electrical System MK1500D Locomotive
Connection plug not making good Check plug for continuity. 1. Repair or replace plug.
contact.
Open motor winding. Check motor resistance. 1. If found open, replace cooling
fan assembly.
Damaged bearings. Rotate fan manually and check for free 1. Replace cooling fan assembly.
rotating.
Dry bearings. As fan is rotated listen for unusual noise. 1. Replace cooling fan assembly.
Mounting bolts are loose. Inspect mounting bolts. 1. Tighten mounting bolts.
Fan blade mounting bolts are loose. Inspect fan blade mounting bolts. 1. Torque fan blade mounting bolts
to 150 ft-lbs.
Fan blade damage. Check for cracks or fan damage. 1. Replace fan blades.
Bearing noise. Check bearing for unusual noise. 1. Replace cooling fan assembly .
Refer to paragraphs 10.7.3 and
10.7.4.
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MK1500D Locomotive Section 10 - Rotating Electrical System
10.7.1 Safety
Cooling Fan Removal 10.7.3 Lifting Device, 2-ton Lift cooling fan assembly.
Cooling Fan Installation 10.7.4 Lifting Device, 2-ton Lift cooling fan assembly.
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Section 10 - Rotating Electrical System MK1500D Locomotive
This paragraph provides instructions for removing the See Section 7, Compressed Air, for removal.
cooling fan assembly. Instructions for installing the cooling
assembly (paragraph 10.7.4) follow the cooling fan 10.7.6 Air Compressor Installation
removal instructions.
See Section 7, Compressed Air, for installation.
3. Connect motor leads to power leads. Traction alternator installation is beyond running main-
tenance. The locomotive must be removed from service
4. Apply power to cooling fans. for heavy repair.
5. Install guard.
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