PRESENTATION ON SUMMER TRAINING

PRESENTED BY :
SHOUBHIK MUKHERJEE
EN(final year)
ABOUT THE ORGANISATION
GORAKHPUR is the headquarters of NORTH
EASTERN RAILWAYS.
The mechanical workshop ,NER GORAKHPUR,was
established in 1903.
Steam engines were maintained here for a long time,but
now diesel engines,coaches,and wagons are the main subjects of
maintenance here.
The workshop became a part of the East Indian Railways
& during the regrouping of the railways,after
independence,GORAKHPUR WORKSHOP emerged as the
major workshop on NORTH EASTERN RAILWAYS.
The GORAKHPUR WORKSHOP is more than 110
years old & is one of the rare workshops.
INTRODUCTION
An alternator is an
electromechanical device that converts
mechanical energy to electrical energy in
the form of alternating current.
A voltage regulator is an
electrical regulator designed to
automatically maintain a constant voltage
level.
1. ALTERNATOR & REGULATOR
1.)SYSTEM DESCRIPTION
Bosch alternators are conventional 3-phase,self-rectifying
type alternators.Bosch 110 amp alternators use 14 diodes.

2.)WIRING CONTINUITY TEST
Connect a voltmeter between alternator Red battery terminal
wire and check ground voltmeter reading.

3.)ALTERNATOR EXCITER CIRCUIT TEST
3.1. CURRENT CHECKING
Check that battery voltage is a minimum of 12 volts.If
not,charge as needed & then disconnect the wire from
alternator terminal & connect Multimeter.
3.2. RESISTANCE CHECKING
Disconnect negative battery cable of the alternator. Connect
Multimeter between cable and positive terminal of the
battery.

3.3. OUTPUT CHECK
Ensure connections at battery,alternator & starter are clean
& tight.Also ensure that alternators are properly grounded.
Connect Ammeter/Voltmeter or equivalent,following
manufacturers instructions.
Repeat test at 2000RPM & alternator output should be 90-
110amps or within 10% of manufacturers specification.
4.)DIODE ASSEMBLY BENCH TESTING
Place ohmmeter on scale & connect ohmmeter leads across
positive terminal & each of the 3 stator terminals.
Connect ohmmeter leads across negative plate and each of the
3 stator terminals.

5.)STATOR BENCH TESTING
Place ohmmeter on lowest scale & connect ohmmeter across
stator leads.
Place ohmmeter on scale & connect ohmmeter between stator
core & stator lead.

6.)ROTOR BENCH TESTING
Place ohmmeter on lowest scale & connect ohmmeter across
slip rings.

If resistance is too low,rotor has short circuit & must be
replaced.
Place ohmmeter on scale & connect ohmmeter between either
slip ring rotor core.
Clean slip rings using fine sandpaper.
If slip rings are beyond repair,remove them or replace them.

7.)BEARINGS BENCH TESTING
Always replace bearings in case of overhauling alternator.
If replacement front bearing is sealed on one side only,open
side must face rotor.
If replacement rear bearing is sealed on one side only,open
side must face away from rotor.

8.)BRUSHES BENCH TESTING
Ensure brushes are longer than 5.56mm.
2. GENERATOR REPAIR STEPS
1.)INSTALLATION FOR THE NEW GEN HEAD
ASSEMBLY
AREMOVAL OF THE OLD STYLE
STEP 1-Remove the end cover off the gen head using a
wrench .
STEP 2-Once the end cover is removed,disconnect the wires
to the capacitor and the stator.
STEP 3-Remove the nuts underneath the support bar on the
frame.
STEP 4-Remove the stator.
STEP 5-Remove the rotor bolt.
STEP 6-Remove the rotor.
BINSTALLATION OF THE NEW STYLE
STEP 1-Install rotor.
STEP 2-Install rotor through bolt & nut.
STEP 3-Install stator.
STEP 4-Install bearing support.
STEP 5-Remove the old one & install the new one.
STEP 6-Remove the old gen head & install the new gen head.
STEP 7-Reconnect the wires to the capacitor.
STEP 8-Connect the remaining wires by colour.

2.)TO RE-EXCITE GENERATOR
If no output,reverse the engine to full for no more than 3
seconds.This will re-excite the gen head.
If still no output,shut engine off.

3.)TO CHECK CAPACITOR
Remove the end cover screws and end cover from gen head.
Remove capacitor leads.
Open circuit from beginning indicates bad capacitor.

4.)TO CHECK STATOR
If the capacitor checks okay,check for open circuits in stator
If open circuits are not found & there is still a problem,check
for circuits grounded in stator.

5.)TO CHECK IDLE CONTROL SWITCH
Place idle control switch in the OFF position.
Remove the two screws from the front of idle control switch.
Disconnect wire harness from idle control switch.