1. Manuals
  2. Brands
  3. CG Manuals
  4. Engine
  5. TAO-659
  6. Maintenance handbook

CG TAO-659 Maintenance Handbook

Traction motor
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
CAMTECH/97/E/TM/3.0
MAINTENANCE HANDBOOK ON
TRACTION MOTOR TAO - 659
TM Maintenance Handbook
January'97

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the TAO-659 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for CG TAO-659

  • Page 1 CAMTECH/97/E/TM/3.0 MAINTENANCE HANDBOOK ON TRACTION MOTOR TAO - 659 TM Maintenance Handbook January’97...

  • Page 2: Table Of Contents

    Maintenance activities with TM in position During IA and IB schedule During IS schedule Flow chart for checking brush holder and Carbon brushes. Steps for Inspection of Tm TAO-659. overhauling Schedule Disassembly 2.7.1 Disassembly of Armature 2.7.2 Disassembly of End shield (PE) 2.7.3 Disassembly of End shield (CE)
  • Page 3 2.8.4 Reassembly of Rocker Ring 2.8.5 Shrink fit of Pinion Chapter 3 FAILURES AND TESTING Common Failures Causes and Remedies Testing of Traction Motor TAO-659 3.2.1 Insulation Resistance Test 3.2.2 Dielectric Test 3.2.3 Polarity Test 3.2.4 Voltage drop test forCommutator segments 3.2.5 Ovality Test...

  • Page 4: Chapter 1 Introduction

    Do’s & Don’ts booklet, Lesson plan, Transparencies, Wall posters & Videocassettes. Since majority of traction-motors are of TAO-659 type, this training-package is kept limited to this type of TM only.
  • Page 5 CAMTECH/97/E/TM/3.0 770 HP 798 HP Shaft output 575 kW Voltage 750 V DC 750 V, Max-800/2 V Current 840 Amps. 855 Amps. Speed 1095 RPM 2500 RPM (max) Air gap Main Pole Inter pole 5.5 mm. 6.0 mm Armature Weight 850 KGs.

  • Page 6: Power Supply Arrangement

    CAMTECH/97/E/TM/3.0 Gear Ratio 62:15, 58:21 Permanent shunt Bearing Type : CE -NJ 318, PE -NU 328 Make : SKF, NBC, FAG, NORMA Lubrication : Shell Albania EP 2. Clearance : Diametrical - CE 0.30 mm - PE 0.035 mm POWER SUPPLY ARRANGEMENT All the six Nos.

  • Page 7: Fixing Arrangement

    CAMTECH/97/E/TM/3.0 6 P Combination 1.3.3 In this combination, all six TMs are connected in parallel, and each gets full voltage as shown in figure 1.3. This com- bination is therefore suitable for low Figure 1.3 torque & high speeds. Advantages 1.3.3.1 There is less tendency of wheel slip.

  • Page 8: Constructional Features

    CAMTECH/97/E/TM/3.0 CONSTRUCTIONAL FEATURES The traction motor TAO-659 has the following main parts: Stator Frame 1.5.1 This is a cast steel magnet frame consisting main poles and interpoles fixed to it. On the Commutator side, opening been provided for upper air...

  • Page 9: Armature

    CAMTECH/97/E/TM/3.0 Armature 1.5.2 It is the rotating member of the motor, consisting of a number of cop- per conductors suitably placed and connected so as to form a closed winding. The armature consisting of slots, teeth, winding and the core is shown in figure 1.5.

  • Page 10: Armature Bearing

    Commutator diameter is approximately equal to the armature diameter. However, when the difference in the two diameters is appreciable as in case of TAO-659 Traction Motors, the ends of the armature coils are con- nected to the Commutator with the half of risers shown in figure 1.6.
  • Page 11 CAMTECH/97/E/TM/3.0 The emf generated in the armature conductor of DC machine is alternating and as such the current in a particular conductor is in one direction when the conductor is moving under the north pole and in the reverse direction, when it is moving under south pole.

  • Page 12: Brushes And Brush Holder

    The numbers of brush holders are usually equal to the number of main poles in DC machine. The brush holder is one of the major component/part of the rocker assembly. One brush holder in TAO-659 contains set of 3 brushes. 1.5.6...

  • Page 13: End Shields

    CAMTECH/97/E/TM/3.0 Insulators - These are glass bonded mica insulators. Connecting leads- made of electrolytic grade copper rods. Final assembly. All six brush holders are positioned exactly 60° apart, on the rocker ring with the help of insulator. The concentricity of all the inner faces of the brush holders with respect to diameter of the rocker ring should be within required limit.
  • Page 14 CAMTECH/97/E/TM/3.0 field (F ) along the magnetic axis while the current flowing through the armature produces an mmf (F ) directed along the brush axis. The two mmfs are in space quardrature and occur simultaneously in the motor. They react with each other and develop a torque under whose action the armature rotates.
  • Page 15 CAMTECH/97/E/TM/3.0 and hence φ will be At light loads I quite low and E will be high, therefore `N’ may become quite high. However as the load on the motor increases, speed will decrease rapidly & with further increase in armature current, the increase in flux is quite small because of saturation effect &...

  • Page 16: Chapter 2 Inspection Schedule

    CAMTECH/97/E/TM/3.0 CHAPTER 2 INSPECTION SCHEDULE MAINTENANCE ACTIVITIES WITH TM IN POSITION (AT A GLANCE) TAO-659 TM Commutator Brush Holder & Rocker ring. Carbon Brush Gearcase & gears Motor suspension unit Connection lead wire, connection bar & terminal External appearance Ingress of rain water and dust...
  • Page 17 CAMTECH/97/E/TM/3.0 Polish /clean complete Commutator surface by taking slight movement of locomotive. Brush Gear 2.2.2 Measure and record size of all carbon brushes (condemn limit 27 mm.) . Examine brush holder insulators for proper glaze. Inspection Cover 2.2.3 Ensure existence, condition and proper fitment of both top and bottom inspection cover.
  • Page 18 CAMTECH/97/E/TM/3.0 Check arcing ring for flash marks. Clean V- cone. Terminals 2.3.4 Examine outgoing interpole leads for any cracks etc. Check the cover gasket of terminal cover , replace if required. Check connections tightness. Check tightness of wooden cleats. Check the gasket of inspection cover and ensure air tightness. Check setting of inter pole and field both .

  • Page 19: Steps For Inspection Of Tm Tao-659

    Rotate rocker ring in order to meet `V’slot & `U’ slot Tightening Dowel bolt Tightening rocker ring in bear- ing bracket by special bolts Setting of connection lead wire with nut. STEPS FOR INSPECTION OF TAO-659 TM ITEMS TM Maintenance Handbook January’97...
  • Page 20 CAMTECH/97/E/TM/3.0 INSPECTION ITEMS SERVICE INSPECTION INTERVAL LIMIT AOH/ 1. TM on general a) Appearance b) Inspection cover. c) Loosening of bolts. d) Ingress of dust & water e) Condition of lead wire , cleat & contact of terminals. f) Grease adding to armature bearing.
  • Page 21 CAMTECH/97/E/TM/3.0 INSPECTION ITEMS SERVICE INSPECTION INTERVAL LIMIT AOH/ 5. Stator a) Dimensions of moun- -ting parts. b) Dent of pole retaining bolt shall be filled with compound. c) Stator coil,lead wire and connector. 6. Brush holder & carbon brush a) Cleaning & checking. b) Spring pressure.

  • Page 22: Overhauling Schedule

    CAMTECH/97/E/TM/3.0 OVERHAULING SCHEDULE Flow chart for Disassembly 2.6.1 Inspection cover Carbon brush Pinion bolt Pinion Outer bearing stopper pinion end. Armature End Shield End shield Magnet frame Rocker ring Brush Holder TM Maintenance Handbook January’97...

  • Page 23: Disassembly

    CAMTECH/97/E/TM/3.0 DISASSEMBLY 2.7.1 Disassembly of Armature Remove the carbon brush from the brush holder. After removing carbon brushes, wind a press board on the Commutator for preventing the Commutator sur- face from being scratched. Dismount the bearing cover from the end shield utilising the taped hole for pulling out.

  • Page 24: Disassembly Of Armature Bearing

    CAMTECH/97/E/TM/3.0 Disassembly of Commutator side End shield 2.7.3 Dismount the CE, end shield together with outer ring of roller bearing (bear- ing bracket) from the magnet frame utilising the tapped hole for pulling out. Pay full attention when handling the bearing bracket. Remove the rocker ring from the magnet frame.
  • Page 25 CAMTECH/97/E/TM/3.0 Set hooks 1 on inner bearing stopper. Fix hooks 1 by keeper plate 2 Screw double-end studs 4 in hooks 1 Set support disk 5 on Ram, set nut 3 on piston. Fix support disk 5 by double-end studs 4 & nuts 6 Press piston with handling oil power pump.

  • Page 26: Cleaning Of Armature Bearing

    CAMTECH/97/E/TM/3.0 Commutator End 2.7.4.2 Similarly dismount the bearing inner ring, inner bearing stopper and bearing outer ring at the same time, after removing CE end shield by exclusive tool according the above procedure. 2.7.5 Cleaning of Armature Bearing To clean the dismounted armature bearings, put them into a vessel contain- ing kerosene heated upto about 60°...

  • Page 27: Maintenance Of Commutator

    CAMTECH/97/E/TM/3.0 Provide Silconite `E-233’ on the rocker leads & bake it at 180°C for four hours or at 150 °C for eight hours. Tape should be cleaned for its smoothness by the sandpaper. Measure the tension of every spring of brush holder. Tension should be 2.4 to 2.2 Kg.
  • Page 28 CAMTECH/97/E/TM/3.0 In case that stepped wear is cased in Commutator surface (when `δw’ exceeds 0.1-mm max.) shown in figure 2.7) In case where it is impossible to rework by a grindstone because the commutator surface is heavily rough When reusing the traction motor after a long-term storage (more than 6 months), oxide film is pro- duced on the Commutator surface...

  • Page 29: Reassembly Of Traction Motor Tao - 659

    CAMTECH/97/E/TM/3.0 When correcting the commutator surface by the lathe, align the armature shaft as shown below in figure 2.10 Figure 2.10 Rush the shaft end of armature shaft on the commutator side by the centre of lathe, align the armature shaft by using the bearing fitting portion A, on the pinion side as reference and check the shaft end on the pinion side.

  • Page 30: Reassembly Of Armature

    CAMTECH/97/E/TM/3.0 Outer Ring 2.8.2.1 Fill the interiors of grease holding chamber of end shield and bearing outer ring with the specified amount of grease, than pressure fit the outer ring to the end shield by using exclusive tools. Never fit the outer race while striking by hammer. Tighten the grease covers by means of bolts.

  • Page 31: Reassembly Of Rocker Ring

    CAMTECH/97/E/TM/3.0 Lock the rocker ring by means of rocker pinion and by inserting a locking pin with the help of an exclusive tool as shown in figures 2.12 & 2.13. Fit the TM inspection cover (figure 2.14). Greasing at both PE & CE end bearings to be done with the help of grease gun.
  • Page 32 CAMTECH/97/E/TM/3.0 Remove the pinion from oil bath and remove oil from pinion surface by air blowing as fast as possible. Perform shrink fitting of pinion immediately by putting together the tally marks on the armature shaft and the pinion and al- low to cool naturally.

  • Page 33: Chapter 3 Failures And Testing

    CAMTECH/97/E/TM/3.0 CHAPTER 3 FAILURES AND TESTING COMMON FAILURES, CAUSES & REMEDIES FAILURE/ TROUBLE POSSIBLE CAUSES AND REMEDIES POOR COMMUTA- CARBON BRUSH TION i) Grade or form : Examine the grade of carbon brushes If found different, replace with the same grade of brushes.
  • Page 34 CAMTECH/97/E/TM/3.0 FAILURE/ TROUBLE POSSIBLE CAUSES AND REMEDIES COMMUTATOR High bar, Low bar, Deformation, Ovality : Colour change, unequal oxygenated film, abnormal wear of brush may be caused a flash over. Polish the commu- tator surface with lathe. ii) Joggle wear and roughening of surface : Polish commu- tator surface with lathe.
  • Page 35 CAMTECH/97/E/TM/3.0 FAILURE/ TROUBLE POSSIBLE CAUSES AND REMEDIES OTHER FAILURE INSULATION BREAKDOWN & EARTHING Coil, commutator, lead wire, inner connection, brush holder: Poor & Overaged condition of insulation, rub- bing & cutting marks on insulation. DC component to be systematically examined so as to find troubled part. Repair the damaged part according to insulation.

  • Page 36: Testing Of Traction Motor Tao-659

    CAMTECH/97/E/TM/3.0 TESTING OF TRACTION MOTOR TAO- 659 3.2.1 Insulation Resistance Test Insulation resistance is measured with 1000 V megger in service, the value should be more than 1 Mega ohm. However if the value is less than 1 Mega ohm it is considered undesirable for service operation. If the insulation resis- tance drop is due to absorption of moisture, dry out must be carried out.

  • Page 37: Voltage Drop Test Forcommutator Segments

    CAMTECH/97/E/TM/3.0 Testing of Neutral Axis 3.2.3.1 Connect a voltmeter in between `N’ and `S’ pole of the TM (at brush holder), apply 50 to 60 V DC to the TM field. The voltmeter reading should stand at zero. 3.2.4 Voltage Drop Test for Commutator Segments Direct current is applied to the armature winding (about 20 to 30% )of rated current of the TM...
  • Page 38 CAMTECH/97/E/TM/3.0 Testing of Neutral Axis 3.2.3.1 Connect a voltmeter in between `N’ and `S’ pole of the TM (at brush holder), apply 50 to 60 V DC to the TM field. The voltmeter reading should stand at zero. 3.2.4 Voltage Drop Test for Commutator Segments Direct current is applied to the armature winding (about 20 to 30% )of rated current of the TM...
  • Page 39 CAMTECH/97/E/TM/3.0 LIST OF RDSO’s MODIFICATIONS AND MAINTENANCE INSTRUCTIONS SN MODIFICATION DESCRIPTION 01. RDSO/WAM4/63 Taping of leads of traction motor type TAO-659 to prevent chafing in cleats. 02. RDSO/WAM4/67 Fixing of Neoprene gasket on the terminal box cover of TAO-659 TM.
  • Page 40 CAMTECH/97/E/TM/3.0 posed surface of V-cone of traction motor. 18. RDSO/WAM4/64 Modification (type 1) to inspection covers of TAO-659 trac- tion motors. (Alternative modification sheet (Type 2) which covers use of mild steel inspection cover as developed by Gaziabad shed will be issued separately).

  • Page 41: List Of Rdso Special Maintenance

    Procedure for drying out of TAO-659 TM. 18. ELRS/SMI/128 Tan Delta measurement of TM Armature. 19. ELRS/SMI/151 Testing of brazing joint of field coils circuits of TM type TAO-659 and HS 15250/ HS 1050 Er. 20. ELRS/SMI/160 Measurement of back lash of traction gears.
  • Page 42 22. ELRS/SMI/167 Precaution while taping of bus bars and clamps of traction motors stators. 23. ELRS/SMI/168 Copper busbar used in stator of TAO-659 traction motors in the locomotives. 24. ELRS/SMI/170 Checks on main pole and interpole coils of TAO-659 TM.

  • Page 43: List Of Machine, Tools And Spares

    CAMTECH/97/E/TM/3.0 APPENDIX C MACHINE, TOOLS AND SPARES LIST OF DESCRIPTION Qty. Pinion extractor 02 Nos. Pinion heating oil bath or induction heater 02 Nos. Auto Transformer rectifier unit. 1000 V, 150 Amp. DC 01 No. Commutator turning lathe. 01 No. Mica under cutting and chamfering machine for armature 01 No.
  • Page 44 CAMTECH/97/E/TM/3.0 Spring balancer 0-5 Kg. 02 Nos. Mano meter 02 Nos. Vibration meter. 01 No. Varnier callipers, Micro meters & feeder gauges. 02 Nos. Revolution counters. 01 No. Commutator profile recorder. 01 No. Torque wrench 0-150 Kgm. 03 Nos. Two pin spanner for movement of rocker assembly. 03 Nos.

  • Page 45: Suggestions From Various Electric Loco Sheds

    CAMTECH/97/E/TM/3.0 APPENDIX - D SUGGESTIONS FROM VARIOUS ELECTRIC LOCO SHEDS Sr.No Shed/Railway Suggestions ELS/JHS Whenever a loco is failed, following points is to be checked: SL connections, its polarities, Manometer reading, applied voltage on each notch, RC network connections, working of Q-20 relay.

Table of Contents