Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches
Field terminals and stator
V-Belt : The existing V-Belts shall terminals
be replaced with the new V-belt. 4
nos. having same make/grade. The (Note : Minimum insulation resistance
old V-belts removed from service should not be less than 1 Mega ohms
to be destroyed. for 4.5 kW under worst weather
conditions and 20 mega ohm for
708 POH SCHEDULE 18/22.75 kW respectively)
708a BRUSHLESS iii. OVERHAULING
ALTERNATOR
The machine received for
The procedure to be followed shall be overhauling should be externally
as per guide lines given below. cleaned with wire brush and wiped
before dismantling.
i. VISUAL INSPECTION
Clean and re-grease the bearing
Carry out visual inspection of the after removing the bearing from
machine and record the following:- the bearing housing. Only Servo
Gem (RR-3) grease shall be used.
Serial number and name plate
particulars of the machine. Clean the mating surface of the end
shield.
Check that rotor rotates freely.
Check the suspension bushes. While removing and placing the
rotor, care should be taken that the
Check insulation resistance rotor does not rub over the field
Check continuity of the field coils.
and stator
If any grease has crept into the
Check alternator tension rod stator surface, clean it before
Check the bearing noise with assembling.
shockpulse meter
If stator and rotor parts are found
rusty, clean. Apply the insulating
ii. ELECTRICAL CHECKS
varnish (air drying) of
recommended grade. Impregnation
Carry out the following electrical
of the varnish shall be done in an
checks and record the following: -
air circulated oven.
Open the cover of the terminal box
Change the alternator suspension
and check whether the internal
nylon bushes 100% and change the
termination and terminal board are
suspension pin on condition basis.
intact.
Tighten all the connections on the Apply the insulating varnish (air
terminal b oard. drying) of recommended grade.
Using a multimeter, check
Impregnation of the varnish shall
continuity between be done in an air circulated oven.
Field terminal F+&F-
Stator terminals U&V, V to W
After complete fitment and
and W to U greasing, the bearing noise shall be
recorded using shock pulse meter.
Check the insulation resistance by
500 V megger between
Only bearing of SKF/FAG shall be
provided as per recommendation of
Stator terminals and frame of
RDSO.
machine
Field terminals and frame
Chapter 7, Page 15 of 21
Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches
iv. TESTING OF ALTERNATORS speed from 600 rpm to 2400
rpm. Setting shall be done at
INSULATION RESISTANCE TEST 1500 rpm and half load 19A
before starting the test.
Check the insulation resistance
Alternator The voltage should
not exceed 5 % of the set
Place of Check Required Value for voltage at a speed from 600
Conventional Coaches rpm to 2400 rpm. The set
voltage can be 120 V, 122 V,
Between stator. Above 1 M 124 V at 19 Amp. 1500 rpm.
winding and earth Check the MFO (minimum
speed for full output) i.e. 37.5
Amp. for 4.5 kW alternator, it
Between field Above 1 M
winding and earth. should not be more than 600
rpm.
Between field Above 1 M
vii. TEMPERATURE RISE TEST
winding and stator.
For 4.5 kW Alternator
Regulator
Run the alternator at 600 rpm
Place of Check Required Value and apply the load. The alternator
Conventional Coaches should be capable of giving 37.5
Amps at 120 Volts. Run the
Short all terminal alternator at 2500 rpm with full
(live parts) together Above 1 M load for five hours with a fan
and check the insulation cooling the body. Check the
resistance between the temperature at different part of the
live parts and earth. alternator and should be as
follows:-
Note: The insulation resistance of all
the above should be measured a) Power diode - Should not exceed
0
by 500 V megger. 100 C at ambient
of 500 C.
v. NO LOAD TEST
b) Alternator terminal - Should
Connect the alternator not exceed 100 0 C
0
and regulator with a at ambient of 50 C.
resistance/battery load. Run
the Alternator at base load (1 c) Bearing temperature - Should not
0
A) at various speed from 357 exceed 85 C at
rpm to 2500 rpm. ambient of 50 0 C.
This voltage should d) Stator and Field - Should not
0
not exceed 5% of set the exceed 90 C at
voltage. The cut in speed win ding load of
should also be checked. It 37.5 Amps.
should not be more than 357
rpm at 108 volts at zero load. 708b RECTIFIER REGULATOR UNIT
vi. LOAD TEST The procedure to be followed shall be
as per guidelines given below.
Connect the alternator
and regulator with Check the terminals and inside
resistance/battery load. Run wires for heating signs and
the alternator at half load i.e. looseness. Blow out the dust.
19 Amp. and full load 37.5
Amp. respectively at various
Chapter 7, Page 16 of 21
Maintenance Manual for BG coaches of ICF design Train Lighting (Non - AC) coaches
ii) Check the air delivery of
one or two fans from a batch Do keep the terminal box
to ascertain the correctness tightly closed.
of the blade angle. The
value of the air delivery Do open the terminal box
shall not be less than that once in a week and clean the
specified in IS:6680. accumulated dust, if any.
NOTE : Do check tightness of the
connection regularly, at least
SKF/FAG (imported) make once in a week.
bearings for alternator procured
directly from manufacturers as Do use the cable grommets
specified in the RDSO or cable gland of correct size
specification shall be used. Use of for reducing the vibration of
other makes of bearing is not terminal connections. It is
permitted. preferable to anchor the
cables externally to avoid
Shock pulse meter shall be shocks and vibrations on the
procured by Railways and terminals.
workshops to monitor condition of
the bearing regularly during ii. DON’TS
maintenance service and after
replacement of defective bearings. Don’t use improper tools to
handle the alternator, it may
Induction heater/oil bath shall be damage parts of the
alternator.
used for heating the bearing to the
required recommended
temperature.
Don’t re-grease the bearing
frequently. Re-greasing
should be done after
The pulley condition such as wear
thoroughly cleaning the
on V group, pulley key way, shaft
bearing with white spirit. It
way, groove angle etc. shall be
is preferable to re-grease the
monitored during POH. Proper
bearing only during POH.
gauges shall be used for checking
"V" groove of the pulley.
Don’t over-grease the
bearing.
709 DO’S AND DON’TS FOR MAJOR
EQUIPMENT
Don’t keep the belts in over
tension as this may reduce
709a ALTERNATOR
life of the belt.
i. DO’S 709b REGULATOR
Do ensure the correct
i. DO’S
polarity of field winding i.e.
positive connected to F +
Do check the regulator
while measuring the terminal box once in a
continuity of the field
month for loose connections
winding, otherwise the
and for cleaning the dust.
alternator will not self
excite.
Do short all seven terminals
of the terminal box before
Do check the proper
measuring the insulation
compression force on the
resistance.
tensioning spring with
indicator plate by tightening
the special nut.
Chapter 7, Page 20 of 21
