esr 0603 - overhaul of 48 class locomotive auxiliary ... · pdf file5.2 summary of tests to be...

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Engineering Standard Rolling Stock

ESR 0603

OVERHAUL OF 48 CLASS LOCOMOTIVE AUXILIARY

GENERATORS

Version 1.0

Issued June 2010

Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.

Owner: Chief Engineer Rolling Stock Approved by:

Stephen White, Technical Specialist Rolling Stock Performance Standards, Rolling Stock Access Integrity

Authorised by:

Michael Uhlig, Manager, Rolling Stock Access Integrity

UNCONTROLLED WHEN PRINTED of 24

RailCorp Engineering Standard — Rolling Stock Overhaul of 48 class locomotive auxiliary generators ESR 0603

© Rail Corporation of 24 Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1.0

Document control

Revision Date Summary of change (RSS 0603) 1.0 August 2007 Based on TRS 1440 (ESR 0603) 1.0 June 2010 Reformatted and renumbered ESR 0603

Summary of changes from previous version

Summary of change Section NOTE – If the final document is small enough for the ‘Contents’ and ‘Document control’ to fit on one page remove the page break between the existing pages 2 and 3. HOWEVER if the ‘Document control’ page carries over to a second page separate pages must be used for ‘Contents’ and ‘Document control’



Contents

1 Scope..................................................................................................................................................6 2 General ...............................................................................................................................................6

2.1 Torque settings .........................................................................................................................6 3 Pre service/overhaul inspection ......................................................................................................6

3.1 Pre cleaning activity ..................................................................................................................6 3.2 Post cleaning activity.................................................................................................................6

4 Service procedures ...........................................................................................................................7 4.1 Armature and commutator ........................................................................................................7 4.2 Brushgear..................................................................................................................................7 4.3 Machine Frame .........................................................................................................................8 4.4 Bearings ....................................................................................................................................8 4.5 Fan ............................................................................................................................................8 4.6 Machine painting .......................................................................................................................8

5 Post service test................................................................................................................................9 5.1 General......................................................................................................................................9

5.1.1 Continuous rating .........................................................................................................9 5.1.2 Rated voltage ...............................................................................................................9 5.1.3 Rated speed .................................................................................................................9 5.1.4 Maximum speed of the machine ..................................................................................9 5.1.5 Direction of rotation ......................................................................................................9 5.1.6 Runout of commutator..................................................................................................9 5.1.7 Eccentricity of commutator ...........................................................................................9

5.2 Summary of tests to be performed on the auxiliary generator..................................................9 5.2.1 Resistance measurement ..........................................................................................10 5.2.2 Insulation resistance test 1.........................................................................................10 5.2.3 Neutral point setting ...................................................................................................10 5.2.4 Direction of rotation test .............................................................................................10 5.2.5 Temperature rise and vibration test ...........................................................................10 5.2.6 Overspeed test ...........................................................................................................10 5.2.7 Insulation resistance test 2.........................................................................................10 5.2.8 Commutator roundness..............................................................................................11 5.2.9 Brush pressure ...........................................................................................................11

5.3 Instrumentation .......................................................................................................................11 5.4 Documentation ........................................................................................................................11

6 Overhaul/rewind procedure............................................................................................................11 6.1 General....................................................................................................................................11 6.2 Armature overhaul...................................................................................................................11 6.3 Brushgear................................................................................................................................12 6.4 Machine Frame .......................................................................................................................13 6.5 Bearings ..................................................................................................................................13 6.6 Fan ..........................................................................................................................................13 6.7 Machine painting .....................................................................................................................13

7 Post overhaul/rewind test...............................................................................................................14



7.1 General....................................................................................................................................14 7.1.1 Continuous rating .......................................................................................................14 7.1.2 Rated voltage .............................................................................................................14 7.1.3 Rated speed ...............................................................................................................14 7.1.4 Maximum speed of the auxiliary generator ................................................................14 7.1.5 Direction of rotation ....................................................................................................14 7.1.6 Runout of commutator................................................................................................14 7.1.7 Eccentricity of commutator .........................................................................................14

7.2 Summary of tests to be performed on the auxiliary generator................................................14 7.2.1 Resistance measurement ..........................................................................................14 7.2.2 Insulation resistance test 1.........................................................................................15 7.2.3 Neutral point setting ...................................................................................................15 7.2.4 Direction of rotation test .............................................................................................15 7.2.5 Temperature rise and vibration test ...........................................................................15 7.2.6 Overspeed test ...........................................................................................................15 7.2.7 Commutator roundness..............................................................................................15 7.2.8 Brush pressure ...........................................................................................................15

7.3 Instrumentation .......................................................................................................................16 7.4 Documentation ........................................................................................................................16

8 AEI AG51 auxiliary generator.........................................................................................................16 8.1 For pre service/overhaul inspection specification ...................................................................16

8.1.1 Armature.....................................................................................................................16 8.1.2 Fields and Interpoles..................................................................................................16

8.2 Service specification ...............................................................................................................16 8.2.1 Armature and commutator .........................................................................................16 8.2.2 Brushgear...................................................................................................................16 8.2.3 Bearings (approved)...................................................................................................16

8.3 Post service testing specification ............................................................................................17 8.3.1 Resistance measurement ..........................................................................................17 8.3.2 Temperature rise and vibration test ...........................................................................17

9 Alco GY27 auxiliary generator .......................................................................................................17 9.1 Pre Service/Overhaul Inspection Specification.......................................................................17

9.1.1 Armature.....................................................................................................................17 9.1.2 Fields and Interpoles..................................................................................................17

9.2 Service specification ...............................................................................................................17 9.2.1 Armature and commutator .........................................................................................17 9.2.2 Brushgear...................................................................................................................17 9.2.3 Bearings (approved)...................................................................................................18

9.3 Post service testing specification ............................................................................................18 9.3.1 Resistance measurement ..........................................................................................18 9.3.2 Temperature rise and vibration test ...........................................................................18

10 Reference standards.......................................................................................................................19 10.1 RailCorp standards .................................................................................................................19 10.2 RailCorp drawings...................................................................................................................19 10.3 Australian/British standards ....................................................................................................19



10.4 Other standards ......................................................................................................................19 10.5 GE drawings............................................................................................................................19

Appendix A – Torque Charts...............................................................................................................20 Appendix B - Drawing 004-653............................................................................................................22



1 Scope This standard sets out the minimum requirements, procedures and tests for the overhaul of auxiliary generators used on 48 class locomotives.

2 General This standard is to be used in conjunction with the Manufacturer's Maintenance Instructions, drawings and technical information, listed herein, for the respective auxiliary generators and Drawing 004-653, Auxiliary electrical machines service flow chart. (see Appendix B)

The goal of this standard is to provide overhauled and tested auxiliary generators which will operate at the specified performance levels for a period of not less than five (5) years. However with new insulation, commutators and bearings they should operate at specified performance levels for a period of not less than twelve (12) years, supported only by scheduled maintenance programs.

2.1 Torque settings The following applications in traction generator assemblies are critical in relation to the tightness of the fastening:

• Mounting of brush holders in frame.

• Inter-field connections (where not brazed).

• Connection of field circuit leads onto brush holders.

• Mounting of main fields in frame.

• Mounting of interpoles in frame.

The checking of the fastening tightness or their installation during assembly must be effected by torque values being appropriate for the size and grade of the fastenings (see Appendix B for torque charts).

3 Pre service/overhaul inspection If it is not visually obvious that a rewind is required the following checks shall be carried out and the results recorded. Any non-conformance with the specification and noted defects shall be reported to the Engineer to determine further action.

3.1 Pre cleaning activity The following inspection is to be carried out prior to the auxiliary generator being dismantled, cleaned of all dirt and grease.

• Measure the position of the brush holders relative to the commutator riser bars and face.

3.2 Post cleaning activity The following inspections are to be carried out after the auxiliary generator has been dismantled, cleaned of all dirt and grease, immersion rinsed (only if required to achieve two volt and PI test standards) and oven dried.



• Visually check commutator for any bar pattern, grooving, high bars, high mica or physical damage.

• Examine the armature insulation for charring, cracking and physical damage.

• Examine glass banding for physical damage, burning or tracking. If fitted with wire bands check for looseness or thrown solder.

• Measure diameter of commutator to ensure it is above condemning size.

• Measure commutator for eccentricity.

• Measure armature winding resistance.

• Measure the resistance of the machine fields.

• Measure resistance of the interpole coils.

• Measure insulation resistance as per Appendix B (Drawing 004-653 auxiliary electrical machines service flow chart).

• Apply surge test and bar-to-bar comparison test to commutator to check for open or short circuited coils.

• Check armature shaft for straightness, size (including 4 points on the bearing seat for ovality or taper, length of shaft overall, and critical sections) and surface integrity.

• Examine the armature for any physical damage.

4 Service procedures Service work shall generally be in accordance with Manufacturer's Maintenance Manual and Appendix B (drawing 004-653) with particular attention being given to the following:

4.1 Armature and commutator • Inspect for indication of high or loose bars and take corrective action as necessary.

• Inspect V-ring band and riser bars for any flashover damage and correct.

• Resurface the commutator (where needed) with the minimum cut to ensure surface integrity and roundness.

• Undercut the mica to width and depth shown in the relevant machine maintenance manual.

• Chamfer the commutator bar edges (45°, 0.2-0.4mm across face).

• Clean debris from commutator/armature after undercutting and chamfering.

• Dip armature in varnish or VPI (compatible with existing insulation) where machines have been recovered by rinsing or there has been visible damage to the insulation.

• Dynamically balance armature. Balance quality grade 2.5 (AS 3709; ISO 1940/1).

• Apply red air drying insulating varnish to armature (shaft, bands and commutator to be suitably masked before applying varnish).

4.2 Brushgear • Remove brush holders and check insulators for any visible damage, and replace if

damaged.

• Inspect for any flashover deposits on brush holders and correct.

• Inspect arc horns and replace if damaged.



• Ensure brush holders are not deformed.

• Sand blast brush holders. Brushways and insulators to be suitably masked.

• Set brush spring pressure. Refer to relevant technical specification.

• Ensure mounting screws and clamps are sound and correctly torqued (see Clause 2.1).

• Ensure brushgear alignment is parallel to commutator centre line.

• Ensure spacing of brush holders is correct.

• Fit new brushes. Ensure brushes move freely in brush holder.

• Inspect braiding of brushes and tightness of brush terminal connections. (Braiding must be positioned to allow free movement of hammers).

4.3 Machine Frame • Inspect for any flashover damage and correct.

• Ensure connections are sound and correctly torqued (see clause 2.1).

• Ensure all mounting bolts and nuts are correctly torqued (see clause 2.1).

• Ensure main field and interpole insulation are in good condition. Apply red air drying insulation varnish to inside assembly.

• Inspect cables, crimp lugs and markers for any signs of mechanical or electrical damage and replace any defective parts.

• Internal field leads must be securely bound to the bracing staples. Replace any loose or defective binding. (Cable ties are not permitted for this purpose.)

• Ensure that flash rings or arc horns are clean and free of paint. Replace if damaged.

• Inspect bearing housing and seals for excess wear as indicated in relevant auxiliary generator data and restore where necessary.

• Inspect condition of cable cleats. Replace if damaged.

• Ensure inspection cover components including locating lugs, latching mechanisms, springs, bolts and sealing strips will provide correct securing of covers and sealing for cooling air.

4.4 Bearings New bearings shall be provided and fitted by the Contractor. Acceptable bearings are listed in the individual auxiliary generator specifications.

4.5 Fan • Inspect fan for evidence of physical damage. Report/repair as required

• Ensure mounting holes are not deformed or damaged.

• Inspect fan blades for physical damage and/or wear. Report/repair as required

• Dynamically balance fan. Balance quality grade 2.5 (AS 3709; ISO 1940/1)

4.6 Machine painting After stripping off old paint work all auxiliary generators shall be painted with 1 coat of suitable primer and 1 coat of enamel paint - which shall be approved under GPC-E-24. The colour will be nominated by the Engineer and shall comply with AS 2700.



Note: Areas to be masked shall include:

• Manufacturer's data plate

• Leads

• Commutator inspection hatches.

• Armature Shaft.

5 Post service test

5.1 General This procedure covers the performance testing of auxiliary generator used on rail vehicles.

The definitions applicable to this standard are:

5.1.1 Continuous rating The rating that corresponds to a load that the auxiliary generator can withstand on the test for an unlimited period, without exceeding the limits of temperature rise as given in BS 173, clause 31. The test being started with the machine cold (see BS 173, clause 34).

5.1.2 Rated voltage The specified value of the voltage at the terminals of the machine.

5.1.3 Rated speed The speed corresponding to the manufacturer's guarantee.

5.1.4 Maximum speed of the machine The maximum rotational speed of the auxiliary generator corresponding to the maximum speed.

5.1.5 Direction of rotation The direction of rotation of the armature when facing the commutator end of the machine.

5.1.6 Runout of commutator Maximum out of round measured over six (6) segments.

5.1.7 Eccentricity of commutator Out of round measured over the full circumference of the commutator.

5.2 Summary of tests to be performed on the auxiliary generator The test program shall, in principle, be carried out in accordance with the requirements of BS 173.1980.



5.2.1 Resistance measurement Measure the resistance value of all windings in the main field, the interpoles and the armature windings. If the ammeter and voltmeter method is used for the measurement of resistance, the current used shall be of a value such as to obtain a suitable accuracy of measurement, whilst being low enough to neither cause the armature to start through the effect of residual flux nor influence the temperature rise.

5.2.2 Insulation resistance test 1 Prior to the rotational test, the machine shall be subjected to a high potential test as detailed below:

60 Sec high New winding Used winding potential testing

Test volts 2,500 AC & DC 2,500 DC

Pass criteria less than 2.5uA DC and no less than 25uA and no disruptive disruptive discharge AC discharge

5.2.3 Neutral point setting Ensure neutral point setting is correct.

5.2.4 Direction of rotation test Connect leads to a suitably rated power supply. Increase the voltage until the armature rotates. Rotation should be counter-clockwise as viewed from the commutator end of the machine when the positive lead of the machine is connected to the positive terminal of the power supply.

5.2.5 Temperature rise and vibration test • Run the auxiliary generator for sixty minutes at the speed referred to in the individual

machine specifications in the counter-clockwise direction.

• Record temperature of the bearing every ten (10) minutes. Listen for any abnormal bearing noise during rotation.

• Measure and record vibration of the machine running. This shall not exceed range classification 1.12, Table 1 AS 2625.

• Measure and record the temperature of the commutator at the end of the test.

5.2.6 Overspeed test An overspeed test as per clause 36 BS 173 shall be carried out.

5.2.7 Insulation resistance test 2 After the overspeed test, the machine shall be subjected to a high potential test as below:

60 Sec high New winding Used winding potential testing

Test volts 1750 AC & DC 650 DC



Pass criteria less than 2.5uA DC and no less than 25uA and no disruptive disruptive discharge AC discharge

Compare results with insulation resistance test 1 (5.2.2).

5.2.8 Commutator roundness Position dial gauge to touch the commutator surface. Rotate armature slowly by hand and measure the commutator eccentricity and run out. Record values on test sheet.

5.2.9 Brush pressure Use a suitable instrument to test the brush spring pressure of all brush springs.

5.3 Instrumentation The serial numbers of all instruments and meters used to perform the tests outlined in section 5.2 shall be recorded, together with the date of their most recent calibration check.

5.4 Documentation The recorded measurements shall be entered in dated test report sheets and returned with the machine.

6 Overhaul/rewind procedure

6.1 General This part of the specification covers the rewind/overhaul of the auxiliary generator. The work shall incorporate rewinding the armature, correcting machine frame and fields and installation of the following new components:

• Commutator (new or rebuilt)

• Armature bearings

• Brushes

The following shall be inspected for suitability for further duty and restored to service specifications. If beyond repair they shall be replaced with new components:

• Armature shaft

• Brush holders

• Commutator inspection covers

• Machine leads and cleats

• Fan

The commutators, fields and bearings removed from machines and replaced shall be returned to the Purchaser.

6.2 Armature overhaul • Remove bearings and commutator.

• Strip the armature of coils and insulation.



• Shafts suitable for resizing may be repaired by Gas Metal Arc Welding - GMAW and machined to specified dimensions. The welding procedure shall be strictly in accordance with AS 1554.1, the electrodes shall be type ESD2 to AS 2717.1 and the gas shall be Argoshield 51. This procedure may be utilised for restoration requiring weld deposits to 6 mm. Repairs exceeding 6 mm deposit shall be referred to the Engineer. All welding shall comply with Australian Standards.

• Fit new shaft, where required, in accordance with the relevant drawing.

• Flux test the core to ensure no shorts or damage exist in the laminations. Defective cores are to be referred to the Engineer.

• Fit new or rebuilt fully seasoned commutator.

• Rewind armature with new main coils insulated to Classification 180 of AS 2768.

• TIG weld/resistance braze coil ends to riser bars.

• VPI the armature with Isonel 772 varnish.

• Oven dry.

• Check torque of commutator bolts. Correct as required or refer to commutator supplier.

• Resurface the commutator with minimum cut to ensure surface integrity and roundness.

• Undercut commutator mica to width and depth specified in the individual machine specification.

• Chamfer commutator bar edges (45°, 0.2 to 0.4 mm across face).

• Clean debris from commutator/armature after undercutting and chamfering.

• Dynamically balance the armature. Balance quality grade 2.5 (AS 3709; ISO 1940/1)

• Apply red air drying insulation varnish to armature (shaft and commutator to be suitably masked before applying varnish).

– Cleaning, drying, rewinding, testing and banding throughout the process shall be in accordance with the Manufacturer's Maintenance Manuals for original equipment or previously approved replacement, (eg. glass band).

• Fit new armature shaft bearing, as approved in the relevant machine specification.

• Fit qualified fan.

6.3 Brushgear • Remove brush holders and check insulators for any visible damage (cracks, chips,

tracking etc).

• Inspect for any flashover deposits on brush holders and correct.

• Sand blast brush holders. (Brushways and insulators to be suitably masked.)

• Inspect arc horns and replace if damaged.

• Replace any deformed brush holders.

• Ensure mounting screws and clamps are sound and correctly torqued (see clause 2.1).

• Ensure brushgear alignment is parallel to commutator centre line.

• Ensure spacing of brush holders is correct.

• Fit new brushes. Ensure brushes move freely in brush holder.



• Check braiding of brushes and tightness of brush terminal connections. (Braiding must be positioned to allow free movement of hammers.)

• Set brush pressure to specified limit. Refer to relevant technical specification.

6.4 Machine Frame • Thoroughly clean the machine inside and outside, preferably by an ultrasonic process

that does not utilise a detergent. Alternatively a spray wash may be used in conjunction with a detergent incorporating a non-ionic surfactant wetting agent and such detergent shall have the Engineer's written approval. Machines so cleaned shall have all traces of detergent removed by a clean water/steam rinse.

• Remove main and interpole coils and pole pieces.

• Inspect insulation quality. Where required re-insulate in accordance with Manufacturer's Maintenance Manual, to ensure suitability for nominated duty requirements. Re-insulation shall be with an approved asbestos-free system incorporating B stage epoxy rich materials to classification 180 of AS 2768.

• Pot the coils onto the pole pieces.

• Fit all coils into the frame and connect. Ensure all mounting and connect bolts and nuts are correctly torqued (see Clause 2.1).

• Inspect cables, crimp lugs and markers, correct any signs of mechanical or electrical damage and replace any defective parts.

• Internal field leads must be securely bound to the bracing staples. Replace any loose or defective binding. (Cable ties are not permitted for this purpose.)

• Ensure that flash rings or arcing horns are clean and free of paint. Replace if damaged.

• Inspect bearing housing and seals for excess wear as indicated in relevant auxiliary generator data and restore where necessary.

• Inspect condition of cable cleats. Replace if damaged.

• Spray the interior of the machine with red air drying insulating varnish.

6.5 Bearings New bearing shall be provided and fitted by the Contractor. Acceptable bearings are listed in the individual machine specifications.

6.6 Fan • Inspect fan and blades for evidence of physical damage or excessive wear. Restore to

serviceable condition.

• Ensure mounting holes are not deformed or damaged.

• Dynamically balance fan. Balance quality grade 2.5 AS 3709; ISO 1940/1).

6.7 Machine painting After stripping of old paintwork all machines shall be painted with 1 coat of suitable primer and 1 coat of enamel paint - which shall be approved under GPC-E-24. The colour will be nominated by the Engineer and shall comply with AS 2700.

Note: Areas to be masked shall include:



• Manufacturer's data plate

• Leads

• Commutator inspection hatches

• Armature shaft

7 Post overhaul/rewind test

7.1 General This procedure covers the performance testing of direct current auxiliary generator used on rail vehicles.

The definitions applicable to this standard are:

7.1.1 Continuous rating The rating that corresponds to a load that the auxiliary generator can withstand on the test for an unlimited period, without exceeding the limits of temperature rise is given in BS 173, clause 31. The test being started with the machine cold (see BS 173, clause 34).

7.1.2 Rated voltage The specified value of the voltage at the terminals of the machine.

7.1.3 Rated speed The speed corresponding to the manufacturer's guarantee.

7.1.4 Maximum speed of the auxiliary generator The maximum rotational speed of the Auxiliary generator corresponding to the maximum speed.

7.1.5 Direction of rotation The direction of rotation of the armature when facing the commutator end of the machine.

7.1.6 Runout of commutator Maximum out of round measured over six (6) segments.

7.1.7 Eccentricity of commutator Out of round measured over the full circumference of the commutator.

7.2 Summary of tests to be performed on the auxiliary generator The test program shall, in principle, be carried out in accordance with the requirements of BS 173.1980.

7.2.1 Resistance measurement Measure the resistance value of the main field, the interpoles and the armature windings.



If the ammeter and voltmeter method is used for the measurement of resistance, the current used shall be of a value such as to obtain a suitable accuracy of measurement, whilst being low enough to neither cause the armature to start through the effect of residual flux nor influence the temperature rise.

7.2.2 Insulation resistance test 1 Prior to the rotational tests, the machine shall be subjected to a high potential test as detailed below:

60 Sec high potential testing New winding

Test volts 2500 AC & DC

Pass criteria less than 2.5uA DC and no disruptive discharge AC

7.2.3 Neutral point setting Ensure neutral point is set correctly.

7.2.4 Direction of rotation test Connect leads to a suitably rated power supply. Increase the voltage until the armature rotates. Rotation should be counter-clockwise as viewed from the commutator end of the machine when the positive lead of the machine is connected to the positive terminal of the power supply.

7.2.5 Temperature rise and vibration test A temperature rise test, generally in accordance with clause 29.1 of BS 173, but of two (2) hours duration and test conditions specified herein. During this test the main, interpole and bearing temperatures shall be logged and the armature winding temperature and commutator temperatures shall be measured immediately upon shutdown.

A Pyrometer shall be used to measure the commutator surface temperature.

Measure and record vibration of the machine running. This shall not exceed range classification 1.12, Table 1 AS 2625.

7.2.6 Overspeed test An overspeed test as per Clause 36 BS 173 shall be carried out.

7.2.7 Commutator roundness Position dial gauge to touch the commutator surface. Rotate armature slowly by hand and measure the commutator eccentricity and run out. Record value on test sheet.

7.2.8 Brush pressure Use a suitable instrument to test the brush spring pressure of all brush springs. Adjust as required.



7.3 Instrumentation The serial numbers of all instruments and meters used to perform the tests outlined in section 7.2 shall be recorded, together with the date of their most recent calibration check.

7.4 Documentation The recorded measurements shall be entered in dated test report sheets and returned with the machine.

8 AEI AG51 auxiliary generator

8.1 For pre service/overhaul inspection specification

8.1.1 Armature - Insulation resistance 20 M Ohms @ 25oC (min)

- Armature resistance 0.024 Ohms +/- 2% @ 25oC

- Commutator diameter 175 mm (min)

8.1.2 Fields and Interpoles - Insulation resistance 20 M Ohms @ 25oC (min)

- Shunt field resistance 9.23 Ohms +/- 2% @ 25oC

- Commutating field resistance 0.013 Ohms +/- 2% @ 25oC

8.2 Service specification

8.2.1 Armature and commutator - Shaft dimensions Refer GE Drawing. D5280935

- Commutator runout 0.010 mm (max)

- Commutator eccentricity 0.025 mm (max)

8.2.2 Brushgear - Spring tension 1.1 kg +/- 0.1kg

- Replacement brushes Refer Drawing 407-526

8.2.3 Bearings (approved) - Commutator end 340 P

- Drive end R345 EV



8.3 Post service testing specification

8.3.1 Resistance measurement - Armature ................. Ohms

- Shunt field resistance ................. Ohms

- Commutating field resistance ................. Ohms

Insulation resistance

- 20 M Ohms @ 25oC (min.)

8.3.2 Temperature rise and vibration test - Test speed 2400 rpm

- Vibration 0.1 mm/sec (max.)

9 Alco GY27 auxiliary generator

9.1 Pre Service/Overhaul Inspection Specification

9.1.1 Armature - Insulation resistance 20 M Ohms @ 25oC (min)

- Armature resistance 0.024 Ohms +/- 2% @ 25oC

- Commutator diameter 191 mm (min)

9.1.2 Fields and Interpoles - Insulation resistance 20 M Ohms @ 25oC (min)

- Shunt field resistance 8.80 Ohms +/- 2% @ 25oC

- Commutator field resistance 0.0091 Ohms +/- 2% @ 25oC

9.2 Service specification

9.2.1 Armature and commutator - Shaft dimensions Refer GE Drawing.

- Commutator runout 0.010 mm (max)

- Commutator eccentricity 0.025 mm (max)

9.2.2 Brushgear - Spring tension 1.35 kg +/- 0.1 kg

- Replacement brushes Refer Drawing 407-350



9.2.3 Bearings (approved) - Commutator end 6309Z

- Drive end NU309

9.3 Post service testing specification

9.3.1 Resistance measurement - Armature ................. Ohms

- Shunt field resistance ................. Ohms

- Commutator field resistance ................. Ohms

Insulation resistance

- 20 M Ohms @ 25oC (min.)

9.3.2 Temperature rise and vibration test - Speed 2400 rpm

-Vibration 0.1 mm/sec (max.)



10 Reference standards

10.1 RailCorp standards ESR 0550 Overhaul of 48 class locomotive engine assembly

10.2 RailCorp drawings 004-653 Auxiliary electrical machine service flow chart

407-350 43, 44 Mk1, 48 Mk1, 442 Mk1 classes GE Aux. generator brush & 442 Mk1, 48 Mk1 class GE exciter brush.

407-526 Diesel electric locomotives AG32 exciter & AG51 aux. gen. brush.

10.3 Australian/British standards AS1554.1 SAA structural steel welding code - welding of steel structures

AS 2625 Rotating & reciprocating machinery – mechanical vibration

AS 2700 Colour standards for general purpose

AS 3709/ISO 1940 Vibration & shock – balance quality of rotating rigid bodies

AS 2717.1 Welding electrodes – gas metal arc ferritic steel electrodes

AS 2768 Electrical insulating materials, evaluation and classification based on thermal endurance

BS 173 Methods of specifying performance of rotating electrical machines for rail and road vehicles

10.4 Other standards GPC-E-24 Full gloss oil and petrol resistant enamel

10.5 GE drawings D5280935


Appendix A – Torque Charts



Appendix A (Continued)



Appendix B - Drawing 004-653 Auxiliary Electrical machines Flow Chart



Appendix B (Continued)


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