M 10

MK RAIL CORPORATION
RUNNING MAINTENANCE MANUAL

FOR MK1500D LOCOMOTIVES
SECTION 10
ROTATING ELECTRICAL SYSTEM

Section 10 - Rotating Electrical System MK1500D Locomotive
This page intentionally left blank.
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MK1500D Locomotive Section 10 - Rotating Electrical System
TABLE OF CONTENTS
SECTION 10 ROTATING ELECTRICAL SYSTEM
Paragraph Description Page
LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
10.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.1 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.2 COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

10.2.1 Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.2.1.1 Frame and Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.2.1.2 Alternator Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.2.1.3 Brushless Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.2.1.4 Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.2.1.5 Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.2.2 Companion Alternator/Auxiliary Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.2.2.1 Stators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.2.2.2 Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.2.2.3 Bearing Bracket, Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.2.2.4 Endbell, Opposite Drive End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.2.2.5 Brushes/Brushholders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.2.2.6 DC Rectifier and Boost Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.2.2.6.1 DC Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.2.2.6.2 Boost Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.2.3 Air Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.2.3.1 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.2.3.2 Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.2.3.3 Bearing and Bearing Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.2.3.4 Fan, Baffle, and Frame Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.2.3.5 Drive Plate and Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.2.3.6 Compressor Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.2.3.7 Flywheel, Flywheel Coupling, and Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.2.3.8 Foot Riser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.2.4 Cooling Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.2.4.1 Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.2.4.2 Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.2.4.3 Fan Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.2.5 Filter Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.3 OPERATIONAL SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

10.3.1 Rotating Electrical Equipment Operational Sequence Diagram . . . . . . . . . . . . . . . . . . . . . . 10-12
10.4 SCHEDULED MAINTENANCE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

10.4.1 Scheduled Maintenance Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
10.4.2 Tools and Test Equipment, Consumables, Supplies, and Lubrication . . . . . . . . . . . . . . . . . 10-14
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TABLE OF CONTENTS (cont.)

10.5 SCHEDULED MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 10-16
10.5.1 Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
10.5.1.1 Inspect Traction Alternator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
10.5.1.2 Inspect Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
10.5.1.3 Clean Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
10.5.1.4 Replace Traction Alternator Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
10.5.1.5 Check Traction Alternator Bearing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
10.5.1.6 Check Traction Alternator Vibration Amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
10.5.1.7 Check Traction Alternator Insulation Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
10.5.1.7.1 Traction Alternator Exciter Field Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
10.5.1.7.2 Traction Alternator Generator Stator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
10.5.1.7.3 Traction Alternator Exciter Armature Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
10.5.1.7.4 Traction Alternator Rotor Winding Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
10.5.1.8 Test Traction Alternator Winding Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
10.5.1.9 Replace Traction Alternator Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
10.5.1.10 Replace Traction Alternator Rotating Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
10.5.2 Companion Alternator/Auxiliary Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
10.5.2.1 Inspect Companion Alternator/Auxiliary Generator Operation . . . . . . . . . . . . . . . . . . . . 10-21
10.5.2.2 Clean Companion Alternator/Auxiliary Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
10.5.2.3 Inspect/Replace Companion Alternator/Auxiliary Generator Brush and Brushholder . . 10-21
10.5.2.4 Inspect Companion Alternator/Auxiliary Generator Bearing . . . . . . . . . . . . . . . . . . . . . 10-21
10.5.2.5 Inspect Companion Alternator/Auxiliary Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
10.5.2.6 Check Companion Alternator/Auxiliary Generator Vibration Amplitude . . . . . . . . . . . 10-22
10.5.2.7 Check Companion Alternator/Auxiliary Generator Winding and Insulation Resistance 10-22
10.5.2.7.1 Companion Alternator/Auxiliary Generator AC Generator Stator . . . . . . . . . . . . . . . . 10-23
10.5.2.7.2 Companion Alternator/Auxiliary Generator Battery Charging Stator . . . . . . . . . . . . . 10-23
10.5.2.7.3 Companion Alternator/Auxiliary Generator AC Generator Rotor . . . . . . . . . . . . . . . . 10-23
10.5.2.7.4 Companion Alternator/Auxiliary Generator Battery Charging Rotor . . . . . . . . . . . . . 10-24
10.5.2.8 Test Companion Alternator/Auxiliary Generator Exciter Field Saturation . . . . . . . . . . . 10-24
10.5.2.8.1 Companion Alternator/Auxiliary Generator AC Generator . . . . . . . . . . . . . . . . . . . . . 10-24
10.5.2.8.2 Companion Alternator/Auxiliary Generator Battery Charging Generator . . . . . . . . . . 10-24
10.5.2.9 Check Companion Alternator/Auxiliary Generator Coupling Alignment . . . . . . . . . . . . 10-25
10.5.2.10 Replace Companion Alternator/Auxiliary Generator Bearing . . . . . . . . . . . . . . . . . . . . . 10-25
10.5.3 Air Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
10.5.3.1 Inspect Air Compressor Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
10.5.3.2 Clean Air Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
10.5.3.3 Check Air Compressor Motor Bearing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
10.5.3.4 Inspect Air Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
10.5.3.5 Check Air Compressor Motor Vibration Amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
10.5.3.6 Check Air Compressor Motor Winding and Insulation Resistance . . . . . . . . . . . . . . . . . 10-27
10.5.3.7 Replace Air Compressor Motor Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
10.5.4 Cooling Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
10.5.4.1 Inspect Cooling Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
10.5.4.2 Check Cooling Fan Assembly Insulation Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
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TABLE OF CONTENTS (cont.)

10.6 TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
10.6.1 Using the Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
10.6.2 Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
10.6.2.1 No AC Voltage from Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
10.6.2.2 Low AC Voltage from Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
10.6.2.3 Fluctuating AC Voltage from Traction Alternator with Constant Speed . . . . . . . . . . . 10-29
10.6.2.4 High AC Voltage from Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
10.6.2.5 Traction Alternator Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
10.6.2.6 Vibration in Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
10.6.2.7 No AC Voltage from Companion Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
10.6.2.8 Low AC Voltage from Companion Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
10.6.2.9 Fluctuating AC Voltage from Companion Alternator with Constant Speed . . . . . . . . 10-31
10.6.2.10 High AC Voltage from Companion Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
10.6.2.11 No Voltage from Auxiliary Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
10.6.2.12 Low Voltage from Auxiliary Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
10.6.2.13 High Voltage from Auxiliary Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
10.6.2.14 Companion Alternator/Auxiliary Generator Overheating . . . . . . . . . . . . . . . . . . . . . . 10-32
10.6.2.15 Vibration from Companion Alternator/Auxiliary Generator . . . . . . . . . . . . . . . . . . . . 10-33
10.6.2.16 Air Compressor Motor Fails to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
10.6.2.17 High Vibration from Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
10.6.2.18 Air Compressor Drive Plates and Flywheel Misaligned . . . . . . . . . . . . . . . . . . . . . . . . 10-33
10.6.2.19 Air Compressor Motor Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
10.6.2.20 Regular Clicking from Air Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
10.6.2.21 Rapid Knocking from Air Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
10.6.2.22 Cooling Fan Is Not Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
10.6.2.23 High Vibration from Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
10.7 REMOVAL AND INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . 10-35

10.7.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
10.7.2 Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
10.7.3 Cooling Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
10.7.4 Cooling Fan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
10.7.5 Air Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
10.7.6 Air Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
10.7.7 Companion Alternator/Auxiliary Generator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
10.7.8 Companion Alternator/Auxiliary Generator Installation . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
10.7.9 Traction Alternator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
10.7.10 Traction Alternator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
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LIST OF ILLUSTRATIONS
Figure Description Page
10-1 Block Diagram - Rotating Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

10-2 Traction Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10-3 Megger Conversion to 40 °C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
10-4 Traction Alternator Rotating Rectifier Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
10-5 A Straightedge and Feeler Gauge Method of Coupling Alignment . . . . . . . . . . . . . . . . . . . 10-25
LIST OF TABLES
Table Description Page
10-1 Scheduled Maintenance Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

10-2 Scheduled Maintenance Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
10-3 Scheduled Maintenance Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
10-4 Scheduled Maintenance Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
10-5 Removal and Installation Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
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10.0 INTRODUCTION Multicircuited alternator windings supply DC output

through parallel rectifier assemblies. The control to the
This section describes the rotating electrical equipment. brushless exciter field is provided by an exciter mod-
It contains the following information: theory of opera- ule in the electrical cabinet.
tion, maintenance procedures, troubleshooting, and
removal and installation. The rectifier assembly is mounted in the terminal box
on top of the alternator. Rectifiers are fuse protected.
The snubber network, consisting of resistors and capacitors,
10.1 THEORY OF OPERATION is mounted across the AC side of the rectifier assem-
bly.
Rotating electrical equipment is used to produce power
for the traction motors, AC power for cooling, and DC Generator components include the frame and stator, ro-
power for locomotive systems. Rotating electrical equip- tor, brushless exciter and rotating rectifier, AC-to-DC rec-
ment also includes electric motors on the locomotive tifier assembly, bearings, and cooling fan.
(Figure 10-1).
10.2.1.1 Frame and Stator
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.
The alternator is cooled by an internal shaft-driven fan.

An outboard blower, attached to the shaft, provides cooling
air for other equipment on the locomotive and rectifier
assemblies.
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
Figure 10-1: Block Diagram - Rotating Electrical
M-10.P65 - 8/96
10-7
WARNING
A snubber circuit, consisting of six capacitors and six
resistors, mounted between phases, suppresses voltage
transients caused by diode commutation.
10.2.1.5 Cooling Fans
The outboard fan mounted on the excitor end provides

CO VER cooling air to the alternator and other equipment on the
locomotive. An inboard fan is mounted at the drive end.
The fan draws the air through the generator.
10.2.2 Companion Alternator/Auxiliary

D R IV E E X C ITE R
END END Generator
11130A.DRW
The companion alternator/auxiliary generator is a two-
Figure 10-2: Traction Alternator
bearing assembly with two independent, six-pole syn-
chronous generators mounted in a common frame. It is
10.2.1.2 Alternator Rotor gear-driven by the engine at 1.333 times crankshaft speed.
The engine operates over a speed range of 600 to 1,800
The alternator rotor consists of the shaft, spider, field RPM. The auxiliary generator is a 6-pole synchronous
poles, windings, and fan. The coupling hub holes are generator. Output frequency varies directly with engine
drilled to mate with the engine flywheel and crankshaft. RPM. At 800 RPM the frequency is 40 Hz; at 1,800
Two balancing rings are bolted to each end of the field RPM it is 120 Hz.
pole coil support shelves.
The companion alternator operates with constant exci-
10.2.1.3 Brushless Exciter tation, at 1.83 volts per Hertz over a range of 40 to 120
Hertz. It includes a boost circuit to enhance its motor
The brushless exciter is an inverted synchronous AC starting capability. This alternator supplies 3-phase AC
generator with the field windings stationary and 3-phase power to the air compressor motor, cooling fan motors,
armature windings rotating with the generator rotor. The and the filter blower motor.
AC output is rectified through a full-wave semiconductor
bridge. A 3-phase full-wave rectifier consists of three The auxiliary generator supplies AC power to a unit-
forward and three reverse diodes. The diodes are mounted mounted rectifier assembly. This unit is self-excited.
on two separate rings. The rings act as negative and positive The rectifier assembly converts the AC to DC. Voltage
diode heat sinks. Both the exciter armature and recti- regulation is provided by a voltage regulator maintain-
fier assembly are dynamically balanced. The exciter stator ing a nominal DC level of 74 volts. The regulated 74
frame is mounted on the bearing bracket (endbell). VDC is used for battery charging and other locomotive
control requirements.
The drive end and opposite drive end use regreasable
ball bearings. The bearing housings are provided with The 3-phase output of the AC portion is rectified to DC
grease fittings for periodic lubrication. The bearing hous- by the full-wave bridge assembly which includes fuses
ings are insulated to prevent the flow of stray electric and a snubber network on the generator side. Most loads
currents. connect directly to the (+) and (-) terminals. The (+)
output to the battery passes through a current limiting
10.2.1.4 Rectifier Assembly resistor assembly and reverse blocking diodes to pre-
vent battery discharge during engine shutdown. To maintain
The rectifier assembly consists of twelve diodes (six constant voltage with widely varying speed, the field
forward and six reverse), aluminum heat sinks, fuses, excitation to the alternator is supplied by a static volt-
and a snubber circuit. age regulator through brushes and sliprings to the ro-
tating field winding.
Each diode is mounted on an aluminum heat sink to conduct
the generated heat. Air flow must be maintained for proper Mounted in the same frame and on the same shaft is
operation. Each diode is protected by a properly sized the auxiliary generator that provides the power to run
fuse in the event of overcurrent. Each fuse contains a the air compressor motor, cooling fan motors, and fil-
failure indication button. ter blower motor. Frequency varies from 40 to 120 Hz
M-10.P65 - 8/96
10-8
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.
M-10.P65 - 8/96
10-9
or damage the fan or the balance of the rotor assembly

Terminal points are provided for: positive (+), negative will be affected.
(-), battery charging (BC), AC load #1, AC load #2, AC
load #3, AC load #4, and excitation terminals for con- A sheet metal baffle is provided to control the air dis-
nection to the separately-mounted DC regulator (P2, F2, charge from the fan. The baffle is mounted to the frame.
P3). The frame adapter bolts to the stator frame. The frame
adapter houses the fan, acts as air discharge chamber,
10.2.3 Air Compressor Motor and creates a mounting face compatible with the com-
pressor adapter.
The air compressor motor is a single-bearing induction
motor that mounts directly onto the reciprocating com- 10.2.3.5 Drive Plate and Shims
pressor frame and shaft with adaptors, flywheel, and cou-
pling. The motor operates from the locomotive’s AC power A drive plate assembly, consisting of two flexible steel
at 1.83 volts per Hertz over a range of 40 to 120 Hertz. A discs, provides the means of attaching the drive end of
foot riser assembly is used to bring the motor foot height the motor rotor to the flywheel on the compressor shaft.
in line with the compressor foot. Three motor leads are To maintain axial alignment within the motor assem-
provided for connection to input power. A fan attached bly, shims are used between the shaft flange and the
to the motor shaft is used for motor cooling. discs to achieve 5/16" offset from the discs to the face
of the adapter. The flex disc arrangement allows easy
The air compressor motor components include the sta- separation of motor and compressor, accurately holds
tor, rotor, bearing, bearing bracket, fan, baffle, frame motor rotor centered in stator, and compensates for thermal
adapter, drive plates and shims, compressor adapter, expansion of the rotor system.
flywheel, flywheel coupling and shims, and foot riser.
10.2.3.6 Compressor Adapter
10.2.3.1 Stator
The compressor adapter bolts to a machined surface on
The stator core is heavily insulated and wound with high the compressor bearing cap on one side and mates with
quality copper magnet wire. After the stator core has the motor frame adapter on the other side. It houses the
been wound and the winding and line leads have been flywheel and supports the motor stator assembly within
attached, the wound assembly is vacuum impregnated the compressor frame.
in epoxy and thoroughly cured.
10.2.3.7 Flywheel, Flywheel Coupling, and Shims
A sheet metal terminal box is bolted to one side to house
the line leads and provide space to make the power con- The flywheel coupling has a tapered bore to match the
nections at installation. compressor shaft and a flange with a bolt pattern to fit
the flywheel. The flywheel coupling is secured on the
10.2.3.2 Rotor shaft with a shaft nut. The flywheel bolts to the cou-
pling and provides the mounting surface for the drive
The rotor consists of a core stack on a large diameter plates on the motor rotor. Shims may be required be-
shaft. The rotor is dynamically balanced to assure vi- tween the flywheel and coupling flange. A 5/16" gap
bration free operation. between the flywheel face and the mounting face of the
compressor adapter is filled by shims.
10.2.3.3 Bearing and Bearing Bracket
10.2.3.8 Foot Riser
The motor has one bearing on the end opposite the com-
pressor. The other end of the rotor is carried by the com- The foot riser adapts the motor mounting foot height to
pressor. The housing area contains an inner bearing cap be consistent with that of the compressor. The foot riser
to hold the bearing in place. The bearing is retained on is a fabricated assembly which bolts to the bottom of
the shaft with a snapring. The bearing bracket has openings the motor.
for air passage since the motor cooling air enters through
the bracket. 10.2.4 Cooling Fan Assembly
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
M-10.P65 - 8/96
10-10
The fan motor is supplied with a 3-pole plug assembly

for making power connections.
10.2.4.1 Frame Assembly
The frame assembly supports the induction motor and

houses the fan. The lower bearing support is an inte-
gral part of the frame assembly.
10.2.4.2 Fan Motor
The fan motor is a conventional squirrel cage motor.

The stator housing mounts on the bottom of the frame
assembly. The stator housing is cast high-strength alu-
minum. Each end of the housing is machined and drilled
to mate the housing end cover to the frame assembly.
10.2.4.3 Fan Blades
The fan blades are high-strength aluminum castings which

are machined and bolted to the fan hub assembly. The
fan hub assembly is mounted on the motor shaft exten-
sion with a tapered bushing.
10.2.5 Filter Blower Motor
The filter blower motor is discussed in Section 6, Iner-

tial Air System, of this manual.
M-10.P65 - 8/96
10-11
10.3 OPERATIONAL SEQUENCE
10.3.1 Rotating Electrical Equipment Operational Sequence Diagram
ENGINE RUNS
COMPANION ALTERNATOR AUXILIARY GENERATOR

TRACTION ALTERNATOR
GENERATES 3-PHASE GENERATES UNREGULATED
GENERATES DC POWER
AC POWER DC POWER
DC POWER IS APPLIED TO VOLTAGE REGULATOR

TRACTION MOTORS REGULATES TO 74 VDC
WHICH ROTATE TO
DRIVE THE GEARS TO
THE WHEEL SET AXLE
BATTERY CHARGER
LOCOMOTIVE ELECTRICAL
ACCESSORIES
AIR COMPRESSOR FILTER BLOWER

COOLING FAN
MOTOR ROTATES MOTOR ROTATES
MOTORS ROTATE
SHAFT ROTATES SHAFT ROTATES
FAN BLADES
AIR COMPRESSOR BLOWER ASSEMBLY
DRIVESHAFT
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
M-10.P65 - 8/96
10-12
10.4 SCHEDULED MAINTENANCE CHARTS
10.4.1 Scheduled Maintenance Matrix

Refer to Table 10-1 for the Scheduled Maintenance Matrix
for the rotating electrical system components. The fol-
lowing paragraphs describe the specific scheduled main-
tenance tasks required for each rotating electrical sys-
tem component.
Table 10-1: SCHEDULED MAINTENANCE MATRIX
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
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 Winding and Insulation Resistance 10.5.2.7
Test Exciter Field Saturation 10.5.2.8
Check Coupling Alignment 10.5.2.9
Air Compressor Motor
Clean Air Compressor Motor 10.5.3.2
Check Bearing Temperature 10.5.3.3
Inspect Air Compressor Motor 10.5.3.4
Check Winding and Insulation Resistance 10.5.3.6
Cooling Fan Assembly
Inspect Cooling Fan Assembly 10.5.4.1
Check Insulation Resistance 10.5.4.2
M-10.P65 - 8/96
10-13
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.
Table 10-2: SCHEDULED MAINTENANCE TOOLS AND TEST EQUIPMENT
Procedure Paragraph Tools/ Test Equipment Notes
Check Traction Alternator Vibration Amplitude 10.5.1.6 Vibration Amplitude

Measurement Tool (Analyzer)
Check Traction Alternator Insulation Resistance 10.5.1.7 500 Volt Megger
Test Traction Alternator Winding Resistance 10.5.1.8 Digital Multimeter
Check Companion Alternator/Auxiliary Generator 10.5.2.6 Vibration Amplitude

Vibration Amplitude Measurement Tool
Check Companion Alternator/Auxiliary Generator 10.5.2.7 Digital Multimeter

Winding and Insulation Resistance 500 Volt Megger
Test Companion Alternator/Auxiliary Generator 10.5.2.8 24 VDC Power Supply

Exciter Field Saturation
Check Air Compressor Motor Vibration Amplitude 10.5.3.5 Vibration Amplitude

Measurement Tool (Analyzer)
Check Air Compressor Motor Winding and 10.5.3.6 Digital Multimeter

Insulation Resistance 500 Volt Megger
Check Cooling Fan Assembly Insulation 10.5.4.2 500 Volt Megger

Resistance
M-10.P65 - 8/96
10-14
Table 10-3: SCHEDULED MAINTENANCE CONSUMABLES
Procedure Paragraph Consumables Quantity Notes
Replace Traction Alternator 10.5.1.4 Air Filter 4

Filter
Replace Traction Alternator 10.5.1.10 Rectifier A/R

Rotating Rectifier
Replace Companion Alternator/ 10.5.2.3 Brushes A/R

Auxiliary Generator Brush
Table 10-4: SCHEDULED MAINTENANCE SUPPLIES
Procedure Paragraph Supplies Quantity Notes
Clean Traction Alternator 10.5.1.3 Cloth, Lint-Free, Wiping A/R

Solvent, Nonflammable A/R
Clean Companion Alternator/

Auxiliary Generator 10.5.2.2 Cloth, Lint-Free, Wiping A/R
Clean Air Compressor Motor 10.5.3.2 Cloth, Lint-Free, Wiping A/R

M-10.P65 - 8/96
10-15
10.5 SCHEDULED MAINTENANCE 10.5.1.3 Clean Traction Alternator

INSTRUCTIONS
(92-DAY MAINTENANCE)
Inspect the rotating electrical equipment for those items
listed and for any other obvious defects.
NOTE
The following components are maintained at the daily If equipment is subjected to excessive moisture,
maintenance, the 92-day maintenance, the yearly, the heat, or dust, the schedule for cleaning and main-
2-year maintenance, or the 6-year maintenance level. tenance should be shortened.
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.
1. Verify the engine is shut off.

10.5.1 Traction Alternator
2. Make a visual check for excessive dirt buildup or
grease leakage. Remove grease and dirt as follows:
10.5.1.1 Inspect Traction Alternator Operation
a. Remove all dust, dirt, oil, grease, and other for-
(DAILY MAINTENANCE)
eign material from the external surfaces, recti-
fier heat sinks, and electrical connections.
1. Start the engine.
2. Inspect the traction alternator for abnormal running

WARNING
conditions. Check for bearing vibration or machine
Exercise extreme care and follow manufacturers’
noise. Investigate any overheating conditions (un-
precautions when using solvents. Use nonflam-
usual radiant heat, discoloration, or smoke). Refer
mable solvents in a well ventilated area away from
to troubleshooting charts.
sparks and flame. Failure to observe this warn-
ing can result in serious injury.
3. Shut the engine off.
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.
c. Vacuum the traction alternator terminal box

WARNING access areas.
Shut the engine off before performing the fol-
lowing procedure. Failure to observe this warn- 10.5.1.4 Replace Traction Alternator Filter
Replace the traction alternator air filters. There are two
2. Check for loose cables and bolts. Tighten loose cables filters located on each side of the traction alternator in
and bolts. the clean air compartment.
M-10.P65 - 8/96
10-16
10.5.1.5 Inspect Traction Alternator Bearing 10.5.1.7.1 Traction Alternator Exciter Field Test
Temperature
(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.
10.5.1.6 Check Traction Alternator Vibration CAUTION

Amplitude Do not megger exciter module. Failure to observe
this caution may result in equipment damage.
5. Apply 500 volts DC from the megger and measure
Vibration amplitude measurements should be taken at start-
the resistance reading after one minute. The mini-
up, after the first 2,000 hours, and annually thereafter.
mum resistance should be 1.0 megohm. If resistance
Readings should be taken on the bearing housing with the
is less than 1.0 megohm, dry the alternator and re-
probe in the vertical, horizontal, and axial directions.
peat the test. The traction alternator may be dried
out by moving the locomotive to a heated building,
Normal vibration readings should be 0.003 inches (peak-
using heat lamps or strip heaters.
to-peak) at start-up. Maximum vibration limit is 0.006
inches (peak-to-peak) at start-up. The vibration readings
6. The minimum insulation resistance at 104 °F (40
taken at start-up can be used as the standard of compari-
°C) should not be less than 1 megohm. For megger
son for future readings. Any significant change in vibration
reading conversion to 40 °C, refer to Figure 10-3.
from previous readings should be investigated.
7. Reconnect exciter leads to terminal strip and close
10.5.1.7 Check Traction Alternator Insulation access door.
Resistance
8. If exciter field insulation resistance is greater than
(YEARLY MAINTENANCE) one megohm, return to service.
If insulation resistance is less than one megohm,

WARNING
perform steps in paragraphs 10.5.1.7.2, 10.5.1.7.3
and 10.5.1.7.4
lowing procedure. Failure to observe this warn-
10.5.1.7.2 Traction Alternator Generator Stator
Test
Check the condition of the winding insulation. All checks
using the 500 volt megger should be made several times
during the first year of operation and annually thereaf-
ter. If the motor is subjected to a dirty or wet environ-
2. Disconnect the alternator leads from the rectifier
ment, the interval between checks should be shortened.
assembly.
Log all winding test and maintenance data, temperature,
humidity, and a brief description of the winding condi-
3. Connect one lead at a time (A1, A2, A3, A4), with
tions at the time of the check. If the data shows any
leads isolated, to one clamp of 500 volt megger.
large changes, a careful winding inspection should be
Connect the other clamp to the alternator frame.
made. Perform the insulation resistance tests as outlined
in the following paragraphs.
4. Apply 500 volts from the megger and take a resis-
tance reading after one minute. The minimum re-
sistance should be 1.0 megohm. If resistance is less
M-10.P65 - 8/96
10-17
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
Figure 10-3: Megger Conversion to 40 °C
M-10.P65 - 8/96
10-18
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.
10.5.1.8 Test Traction Alternator Winding
2. Disconnect the exciter armature leads from the ro- Resistance
tating rectifiers.
CAUTION The alternator winding resistance should not change during

Do not megger the rotating rectifier assembly. its life except for minor variations due to temperature.
Failure to observe this caution can result in equip- Before checking winding resistance, ensure the alter-
ment damage. nator is at room temperature and the meter used is suit-
able for the range of resistance.
1. If either a winding short or open is suspected, measure

3. Connect the exciter armature leads to one clamp of
the resistance between each pair of generator leads
the 500 volt megger. Connect the other clamp to
(3-1, 1-2, 2-3).
the exciter sleeve tubing.
2. The three readings should be within 10 percent of
4. Apply 500 volts DC from the megger and measure
one another and the average of the three should be
resistance after one minute. Record the resistance.
between 0.017 and 0.020 ohms.
If resistance is less than 1.0 megohm, dry out the
alternator and make another megger check. The trac-
3. If the alternator windings are opened or shorted,
tion alternator may be dried out by moving the lo-
replace the alternator.
comotive to a heated building and using heat lamps
or torpedo heaters.
4. Connect all leads to their original terminals and close
access door.
5. If the exciter armature resistance is less than 1.0
megohm after it has been dried out, the traction al-
10.5.1.9 Replace Traction Alternator Bearing
ternator must be replaced.
(6-YEAR MAINTENANCE)
6. Reconnect exciter armature field leads to rectifier
assembly.
Replace the traction alternator bearings every six years.
10.5.1.7.4 Traction Alternator Rotor Winding Test
2. Disconnect the alternator field leads from the ro-

tating rectifiers.
3. Connect the alternator field leads to one clamp of

the 500 volt megger. Connect the other clamp to
the shaft.
M-10.P65 - 8/96
10-19
10.5.1.10 Replace Traction Alternator Rotating 4. Remove 12 screws holding clamping ring to fan hub.
Rectifier
5. Remove fan clamping ring.
6. Slide the fan out of the traction alternator.
NOTE 7. Reach through the endbell and remove three for-

The rotating rectifiers must be replaced when a ward diodes and three reverse diodes.
failure occurs.
8. Reach through the endbell and install three forward
diodes and three reverse diodes.
WARNING
Verify engine is shut down before disconnecting 9. Slide the fan into the traction alternator.
power leads. An electrical shock hazard exists.
Failure to observe this warning can result in se- 10. Install fan clamping ring.
rious injury.
11. Install 12 screws to secure clamping ring to fan hub.
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
M-10.P65 - 8/96
10-20
10.5.2 Companion Alternator/Auxiliary 10.5.2.3 Inspect/Replace Companion Alternator/

Generator Auxiliary Generator Brush and
Brushholder
10.5.2.1 Inspect Companion Alternator/Auxiliary
Generator Operation (92-DAY MAINTENANCE)
(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.
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.
ing can result in serious injury. 4. Ensure spring fingers are not broken and have spring
tension.
NOTE 5. Obtain a new brush and measure its length. Replace

If equipment is subjected to excessive moisture, the brushes if they are worn more than one-half their
heat, or dust, the schedule for cleaning and main- original length, damaged, broken, chipped, or if they
tenance should be shortened. have damaged electrical leads.
6. Install brushes in holders and verify brush electri-

1. Make a visual check for excessive dirt buildup or cal leads are not pinned by spring fingers.
grease leakage.
7. Verify brushes move freely and fit closely in hold-
2. Remove all dust, dirt, oil, grease, and other foreign ers to prevent chatter.
material from the external surfaces of the frame by
wiping with a lint-free wiping cloth. 8. Ensure brush electrical leads are completely verti-
cal and are not following armature riser.
WARNING 9. Close brush access covers.

Exercise extreme care and follow manufacturers’
precautions when using nonflammable solvents. 10.5.2.4 Inspect Companion Alternator/Auxiliary
Use nonflammable solvents in a well-ventilated Generator Bearing
area away from sparks and flame. Failure to
observe this warning can result in serious injury. (YEARLY MAINTENANCE)
1. Check bearing temperature during operation. Bearing

3. Use a lint-free wiping cloth moistened with a non- housing temperature should not exceed ambient air
flammable cleaning solvent to remove hardened de- temperature by 63 °F. Bearing can operate at 200
posits of grease, oil, and other substances. °F, but once overheating occurs, this limit may be
exceeded rather quickly and the problem should be
4. Vacuum the generator terminal box access area. identified and remedied immediately.
M-10.P65 - 8/96
10-21
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.
Vibration amplitude measurements should be taken at start- NOTE

up, after the first 2,000 hours, and annually thereafter. The stator has three leads. Each lead consists of
Readings should be taken on the bearing housing with two cables in parallel.
the probe in the vertical, horizontal, and axial directions.
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.
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.
M-10.P65 - 8/96
10-22
7. Ground leads to frame. 7. The minimum insulation resistance at 104 °F (40

8. The minimum insulation resistance at 104 °F (40 reading conversion to 40 °C, refer to Figure 10-3.
reading conversion to 40 °C, refer to Figure 10-3 8. If insulation fails to meet the minimum test stan-
dard, the unit may be dried out and the test repeated.
9. If insulation fails to meet the minimum test stan- If the insulation fails to meet the minimum test stan-
dard, the unit may be dried out and the test repeated. dard after dry out, the auxiliary generator must be
If the insulation fails to meet the minimum test stan- replaced.
dard after dry out, the companion alternator/auxil-
iary generator must be replaced. The generator may 9. Reconnect battery charging stator leads to rectifier
be dried out by moving the locomotive to a heated assembly.
building and using heat lamps or torpedo heaters.
10. Reconnect three AC generator stator leads to ter- CAUTION

minal block. Drying temperatures must not exceed 167 °F. If
this caution is not observed, equipment damage
can occur.
CAUTION
Drying temperatures must not exceed 167 °F. If
this caution is not observed, equipment damage 10.5.2.7.3 Companion Alternator/Auxiliary
can occur. Generator AC Generator Rotor
1. Disconnect the AC generator rotor leads from the

10.5.2.7.2 Companion Alternator/Auxiliary
terminal block (F2), and boost module (P1).
Generator Battery Charging Stator
2. Place one meter probe on the center slipring. Place
the other probe on the outer slipring.
NOTE
The battery charging stator has three leads. Each
lead consists of two cables in parallel.
NOTE
Do not measure through the brushes.
1. Isolate the battery charging generator stator leads
from the rectifier assembly.
3. The resistance should be between 4.9 and 5.9 ohms.
2. Measure the resistance between each pair of stator
leads (1-2, 2-3, 3-1). 4. If the resistance is not as specified in step 3, the com-
panion alternator/auxiliary generator must be replaced.
one another. The average of the three readings should 5. Tie P1 and F2 (AC generator rotor) leads together
be between 0.0106 and 0.0130 ohms. and clamp to one lead of the megger. Connect other
clamp to frame. Apply 500 VDC to the leads. Record
4. If the resistance is not as specified in step 3, the the resistance reading. Disconnect megger.
companion alternator/auxiliary generator must be
replaced. 6. Disconnect AC generator rotor leads P1 from F2.
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
leads. Record the resistance reading. Disconnect
megger.
conversion to 40 °C, refer to Figure 10-3.
6. Ground leads to frame.
M-10.P65 - 8/96
10-23
9. If insulation fails to meet the minimum test stan-

dard, the unit may be dried out and the test repeated. CAUTION
If the insulation fails to meet the minimum test stan- Drying temperatures must not exceed 167 °F. If
dard after dry out, the companion alternator/auxil- this caution is not observed, equipment damage
iary generator must be replaced. can occur.
CAUTION 9. If the resistances in the above paragraphs are within

Drying temperatures must not exceed 167 °F. If prescribed parameters, reconnect all leads to their
this caution is not observed, equipment damage original terminals and install removed covers and
can occur. access panels.
10. Connect AC generator rotor leads to terminal block

10.5.2.7.4 Companion Alternator/Auxiliary C and boost module.
Generator Battery Charging Rotor
10.5.2.8 Test Companion Alternator/Auxiliary
1. Disconnect battery charging rotor lead from termi- Generator Exciter Field Saturation
nal block F3.
2. Place one meter probe on the center slipring. Place
the other probe on the inner slipring. As a further check of winding integrity, the output voltage
can be measured at a preset speed and field or rotor current.
NOTE 10.5.2.8.1 Companion Alternator/Auxiliary

Do not measure through the brushes. Generator AC Generator
1. Apply 24 VDC to P1 (+) and F2 (-).

3. The resistance should be between 6.2 and 7.5 ohms.
2. Start the engine and run it up to 900 RPM.
4. If the resistance is not as specified in step 3, the
auxiliary generator must be replaced. 3. With no load on the auxiliary generator, the volt-
age at terminal block 1-2, 1-3, and 2-3 should be
5. Tie F2 and F3 (battery charging generator field leads) between 42 and 52 VAC.
together and clamp to one lead of the megger. Connect
other clamp to frame. Apply 500 VDC to the leads. 4. Shut the engine off. Remove 24 VDC from P2 (+)
Record the resistance reading. Disconnect megger. and F2 (-).
6. Ground leads to frame. 5. If the generator output voltage is not as specified,

the companion alternator/auxiliary generator must
7. The minimum insulation resistance at 104 °F (40 °C) be removed and replaced.
should not be less than 1 megohm. For megger reading
conversion to 40 °C, refer to Figure 10-3. 10.5.2.8.2 Companion Alternator/Auxiliary
Generator Battery Charging
Generator
If the insulation fails to meet the minimum test stan-
1. Disconnect wires from rectifier assembly terminal
dard after dry out, the companion alternator/auxil-
(+) and (-).
iary generator must be replaced.
2. Apply 24 VDC to F3 (+) and F2 (-).
3. Start the engine and run it up to 900 RPM.
M-10.P65 - 8/96
10-24
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
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
10.5.3.1 Inspect Air Compressor Motor

Operation
(DAILY MAINTENANCE)
1. Inspect the air compressor motor for abnormal running

conditions. Check for bearing vibration or machine
noise. Investigate any overheating conditions (un-
usual radiant heat, discoloration or smoke). Refer
FEELER GAUGE to troubleshooting charts.
10.5.3.2 Clean Air Compressor Motor
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
If the method illustrated is used to check the alignment

WARNING
of the engine and generator, correct alignment exists if:
a. The outer edge of the coupling halves are true
circles of the same diameter.
b. The faces are flat when the separation between

the faces is held to within the specified toler-
M-10.P65 - 8/96
10-25
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)
Vibration amplitude measurements should be taken at

a. Remove all dust, dirt, oil, grease, and other for-
start-up, after the first 2,000 hours, and annually there-
eign material from the external surfaces of the after. The following instructions provide procedures for
frame by wiping with a lint-free wiping cloth. vibration amplitude measurements.
1. Follow the manufacturer’s operating instructions and

WARNING observe all warnings and cautions when using the
Exercise extreme care and follow manufacturers’ vibration analyzer.
precautions when using nonflammable solvents.
Use nonflammable solvents in a well-ventilated 2. Ensure air compressor motor is not running.
area away from sparks and flame. Failure to ob-
serve this warning can result in serious injury. 3. Place the vibration analyzer probe in a vertical po-
sition on the air compressor motor bearing housing.
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.
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).
16. Vibration readings taken at start-up can be used as

the standard of comparison for future readings.
17. Any vibration readings greater than 0.006 inches

(peak-to-peak) or any significant change in vibra-
M-10.P65 - 8/96
10-26
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.
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.
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.
3. Measure the resistance between each pair of motor

leads (1-2, 2-3, 3-1). 10.5.4.1 Inspect Cooling Fan Assembly
(92-DAY INSPECTION)
one another. The average of the three readings should
be between 0.017 and 0.020 ohms.
1. Verify engine is shut down.
5. If the winding resistance is not as specified the air
2. Inspect the cooling fan assembly mounting bolts to
compressor motor must be replaced.
ensure they are securely fastened.
6. Tie the three leads together and connect to one lead
3. Check the cooling fan blades for damage such as
of the megger. Connect other megger terminal to
the frame. Apply 500 VDC to the leads. cracks and dents. If a blade is damaged, the cool-
ing fan must be replaced with a qualified fan as-
sembly. Refer to paragraphs 10.7.3 and 10.7.4 for
cooling fan removal and installation instructions.
reading conversion to 40 °C, refer to Figure 10-3.
M-10.P65 - 8/96
10-27
4. Verify there are no restrictions to the fan rotation

or air flow. Clean the fan screen of debris.
5. Start engine.
6. During continuous operation, check fan vibration.

Note and investigate any unusual noises that indi-
cate possible trouble.
NOTE
Common symptoms, probable causes and remedies
are listed in the troubleshooting charts.
10.5.4.2 Check Cooling Fan Assembly Insulation

Resistance
NOTE
If the cooling fan motor has been subjected to
long term high humidity, check motor winding
insulation resistance.
1. Connect one terminal of a 500-volt megger to any

motor terminal. Connect the other terminal of the
megger to the motor frame.

conversion to 40 °C, refer to Figure 10-3.

dard after dry out, the cooling fan assembly must
be replaced using paragraph 10.7.3.
M-10.P65 - 8/96
10-28
10.6 TROUBLESHOOTING CHARTS
10.6.1 Using the Troubleshooting Charts
The troubleshooting charts provide common symptoms,

the possible causes, and remedies. If appropriate, a test
procedure may follow the troubleshooting instructions.
In some cases the symptom is obvious from the para-
graph title and will not be repeated in the text.
10.6.2 Troubleshooting Charts
Possible Cause Inspect For: Corrective Action
10.6.2.1 No AC Voltage from Traction Alternator
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
10.6.2.2 Low AC Voltage from Traction Alternator
Excessive load. Check for an overload condition. 1. Reduce load.
Check connections at rectifiers for an 2. Tighten connections.

overheating condition.
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.
10.6.2.3 Fluctuating AC Voltage from Traction Alternator with Constant Speed

Excitation circuit not functioning Faulty exciter module. 1. Replace exciter. Refer to Section
properly. 11, Electrical System.
Defective bearing causing uneven Defective bearing. 1. Replace traction alternator.

air gap.
M-10.P65 - 8/96
10-29
10.6.2.4 High AC Voltage from Traction Alternator

Excitation circuit not functioning Faulty exciter module. 1. Replace exciter module. Refer to
properly. Section 11, Electrical System.
Overspeed. Prime mover rpm. 1. Correct speed of prime mover.
10.6.2.5 Traction Alternator Overheating

Traction alternator overloaded. Equipment overload. 1. Reduce load.
Blocked ventilation passages. Blocked ventilation passages. 1. Clear air passages.
High ambient temperatures. Generator cleanliness and blower operation. 1. Improve circulation to lower heat
buildup.
10.6.2.6 Vibration in Traction Alternator

Improper mounting or misalignment Check coupling alignment. 1. Correct alignment.
of coupling.
Defective bearing. Defective bearing. 1. Replace traction alternator.
Rotor out of balance due to winding Check for alternator overspeed condition. 1. Replace traction alternator.
failure.
10.6.2.7 No AC Voltage from Companion Alternator
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.
No excitation to dual auxiliary generator. 1. Refer to battery charging

generator and voltage regulator,
Section 11, Electrical System.
Short circuit on output. Short in loads. 1. Disconnect loads one at a time to

isolate trouble.
2. Open Filter Blower Motor circuit
breaker.
3. Shut off outputs to fans and air
compressor.
4. Refer to Section 11, Electrical
System.
5. If short persists, repair wiring.
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.
M-10.P65 - 8/96
10-30
10.6.2.8 Low AC Voltage from Companion Alternator

Excessive load. Excessive load. 1. Reduce load to rated value.
Disconnect leads one at a time to locate 2. Repair or replace faulty equipment

trouble. or wiring as required.
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.
10.6.2.9 Fluctuating AC Voltage from Companion Alternator with Constant Speed

Excitation circuit not functioning 1. Refer to companion alternator
properly. and voltage regulator section,
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.
Sliprings out of round or pitted. 1. Replace companion alternator.
Loose terminal or load connection. Loose terminal or load connection. 1. Tighten or replace defective
connectors.
Defective bearing Defective bearing. 1. Replace companion alternator.
10.6.2.10 High AC Voltage from Companion Alternator

Excitation circuit not functioning 1. Refer to auxiliary generator
properly. and voltage regulator section,
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.
M-10.P65 - 8/96
10-31
10.6.2.11 No Voltage from Auxiliary Generator

Fuses blown in rectifier assembly. Check for shorted diode modules. 1. Correct fault as required and
Check for load faults. replace fuses.
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.
No excitation to generator. 1. Refer to voltage regulator section,

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.
10.6.2.12 Low Voltage from Auxiliary Generator

Voltage regulator VOLT ADJUST set Check setting of voltage regulator. 1. Adjust voltage regulator
too low. adjustment clockwise to raise
voltage.
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.
10.6.2.13 High Voltage from Auxiliary Generator

Voltage regulator VOLT ADJUST Check setting of voltage regulator. 1. Adjust voltage regulator
set too high. adjustment counterclockwise to
lower voltage.
Positive lead from generator to voltage Check for continuity. 1. Repair lead as required.
regulator open.
10.6.2.14 Companion Alternator/Auxiliary Generator Overheating

Generator overloaded. Equipment overload. 1. Reduce load to within generator
rating.
Blocked ventilation passages. Blocked ventilation passages. 1. Clear air passages.
High ambient temperatures. Generator cleanliness and blower operation. 1. Improve circulation to lower heat
buildup.
M-10.P65 - 8/96
10-32
10.6.2.15 Vibration from Companion Alternator/Auxiliary Generator

Improper mounting or misalignment Check coupling alignment. 1. Correct alignment.
of coupling.
Defective bearing. Defective bearing. 1. Replace companion alternator/

auxiliary generator.
Rotor out of balance after repair. Rotor balance with cooling fan in place. 1. Replace companion alternator/
Rotor out of balance due to winding Check for dual auxiliary generator overspeed 1. Replace companion alternator/
failure. condition. auxiliary generator.
10.6.2.16 Air Compressor Motor Fails to Start

Motor fails to start. Voltage to air compressor motor. 1. Replace air compressor motor.
Thermal overloads open. 2. Check continuity through
thermal overloads.
Input fuses, circuit breaker, or Check suspected components. 1. Replace or reset.

contactor open.
Load too heavy. High load. 1. Check unloader valves. Refer to

Section 7, Compressed Air
System.
10.6.2.17 High Vibration from Air Compressor

Misalignment of frame or compressor Check alignment. 1. Realign frame or compressor
adapter. adapter.
10.6.2.18 Air Compressor Drive Plates and Flywheel Misaligned

Misalignment of drive plates and Check alignment of drive plates and flywheel. 1. Realign drive plates and
flywheel. flywheel.
10.6.2.19 Air Compressor Motor Overheating

Overload. Check for excessive friction in compressor. 1. Replace air compressor.
Refer to Section 7, Compressed
Air System.
Improper input voltage. Perform paragraph 10.5.2.8.1 maintenance. 1. Replace companion alternator/
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
System.
Defective bearing. 1. Replace air compressor. Refer to

System.
10.6.2.20 Regular Clicking from Air Compressor Motor

Foreign material in air gap. Check for foreign material in air gap. 1. Remove foreign material from the
air gaps.
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10.6.2.21 Rapid Knocking from Air Compressor Motor
Defective bearing. Vibration, heat, and noise. 1. Replace air compressor.

Refer to Section 7, Compressed
Air System.
10.6.2.22 Cooling Fan Is Not Rotating

No voltage. Check power source. 1. Refer to Section 11, Electrical
System. Refer to paragraph
10.6.2.7.
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.
10.6.2.23 High Vibration from Cooling Fan

Fan assembly not properly mounted. Check mounting surfaces. 1. Loosen cooling fan assembly,
place into proper position and
retighten 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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10-34
10.7 REMOVAL AND INSTALLATION

INSTRUCTIONS
The following paragraphs describe the removal and in-

stallation of the rotating electrical equipment from the
locomotive. Rotating electrical equipment installation
instructions follow the removal instructions.
10.7.1 Safety
Exercise extreme caution and manufacturers’ safety rules

relating to the use of tools, materials, equipment, and
personal safety in the performance of these procedures.
10.7.2 Tools and Test Equipment
Table 10-6 lists specialized tools and test equipment

used in the removal and installation procedures for the
rotating electrical equipment. Standard tools, which are
found in a typical tool kit (such as wrenches, screw-
drivers, etc.) are not included in this specialized tool
listing.
Table 10-5: REMOVAL AND INSTALLATION TOOLS AND TEST EQUIPMENT
Procedure Paragraph Tools/Test Equipment Notes
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.
M-10.P65 - 8/96
10-35
10.7.3 Cooling Fan Removal 10.7.5 Air Compressor Removal
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.
WARNING 10.7.7 Companion Alternator/Auxiliary

Verify power has been removed from the cool- Generator Removal
ing fan motor before disconnecting power leads.
An electrical shock hazard exists. Failure to ob- Companion alternator/auxiliary generator removal is be-
serve this warning can result in serious injury. yond running maintenance. The locomotive must be re-
moved from service for heavy repair.
1. Remove power from cooling fan motors. 10.7.8 Companion Alternator/Auxiliary

Generator Installation
2. Remove guard.
Companion alternator/auxiliary generator installation is
3. Disconnect the motor leads from the power source.
beyond running maintenance. The locomotive must be
removed from service for heavy repair.
4. Remove the fan mounting bolts and fan assembly.
10.7.9 Traction Alternator Removal
10.7.4 Cooling Fan Installation
Traction alternator removal is beyond running mainte-
1. Verify power is removed from cooling fan
nance. The locomotive must be removed from service
circuits.
for heavy repair.
2. Place cooling fan in position and secure with fan
mounting bolts.
10.7.10 Traction Alternator 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.
6. Perform operational check of cooling fans.
M-10.P65 - 8/96
10-36

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MK RAIL CORPORATION

RUNNING MAINTENANCE MANUAL

ROTATING ELECTRICAL SYSTEM

This page intentionally left blank.

SECTION 10 ROTATING ELECTRICAL SYSTEM

Paragraph Description Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

10.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

10.1 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

10.2 COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

10.3 OPERATIONAL SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

10.4 SCHEDULED MAINTENANCE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

TABLE OF CONTENTS (cont.)

TABLE OF CONTENTS (cont.)

10.7 REMOVAL AND INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . 10-35

Figure Description Page

10-1 Block Diagram - Rotating Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

Table Description Page

10-1 Scheduled Maintenance Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

10.0 INTRODUCTION Multicircuited alternator windings supply DC output

The alternator is cooled by an internal shaft-driven fan.

Figure 10-1: Block Diagram - Rotating Electrical

10.2.1.5 Cooling Fans

The outboard fan mounted on the excitor end provides

10.2.2 Companion Alternator/Auxiliary

or damage the fan or the balance of the rotor assembly

The fan motor is supplied with a 3-pole plug assembly

10.2.4.1 Frame Assembly

The frame assembly supports the induction motor and

10.2.4.2 Fan Motor

The fan motor is a conventional squirrel cage motor.

10.2.4.3 Fan Blades

The fan blades are high-strength aluminum castings which

10.2.5 Filter Blower Motor

The filter blower motor is discussed in Section 6, Iner-

10.3 OPERATIONAL SEQUENCE

10.3.1 Rotating Electrical Equipment Operational Sequence Diagram

COMPANION ALTERNATOR AUXILIARY GENERATOR

DC POWER IS APPLIED TO VOLTAGE REGULATOR

AIR COMPRESSOR FILTER BLOWER

10.4 SCHEDULED MAINTENANCE CHARTS

10.4.1 Scheduled Maintenance Matrix

Table 10-1: SCHEDULED MAINTENANCE MATRIX

Table 10-2: SCHEDULED MAINTENANCE TOOLS AND TEST EQUIPMENT

Procedure Paragraph Tools/ Test Equipment Notes

Check Traction Alternator Vibration Amplitude 10.5.1.6 Vibration Amplitude

Check Traction Alternator Insulation Resistance 10.5.1.7 500 Volt Megger

Test Traction Alternator Winding Resistance 10.5.1.8 Digital Multimeter

Check Companion Alternator/Auxiliary Generator 10.5.2.6 Vibration Amplitude

Check Companion Alternator/Auxiliary Generator 10.5.2.7 Digital Multimeter

Test Companion Alternator/Auxiliary Generator 10.5.2.8 24 VDC Power Supply

Check Air Compressor Motor Vibration Amplitude 10.5.3.5 Vibration Amplitude

Check Air Compressor Motor Winding and 10.5.3.6 Digital Multimeter

Check Cooling Fan Assembly Insulation 10.5.4.2 500 Volt Megger

Table 10-3: SCHEDULED MAINTENANCE CONSUMABLES

Procedure Paragraph Consumables Quantity Notes

Replace Traction Alternator 10.5.1.4 Air Filter 4

Replace Traction Alternator 10.5.1.10 Rectifier A/R

Replace Companion Alternator/ 10.5.2.3 Brushes A/R

Table 10-4: SCHEDULED MAINTENANCE SUPPLIES

Procedure Paragraph Supplies Quantity Notes

Clean Traction Alternator 10.5.1.3 Cloth, Lint-Free, Wiping A/R