⠜ᴗሲѢफ䔺៮๙คᴎ䔺᳝䰤݀ৌ

COPYRIGHT CSR QISHUYAN CO.,LTD.

Repair Manual of DF8BI Locomotive

ELECTRIC MOTOR AND ELECTRIC

APPARATUS MANUAL

CSR QISHUYAN CO.,LTD

2011.1
 Content

CONTENT

Chapter 1 Electric Equipments & Electric Circuit of DF8BI Locomotive ... 1

1 Electric equipments general arrangement of DF8BI locomotive........................................... 1
1.1 Electric equipments arrangement in operator’s cab .......................................................1
1.2 Apparatus Arrangement in the electric apparatus room .................................................1
1.3 Electric apparatus Arrangement in the power room.......................................................3
1.4 Electric equipment arrangement in the cooling and auxiliary room ..............................3
1.5 Electric apparatus arrangement on the bogie and fuel tank............................................3
2 Electric apparatus & electric circuit .................................................................................... 8
2.1 Resistor ...........................................................................................................................8
2.2 Fuses ..............................................................................................................................9
2.3 Miniature circuit-breaker................................................................................................9
2.4 Knife switch.................................................................................................................11
2.5 General changeover switch..........................................................................................12
2.6 Overhaul methods........................................................................................................13

Chapter 2 Electric Machine .............................................................................. 18

1 Synchronous Alternator .................................................................................................... 18
1.1 Operating principle and structure .................................................................................18
1.2 The main technical parameters.....................................................................................21
1.3 The original dimensions and limits ..............................................................................21
1.4 Inspection and repair process ......................................................................................22
1.5 Content of the main components.................................................................................28
2 Traction Motor .................................................................................................................. 29
2.1 Operating Principle and Structure ................................................................................29
2.2 Main Technical Parameters .........................................................................................33
2.3 Original Dimension and Limit.....................................................................................33
2.4 Inspection and Repair Process.....................................................................................35
2.5 Main parts list ..............................................................................................................46
3 The Start-up Generator...................................................................................................... 48
3.1 Operating Principle and Structures..............................................................................48
3.2 The Main Technical Parameter ...................................................................................51
3.3 The Original Dimension and Limit .............................................................................51
3.4 Inspection and Repair Process.....................................................................................52
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3.5 Main Parts List ............................................................................................................58

4 Inductor Exciter .................................................................................................................60
4.1 Operating principle and structure................................................................................60
4.2 The main technical parameters....................................................................................63
4.3 The original dimension and limitation list ..................................................................63
4.4 Inspection and Repair Process.....................................................................................64
4.5 Main Parts List ............................................................................................................67
5 Air compressor motor ........................................................................................................68
5.1 Function.......................................................................................................................68
5.2 Structure ......................................................................................................................68
5.3 Motor disassembly and assembly...............................................................................69
5.4 Maintenance ................................................................................................................70
5.5 Motor using standard...................................................................................................71
5.6 Safety technology........................................................................................................72
5.7 Motor idle test .............................................................................................................72
5.8 Checking tool: .............................................................................................................72
6 The Blower Motor for Braking Resistor............................................................................73
6.1 Operating Principle and Structure ...............................................................................73
6.2 Main technical parameters ..........................................................................................75
6.3 Inspection and Repair Process.....................................................................................75
6.4 The limit of inspection and repair ...............................................................................77
7 The Other Microminiature Motors.....................................................................................77
7.1 The main technical parameters....................................................................................77
7.2 The basic technical requirements ................................................................................78

Chapter 3 Silicon Rectification and Dynamic Braking Device ......................79

1 Main silicon Rectifier Cabinet and Rectifying Tube .........................................................79
1.1 Main technical parameters ..........................................................................................79
1.2 Main circuit connection................................................................................................79
1.3 Configuration, installation and dismantle of the rectifier ...........................................81
1.4 Operation, repair and maintenance..............................................................................83
1.5 Limitations ..................................................................................................................84
1.6 List of components ......................................................................................................84
1.7 Structure and main technical parameters of main rectifier ..........................................84
2 Excitation Rectification cabinet and Rectifying Tube .......................................................84
2.1 Structure and main technical parameters of rectifier ..................................................84
2.2 Structure and main technical parameters of silicon rectifier tube...............................87
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2.3 Maintenance method ...................................................................................................88

2.4 Components easy to be damaged ................................................................................91
3 Braking Resistance Device ............................................................................................... 91
3.1 Structure ......................................................................................................................91
3.2 Working Principle .......................................................................................................92
3.3 Main Technical Data ...................................................................................................92
3.4 Maintenance Method ...................................................................................................92

Chapter 4 Locomotive Electric Apparatus...................................................... 97

1 General Introduction ......................................................................................................... 97
1.1 Basic complexion ........................................................................................................97
1.2 Characteristic...............................................................................................................97
2 Contactor ........................................................................................................................... 98
2.1 Contactor group ............................................................................................................98
2.2 DC electromagnetic Contactor ..................................................................................103
3 Master Controllers, Operating Mode Transfer Switch and Direction Transfer Switch .. 117
3.1 Master Controller.......................................................................................................117
3.2 Operation mode changeover switch and direction changeover switch .....................122
4 Relay ............................................................................................................................... 127
4.1 Grounding fault relay ................................................................................................127
4.2 Over-current relay .....................................................................................................132
4.3 Wind speed relay .......................................................................................................136
4.4 Intermediate relay......................................................................................................139
5 differential manometers .................................................................................................. 143
5.1 Cconfiguration...........................................................................................................143
5.2 Examine and repair....................................................................................................143
6 Toggle switch and pedal switch ...................................................................................... 144
6.1 Toggle switch ............................................................................................................144
6.2 S126D Lock Switch...................................................................................................149
6.3 Paddle Switch .............................................................................................................149
7 The locomotive head lamp .............................................................................................. 152
7.1 Technical parameter ..................................................................................................152
7.2 Configuration.............................................................................................................153
7.3 Examine and repair method.......................................................................................153
8 The electric equipment repair limit of DF8BI locomotive................................................ 154

Chapter 5 Semiconductor device .................................................................... 156

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1 PRS series protection device............................................................................................156

1.1 PRS-80 (160) protection device ................................................................................156
1.2 PRS-80C protection device .......................................................................................159
2 Voltage Regulator ............................................................................................................160
2.1 Summarize.................................................................................................................160
2.2 Technical specification..............................................................................................161
2.3 The principle of voltage regulator.............................................................................161
2.4 Installation.................................................................................................................161
2.5 Overhaul method .......................................................................................................162
3 Voltage Boosting Modules ..............................................................................................164
3.1 Summarize.................................................................................................................164
3.2 Technical specification..............................................................................................164
3.3 Operating principle of voltage boosting and filtering module ..................................165
3.4 Operating Specification.............................................................................................166
3.5 Overhaul method .......................................................................................................166

Chapter 6 Ammeter Module, Anemometer Module, Sensors and Battery 169

1 The ammeter module .......................................................................................................169
1.1 Summarize.................................................................................................................169
1.2 Function.....................................................................................................................169
1.3 Transmitting mode ....................................................................................................169
1.4 Main technical parameters ........................................................................................169
1.5 Circuit principle diagram ..........................................................................................170
1.6 Outline and Definition of connection........................................................................171
1.7 Maintenance and Note...............................................................................................173
1.8 Examine and repair method.......................................................................................174
2 Anemometer modules ......................................................................................................178
2.1 General introduction..................................................................................................178
2.2 Main technical parameter ..........................................................................................178
2.3 Outlineǃmountingǃhole dimension and weight ....................................................179
2.4 Configration and connection .....................................................................................180
2.5 Maintenance and Note...............................................................................................180
2.6 Examine and repair method.......................................................................................181
3 Sensors .............................................................................................................................183
3.1 LEM current sensor...................................................................................................184
3.2 SCM sensor ................................................................................................................187
4. Storage battery ................................................................................................................193
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4.1 Application ................................................................................................................193

4.2 Basic parameters.........................................................................................................193
4.3 Construction of batteries............................................................................................194
4.4 Battery operating theory ............................................................................................195
4.5 Main electrical performance......................................................................................195
4.6 Preparation of electrolyte ..........................................................................................196
4.7 Checking and storage ................................................................................................197
4.8 Preparation before operation .....................................................................................197
4.9 Charge........................................................................................................................198
4.10 Daily maintenance. ..................................................................................................199
4.11 Periodic maintenance...............................................................................................199
4.12 Overhaul ..................................................................................................................200
4.13 Transportation and storage ......................................................................................201
4.14 Main troubles and trouble shootings .......................................................................201

Chapter 7 Microcomputer Control System.................................................. 203

1 Microcomputer Control box............................................................................................ 203
1.1 Summarize.................................................................................................................203
1.2 Physical Parameters...................................................................................................204
1.3 Electric Parameters....................................................................................................204
1.4 Electric Structure .......................................................................................................204
1.5 Illustration of Subassembly .......................................................................................211
1.6. Microcomputer operating principle block diagram..................................................220
1.7 Operating Precautions ...............................................................................................220
1.8. Fault judging and processing....................................................................................220
1.9 Simple checking method ...........................................................................................222
1.10 Environmental conditions........................................................................................222
1.11 External interface of microcomputer control device ...............................................222
2 Control Software ............................................................................................................. 229
2.1 Constant power characteristic control ........................................................................230
2.2. Dynamic brake characteristic ...................................................................................231
2.3 Anti-slip/anti-slide control.........................................................................................231
2.4 Software setting function...........................................................................................232
2.5 Diagnosis Of fault and protection..............................................................................233
2.6 Fault excitation ..........................................................................................................238
3 Overhaul method of microcomputer control box............................................................ 238
3.1 Overhaul device, equipment and tool, measure and material....................................238
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3.2 Main technical procedure ..........................................................................................238

3.3 Inspection and repair .................................................................................................239
4 Color display screen.........................................................................................................241
4.1 Operating principle....................................................................................................241
4.2 Main technical qualification......................................................................................241
4.3. Systemic constitution ................................................................................................241
4.4 Operating explanation ...............................................................................................242
4.5 Main technical process ..............................................................................................242


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 Chapter 1 Electric Equipments & Electric Circuit of DF8BI Locomotive

Chapter 1
Electric Equipments & Electric Circuit of
DF8BI Locomotive

1 Electric equipments general arrangement of DF8BI

locomotive
Both single-unit operation and double-heading operation are provided with the DF8BIlocomotive, its electric
transmission control system is designed according to the principle of advance, mature, credibility and
utilityˈwhich can suit Iranian operation ambient. The locomotive adopt whole EXP control system, which
has backup, EXP communication multiple and cable multiple. The switching off of the functions, such as
traction motor fault, power circuit over current, power circuit earth fault, racing, sliding protection,
lubrication pressure protection, blower protection, water temperature protection, lubrication temperature
protection, each of them shall be operated at the EXP LCD. The locomotive has the dead-man protection
function. The driver’s console is streamlined and meets the human-engineering principle. The arrangement
of electric equipments on the DF8BI locomotive is shown in Fig. 1-1, and the main feature will be described
in the following.

1.1 Electric equipments arrangement in operator’s cab

The locomotive has two cabs, and the equipments arrangement in these two cabs is basically symmetric. In
the cab, there is a console showed in Fig. 1-2, and the operation position is located on the right side. The
console is designed for single driver operation, and equipped with assistant driver monitor, on which
mounted whole driving and information control equipments. The structure and equipments installation
position of operator’s console is designed according to the human engineering principle. The hidden
mounting brake valve and EXP LCD are mounted on the right of desk, and the fridge is mounted on the left
down side, and also the handspike type driver controller with luminous, electric meter module, air gauge
module, toggle switch, general changeover switch, push button, etc are mounted. The refrigerator is
mounted in the lower left. In the left top of the desk equips with spring connecting strip, connecting wire by
unpacking the upper cover plate. Headlamp and overhead air- conditioner are mounted in the back of the
cab top. Moving leaf fans are fixed on the right and left side of cab ceiling, in the middle of ceiling setting
roof-door and inlet/outlet of air conditioner, and headlight is mounted beside the inlet/outlet of air
conditioner. Electric windscreen wiper is mounted on the front screen.

The power supply of meter lighting is DC110V.

1.2 Apparatus Arrangement in the electric apparatus room

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

Fig. 1-1 The arrangment of electric equipments

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 Chapter 1 Electric Equipments & Electric Circuit of DF8BI Locomotive

There is an electric equipment cabinet in the electric apparatus room. Main silicon rectifier cabinet is in the
left side, below which is the blower for main alternator and main silicon rectifier cabinet. The electric
apparatus cabinet will use spring connector. Vehicle control wire adopts high heat-resisting, low-smoke no-
halogen radiation cross-linkage ultrathin rolling stock cable. According to the requirements of TB1507-93
and TB1508-93, that the high voltage wire and low voltage wire should be divided, so the cabinet will be
divided into two areas, high voltage and low voltage electric equipments, just like Fig. 1-3A,B,C.

Most of control electric equipments for vehicle are fixed in the high voltage and low voltage area. The EXP
system, the cooling fan for the EXP reliable operating, voltage regulator, DC motor controller for car body
blower, step-up power model, control relay, DC contactor, 3UR&4UR rectifier, external electric supply
transformer, SCM board are mounted in the low voltage electric apparatus cabinet. The changeover switch,
reverser, electromagnetic contactor, contactor group, field-weakening resistance are mounted in the high
voltage area of the cabinet.

1.3 Electric apparatus Arrangement in the power room

In the power room, there is main alternator, starting generator, exciter motor, exciter silicon rectifier cubicle
and fuel pump motor.

Braking resistor unit is located on the upper of the front wall, which across the electrical room and the
power room, exciter silicon rectifier cubicle is on the lower left of the wall; on the right mounted the
braking system electric magnetic valve and the installation box I for pressure sensor, temperature relay,
differential manometer.

1.4 Electric equipment arrangement in the cooling and auxiliary

room
In the cooling chamber, there are two screw air compressors moved by DC motor, priming lubrication pump
motor, there are two tachometric sensors for cooling fan and the ventilator blower for rear bogie traction
motors in the cooling unit.

In the auxiliary room, there is an air filter unit. The braking system electromagnetic valve and sensor
mounting box II is located on the upper right of the wall, dead-man protection valve is on the lower.

1.5 Electric apparatus arrangement on the bogie and fuel tank

Traction motor is fixed on the bogie using nose suspension, with sequence arrangement. On the left of the
third moving axle box of the locomotive, there is a four-channel TQG15 speed sensor about locomotive,
which drives the locomotive speed gauge through digital-analogue converter. The temperature sensor of the
motor left bearing and right bearing are separately mounted on the six axle position from left to right.
Rotation speed sensor will be mounted on every traction motor.

Valve control sealed acid battery is mounted on the two sides of fuel tank, the type is GNC 210Ah,. There
are totally 78 pieces in ten boxes and the whole voltage is 93.6V DC.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

1-Phoenix terminal; 2-left door; 3-door lock; 4-electrical heater; 5-electrical heat glass switch; 6-trailing
locomotive microcomputer changeover switch; 7-fan changeover switch; 8-excitation changeover switch; 9-
electric wiper switch; 10-horn changeover switch; 11-electric gauge module; 12-multi-unit phone;14-air
gauge module; 15-ashtray; 16-foot switch; 17-three toggle switch group; 18- master controller; 19-
emergency stop button; 20-shunting button; 21 trailing locomotive starting button; 22-leading locomotive
starting button; 23-horn button; 24-dead-man button; 25-twelve toggle switch group.

Fig. 1-2 operator’s cab

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 Chapter 1 Electric Equipments & Electric Circuit of DF8BI Locomotive

1 Voltage regulator 2 General changeover switch˄A/B˅3 Knife switch 4 General changeover switch(lighting) 5
Grounding indicator light 6 Grounding test button 7 Illuminating 8 Diverter 9 Resistance 10 Breaker 11 Digital-analogue
converter 12 Relay 13 Fire alarm 14 LCS32 microcomputer case 15 Digital recorder 16 Voltage Boosting Module
Fig. 1ˉ3A electric equipment cabinet

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

17 Diverter 1RS 18 Fuse 19 Protecting device PRS-80C 20 Protecting device PRS-80 21 Protecting device
PRS-160 22 Diverter 2RS 23 Fuse 24 Fuse 25 Charging resistor 26 Countercurrent device 27 Diode unit 28
Rectifying module 5UR 29 DC contactor S 195 SE 30 DC contactor S 140A 31 Transformer 32 Startup contactor
33 Air compressor contactor 34 Exciting contactor

Fig. 1ˉ3B electric equipment cabinet

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 Chapter 1 Electric Equipments & Electric Circuit of DF8BI Locomotive

1 Direction Transfer Switch 2 Working condition transfer switch 3 Electric-magnetic contactor 4 Electric-magnetic
contactor 5 Contactor group 6 Grounding relay 7 Over current relay 8 Intermediate relay 9 Differential relay 10
Operation/test switch 11 Grounding switch 12 Self-load knife switch 13 Braking resistance isolating switch 14 Multiplicator
15 front bogie field weakening resistance 16 Rear bogie field weakening resistance 17 Illuminating light 18 Terminate plate
in Row 0 19 X1-X4 terminate plate 20 Current transformer 21 Over current silicon rectifier component 22 Earth silicon
rectifier component 23 Signal processing board 24 Current sensor 25 Fire alarm probe
Fig. 1ˉ3C electric equipment cabinet

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

2 Electric apparatus & electric circuit

The main electric apparatus in DF8BI mainly includes the vehicle control and protecting equipments. The
control apparatus include all kinds of contactor, relay, working condition transfer switch, reverser, driver
controller, while the protecting apparatus include all kinds of relay, fuse, miniature circuit-breaker, protector,
all kinds of resistance, capacitance, transformer, reactor, switch, lamps and lanterns, plug, socket, wire-pipe,
trunk, connection box, terminal strip, some of sensors, all busbars, etc.

The overhaul quality of electric apparatus and electric circuit during the medium repair will affect the
integrate medium repairing quality of the locomotive directly.

The electric apparatus mainly include kinds of resistance, capacitance, transformer, reactor, switch, fuse,
lamps and lanterns, plug, socket, wire-pipe, trunk, connection box, terminal strip, some of sensors, all
busbars, etc.

2.1 Resistor

2.1.1 Winding resistor

The DF8BI Diesel locomotive uses the charging resistance and field-weakening resistance as the winding
resistances which are made up by edgewise winding the ribbon resistance consist of iron, chromium,
aluminum on the electrician’s ceramics frame. The code of field-weakening resistance is 1-2RX, and the
charging resistance is 8R.

Main technical parameter

a. Field-weakening resistance (1~2RX), showed in Fig.1-4.

Rated current 475A

Resistance value 1RX 0.01109¡

2RX 0.01335¡

b. Charging resistance (8R) , showed in Fig.1-4.

Rated current 100A

Fig. 1-4 Winding resistor
Resistance value 0.122¡

2.1.2 Tubular enamel resistor

Lots of tubular enamel resistors are used in the DF8BI diesel
locomotive, mainly for adjusting current and voltage in the electric
equipments. Tubular enamel resistor is made by winding monolayer
nichrome wire on the ceramic tube, and then painting enamel on the
surface. When moving the clamp along the tube, the resistance
value will be changed. The resistor is showed in Fig.1-5. Fig. 1-5 Tubular enamel resistor

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 Chapter 1 Electric Equipments & Electric Circuit of DF8BI Locomotive

2.1.2.1 Main technical parameter

a. Model RXG20T-200W

Rated power 200W

b. The specification is listed in following table.

List table of Tubular resistor in DF8BI locomotive

Serial number Code number Resistance value(¡) Number
1 2R1-2 10 2
2 3R 1000 1
3 4R1-5 50 5
4 5R1-2 100 2
5 6R 200 1
6 7R 600 1
7 12R1-2 5 2

2.2 Fuses
The RT20 type fuse used in DF8BI is made of base, porcelain tube and
fused mass, see in Fig.1-6. There are four R20 fuse in the locomotive, used
as protection circuit for battery charging, auxiliary generator and air
compressor motor. The technical parameter of fuse is listed in the
following table.

List Table of RT20 model fuse in DF8BI diesel locomotive Fig. 1-6 fuse

Serial number Code number Name Fuse(A) Number

1 1FU Battery charging protection fuse 125 1
2 2FU Auxiliary generator protection fuse 160 1
3 4FU Air Compressor motor 1 protection fuse 350 1
4 5FU Air Compressor motor 2 protection fuse 350 1

2.3 Miniature circuit-breaker

5SJ5 model automatic circuit-breaker is used for the overloadand
short-circuit protection of locomotive control circuiWǃlighting circuit
and air-condition circuit.

5SP4 model automatic circuit-breaker is used for the overload and short-
circuit protection of locomotive lubrication pump circuit.

2.3.1 Main technical parameter

Rated voltage: 440V(2P)

220V(1P)
Fig. 1-7 automatic circuit-breaker
Rated breaking capacity: 10000A

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

2.3.2 Structure
The miniature circuit-breaker is made up of contact system, operating mechanism, electromagnetism
breaker, etc. Fig.1-7 shows the 5SJ5 and 5SP4 models automatic circuit-breaker external appearance.

List Table Miniature circuit-breaker in DF8BI locomotive

Code number Rated current Protecting position Pole number
11QA1 10A Auxiliary generator generate electricity Single
11QA2 10A D/A Transform Box Single
11QA3 10A Electric heater Single
11QA4 10A Exciter Single
11QA5 10A Electric cabinet light Single
11QA6 10A Reservation Single
11QA7 10A Fan Single
11QA8 10A Horn Single
11QA9 10A Cab lamp Single
11QA10 10A Console lamp Single
11QA11 10A Reservation Single
11QA12 10A Auxiliary light(white) Single
11QA13 10A Electro thermal glass Single
11QA14 10A Red light Single
11QA15 10A Head lamp Single
21QA1 10A Fridge Double
21QA3 10A Left bodywork lamp Double
21QA4 10A Right bodywork lamp Double
21QA5 10A Under frame lamp Double
21QA6 10A Air drier Double
21QA7 10A State display Double
21QA8 10A Electric injection controller Double
21QA9 10A Sensor 15V power supply Double
21QA10 10A Microcomputer power supply Double
21QA11 10A Blower for eliminating dust 5FD Double
21QA12 10A Blower for eliminating dust 6FD Double
21QA13 10A Blower for eliminating dust 7FD Double
21QA14 10A Blower for eliminating dust 8FD Double
14QA 1A The fan of monitor Single
16QA1 16A Locomotive control Single
22QA1 20A Oil pumpĉ Double
22QA2 20A Oil pumpĊ Double
22QA3 20A General controller Double
22QA4 20A Socket Double
23QA1 3A Windscreen wiper Double
24QA1 4A Blower (ĉ) Double
24QA2 4A Blower (Ċ) Double
25QA1 25A Electric oven Double

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 Chapter 1 Electric Equipments & Electric Circuit of DF8BI Locomotive

Code number Rated current Protecting position Pole number

50QA1 50A Air conditioner(ĉ) Double
50QA2 50A Air conditioner(Ċ) Double
280QA 80A Lubrication pump Double

2.4 Knife switch

2.4.1 Battery knife switch

The model number of locomotive battery knife switch is N209, and the
code number is 1QS.
2.4.1.1 Main technical parameter

Rated voltage: 110V Fig. 1-8 battery knife switch

Rated current: 400A

Style: double-pole single-throw

Structure

The knife switch is composed of the soleplate, hand hold, static blade, moving blade and leaf spring. See
Fig.1-8 for the N209 battery knife switch external appearance.

2.4.2 Self-load knife switch & braking resistance isolating switch

The locomotive self-load knife switch and braking resistance isolating switch is all T757G model, the self-
load knife switch code number is 4QS1-2, and the braking resistance isolating switch code number is 5QS1-
2.

2.4.2.1 Main technical parameter

Rated voltage 930V

Rated current 800A

Style Three knife per group, single-pole single-throw

Micro-active switch
Fig. 1-9 knife switch
Rated voltage 110V

Rated current 5A

Contactor pair number 6 normal open, 6 normal closed

2.4.2.2 Structure

The knife switch is composed of baseboard, bladeǃstatic blade set, leather bowl,
micro-active switch and handle set. Fig.1-9 shows the switch appearance.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

2.5 General changeover switch

2.5.1 Main technical parameter

(1)Rated voltage of contacts

Rated voltage (Ue): DC 110V

Minimum voltage /current 12VDC/5mA

(2) Current of contacts

aǃConventional thermal current of contacts ( Ith ):

DC 10 A (contacts S806bǃS826bǃS847W2A2a)

bǃRated current of contacts ( Ie) :

DC 1A( contacts S806bǃS826bǃS847W2A2a )

aǃ Conventional thermal current of contacts ( Ith ):

DC 20 A (contacts S800b SB)

bǃRated current of contacts ( Ie ) :

DC 10A (contacts S800 SB)

(3) Features of contacts: fast – actuation, having self – clean function and sealed structure ;

(4) Protection grade (pollution grades 3)

Contacts S806bǃS826bǃS800b SB IP 00 ( wiring part )

IP 40 (contacts part)

Contacts S 8472A2a IP 00 (wiring part)

IP 60 (contacts part)

(5) Service life

Mechanical life > 3 ×105 operations

Electric life > 1 ×105 operations

(6) Operational frequency: 10 times/min

Fig.1-10 shows the outline of general transfer switch. The general changeover switch in locomotive is listed
in following table.

General changeover switch table in DF8BI diesel locomotive

No. Code name Name Specification Number
1 1SA Electro thermal glass switch SMDC-C1/C1 1h2
2 3SA Fan switch SMBC-B5/B3 1h2
3 5SA Lighting transfer switch SMCBˉC4/C1/C4/C1 1

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 Chapter 1 Electric Equipments & Electric Circuit of DF8BI Locomotive

No. Code name Name Specification Number

4 6SA Exciter transfer switch SMCA-B3/B17 1h2
5 9SA1-3 Multiple unit traction switch YSONCA2719-59MOB W 3h2
6 10SA Operation/test switch SMCB-B4/B1 1
7 14SA A/B position switch SMAC-B1/B1/B1 1
8 15SA Electric wiper switch SMBB-B1/B1/B2/B2/B4/B4 1h2
Remote locomotive EXP
9 18SA SMAC-B1/B1 1h2
changeover switch
10 19SA Grounding switch SMCB-B4/B1 1

2.6 Overhaul methods

2.6.1 Overhaul facilities, fixtures, measurement tools and materials

a. Facilities: AC dielectric strength tester, contact resistance meter, sweeping device.

b. Fixtures: special terminal fixing tool, normal electrician small tool.

c. Measurement tools: 500V Meg-ohmmeter, 1000V Meg-ohmmeter, universal meter, capacitance meter.

d. Materials: blade cloth, absolute alcohol.

2.6.2 Main technological process

2.6.2.1 Sweeping

Sweep the cab console inner side and electric cabinet with compressed air.

Wipe off the dust and greasy dirt on the electric appliances of the locomotive with brush and blade cloth.

Unpack all trunking and remove the impurity, greasy dirt, dust and water. Find out disrepair and leak of the
trunking and solve those problems.

2.6.2.2 Inspection and repair

2.6.2.2.1 Electric circuit

a. Busbar

A1. The wires shall be straight without breakage and sectional crack.

A2.Ends of busbar should be smooth. If the surface of strip have oxidize, overheat off-color, plating layer
peel or wear and tear, the contact surface should be loosen. Fasten it after dressing it with thin sand cloth. If
the defect area exceeds 5% original area, repairing welding is permitted and it shall be filed smooth.

A3.Insulating support and cushion for busbar shall have no breakage, disengage, and loose.

B. other wires

b1. Insulating layer

ĉˊThe insulating layer is not allowed having severity overheat, burning loss, aging chap and oil-filled
soften. If the following situations exist, it must be changed. visible expansion of the rubber surface,

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

extrusion rubber-knot, loss of flexibility, pasty, half pasty or extrusion rubber phenomena while bending,
surface crack-damage, reveal core or shell off the insulating layer, and becoming powder while press it, after
back-folding 4 times. If occurred partial mechanical damage and mentioned above phenomenon, it would be
permitted to wrap in the condition of ensuring the dielectric strength and mechanical strength. The distance
from the base to the insulating wrapping and repair position of traction motor outgoing line should be
greater than 50mm.

ĊˊWhile partial changing the cable, where sectional area is greater than or equal to 25mm2, the joint shall
be sealed with heat-shrink tube after wrapped by the insulating layer.

b2. If the breakage number of cable core or braided wire is greater than 10% of original number, the cable
should be changed, and the specification & model is listed in the circuit diagram.

b3.It’s not allowed to tense the connecting wire between two terminals. The length of wire shall be 110%
to130% of the distance between two terminals. While joints must be added in the middle of the two
terminals for repair and the joints number is more than two, the joints should be staggered, the distance
should not be less than twice length of the joint, and the two ends of the joints shall be tied to the wire on
the stand or wiring harness. In the middle of the wires of the electric measurement meter which affect the
measurement precision, no joints is allowed to be added.

c. Terminals

c1. The terminals shall be unknit, smooth, and perfect plating, equality and without crack damage. There
shall be no loose, break, oxidation, overheating, burning loss, erosion, wear on the connecting site between
the terminal and the cable. Normal oxidation should be use after smoothing.

c2. While changing the cable terminal, skinned off the insulating layer according the connecting length.
Then wash the connector by acid, select new terminal with suitable inner diameter. The terminal must be
clean, and no dirt objects in the inner surface. While fixing the terminal using the special tools, measure the
connecting resistance, if the value is less than 0.03m¡, then sealing the terminal with heat-shrinkable
tubing.

c3. There shall be no burn, disrepair and aging embitterment on the jacket. If the terminal jacket has
overheat phenomenon, retreating it then change the jacket.

c4. When repairing the cable connection of power circuit, motor and electric apparatus, the connecting
resistance value shall be tested after filling with the stannum, which shall not exceed two times of assembly
average. If the parallel cable in the power circuit needs pressure welding, the cable resistance value shall be
measured, which shall not exceed the minimum among the parallel cables.

c5. The wire-size should be complete and clear, conducting wire and bale of wire should be in arranged
order. The wire should be tied even and tight.

d. Conducting wire fixation

d1. The fixture group shall be complete and in good condition. There shall be no break, loose and damage
occurred on the wire stand, while the heat-shrinkable tube or plastic insulating tape shall be in good
condition.

d2. Wire and cable shall be in order and have no extrusion and touch with other thing.

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 Chapter 1 Electric Equipments & Electric Circuit of DF8BI Locomotive

2.6.2.2.2 Wire pipe, trunk and terminal box

a. No breakage and loose, and the fittings about cap, fixture and firmware should be complete and well.

b. The inner sides should be dry, clean, without dust and grease.

c. The connecting wire shall be in order without deforming. The antiwear bandaging or lagging should be
providing in the port, while it should be reliable and firm.

d. if there are some breakages, the welding repair treatment must be done after withdrawing the wire.

2.6.2.2.3 Line bank

a. There shall be no loose, breakage, and overheat oxidation on the line bank. The connection strap shall be
in good condition. The damaged area of insulating barrier for line bank should not exceed 30% of original
area.

b. The fittings such as nut, gasket, and spring coil shall be complete. The screw thread shall be perfect,
while the connector shall not be loose.

c. the connecting wire on the adjacent terminal shall not be touched each other.

d. The location of connecting wire on the line bank must be the same with location on the electric circuit
drawings, and shall be arranged in order for easily examine.

2.6.2.2.4 Kinds of switch and socket

a. Action shall be flexible, and indication shall be correct. Auto-reset, allocation, and self-lock mechanism
shall be in good condition. The parts shall be complete, and there shall be no disintegration or burning loss
occurred on the Bakelite. The rated current value of automatic circuit-breaker should be according to the
electric circuit plan.

b. The action of on and off shall meet with the requirement, that contacting shall be credibility and the
connection shall be without loose.

c. Kinds of plugs and sockets shall be complete. There shall be no overheating, burning loss, bend, and
abruption on the contact pin and sheet. The connecting of plug and socket shall be well, and the clamp force
of gasket shall be normal. Location and locker shall be credibility, while the clamp and the cap for dust-
proof and water-proof shall be prefect.

2.6.2.2.5 Battery knife switch, self-load knife switch, and resistance braking insulating switch

a. Blade and clamp must contact closely, and the connect length must exceed 80% length of the clamp. The
moving section should be flexible, and without loose, while the fasten force shall be suitable.

b. No severity burning is allowed on the blade and clamp. Normal burning can be filed for repair. The loss
width of the blade shall not exceed 10% of the original dimension, and the decrease thickness not exceeds
33% of the original dimension.

c. No burning loss and breakdown is allowed on the base, all parts should be mounted firmly and without
loose.

d.The connecting post should be without overheating and breakage. The screw thread shall be in good
condition.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

2.6.2.2.6 Fuse and diverter

a. they shall be mounted firmly and the contact shall be credible. The oxidized contact site can be sanded
with emery paper.

b. there shall be no crack and burn on the shell, the capacity of fuse should meet the requirement.

c. there shall be no overheat, oxidization, abruption and distortion on the slices of diverter.

d. there shall be no overheat and burning out on the connecting post. The screw thread shall be in good
condition.

2.6.2.2.7 Resistor

a. Strip-round resistor

a1. No sealing-off, rupture, touch and short-circuit among resistor strips, sectional breakage area should not
exceed 10% original cross-section.

a2. Ceramic chip and stand shall be complete and without rupture.

a3. Tapping and connection should be firmly welded.

a4. Measured value of resistance should not exceed 5% rated value.

b. Enamel resistor

b1. The resistance should not have phenomena of short-circuit, turnoff, porcelain rupture and outer pack
enamel defect. The difference of resistance value should not exceed 10% of rated value.

b2.The terminal strips shall have no split and damage, while tap clamp should contact well and mounted
firmly. Scrap off the original setting mark.

b3.The resistance should be fitted well and felt pad shall have no disrepair.

2.6.2.2.8 Light fitting

All light fitting and accessory shall be complete and well, fitted firm, lighting well and displaying right.

Light wire should be connected well and the wire shall have no damage.

Irradiated direction should be right, and focus shall be good.

The outside lamp with protector should be sealed well.

The voltage and power of all lamp bulbs should meet the specification.

2.6.2.2.9 Sensor

There shall be no crack and damage on the shell, no loose in the socket. The plug and socket shall be fitted
well.

There shall be no loose, aging, burning and breakage on the wire.

There shall be no damage and corrosion on induction end of temperature sensor. There shall be no crack and
damage on the nozzle and the clearance shall be sealed well.

The shielding layer of Hall sensor should not touch the carbody and box.

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 Chapter 1 Electric Equipments & Electric Circuit of DF8BI Locomotive

2.6.2.2.10 there shall be no short-circuit, shutdown, and weeping in the capacitance. The difference between
measured value and rated value of capacitance shall be less than 10% of rated value using capacitance meter.

2.6.2.2.11 The transformer and reactor should be clean, and the leading-out wire and connection shall not be
loose. No virtual-connecting, shutdown, and short-circuit in the winding. All windings and iron core should
be firmly mounted, no loose, and shall be perfectly installed.

2.6.2.2.12 The fittings of electric oven should be complete, and heat efficiency shall be normal. The
protection device shall be well.

2.6.2.2.13 All kinds of temporary lay-side wire because of burning loss, breakage, grounding must be
removed. New adding wires because of technical reform should be merged sorting, mounted and wrapped
on the wire-stand according to the specification.

2.6.2.3 Dielectric test

2.6.2.3.1 After all the electric equipments assembly is finished in the locomotive, pull out all the electronic
installation plug, short-circuit the input and output terminal of main silicon rectifier cabinet and exciter
rectifier cabinet. Use Meg-ohmmeter to measure the insulation value between the main circuit, auxiliary
circuit, control circuit, lighting circuit and exciter circuit with ground and each other, which should meet the
specification.

2.6.2.3.2 Use 50Hz, 1300V power between high voltage system with low voltage system and with ground,
lasting 1min, no breakdown and flashover. Use 50Hz, 500V power between low voltage system with ground,
lasting 1min, no breakdown and flashover.

2.6.2.4 Filling out the inspection record.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

Chapter 2
Electric Machine

There are two types of electric machines fixed in DF8BI diesel locomotive:

a. The special electric machines

These electric machines are specially designed for the locomotive, according to the performance
requirements and structural features of the locomotive. The special electric machines include the main
alternator, the traction motors, the starting generator, the inductor exciter, the air compressor motors, and
also the ventilator motors for braking resistor etc.

b. The auxiliary electric machines

These electric machines mainly are ZTP series DC motors, and various micro-miniature motors which
power is less than 1KW, such as the starting lubricating pump motor, the fuel pump motors, and cab fan
motors etc.

1 Synchronous Alternator
1.1 Operating principle and structure
The main alternator is a kind of rotating electric machine that transforms machinery energy into electric
energy. While the excitation winding of the rotator is supplied with DC excitation and driven at a uniform
speed by the diesel engine, the air gap permeance in the rotor core gullet will be in a periodic variation, and
then the magnetic flux generated from excitation magnetic pole will also be in a periodic variation in the
active layer of stator core, finally, the alternating electromotive force in the tri-phase symmetrical armature
winding of the stator will be generated, in other words, the mechanical power of the diesel machine is
transformed into the electric power. Why call it “synchronous”? Because the rotating field generated from
the stator rotates in the same direction and at the same speed as the rotator.

In DF8B diesel locomotive, JF204D, the three-phase salient pole alternator, is shown as a horizontal type and
mono-axial structure (refer to Fig.2-1). At the output end, there is an E32626QTY single row cylindrical
roller bearing of collector rings, and the shaft extension taper is 1:10. At another end, on the rotator magnet
yoke, there are 24 screws as M20u1.5, which are used to link to the engine through the spring coupling.

Forced draft along the axial direction is used to cool down the main generator, the cooling air enters the
generator through the bottom air inlet of end cover, after cooling down the generator along the axial
direction, it will exhaust from the other end.

The elementary diagram of the main alternator is shown on Fig.2-2.

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 Chapter 2 Electric Machine

Fig. 2-1 the Main Alternator JF204D

1-circular nut; 2-lock washer; 3-bolt M16h160; 4-filler ring;5-oil cap 10h1;6-outer bearing cover;7-cover plate
assembly;8-bolt M20h60;9-filler ring 20;10- end cap;11-brush rod;12-Bush holder;13-filler ring 6(GB/T 93ˉ1987);14-
filler ring 6(GB/T 97.1ˉ1985);15-bolt M6h12;16-bolt M8h35; 17-bucket plate; 18-brush rod gag; 19-electric brush; 20-
brush box; 21-cap nut M20; 22-buckle plate; 23-brush box bolt; 24-rotator assembly; 25-stator coil; 26-inner seal ring;27-
axle bearing; 28-outer seal ring;29-inner bearing cap; 30-bolt M12h35;31-lock sheet;32-collector ring assembly;33-bolt
M16h45; 34-bear frame assembly;35-cushion block;36-filler ring;37-lock sheet;38-magnetic pole bolt;39-magnetic
yoke;40,41-magnetic pole assembly.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

1.1.1 Stator
The stator core, which is fixed tightly on the machine frame through the tensile stud, is made of high quality
fanning strip that is made of pressed cold rolled silicon steel plate.

The armature coil is made of 2 flat copper wires in spec of 1.9 *8 mm, after being duplex winding for 3
loops. After insulation wrapping, the four conducting rings will be fastened by the support clamping device.

The outgoing wires are on the upper of the generator, the three phases wires and neutral wire are signed as
U, V, W and N.

1.1.2 Rotor
Rotor is comprised of magnet pole assembly, bracket assembly, and collector ring assembly etc.

Magnet pole mainly consists of pole core and pole coil, the gaps between them is stuffed by insulating
materials, so it is an integrating magnet pole structure, and there is no damping winding. Pull rod is
provided in pole core with both ends tightened by the hold-down plates through bolts. The magnet pole is
fixed at magnet yoke through high strength bolts. The pole coil is wrapped with TDR copper belts in spec of
2.24u28mm.

Bracket assembly, which connects with magnet yoke through bolts, consist bracket and axle head with
interference fit. The collector ring assembly is fixed at bracket through bolts.

Collector ring assembly consists collector ring casing and collector ring. On the surface of the collector ring
that is made of brass or ZcuZn16Si4, there are some helical flutes, which are designed for the powdered
carbon exhausting conveniently. The hot jacket will cover the ring casing which is insulation processed.
After assembling collector ring on the bracket, integrating vacuum pressure varnishing treatment will be
done to the rotor, and then process collector ring ex-circle and cut helical flute. Finally, polish the surface.

While carrying out the dynamic balance calibration for the rotor, the residual unbalance value should be less
than 0.302 N.m.

1.1.3 Brush yoke system

Brush yoke system is fixed inside of the
end cover with brush rod and clamp plate.
Excitation connecting box is fixed
outside of the end cover. The brush yoke
system consists of two brush rods, four
brush holders, and also eight electrical
brushes.

One end of the excitation leading wire

connects to brush holder, and another end
leads out through the excitation fairlead
on the end cover. Open the connection Fig. 2-2 Elementary Diagram of the Stator in JF204D

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 Chapter 2 Electric Machine

box, the connecting terminal of exciting leading wire can be seen.

1.1.4 End shield

The end shield is a welding structure with an air inlet at the bottom.

1.2 The main technical parameters

Name Parameter Name Parameter
Motor Type JF204D Service Character Continuous
Rated Capacity 3700kVA Phases 3
Rated Voltage 507/770V Coiling System Axial forced Draft
Rated Current 4215/2775A Air Rate 290m3/min
Max. Current 5900A Excitation Means Separate Excitation
Rated Speed 1000r/min Rated excitation voltage 62/77V
Rated Frequency 116.7Hz Rated Excitation Current 289/358A
Rated Power Factor 0.95 Rated Efficiency 96%
Stator Connecting Y (with neutral line) Insulating Class H/H (Stator/rotor)
Model
Sway clockwise (facing shaft Bearing type E32626QTY
extension end)
Outside diameter of the 394mm Initial gap of Bearing 0.18~0.23
Collector Ring
Collector Ring Width 32mm Brush Qty. 8
Brush Brand D172 Brush Pressure 12~16N
Air Gap 4mm Rotor Outside Diameter ¶1172mm
Magnatic Pole Qty. 14 Electric Motor Stator 2821 kg
Weight
Stator coil Nrs. 126 Rotor 2758 kg
Rotor winding resistance 0.157 ȍ (20ć/h) Total Mass 6032 kg
Stator winding resistance 0.00116 ȍ(20 ć /h)

1.3 The original dimensions and limits

Limit
No. Description Original Shape
Medium Repair Forbid
Clearance Along brush thickness direction
0.07~0.33 0.07~0.65
1 between brush (axial direction)
and brush box Along Brush width direction 0.08~0.4 0.08~0.50 1.00
2 Distance between brush box and collector ring surface 2~5 2~6 ˚7
3 Brush Pressure (N) 12~16 12~16
4 Brush Height 50 27
0DŽ
23
5 Dia. Of collector ring surface ¶394 0 ¶382 ¶380

Runout of collector ring working face after electric

6 İ0.05 İ0.15
machine assembling.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

Limit
No. Description Original Shape
Medium Repair Forbid
the axle diameter of the rotator axle at the rolling bearing 0.055 0.055
7 ¶130 0.035 ¶130  0.035
installation place
Incorporating interference between rolling bearing inner
8 0.035~0.073 0.035~0.073
ring and axle
Radial clearance between bearing outer ring and end cover
9 0~0.077 0~0.013
dead eye
10 Radial clearance of bearing after assembly 0.105~0.165 0.105~0.25
Incorporating interference of shaft extension cone and
11 1.25~1.6 1.25~1.6
Flange(axial pressure pressing )
12 Cylindricity of end cover dead eye 0.025 0.030

1.4 Inspection and repair process

1.4.1 Special Equipments, fixtures, Tools and Materials

1.4.1.1 Equipments and fixtures: dry oven, withstanding pressure machine, electromagnet induction heater,
barring engine, and purge unit; assembling sling, coupling panel, brush pre-grinding ring, brush yoke and
plate, grease gun, and tensile stud.

1.4.1.2 Measuring Implements: Double bridge, 1000V meg-ohmmeter, universal meter, magnetic holder,
bore dial indicator (100~250,250~450), outside micrometer (260~400,120~140), point thermometer,
asbestos gloves, balance, and copper rod.

1.4.1.3 Materials: Polyimide film, H class silicon Plexiglas powder mica tape, non alkali glass tape, white
cloth tape, silver solder, scaling powder, bearing grease, epoxy glass cloth plate, H class insulating varnish,
anti-shock tray, rotor pole kingbolt gasket, and locking gasket.

1.4.2 Main technological process

1.4.2.1 Inspection before disassembling

a. Find out the running status of the main alternator during the diesel locomotive operation, especially the
status of slip ring spark, bearing vibration and temperature rise.

b.Before disconnecting the main alternator and diesel engine connecting box, magnetic dial gage should be
provided to measure the runout of slip ring of jagger.

c.After disconnecting the main alternator from the diesel engine connecting box, double bridge should be
provided to measure pole winding resistance and stator winding resistance. 1000V meg-ohmmeter should be
used to measure the stator winding insulation resistance against ground, and the 500V meg-ohmmeter to
measure the rotor winding insulation resistance against ground.

d.All the inspection data of the electric machine must be recorded according to inspection and repair data
sheet.

1.4.2.2 Disassembly

a. Dismantle flange at the small shaft extension end

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 Chapter 2 Electric Machine

a1.Use hand hammer and flat spade to open the flange and press locking gasket of circular nut;

a2.Use special tools and hand hammer to release the circular nut till there are only three screw threads from
the axle head;

a3.Use grease gun to dismantle flange: Clean the bolt hole of the shaft extension end; fix grease gun and
apply with appropriate bearing grease and rotate the handle of grease gun till the flange is released thereafter.
If it is difficult to dismantle the flange, while using grease gun, it is allowed to uniformly heat the flange,
but the temperature can not exceed 120ć.

Attention: Take strict precaution against any injury due to flange flying.

a4. Take off the compression nut and driving flange;

a5. Dismantle 4 cover plates and take off the carbon brush from brush holder bracket.

b. Rotor Lifting

b1. Dismantle the 6 M16 bolts at the outer bearing cover of E32626QTY bearing. Use 2 M16 process bolt
holes to dismantle outer bearing cover and sealing gasket;

b2. Hang the hook on the sling with the center of the rotor’s gravity is at the same vertical line with the hook;

b3.Use 4 M20h80 bolts to fix the connect panel to the flange at the big shaft extension end;

b4.Make good alignment of sling and connecting panel, and then use 4 M30h130 bolts for necessary
fastening;

b5. Lift the rotor inch by inch, push the inner bearing cover through 2 tensile rods, at the same time, use
crown block to move the rotor towards shaft extension end inch by inch;

Warning: While lifting rotor, make sure that the steel cable is reliable and solid (sling).

b6. Put the rotor on the rubber plate or bed timber and dismantle sling thereafter.

c.End shield dismantling

c1. Dismantle all the 18 M20 bolts at the end shield;

c2. Pass the steel cable through the steel plane on the end shield, use crown block to hold the end cover (just
tighten the steel cable) and dismantle the end cover. Before separation of end cover and machine frame, a
person should be specially assigned for safety protection. Use 3 M20 bolts to push the rabbet of the end
shield. While end shield is lifted from the machine frame, the brush bracket should be horizontally placed
with one face up warding.

1.4.2.3 Sweeping and cleaning

a. Use 3 M16 bolts to fasten the outer bearing cover, E32626QTY bearing and inner bearing cover so as to
protect the bearing;

b. Lift the rotator and stator to air lancing room and use the dry compressed air to sweep the dust (air
pressure must not exceed 0.29Mpa, so as to protect motor insulation);

c. Lift the rotator and stator to special cleaning room for necessary cleaning. Cleaning mixture shall be
3~5% concentration low bubble neutral washing agent with PH value no more than 9 and temperature
23
ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

60~80ć. Flush them for 10 mins with cleaning agent. After discharging cleaning agent, use clean water
50~70ć for repeat flushing 4~5min so as to wash off the cleaning agent remained at surface of motor
insulating layer;

d. If some dirt at the stator and rotator is unable to be cleared up by the cleaning machine, hand cleaning
should be carried out continuously with hair brush, soft cloth and bamboo strip. After cleaning, the
insulating varnish and surface paint shall be exposed of its essential color;

e. The front and back end shields of stator can be flushed directly with pressed clean water at high
temperature or use cleaning agent with concentration around 5% for boiling washing. Brush and shovel nose
tool shall be provided incorporating with scraping brush for complete cleaning;

f. After lifting out the cleaned stator and rotor from container cleaning, use 0.5~0.6Mpa compressed air to
dry the moisture remains on the inner/out surface of stator and in rotor magnet yoke;

g. Lift the cleaned motor stator and rotor into oven for drying. In the course of drying the stator and rotor,
the temperature inside of the oven should be raised gradually about 30ć per hour. While the temperature
reaches 100ć, it shall be maintained for 2~4h so as to ensure water be vapored completely. Then the
temperature should be raised to 130~140ć for continuous drying for 8 to 10h;

h. In the course of drying the stator and rotor, 1000V megohmmeter should be used every 1 hour to measure
the insulation resistance against ground of primary winding. After being in the oven for 8 hours, the
insulation resistance should be measured for three times, if the insulation value is stable and above 5M¡
with deviation among them not exceeding 10%. Then the drying processing has met the requirement.

1.4.2.4 Bearing cleaning and inspection

a. Clean the bearing at the axle: Open the outer bearing cover and remove residual oil remains in oil
chamber and bearing. Use diesel oil to clean the residual oil in bearing chamber and then use gasoline to
clean bearing carefully. Assemble outer bearing cover after cleaning completion or provide clean silk cloth
for necessary package.

b. The bearing must be replaced unless meet the following requirements:

b1. No surface stripping or crack on the bearing roller, inner or outer ring raceway;

b2.If the inner ring indicates blue color and the blue width exceeds 1/3 of the inner ring width, the bearing
should be replaced, but, the faint yellow, bronzing and baby blue are allowed to be at the outer ring and
roller surface;

b3.There should be no crack, buckle, crimping, and rivet break or loosening on the cage;

b4.The bearing should run freely and be in good condition without abnormal noise;

b5.Use the feeler to check the bearing radical clearance. The radical clearance of bearing should be about
0.18 to 0.28mm at free state and be about 0.115 to 0.217mm after assembly;

c.The bearings should be replaced for the whole sets and assembly date should be marked on the inner and
outer rings while carrying out such replacement. Meanwhile corresponding signs should be marked on the
bearing outer ring and end shield bearing pedestal. During the next medium repair, the outer ring should be
turned 90 to 120ebefore installation.
24
 Chapter 2 Electric Machine

d. Method and process of bearing replacement

d1. Use inductor heating collar or flame heating to dismantle outer seal ring and bearing inner ring;

d2. Defect detection should be carried out to the axle journal and no crack is allowed;

d3.Inductor heater should be used to heat bearing up to 120ć, but the highest temperature should not
exceed 140ć. Keep the temperature for 15min and then fix the bearing on the axle neck. Straight ramming
should not be prohibited during bearing assembling;

d4.Heat the outer seal ring up to 160ć and keep the temperature for 15min, then fix the bearing at the axle
journal.

Notice: Wear on heat-insulation gloves while heating the bearing and seal ring.

1.4.2.5 Rotor inspection and repair

a. Revolution axis

a1. Slight fish tails on the contact area should not exceed 15% on the surface of axle journal;

a2. During erection to shaft extension end cone face ring and bearing axle journal (while replacing bearing),
defect detection shall be carried out to confirm no crack therein;

a3.If depth of the fish tails do not exceed 0.25mm at the axle journal found during bearing assembly,
painting and plating treatment are allowed.

b. Magnetic Pole Bolts: If one bolt has crack during inspection, all the bolts should be dismantled in batches
for necessary defects detection. The damaged lock sheet should be replaced, and bolts need to be fastened
accordingly. The tightening torque of magnetic pole bolts is 1400-1540 N·m, it is good to make each bolt be
under homogeneous press. After locking of bolt, the locking sheet shall be turned over to cling to face plane
of bolt head.

c. Collector ring: Check the collector ring diameter and confirm whether it meets the requirements of limit
table or not. Dismantle and check the collector ring connecting wire and ensure no insulating abrasion. The
pack buckle should be complete and at a state of close sticking and fastening. The radical runout of collector
ring outer surface (ex-circle surface of bearing) if exceeds 0,15mm or has dummy club, it shall be sent for
lathe for finishing turning. After the turning, the roughness shall not be more than 1.6 whereas radical jump
of collector ring outer surface not more than 0.05mm. Abrasion depth of slip ring: The medium repaired
diesel locomotive should not exceed 0.2mm whereas not more than 0.5mm for minor repaired diesel
locomotive.

d. The pole winding should be in good insulation with no breakage at the adaptor. If not welded properly,
silver bearing copper welding should be provided for repeat welding.

e. Dry compressed air 0.3Mpa should be provided for repeatly sweeping so as to remove all the residues;

f. Use resistance detector to check resistance value of all the coils. During such detection, vibration should
be provided to the adaptor, if resistance value deviation is more than f10%, open stub package insulation
and check it carefully.

g. Check the resistance value of excitation windings. While recalculating up to 20˚C, the resistance value

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

comparing with typical value (see Clause II – main technological parameters) , and the allowed tolerance
can only be f10%. If it indicates big deviation, inspection should be taken to confirm if any loose or break
happens and take necessary treatment action.

h. Use 500V meg-ohmmeter to check the ground insulation resistance of rotor which can not be less than
2M¡.

i. The withstand voltage test, simple alternating current with 50Hz and1125V (all newly insulated, plus
1500V) should be provided for 1 min against ground. There can not be breakage and flashover.

Precaution: This test must be carried out at rubber ground and the operator shall be no less than 2 meters
away from the work piece.

j. If insulating resistance is on the low side or withstand voltage breakage occurs, the magnetic pole shall be
assembled after decomposition. Inspection should be carried out to single pole coil and treatment is required
to fault parts. If the fault is serious, the pole coil should be replaced completely. During pole assembly
silver bearing copper welding should be undertaken to the poles. Repeat the processes as aforesaid sub-
clause A ~ I.

k. Dynamic balancing test for rotor should be done if the following phenomenon occur, such as loss or loose
of balancing weight, idle run with much vibration, or varnish soaked freshly. The allowed unbalance is
0.302 N·m. The balance piece and magnet yoke should be welded tightly after balancing.

1.4.2.6 Stator inspection and repair

a. The winding joint should have no breakage or improper welding. Carry out the silver soldering to the
improper welding;

b. Dismantle buckle of outgoing line which should be in good insulation. The outgoing line should also be
installed tightly and shall not be loose. The nomenclature plate shall be clear;

c. The slot wedge of windings shall not be loose;

d. Check if the stator core is loose. If it is loose, thin wedge made of insulating material can be inserted into
the space between the laminates. Use epoxide resin for adhesion to make stator core tight.

e. If the winding insulation is proved with defects such as damage, ageing and burns, the insulation shall be
renewed according to practical condition (or brush epoxide resin to enhance the insulation).

f. The machine body shall have no crack. Welding repair is allowed if there are cracks.

g. Repeatedly sweep the stator with 0.3Mpa dry compressed air.

h. Use double bridge to measure the inter-phase resistance (namely the line resistance) and make records
correspondingly. Compare with typical value after recalculation up to 15ć, the phase difference shall not
exceed f10% and the resistance unbalance of three phase shall be less than 4%.

i. Use 1000V meg-ohmmeter to measure the ground insulation resistance which shall not be less than 5M¡,
otherwise the drying treatment shall be carried out.

j. Simple alternating current 50Hz and 1780V (all newly insulated plus 2540V) shall be provided for 1 min
high voltage holding test against ground. It shall be no phenomenon of breakage and flashover.

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 Chapter 2 Electric Machine

1.4.2.7 Inspection and Repair of End Cover and Brush Yoke

a. No crack and deformation is allowed on the end cover. Welding repair is allowed when there are cracks. If
overproof is found in cylindericity of bearing hole, buffing wheel shall be used for handling.

b.The brush yoke should be fixed tightly. The phenolic aldehyde insulator shall have smooth and tidy
surface and without irregular arrangement and cracks.

c.The brush box shall be free from overburning and deformation.

d.The brush yoke insulation shall be tight and have no phenomenon of breakage, ageing and overheating.

e.Use 500V megohmmeter to measure the ground insulation resistance of brush yoke which shall not be less
than 10M¡.

1.4.2.8 Assembly

a. Check up carefully and confirm there is no tool or other things remain on the stator and rotor. The
generator should be clean and tidy with clear nameplate and accurate marks of outgoing line. All the
components shall be fixed solidly and shall not be loose.

b.Fix the end cover on the electric machine body. Fix brush yoke apparatus on the end cover.

c.Dismantle outer bearing cover after cleaning, and apply the L-XEGEB2 motor bearing grease 0.8kg to the
locomotive bearing chamber. The bearing room shall be filled fully. The remaining grease shall be filled into
the inner and outer bearing cover oil chamber half for each.

Precaution: Assure the cleanness of bearing and grease.

d.Put the rotor into the stator with special sling. The axle hole of the end cover should be aligned with the
bearing outer ring and then push the rotor to its position slowly. (If it is difficult, insert three pulling stem
into bolt holes of bearing cover and turn the tensile rod so as to make the rotor to its position, and then
dismantle the pulling stem).

e. Install the outer bearing cover and tighten the bolts of the bearing cover so as to connect the inner and
outer bearing cover.

f. Install the wind shield at the big shaft extension end, and assemble the driven disk according to the
original location mark.

g. Adjustment of Brush Yoke Apparatus: The distance between brush box and slip ring surface is 2 to 5mm,
whereas it should be no more than 6mm for the medium repair locomotive. Electric brush of same brand
(D172) and with height more than 40mm should be provided to the electric machine. The clearance of brush
after being put into brush box shall be less than 0.65mm in thickness direction (axial direction) and less than
0.50mm in width direction (rotation direction). The brush pressure should be between 12 and 16N, and the
pressure can be adjusted through changing the location of the supporter in the gear rack of brush box.

Notice: Only the specified brush made by the specified manufacturer can be used, and the brushes of the
same electric machine should be replaced at the same time even if someone is still in good condition.

h. Slip-on flange: Use red oil powder to check the contact area between flange inner hole and shaft
extension cone face, and the value should be no less than 75%. Remove the red oil powder and fix the
flange on the cone. Fix the localizer at one of the bolts on bearing cover, then adjust registration arm to
27
ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

make the distance between its end surface and flange facies medial be at 1.6 (check with feeler). Tighten the
nut and lock it to the position. Take off the flange and heat it in oven to about 160 to180ć, and keep the
temperature for about 2 hours. Install the heated flange onto the axle promptly and close to localizer. This
can ensure the flange axial pressing value is 1.25 to 1.6. Install the lockwasher and circular nut. Tighten the
circular nut with special tools and fix lockwasher after flange cooled down to room temperature. The end
face runout value at the lateral surface of flange should not exceed 0.15.

i. Measure insulation resistance of stator and rotor to the ground, and the value should lie in the limits.

j. The generator should run stably and flexibly with no abnormal noise.

1.4.2.9 Inspection after assembly of the main alternator and diesel engine

a. The distance between brush and ring collector flank shall be more than 1mm.

b. The surface runout value of the collector ring should be less than 0.15mm.

c. The brush contact area should be more than 75% of its whole area.

d. All the inspection and repaire record should be filed in the repair log sheet in details.

1.5 Content of the main components

No. Description Code Qty. Manufacturer
1 Circular Nut ZD1-000-000 1 Chengdu Factory, Qi Factory
(Qisuyan locomotive and rolling
2 Lockwasher ZD1-000-009-1 1 stock works)
3 Bolt M16h100 GB/T 5782-2000 6
4 Gasket 16 GB/T 93-1987 28
Standard
5 Lubricating cup M10h1 JB/T 7940.1-1995 1
6 Outer Bearing Cover TF6D-000-002 1
7 Cover Plate Assembly TF6-010-000-1 4 Chengdu Factory
8 Bolt M20h60 GB/T 5783-2000 18
Standard
9 Gasket 20 GB/T 93-1987 18
10 End Cover TF6-400-000-2 1
11 Brush Rod TF6A-300-100 2 Chengdu Factory
12 Brush Holder TF6-300-005 4 Chengdu and Qi Factory
13 Gasket 6 GB/T 93-1987 8
14 Gasket 6 GB/T 97.1-1985 8
15 Bolt M6h12 GB/T 5783-2000 8 Standard Component,Outsourcing
16 Bolt M8h35 GB/T 5782-2000 8
17 buckle sheet TF6-300-003 4 Chengdu Factory
18 Brush Rod Clamping Plate TF6-300-004 4 Chengdu and Qi Factory
Shanghai Mogen Electric Carbon
19 Electric Brush TF6D-300-400 8
Products Co. Ltd.
20 Brush Box Assembly TF6-310-000 8 Chengdu Factory
21 Nut M20 GB/T 6170-2000 8 Standard
22 Buckle Sheet TF6-300-001 8
23 Brush Box Bolt TF6-300-002 8

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 Chapter 2 Electric Machine

No. Description Code Qty. Manufacturer

24 Stator Assembly TF6DZ-200-000 1 Chengdu Factory
25 Stator Coil TF6DZ-200-100 126
26 Inner Seal Ring TF6-000-005 1 Chengdu and Qi Factory
27 Bearing E32626QTY 1 Dalian Bearing Plant
28 Outer Seal Ring TF6-000-006 1 Chengdu Factory
29 Inner Bearing Cover TF1E-000-001 1 Chengdu and Qi Factory
30 Bolt M12h35 GB/T 5783-2000 4 Standard
31 Lock Sheet TF6-100-013 4
32 Ring Colletor Assembly TF6-130-000ˉ2 1 Chengdu Factory
33 Bolt M16h45 GB/T 5783-2000 12 Standard
34 Bracket Assembly TF6A-120-000 1
35 Fill Block TF6A-100-002-1 42
36 Gasket TF6A-100-004-1 84
37 Lock Sheet TF6A-100-003 42
38 Pole Bolt TF6A-100-001-2 84
39 Magnet Yoke TF6D-120-001 1
Chengdu Factory
40 Pole Assembly TF6D-121-000 12
41 Pole Assembly TF6D-122-000 2
42 Motor Bearing Grease L-XEGEB2 0.8kg Tianjin Tanggu Chemical Plants

2 Traction Motor
DF8BIadopts 6 DC traction motors (model: ZD109E), which are series excited.

2.1 Operating Principle and Structure

While the exciting winding of the stator and armature winding of rotor is supplied for DC (3-phase
alternating current generated by the main alternator and then be rectified into the DC by the main silicon
rectifying cabinet), the armature winding under the action of stator field will move along the action direction
of electromagnetic force and then make the rotor run. The electric energy of the main alternator is
transmitted to mechanical energy, which can drive the wheels through the gear, and then the locomotive will
move towards a certain direction. For ZD109 E traction motor, see Fig.2-3.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

Fig. 2-4 Structural Figure of ZD109Ee Traction Motor

1-Front End Cover Assembly;2-Bearing(NJ318ECM/C4+HJ318EC);3-Clamping plate;4-Front
Bearing Cover;5-Brush Yoke Assembly;6-Stator Assembly;7-Armature Assembly;8-Back End Cover
Assembly;9-Back Bearing Cover;10-Bearing (NU330ECM/C4);11-Seal Ring.

Fig. 2-3 ZD109E Type Traction Motor

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 Chapter 2 Electric Machine

ZD109E (Fig.2-4) is a quadrupole series excitation DC traction motor with forced ventilation. The machine
base, which is of all direction profiling welded structure, is not only a part of motor magnetic circuit but also
a main structural component of the motor. At commutator of the machine base, there are 2 big and 2 small
inspection windows for the convenience of brush replacement and maintenance of commutator and brush
holder system. While in operation, these windows should be covered properly. Nose suspension is applied
during motor installation on the bogie. One side of the traction motor is fixed at the axle through rolling
bearing whereas the other side suspended at the cross beam of bogie truck with rubber overhang apparatus.
While under rated conditions, the out ventilation quantity shall not be less than 110m3/min.

The motor’s adopts cylindrical roller bearing, the driving end is NU330ECM/C4 (type) and the commutator
end is NU330ECM/C4 +HJ318EC (type). These two-type bearings are made in NTN, Japan and they adopt
special grease.

For elementary diagram of traction motor, see Fig.2-5 as below:

(commutator end ) (driving end)

Fig.2-5 Elementary Diagram of Traction Motor

2.1.1 Stator
The stator has 4 main poles and 4 accessory poles. Each main pole is fixed at the machine base with 3 M33
bolts whereas each accessory pole fixed at the machine base with 3 M33 non magnetic bolts. To prevent oil
and water from entering the traction motor, the counter sink of pole bolt at machine base shall be sealed
with lacquer putty.

The main pole coil is of double layer flatwise structure which is divided into intercrossing and cutout two
types. The wire parameter is 7.3u31mm and with each coil wrapped for 18 circles. The accessory pole coil
is of edgewise structure. The wire parameter of accessory coil is 6.3u37mm and with each coil wrapped for
18 circles. Both main pole coil and accessory coil feature integral profiling structure which is good for
improving ventilation conditions. The main pole iron core is laminate structure. The air gap between main

31
ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

pole iron core and armature core applies non circular curve air gap to improve the commutation. Accessory
pole iron core is made of monoblock forged steel. In order to ensure no loosening of main and accessory
iron core during movement, profiled felt shall be filled in the straight portion between coil and iron core
with both ends plugged with insulating block. Both the main pole and accessory pole have elastic backing
plate. The stator shall be handled with varnish soaking treatment so as to form integrity of coil, core and
machine base and thus improve the reliability of the electric motor.

Main pole connecting wires adopt the short copper knitting flexible cord with joints directly connected with
bolts. The accessory pole connecting wires is made of hard copper flat wire and is fixed with cramp iron. In
order to improve the anti-vibration of the connecting wires, special rubber bush is used to support the
binding place of accessory pole connecting line. The rubber bush is made of neoprene gasket after necessary
rubber pressing. Four lead-covered cable is led out directly. The stub signs of 4 lead-covered cables are as
below separately:

S1-Armature head end; H2-accessory pole winding end; C1-main pole winding head end; C2-main pole
winding end.

2.1.2 Armature
Armature comprises of armature winding, front axle housing, rear axle housing, armature core, commutator,
rear support bracker and revolution axis etc.

The armature winding is single lap winding. Each armature has 58 coils which is equipped with 4 elements.
Each elements has one conducting wire which made of 4.22h8.6/4.6h8.98 monofil polyimide film
sintering line. The element arrangement in the chute is kept staggered upright. Every chute has one
equalizing cable with total 58. The conducting wire is of double wire varnished copper clad flat wire. The
insulation at chute is made of NHN compound foil after pressing. The slot wedge is processed from 4.5mm
veneer sheet after abrasive machining.

The stub of armature coil and equalizing cable will be connected with commutator riser by argon arc
welding. The welded place will have good electrical specification and mechanical property.

The rear support bracker is made of ZG230ˉ450 cast steel material. The intermediate steel bar will be cast
as treeing so as to improve the strength and air ventilation.

Armature will use high quality DW465ˉ50 cold rolled silicon steel sheet 0.5mm thickness after repeat
pressing. The external diameter of armature core will be 493mm whereas axial length 390mm. There are
three rows of vent holes totally 48 in the armature iron core. The pressing sheet and end plate is pressed
directly on the revolution axis. The revolution axis is made of 35CrMo alloy steel.

The commutator features dovetail arch structure with 232 commutator bar and mica sheet. The commutator
bar is made of silverbearing copper with wearing capacity allowance 9mm at one side radical direction and
its insulation degree is B. The extension part of V shaped mica ring of commutator clamping ring is fixed
with fluroplast 4 masking tapes for the improvement of arc resistance ability and sealing humidity resistance
of the commutator.

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 Chapter 2 Electric Machine

2.1.3 Brush Yoke System

The brush yoke system of electric motor has 4 brush holders with each one provided with 3 nos. of binary
fission electric brush. The brush label is CE-7 and brush size 19.1mmh43mmh70mm. The brush holder is
fixed at the brush rod support with M20 lag bolt through flank profile surface. The brush rod is fixed at the
machine base of motor commutator with 2 M16 bolts. In order to improve the arc resistance property, the
brush rod is covered with fluroplast 4 pipe. The press finger spring of the brush holder comprises of two
big/small straight screw pressure spring, spring holder, guiding axle, and tab washer. If it needs to adjust the
pressure of press finger, it may dismantle spring and adjust the tab washer at both ends of spring or replace
the spring.

2.1.4 End Cover

One bearing is fixed separately at the front and rear end cover of the electric motor. Each end cover is
equipped with one M10h1 lubricating cup. There are 4 nos. of M16h25 bolts. Dismantle these bolts and
observe the condition of commutation of electric motor.

2.2 Main Technical Parameters

Model ZD109E Service Character Continuous
Rated power 630kW Excitation Means Series Excitation
Rated Voltage 755V Field Weakening Coefficient 0.48
Rated Current 900A Insulation Class H/H
Specified Speed 855r/min Cooling System Forced Draft
Rated Efficiency 92.7% Ventilation Qty. 110m3/min
Rated High Voltage 1000V Motor Quality Rotor 849kg
Maximum Current 1260A Stator 1752kg
Max. Constant Power Speed 2200r/min Total Mas 2950kg
Top Speed 2465r/min Armature Winding Single lap winding
Nos. of Commutator Segment 232pcs. Armature winding branch 4
Outer Dia. Of Commutato ij390mm Armature winding pitch 1-15
Commutator length 150mm Commutator Pitch 1-2
Actual number of slots 58 slots Main pole winding resistance (20ć) 0.008364ȍ
Equalizing cable Nos. 58nos.Accessory pole winding resistance(20ć) 0.006466ȍ
Equalizing cable pitch 1-117 Armature Winding resistance (20ć) 0.012424ȍ

2.3 Original Dimension and Limit

Limit
No. Description Original Shape
Medium Repair Forbid
Brush thickness direction (axial
Clearance between 0.065~0.247 0.3 0.4
1 direction)
brush and brush box
Brush width direction 0.08~0.40 1 1.5
Distance between brush box and commutator working
2 2 2~3
face
3 Distance between brush box and commutator riser 9 13

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

Limit
No. Description Original Shape
Medium Repair Forbid
Parallelism between brush box and commutator axial
4 İ1 İ1
line
The distance deviation of two adjacent brushes along
5 İ1 İ1
circular direction of commutator working surface.
6 Brush Pressure (N) 38f3 35~41
7 Grave depth of Commutator mica 1.2~1.6 1 0.5
8 Commutator’s Diameter ¶390 ¶374 ¶372
Main Pole 509.3f0.4 509.3f0.4
9 Pole Spacing (dia.)
Commutating Pole 514f0.4 514f0.4
Rear Axle ˇˌˊˌ˕ˏ
¶170ˇˌˊˌ˒˔ 5
Dia. Reducing Housing
Driving Side
amount at Axis ˇˌˊˍˍ˓
10 Sealed Ring ¶140ˇˌˊˌ˕ˎ 2
sleeve (oil seal) of
Armature shaft Commutator side (front axle ˇˌˊˌːˑ
¶90ˇˌˊˌˎˏ 1
sleeve)
11 Armature axial movement after assembly 0.15~0.40 0.50

Runout of roll track 0~0.03 0.04 0.05

12 after bearing inner Driving Side
ring installation
Commutator side 0~0.025 0.035 0.045
Runout of Commutator working surface after motor
13 0.03 0.06 0.1
assembling
Distance mutual Deviation of main poles at
14 İ1 İ1
cirumferential direction
Distance mutual Deviation of commutating pole and
15 İ1 İ1
adjacent main pole
Central Axiality of magnetic pole against end cover
16 ¶0.3 ¶0.3 ˚¶0.3
rabbet of machine base
Corporating Driving Side 0.043~0.093 0.043~0.093
interference between
17
bearing inner ring Commutator side 0.025~0.065 0.025~0.065
and bearing
Fit clearance between Driving Side -0.018 ~0.079 -0.018~0.079
bearing outer ring
18
and end cover dead Commutator side -0.016~0.060 -0.016~0.060
eye
19 Abrasion Depth of Commutator İ0.2
Radical free gap of Driving Side 0.165~0.215 0.165~0.260
20
bearing Commutator side 0.105~0.140 0.11~0.19
Radical Clearance of Driving Side 0.10~0.19 0.22 0.25
21 Bearing after
assembling Commutator side 0.06~0.12 0.20 0.25

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 Chapter 2 Electric Machine

2.4 Inspection and Repair Process

2.4.1 Main Equipment, Tools, Measuring Device and Materials

a. Main Equipment: Load test bed, racing test bed, purge device, drying plant, pressure test bed, bearing
washing machine, dynamic balancing machine, down cut chamfering machine, commutator lathe.

b. Main Tools: Pinion gear puller, magnetic inductor heater, big/small bearing puller, oil seal puller,
armature sling, armature storage rack, armature roll over stand, and main and accessory pole sling.

c. Measuring Device: double bridge, two way millivoltmeter, point thermometer, 1000V meg-ohmmeter,
tachometer, TZ micro electric resistance detector, TY electric resistance detector, TA turn withstand voltage
detector, bore dial indicator (75~100,125~150), outer diameter measuring scale (370~400), inner diameter
measuring scale (501~700,130~150,40~45), magnetic holder, vernier caliper (0~200), depth vernier caliper
(0~300), steel rule, thermometer (0~200ć).

d. Materials: polyimide film, H class mica belt, non alkali glass tape, diphenyl ether varnished cambric,
white cloth tape, bearing grease, epoxy glass cloth plate, epoxy resin, H class insulating varnish, fluroplast 4
self-adhesive belt.

2.4.2 Main Technological Process

a. Inspection before Disassembly

a1. Determine main inspection items with reference to record list and according to practical technical status,
repair record and making use of dynamic variation.

a2. Visual Inspection: Check the status of electric motor parts. Take precaution to confirm if there is any
crack, loosening, rupture, burn, commutator darkening, and abrasion etc.

a3. Check the surface runout of commutator and confirm if there is any lug and deformations so as to
determine if need lathing treatment. If the commutator surface indicates burning deformation, this
inspection is unnecessary.

a4. Measure Insulating Resistance: Use 1000V meg-ohmmeter to check ground cold insulation resistance of
the main pole, accessory pole, and armature.

a5. Free run the electric motor for 10min under operating condition 2465r/min so as to determine if it needs
dynamic balance to the armature. Check if any abnormal noise of bearing and observe brush runout and
other abnormal status and find fault localization.

b. Disassembly

b1. Pull out traction pinion gear and seal ring

1) Open the locking gasket of gear anti-relax bolt and use special wrench to loose the anti-relax bolt till it
has three buckles distance to the bearing end and prevent from gear flying. Fasten the oil pressure puller in
the bolt hole of axle head and screw the puller with wrench. Increase oil pressure till the gear is pulled out.
(Hydraulic pump also allowed pushing down the gear).

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

2) If it is difficult to pull out the gear due to tight fastening or other reasons, preheating may be provided
with electric magnetic inductor heater and then use oil pressure puller to pull out the gear.

3) During gear assembling, mark shall be made so as to ensure correct assembly complying with
corresponding number.

4) Screw the oil seal puller on the screw treads of seal ring and turn the puller till it push out the seal ring.

b2. Armature Pulling Out

1) Dismantle filling pipe and clamp of bearing at both ends.

2) Dismantle front and rear bearing cover and planish the triangle check washer of front axle head.
Dismantle check screw and take off fluted disc and bearing ring.

3) Install the front process bearing cap.

4) Install the process nuts on the front end axle. Install the front end bearing guide sleeve after three M16h
40 bolt is fastened.

5) Clean the end axle surface at driving end. Lay the motor flat on the final assembly support bracket.

6) Push the final assembly sling bow horizontally into the axial cone portion of motor. Fasten the bolts to
prevent from being loose.

7) Pull out all the brushes and use vulcanized fiber to protect the commutator surface if necessary.

8) Dismantle the end cover bolt at driving end and screw the bolts into terminal strand hole of end cover and
push out end cover from rabbet of machine base.

9) Move the overhead crane slowly to pull out the armature horizontally from the stator and then put it on
the stator bracket.

10) Dismantle suspend arch and fix protective sleeve of axial cone and screw the lifting bolt into terminal
strand hole of end cover and lift out the end cover thereafter. Dismantle the front bearing cover.

11) Remove the guide sleeve on the front end bearing, loosen the three bolts and remove the process nuts on
the axle head.

12) Dismantle the end cover bolts of commutator and screw the bolt into terminal strand hole of the end
cover. Push out the end cover from the rabbet of machine base. Dismantle technological bearing cover.

13) Dismantle the rear bearing cover bolts and disassembly rear bearing cover.

c. Dismantle the Bearing

1) Use big/small bearing pullers to pull out the big/small bearing outer ring from the end cover.

2) Use inducting heating coil or hydraulic wheel puller to dismantle the big/small inner ring from the rotator.
(If bearing replacement is necessary).

3) Take off the bearing and mark correspondingly for the convenience of assembly.

d. Dismantle Brush Yoke System

1) Dismantle accessory pole--- brush yoke line and bolts, loosen coach bolts and nuts and dismantle brush
holder. Back off the bolts of fastening brush rod and dismantle the rod thereafter. Precaution shall be taken
36
 Chapter 2 Electric Machine

during dismantling to make mark so as to ensure future assembly according to its corresponding number.

2) Dismantle the clamp plate of the tensioned thread and take off the brush yoke line and outlet line.

2.4.3 Sweeping and Cleaning

a. Scrape off the residue oil remains at big/small bearing surface and put into special cleaning machine for
cleaning. The cleaned bearing shall be stored at special storage rack according to its number arrangement.
Cotton yarn scrubbing is not allowed during bearing cleaning. If bearing needs scrubbing, only cotton cloth
will be allowed for use.

b. Clean the hauling gear, seal ring, bearing cover, and end cover etc. Precaution shall be taken that all the
tools shall be cleaned at the same time and stored properly thereafter.

c. Cleaning of Stator and Armature

1) Use shovel nose tool and brush to clean the oil sludge remains at electric motor surface. The dirt crust
adhered at the machine body and rotator shall be removed carefully with shovel nose tool or bamboo chips.

2) Lift the stator and armature into the blow off cabinet. Use compressed air with pressure not more than
0.6MPa to sweep the dust from stator pole winding, armature winding and armature bracket.

3) Lift the stator and armature separately into the special cleaning machine for necessary cleaning. Cleaning
mixture shall be 3~5% concentration low bubble neutral washing agent with PH value not more than 9 and
temperature 60~80ć. Flushing shall be carried out for 10 min with cleaning agent. After discharging
cleaning agent, use clean water 50~70ć for repeat flushing 4~5min so as to wash off the cleaning agent
remained at surface of motor insulating layer.

4) If any dirt at the stator and rotator is unable to remove with cleaning machine, hand cleaning shall be
carried out continuously with hair brush, soft cloth and bamboo strip. After cleaning, the insulating varnish
and surface paint shall be exposed of its essential color.

5) The front and back end cover of stator can be flushed directly with high temperature compressed clean
water or use cleaning agent with concentration around 5% for boiling washing. Brush and shovel nose tool
shall be provided incorporating with scraping brush for complete cleaning.

6) After lifting out the cleaned stator and rotor from container cleaning, use 0.5~0.6Mpa compressed air to
dry the moisture remains on the inner/out surface of stator and in rotor magnet yoke.

7) Lifting the cleaned motor stator and rotor into oven for drying. In the course of stator and rotor drying,
the temperature inside the oven shall be raised gradually with rising range at 30ć per hour. While the
temperature reaches 60ć, it shall be maintained for 2~4h so as to ensure complete water vapor. The
temperature shall then be raised to 110~120ć for continuous drying 8~10h.

8) In the course of stator and rotor drying, 1000V meg-ohmmeter shall be used every 1 hour to measure the
insulation resistance against ground of primary winding. Insulation value shall be checked continuously for
three times to the stator and rotor put into oven. If the insulation value is stable above 5M¡and with
deviation not exceeding 10%. The drying processing will be deemed as satisfactory.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

2.4.4 Inspection and Repair

a. Stator Repair

1) Use 1000V meg-ohmmeter to check the cold insulation resistance of main pole and accessory pole
against ground and between each other. The cold insulation resistance shall not be less than 5M¡. The cold
insulation resistance of brush yoke against the ground shall not be less than 10M¡.

2) Sweep the machine base and check if there has any crack and defects. All the bolt holes and screws shall
be in good condition whereas electric motor has good indication in numbers. The magnetic pole erection
face of machine base shall be tidy without burr. The dummy club plain installed at the machine base shall be
level and without burr and dirt.

3) The middle hole of main pole at upper location of machine base is pilot hole and thus the pole bolts shall
be assembled there in advance. Special precaution shall be taken that only non magnetic steel bolts is
allowed for the accessory pole use. The bolts fasten moment at main pole and accessory pole shall be 1075-
1225 N·m.

4) Iron core shall be tightly adhesive to machine base and coil.

5) Treatment shall be taken to any insulation damage, burning or over heating and discoloration of coil.
However, if the coil is seriously deformed it shall be replaced immediately. The outgoing line and
connection line shall have good insulation. If damaged it shall be repaired without delay. If any improper
connection or overheating and discoloration happen to outgoing line lug, it shall be replaced without delay.
The connect surface of connector shall be smooth, level, even and with good hot dipping. The
interconnection while connecting shall be in good condition. The internal line connection of electric motor
shall be fixed stably and with proper arrangement. The clamps or bindings shall be tightened accordingly.
No friction or extrusion pressing is allowed between conductor and machine base.

6) Use simple alternating current 50Hz, 2200V (completely new insulation plus 3000V) to check withstand
voltage of the main pole, accessory pole and brush yoke apparatus. No break down or flashover
phenomenon will be allowed.

Precaution: High voltage holding test shall be carried out at rubber ground and the operator shall be at least
2m away from the work piece.

7) Use double bridge or TZ measuring apparatus to check the winding resistance value of main pole and
accessory pole. The resistance value at 20ć shall be calculated according to the following formula.
Comparison shall be made with the standard value (see Clause 2---Main Technical Parameters) and the
deviation shall not exceed 10% that of standard value.
235  20
R 20 x Rt
235  t

t--- Actual measured temperature;

Rt --- Resistance Value at temperature t;
R20 --- Resistance value while calculated at 20ć.

8) 2500V meg-ohmmeter or boosting voltage is allowed to determine the breakdown point.

38
 Chapter 2 Electric Machine

9) Check gasket of main pole and accessory pole and confirm no defects or loosening.

10) Check the installation dimension of magnetic poles. The core diameter of main pole shall be 509.3f
0.4mm whereas core diameter of accessory pole 514f0.4mm. The mutual distance deviation between main
poles shall not be more than 1mm. The mutual distance deviation between accessory pole and adjacent main
pole shall not be more than 1mm. The allowed axiality deviation of main and accessory iron core comparing
with rabbet axis of end cover at both ends of machine base shall be¶0.3mm . The verticality allowance
between main pole and accessory pole lateral surface and machine base end face will be 0.5mm.

11) The replaced or partially repaired magnetic pole winding shall have resistance measurement before
assembling and take records accordingly. After iron core installation, use 1000V meg-ohmmeter to check
the cold insulation resistance which shall not be less than 5M¡. Use simple alternating current 50Hz,
2800V to check withstands voltage. No break down or flashover phenomenon is allowed.

12) The pole bolt head shall be filled level with putty or bitumen.

b. Armature Inspection and Repair

1) The rotator shall be kept clean and in good condition. No oil stain and carbon powder is allowed in the
winding overhang, notch, front and rear support bracket, and vent hole.

2) No crack or deformation or loosening is allowed on the axle, seal ring, rear support bracket, balance piece,
iron core, winding component, slot wedge, and clamping bolts.

3) Detection shall be carried out to the rotating shaft. No crack is allowed to the bearing shield and bearing
extension portion. It is allowed for the axle journal surface to have slight sprain with effective connection
area exceeding 15% but should be treated smoothly. The axle neck conical surface shall have no axial
through sprain. The oil gallery shall be passage clear and free of defects such as scratching and scoring.

4) The axle end screw thread shall have no damage. If any damage happened to the screw thread, welding
repair is allowed but the preheating before the welding, temperature maintaining during and after welding
shall be carried out strictly.

5) Check if there is any crack or breakage on the rear support bracket. Welding is allowed to repair the crack
part. Before welding repair, groove shall be enlarged by shoveling. The welding slag shall be removed after
welding is completed.

6) The laid tape shall have no mark of aliquation and breakdown. If there is any damage, the laid tape shall
be rewrapped. The numbers of the turns shall not be less than 95 turns (the wrapping tensile force is
600~1000N). After wrapping, the surface of laid tape shall be level and solid. Any parts exceeding 2mm of
the armature core or roughness exceeding 2mm are not allowed.

7) All the parts of rotor shall have good insulation. No breakage, burning and ageing is allowed. If there is
any partial breakdown and mechanical damage, epoxy resin is allowed to be used for repair. The epoxy resin
shall be mixed according to specified proportion. Overspeed test shall be carried out after such repair. The
slot wedge shall be tight and joints shall be level.

8) Dynamic balance test shall be carried out, if the rotor’s counterbalance drops off, is loose, has big
vibration during idle operation, or its laid tape is rewrapped. The amount of unbalance allowed for traction
motor rotator shall not be more than 333g·cm. (The unbalance weight at balancing piece location shall be: at
39
ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

commutator side İ12g, at transmission side İ9g).

9) The commutator shall be sealed properly at the front end. No breakage and damage is allowed to the
commutator clamping ring and no loose shall occur to bolts. Check the working surface diameter of
commutator which shall be in compliance with limit requirements.

10) The commutator surface shall not have lug, serious burning and drag. The abrasion depth of commutator
shall not exceed 0.2mm. When the center of the commutator is need to be found during the finish turning,
the installation surface of bearing inner raceway at both sides or bearing inner race shall be treated as the
basis reference. The runout shall not exceed 0.03mm. The surface roughness of commutator shall be 1.6­m
and the end socket of commutator shall be R2 round angle while carrying out lathe turning. The bottom
cutting depth of commutator mica shall be in compliance with limit requirements and the chamfered angles
at both sides of commutator bar shall be 0.5h45e. After the chamfering is completed, there shall be no
residual mica powder and copper scale and all the burrs shall be removed accordingly. The commutator bar
at both sides of mica groove shall be cut a bell mouth 2~3mm wide with file.

11) The riser shall have no sealing-off, overheating and discoloration. The armature coil shall be welded
tightly to commutator and connection shall be good. Compare the resistance value between pieces with the
average value, the difference shall not be more than 5% (when using argon arc welding). Segment voltage
drop method is allowed for resistance measuring. The requirement shall be as the same as that of electrical
resistivity method.

12) Use 1000V meg-ohmmeter to check the cold insulation resistance which shall not be less than 5M¡,
otherwise drying or cleaning shall be carried out according to practical conditions.

13) Use simple alternating current 50Hz, 2200V (completely new insulation plus 3000V) to take withstand
voltage test to the ground for one minute. No break down or flashover phenomenon is allowed.

14) The withstand voltage between winding shall be carried out either with intermediate frequency or
impulse. There shall be no breakdown or flashover phenomenon in the windings. When intermediate
frequency is applied, the winding voltage shall be 60V. When the impulse is applied, the winding voltage
shall be 450~500V, 5s.

c. Inspection and Repair of Brush Yoke Apparatus

1) The brush yoke shall have good fastening and with no breakage and damage. The line connection shall be
regular and solid without any breakage. Any partial burn or deformation rectification should be carried out
without delay.

2) The surface of the brush rod shall be clean, without fracture and damage. If any fracture or damage
occurs to insulator spindle polytetrafluoroe thylene out coating, it shall be replaced without delay.

3) The brush pressing structure shall be flexible in movement. Serious burn or deformation is not allowed to
the brush box. No fracture or damage is allowed to the pressure finger. The spring shall not have rust spot
and shall be in good working condition.

4) The spring pressure difference on the same motor shall not be more than 20%. Brush box which is burned
or deformed, the press finger and spring which is damaged or do not reach the flexibility requirement shall
be repaired or replaced. Use dynameters to check the spring pressure of brush finger, it shall be within a

40
 Chapter 2 Electric Machine

range of 38f3N.

5) The brush shall have no fracture, and the breakage contact surface not exceeding 10%. The brush cord
shall not be loose, overheated or discolored. The same electric motor shall have the same brushes from the
same supplier and with the same brand. The brush length on medium repairing locomotive shall not be less
than 2/3 of the original length. The length on the operation locomotive shall not be less than 1/2 of the
original length. If there is a limitation mark on the brush, the abrasion shall not exceed this mark.

6) The brush shall be free in movement in the brush box. The clearance between brush and brush box shall
not exceed 1.0mm in axial direction and 0.3mm in rotation direction.

7) The brush box shall be parallel with the commutator. All the brushes shall be located at the working face
of commutator and with cycle distribution around the commutator. The brush yoke shall be located at
neutral position. The contact area shall not be less than 80% of the brush section area. The distance between
brush box and commutator working face shall be 2~3mm.

d. Inspection and Repair of End Cover

1) Carry out visual inspection to the bolt hole of end cover. The access of oil pipe and oil seal shall be in
good condition. If any fracture exists in the end cover, welding repair is allowed for consolidation treatment.

2) When there are drags on the end cover bearing installation seat or front and rear axle bush, the method of
metal spray plating or brush plating can be used for repairing to recover the dimension to the original size.

3) Use oil gun to check whether the oil pipe at both sides are unobstructed. The nozzle which is not in good
condition shall be replaced immediately. The blocked oil pipe shall be opened up without delay.

e. Bearing Inspection and Repair

1) The inner and outer bearing ferrules, rolling element, working surface and ferrules fitting face shall be
clean and free from defects such as fracture, abrasive damage, indentation, corrosion, uncovering, and
fatigue flaking.

2) Cleaning agent, which can leave a remaining oil film at bearing surface, shall be used for bearing
cleaning.

3) The bearing retainer shall have no fracture, flash and deformation. The rivet or screw shall have no
breakage or loose. The buffer shall be in good condition. The thickness of the retainer girder shall not be
less than 95% that of the original thickness.

4) During bearing dismantling, direct hammering is not allowed. The heating up temperature shall not
exceed 120ć. If electromagnetic induction is used for heating, the retentivity induction strength shall not be
more than 3h10ˉ4T. For the non disassembly inner ring, when inspect its interference fit condition with
related components, the contact resistance method can be used. The contact resistance between inner ring
and bearing shall not be more than 2 times that of statistic average value.

5) The bearing shall be replaced in complete set and with marks indicated at relevant places of inner and
outer rings. While carrying out next medium repair, it shall turn 90~120e. The acid liquor proportion while
marking at bearing shall be: copper sulfate 8.5%, selenious acid 7.5%, and nitric acid 10%.

6) When replacing bearing inner ring, the fitting dimension between bearing inner ring and the

41
ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

corresponding position of the rotation axle must be inspected. The selected interference shall meet the
requirements of the technique requirements and limits.

7) Use gasoline to clean up bearing. After blowing dry, put the bearing on the inner ring of revolution axis
and measure bearing clearance. The clearance at transmission side and commutator side separately shall be
0.10~0.22mm and 0.06~0.20mm.

f. Pinion Inspection and Repair

1) Detection shall be carried out to the pinion. No fatigue fracture and uncovering are allowed to the
dedendum and tooth face. The corrosion length at tooth face shall not exceed 15% of total pinion length
whereas corrosion depth not exceeds 0.5mm. The abrasion at one side of tooth face shall not exceed 1mm.
No axial through drag is allowed at the tapered fit surface between pinion and motor bearing.

2) Use tooth block and feeler whose width is not bigger than 3mm to inspect the gear form error. The
involute tooth profile deviation shall not be more than 0.35mm; the tooth head thickness decrement shall not
exceed 2mm and dedendum surplus boss height shall not be more than 0.8mm.

2.4.5 Electric Motor Assembly

a. Roller Bearing Assembly at Both Ends

1) Supply railway motor bearing grease evenly on the bearing which is in good condition.

2) Use oil gun to press grease in through the oil plug. Press out the oil remained in the oil pipe till fresh oil
flows out so as to ensure free flow.

3) Add grease in end cover oil storage chamber till it achieves 1/2~2/3 volume of the oil chamber. The
bearing grease add on shall be: 500f50g at transmission side and 250f50g at commutator side.

4) Put the bearing horizontally at the mounting hole of end cover with bearing mark out towards.

5) Use electromagnetic induction heater to heat the bearing seat hole and install the bearing. (Or press in the
bearing into bearing seat hole with oil hydraulic press).

6) Process bearing cover shall be installed on front end cover and the rear bearing cover shall be installed on
the rear end cover. Assembly shall be done according to the original location.

b. Brush Yoke Assembly

1) Install the brush rod on the machine base. Install brush line and accessory pole brush line and fasten it
with pressure plate.

2) Put the stator on the rubber ground with the commutator end upwards and fix the brush holder setting
dies.

3) Install the brush holders one by one and correct the installation position of the brush holders.

4) Dismantle brush holder setting dies and install electric brush. Caution: The brush shall not be put in the
square hole of the brush box for some time.

c. End Cover Assembly of Commutator End

Lift the end cover on the machine base and make it align to the rabbet of machine base. Use end cover bolts
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 Chapter 2 Electric Machine

to press end cover into rabbet. Hammering on end cover is not allowed so as to prevent it from deformation.

d. End Cover Assembly at Transmission Side

1) Put the rotator horizontally on the rotor support and install transmission end bearing guide sleeve.

2) Lift the rear end cover and keep bearing center of gyration center level and fix it into the bearing inner
ring of rotation axle bearing.

3) Dismantle the bearing guide sleeve at transmission end.

e. Main Assembly

1) Turn over the stator and put it horizontally on the main assembly support.

2) Install the front end bearing guide sleeve (at commutator end). Pay attention to the tightening of the
sleeve.

3) Pack 00# glass cloth with abrasive surface outwards on the working face of commutator. The overlapping
width shall not be less than 300mm. One end of the inner side part shall be adhesive to the working face of
commutator. Pay attention to ensuring the adhesion is flat and even.

4) Dismantle the axial cone protective sleeve at transmission side and fix final assembly lifting bow. Use
bolts for tightening.

5) Lift up rotator and push slowly into the stator. Caution: Stator and rotor shall touch each other.

6) Adjust the lifting bow and make alignment of rear end cover with the rabbet of machine base. Use bolt to
press end cover evenly into the rabbet. Dismantle the lifting arch and fix the end axial cone protective cage.

7) dismantle the front bearing guide sleeve and the process bolts (at commutator side). Dismantle the front
process bearing cover.

8) Install bearing angle collar, axle head fluted disc and triangular lock washer, and fasten them with three
M16h60 bolts. The washer shall be edge folded and locked tightly. Install front bearing cover.

The upward assembly is horizontal installation method. Vertical installation method can also be used. The
installation sequence is: put the machine base with commutator upwards and install brush yoke system;
install the end cover (including bearing) at commutator side on the machine base; Turn over the commutator
with transmission end upwards and install the end cover (including bearing) at transmission side on the rotor
bearing inner ring; Lift the rotor vertically into the machine base and fix the end cover at driving side on the
machine base; Turn over rotator with commutator side upwards and dismantle front bearing cover; After
installing bearing angle collar and fluted disc, install the front bearing cover. The vertical assembly method
is easy for adjustment during assembly but it needs more turning.

9) After the seal ring is heated to 140ć, put it onto the rotor shaft. Turn the armature; it shall have no touch
and friction.

10) Assemble electric brush. Caution: the press finger shall not press over the brush cord line.

11) Turn the rotator and grind the brush. The grinding surface at circle direction shall be 100%. Pull out the
abrasive cloth.

12) Assemble front and rear end cover oil pipe and fix clamp. Check the oil pipe screw thread and confirm
43
ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

there shall be no damage. The oil pipe shall not be loose at any time.

13) Turn the rotor and use high pressure blast to sweep off carbon powder remains in the inner chamber of
electric motor.

14) After final assembly, check the bearing assembly clearance at two sides and the axial movement of
rotor as well as the runout of commutator working face which shall be in compliance with requirements as
stated in limitation sheet.

15) Check the radical runout of turning axle cone which shall not be more than 0.1mm.

16) Fix pinion gear: refer to Fig.2-6.

16-1). Check contact surface: clean the motor

cone face and gear inner hole and smear evenly a
thin layer of red lead oil on the cone. Put the gear
on the cone and check the contact area between
gear inner hole and cone which shall not be less
than 75%. Remove the red lead oil thereafter.

16-2). Position Fix of Gear: knock the rotation

shaft and eliminate the axial clearance of rotation
shaft. Put the gear on the shaft and push it tightly.
The pinion localizer shall be fixed on the gear as
shown in the Figure. Turn the big nut and fix the
localizer on the gear. Adjust the locating rod of
Fig. 2-6 Pinion Gear Installation
localizer with clearance between rod end and
bearing cover end face 1.5~1.7mm (check with feeler). Fasten nut and stop screw so as to lock the locating
rod. Make marks at the places of gear localizer and locating rod contacting area. Take off the localizer and
dismantle the gear.

16-3). Shrinkage Gear: Heating the gear to 128~180ć and fix the localizer according to the marks. Fix the
gear on the shaft as soon as possible. The locating rod shall be contacted tightly at the marked position of
bearing end face. Withstand the gear with hand for 15 seconds and cool down the gear to room temperature.
Use feeler to check the clearance between locating rod and backstop which shall not be more than 0.1mm.
The outer end face of gear shall be higher than shaft end face. Fix the press plate and locking backup plate.
Screw down bolts and fix locking backup plate.

2.4.6 Test
In order to assure the quality of motor inspection and repair, operation test shall be carried to all the repaired
motors so as to confirm the running state and working performance. The defects found during operation test
shall be eliminated as soon as possible. The motors after medium repair shall have tests as follows:

a. Motoring Test: run the motor at positive and negative direction according to following operation
conditions. Increase slowly voltage during motoring test so as to ensure stable increasing of rotation speed
till it achieves required rotation speed. No abnormal noise or oil sprinkling is allowed during motoring test.
The bearing temperature measured in the temperature hole shall not exceed 70ć (temperature rising shall

44
 Chapter 2 Electric Machine

not exceed 35K). After completion of free running, check contact area between brush and commutator
which shall not be less than 75%. Clean the carbon powder remains on the surface of commutator.
Rotation Rate (r/min) 100 400 800 1600
Time (min) 20 10 10 30

b. Rotation Reversal Test: The test shall be carried out while the motor is still under thermal state. Run the
motor at positive and negative direction for 30s according to following operation conditions. The spark
produced shall not exceed the specified level as listed below:
Working Rotation Rate
Voltage (V) Current (A) Exciting Power (%) Spark Level Allowed
Condition (r/min)
1 539 1260 100 2
1
2 755 900 48 12
1
3 1000 680 48 12
1
4 1000 48 2465 12

c. Speed Rate Attribute Testing: Under rated working condition of Motor: I = 900A, V =755V. Under full
field, the ratio between positive and negative rotation speed difference and that of arithmetic average shall
not be more than 4%. It shall not be more than 6% while field weakening. Under rated condition, the
difference of positive and negative rotation speed of the 6 traction motors shall all not exceeding 25r/min.

d. Overspeed Test: the motors whose weftless tapes are rebinded shall run continuously for 2min at rotating
speed of 2958r/min. No mechanical damage and permanent deformation which may affect the normal
running of the electric motor is allowed.

e. Interturn Insulation Dielectric Strength Test: the treated armature winding shall be applied with 1.1 times
rated voltage to carry out the over voltage test for 3min or applying TA interturn withstand voltage
determinator to check the over voltage capability. There shall be no break or flash.

f. Ground Insulation Dielectric Strength Test: While under thermal state, apply 2200V voltage (if new
insulation plus 2960V) and 50Hz simple alternating current to the windings and cabinet for 1min. There
shall be no break or flash.

g. Thermal State Insulation Resistance: After motor loading test, use 1000V meg-ohmmeter to check the
insulation resistance between motor windings and against cabinet. The insulation resistance shall not be less
than 1M¡.

2.4.7 Inspection after Motor Completion

After motor testing, inspections shall be carried out as follows;

Check if commutator has any lug and if the welding between the armature winding and commutator riser is
good.

Check if any loose occurs to armature slot wedge, and if there is any loose or translocation of the balance
weight. Confirm if there is any crack and loose of the weftless tape.

The filling mud of motor pole bolts (except that at bottom) shall have no crack.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

After the motor is cooled down to room temperature, use compressed air of 290~340kPa to sweep the motor.

The motor observation hole cover shall be tight and the hasp shall be reliable.

Motor inspection/repair and testing data shall be recorded in detail.

2.5 Main parts list

No. Description Code Qty. Manufacturer
1 Bolt M16h40 GB/T 5783-2000 13 Standard
2 Washer 16 GB/T 93-1987 13
3 Front Bearing Cover ZD13C-000-004 1 Chengdu and Qi Factory
4 Bolt M8h20 GB/T 5783-1987 2 Standard
5 Washer 8 GB/T 93-2000 10
6 Plug block ZD13C-000-003 1 Chengdu Factory
7 Bolt M16h50 GB/T 5783-2000 11 Standard
8 Gasket ZD1-000-003-1 1 Chengdu Factory
9 Fluted disc ZD13C-000-001 1
10 Commutator end bearing NJ318ECM/C4+HJ318EC 1 Japan NTN Company
11 Front End Cover ZD13C-400-001 1 Chengdu Factory
12 Oil Cup M10h1 GB1152-1989 2 Standard
13 Bolt M8h16 GB/T 5783-2000 4
14 Washer 8 GB/T 97.1-1985 4
15 Tubing Clamp ZD13-400-001 2 Chengdu Factory
16 Oil Duct ZD13-400-002 2
17 Bolt M20h50 GB/T 5783-2000 16 Standard
18 Washer 20 GB/T 93-1987 16
19 Small observation hole Cover ZD13C-050-000 2 Chengdu Factory
20 Observation hole Cover ZD13C-010-000 2 Chengdu and Qi Factory
21 Nut M20 GB/T 6170-2000 4 Standard
22 Washer 16 GB/T 97.1-1985 4 Standard
23 Coach Bolt ZD13C-300-002A 4 Chengdu and Qi Factory
24 Brush Rod ZD13E-320-000 4 Chengdu Factory
25 Brush Holder ZD13C-340-000A 4
Shanghai Mogen Electric
26 Electric Brush ZD13C-300-001A 12
Carbon Co. Ltd.
27 Connecting Plate ZD13C-300-004A 1
28 Connecting Plate ZD13C-300-003A 1
29 Brush-Yoke Linking Wire ZD13C-330-000 1
30 Machine Base ZD13E-290-000 1
31 Insulating Gasket ZD13C-200-001 4
32 Main Pole Iron Core ZD13C-210-000 4
33 Latch Bracket ZD13C-200-100 4 Chengdu Factory

34 Gasket ZD13C-200-013 4
35 Main Pole Coil (opening) ZD13E-220-000 2
36 Main Pole Coil (intercross) ZD13E-230-000 2
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 Chapter 2 Electric Machine

No. Description Code Qty. Manufacturer

37 Gasket ZD13C-200-013 4
38 Washer 33 GB/T 93-1987 9 Standard
39 Main Pole Bolt ZD13C-200-005 9 Chengdu and Qi Factory
40 Main Pole Bolt ZD13C-200-004 3
41 Adapter Plate ZD1-200-018 16
42 Main Pole Linking Wire ZD13-250-300-1 3
43 Pressure plate ZD1-200-019 16 Chengdu Factory
44 Locking gasket ZD1-200-020 16
45 Bolt M8h30 GB/T 5783-2000 32 Standard
Accessory Pole-Brush yoke Linking
46 ZD13C-200-400 1
Wire
47 Accessory poles Linking Wire ZD13C-200-500 1 Chengdu Factory
48 Accessory poles Linking Wire ZD13-240-300 2
49 Plug of accessory pole ZD13C-200-014 8
50 Accessory Pole Iron Core ZD13C-240-000 4
51 Insulation Spacer ZD13E-200-001 4
52 Accessory Pole Coil ZD13E-260-000 4
53 Insulation Spacer ZD13E-200-002 4
54 Latch Bracket ZD13E-200-200 4
55 Accessory Pole Gasket ZD13C-200-002 4
56 Accessory Pole Bolt ZD13C-200-009 12 Chengdu and Qi Factory
57 Bolt M16h60 GB/T 5783-2000 3 Standard
58 Front axle housing ZD13-100-001 1 Chengdu Factory
59 Rear Axle housing ZD13-100-002 1
60 Rear end cover ZD13F-500-001 1 Chengdu and Qi Factory
61 Bearing at driving side NU330ECM/C4 1 Japan NTN Company
62 Rear bearing cover ZD19F-000-002 1 Chengdu and Qi Factory
63 Seal ring ZD13-000-005 1
64 Locking gasket ZD19-000-006 1
65 Pressing plate ZD19-000-005 1 Chengdu Factory
66 Armature coil ZD13E-140-000 58
67 Armature assembly ZD13E-100-000 1
68 Slot wedge ZD13E-100-001 116 Chengdu Factory
69 Armature core ZD13E-110-000 1
70 Revolution axis ZD13-110-002 1 Chengdu and Qi Factory
71 Notch insulation ZD19-100-003 116 Chengdu Factory
72 Equalizing Cable ZD19-160-000 58 Chengdu and Qi Factory
73 Commutator ZD13E-111-000 1
74 Pressing Plate ZD1-200-019 16
75 Outgoing Line H2 ZD19-200-300 1 Chengdu Factory
76 Brush holder outgoing line S1 ZD19-310-000 1
77 Lead clamp ZD13B-200-006 11
78 Adapt Plate ZD1-200-018 16

47
ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

No. Description Code Qty. Manufacturer

79 Bolt M12h55 GB/T 5782-2000 8 Standard
80 Seat Pad ZD1-200-025-1 2
81 Air Port Cover ZD13C-000-007 1 Chengdu Factory
82 Outgoing Line C1 ZD19-200-200 1
83 Outgoing Line C2 ZD19-200-100 1
84 Motor bearing grease L-XEGEB2 Tiensin Tanggu Chemical plant

3 The Start-up Generator

3.1 Operating Principle and Structures

The Start-up Generators in the DF 8BI
locomotive is a DC electrical machine of
ZQF412, it has two working condition: starting
and generating, and the schematic diagram is
shown in Fig.2-7.

When starting the diesel engine, terminal Q1

connects to anode of the battery and terminal S2
connects to the cathode of the battery, the start-
up generator is supplied by the battery and acts
as a series excitation motor to start the diesel
engineˊAfter the diesel engine is running, the
start-up generator is automatically turned to be
Starting Condition Generating Condition
generating condition by the locomotive control
system, at this time, it is driven by the diesel
Fig. 2-7 the Schematic Diagram of the Starting generator
engine and works as a separate excitation
generator, and the excitation is controlled by the
voltage modulator, so the voltage of the DC
generated by the starting generator can keep at 110f2V, and the DC is provided for the auxiliary power use,
such as locomotive control, the battery recharge and the air compressor motor etc. The rotating direction of
the starting generator is the same in the two working conditionsˊ

That motor is a horizontal structure, the single-row centripetal ball bearing of 6312/C4 is installed at the
commutator end, and the single-row cylindrical roller bearing of NU317/C4 is installed at the transmission
end, the locomotive motor bearing grease is filled in the bearing cavity .

The appearance of the ZQF412 DC Start-up Generators is shown in Fig.2-8, and the structure of ZQF412
DC Start-up Generators is shown in Fig.2-9.

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 Chapter 2 Electric Machine

Fig.2-8 The appearance of ZQF412 DC Starting Generator

3.1.1 Stator
The stator consists of the base, main poles, and commutating-poles etcˊThe magnetic yoke part of the base
uses the structure of square full lamination. The pressing rings of two ends are welded firmly with four rib
block after they are pressed tightly. The locating of the main pole and base is controlled by the locating slot.
The main pole iron core, which is laminated with 1mm steel plates, has separate exciting coil and starting
coil. The starting coil adopts of two-layer flat wise no arc pressing structure. It is arranged at the armature
side. The commutating pole iron core is made by the forged steel and the winding adopts the edge wise. The
stator coil and the iron core adopt the one-piece insulation structure and VPI insulation treatment. At outside
of the base, there is a connection box, which has the schematic diagram and the mark plate. it is convenient
to connect the wires. For the air inlet and outlet at the both ends, there are shield with the elastic pothook.

3.1.2 Rotor
The rotor consists of armature core, armature coil, rotor shaft, commutator and fan etcˊThe armature coil is
embedded in the core slots and fixed with slot wedges. The end of the armature coil is bound tightly with
weftless tapes. The terminals of armature coil and equalizing cable is embedded in the commutator riser slot,
and welded with TIGˊ The armature core is made of lamination of 0.5mm cold-rolled silicon steel sheets
of DW470-50. There is no ventilation hole on the core. The commutator uses the arch structure and is
pressed tightly through the big nut. This motor uses self-ventilation. On the rear bracket of the motor, there
is an aluminum cast centrifugal unequally spaced fan.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

Fig. 2-9 The ZQF412 Starting Generator

1-Bolt M12h30;2-Washer12;3-Locking Backing;4-BoltM10h25;5-Press Plate;6-Front Bearing
Cover;7-Oil cup M10h1;8-Bolt M8h65;9-Washer8;10-Bearing 6312C4;11-Front inner oil seal;12-
Front bearing inner cover;13-Front end shield brush yoke assembly;14-Air inlet shield assembly;15-
Stator assembly;16-Nameplate;17-ScrewM4h6;18-Turning board;19-Air outlet shield assembly;20-Back
end shield;21-Armature assembly;22-Back bearing cap;23-BoltM8h25;24-Bearing NU317C4;25-
Grease;26-BoltM8h16;27-Tablet of elementary diagram;28-Tablet of binding post;29-outlet box;30-Bolt
M6h16;31-Washer 6;32-Outlet box cover plate;33-Nut M10;34-Washer 10;35-Binding clip;36-Bolt
M10h60;37-Washer10;38-Bolt M10h80.

3.1.3 Brush Yoke System

This system consists of the brush yoke ring, the yoke, brush holder and brush. The brush yoke ring is hot
pressed by moulding material. It is fixed on the forward end cover by the bolts. Four brush holders are fixed

50
 Chapter 2 Electric Machine

uniformly along the circumference on the brush ring through the yoke. Each brush holder carries three
double-split brushes, with the label NY28 or D104 and diameter 22*40*55 mm.

3.2 The Main Technical Parameter

Model: ZQF412 Type˖ Safety-guard
Rated power˖ 80kW Excitation type˖
Generator working condition: separate excitation
Motor working condition: series excitation
Rated voltage˖110v Rated current˖728A
Rated speed˖1051rˋmin Excitation current˖İ8A
Maximum speed˖2728 rˋmin Excitation voltage˖96V
Working form˖80kW 5min, 30kW 5min
Maximum starting current˖1900A corresponding electromagnetic torqueı2842Nm
When started with the power supply of 96V battery, at the speed of 324 rˋmin, the torque is not less than
1088Nm.
Starting time˖İ15s each time, 5 times of continuous starting is allowed, with an interval ı2mm.
Insulation class˖statorˋrotor F/H Cooling method˖Self-ventilation
Armature external diameter:Ï280mm Rotational direction˖clockwise when viewing
from the transmission end
Commutator external diameter:Ï210mm Commutator length: 140mm
slot number˖38 Pole number˖4
Form of armature windings˖single-lap Armature winding branches˖4
Commutator riser width˖15mm Separate excitation windings resistance 8.514¡(15ć)
Commutating pole windings resistance:0.00296¡(15ć) Starting windings resistance: 0.00335¡(15ć)
Armature windings resistance: 0.00342¡(1~15flake) (15ć)
Motor weight: Electric machine(for shortĀmachineāas follow)˖850kg
Rotor˖272kg
Stator˖525kg

3.3 The Original Dimension and Limit

Limits
No. Name Original Dimensions
repair forbidden
Thickness direction (Shaft
Clearance between 0.10~0.30 0.10~0.40 0.60
1 direction)
brush and brush box
Width direction 0.08~0.254 0.08~0.3 0.4
Distance between brush box and commutator working
2 3f1 3f1
surface
3 Distance between brush box and commutator riser 8f1 7~10
Parallelism and obliquity of brush holder to
4 İ0.8 İ0.8
commutator shaft line
5 Brush pressure (N) 22f2 18~24

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

Limits
No. Name Original Dimensions
repair forbidden
6 The brush height 55 40 27

7 Commutator working surface diameter +1.5 ı¶196 ¶194

¶210 0

8 Undercut depth of commutator mica groove 1.2f0.2 1.2f0.2 <1

9 Wear depth of commutator İ0.2 0.5
10 Commutator roundness İ0.03 İ0.06

Commutator end +0.03 +0.03

Diameters of armature ¶65+0.01 ¶65+0.01
11 shaft for mounting
bearing inner circle transmission end +0.045 +0.045
¶85+0.023 ¶85+0.023

Radial air gap between Core of main pole 2.5f0.2 2.5f0.2

12
core and armature Core of commutating pole 4f0.2 4f0.2
deviation of distance between main pole tips and one
13 İ0.5 İ0.5
another by circumference
deviation of distance between main pole tips and
14 İ0.5 İ0.5
adjacent commutating pole tips
15 Run-out of Commutator surface after assembly İ0.03 İ0.06 0.10

Fit interference of shaft 0.011~0.045 0.011~0.045

16 Commutator end
to bearing inner ring
transmission end 0.023~0.065 0.023~0.065
Fit clearance between Commutator end -0.041~0.044 -0.041~0.044
17 shield bore to bearing
outer ring transmission end -0.041~0.044 -0.041~0.044

Bearing radial Commutator end 0.01~0.05 0.01~0.05

18 clearance after
assembly Transmission end 0.04~0.11 0.04~0.11
0.2 0.2
Inner diameter of iron Main pole ¶285 0.4 ¶285 0.4
19
core
Commutating pole ¶288f0.2 ¶288f0.2
Main pole İ0.5 İ0.5
20 Verticality of core
Commutating pole İ0.5 İ0.5
21 Fit interference between fan and rear bracket 0.021~0.07 0.021~0.07

3.4 Inspection and Repair Process

3.4.1 The main equipments, tools, measuring tools and materials

a. Equipments: argon weld machine, Idle run test bed, withstand voltage test machine, dynamic balancing
machine, oven, bearing heater.

b. Tools: hydraulic detacher for flange, joint lifter for armature, lifting tools for main assembly, puller for
bearing, shaft puller for fan, storage rack for the rotor.

c. Measuring Tools: double bridge, universal meter, 500V meg-ohmmeter, tachometer, inside micrometer
calipers, outer micrometer calipers, vernier caliper, dial indicator of magnetic holder, the TZ micro-
resistance detecting instrument.
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 Chapter 2 Electric Machine

d. Material: The polyimide film, mica tape, non alkali glass tape, white cloth strap, bearing grease, epoxy
resin, F( H) insulation lacquer, abrasion cloth, wax wire.

4.2 Main process course

a. Inspection before disassembly

a1. Visual inspection shall be carried out to check the condition of every part of the motor to see if there is
any deformation or cracks in the cover, base and coupling,and to see if the wire connection is good or not.

a2. Measure the insulation resistance with 500V meg-ohmmeter.

a3. Measure each winding resistance with double bridge.

a4.Inspect working condition of the commutator and measure its run-out with a dial indicatorˊ

a5. Idle run tests: Find out whether there is any abnormal noise, temperature rise or vibration on the bearing
when the motor is running.

b. Disassembly

b1. Screw out the gudgeon nut at the transmission end; disassemble the flange with hydraulic flange
detacher.

b2. Place the machine horizontally, and take off the air inlet cover and air outlet cover. Disconnect the outlet
line S2, and the connection line between commutating pole and brush holder, and pull out the brush. Put a
piece of electrician paper into the space between the main pole core and armature from the commutator end.

b3. Make positioning marks on both end covers and bearing covers for the convenience of the locating when
assembly.

b4. Dismantle the bolts of the bearing cover on the front and rear end. Use this bolt to push out the front and
rear end outer bearing cover.

b5. Dismantle the bolt of the front end cover and use this bolt to push the front end cover out from the stop
hole of the machine base. When the end cover can be turned, lift the front end cover out. (Attn: preventing
the brush box and commutator from touching each other)

b6. Dismantle the bolt of the rear end cover and use this bolt to push the rear end cover out from the stop
hole of the machine base. When the end cover can be turned, lift the front end cover out. (Attn: protect the
transmission end bearing from being hit), remove the rear end bearing cover.

b7. Knock the roller and outer ring of the big bearing from the rear end cover with copper bar.

b8. Cover the rotor hanger on the cone face of the rotation shaft rear end, fix the gudgeon nut. Move the
rotor slowly along motor shaft line to pull the rotor from the machine base.

b9. If replacing the bearing is necessary, screw out the bolts on the pressing plate for front gudgeon and
detach the gudgeon pressing plate. Pull out the inner ring of the small and big bearing with a bearing puller
from the rotation shaft.

c. Cleaning after disassembly

c1. Lift the stator, armature, and end shields to the sweeping room. Clear them with dry compressed air
whose pressure shall be no more than 0.3Mpa. When clearing the armature, the carbon powder in the
53
ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

commutator mica groove should be cleaned up, but pay attention to stop carbon powder from entering the
armature windings, the tuyere should be kept more than 150mm far away from the insulation to prevent the
insulation from being damaged.

c2. Clean inner parts of the stator with gasoline or cleaning agent, and then dry them with dry compressed
air, wipe the armature clean with clothˊ

c3. Clean the front and rear end cover, brush bracket, bearing covers, bearing sleeves and bearing pressing
plate etc.

c4. Clean the bearings with gasoline and dry them with the dry compressed air.

d. inspection and repair

d1. The inspection and repair of the stator

ķ There shall be no crack and defect on the machine body.

ĸ Check the insulation of each windings and there shall be no damaged and ageing. There shall be no burns,
worn out on the insulation of connection wires. There shall be no crack, loss or sealing-off on each
connection joints of the winding, otherwise the coils shall be dismantled, peel off the damaged insulating
lamella, and re-tie them up according to the former insulated provision, and lay on the insulation lacquer to
dry disposal. Make sure that every winding should have no loose; the pole screw bolt should be tightened.

Ĺ Check each outlet line in outlet box: There shall be no burns and loss in the joints. There shall be no
burns and cracks on the line board and insulating plate.

ĺ Use the 500 V Meg-ohmmeter to test cold insulation resistance between each winding and brush yoke
and the resistance of them to the ground, they can not be less than 5Mȍ . If the insulation resistance can not
meet the request, the stator can be put into the over for dry treatment.

Ļ Use the double bridge to measure each winding resistance, and then convert them into the value under
15 ć, the difference between them and the specified value in the main technical parameters should be no
more than f10%.

ļReplace or dismantle each winding of stator: If some stator windings are grounding or short circuit, they
shall be replaced or dismantled for treatment. The method is as following:

a. The assembly of main pole coils and iron core. Clean the core; install the frame and the main pole's
insulating plate. fill up two sheets of felt (2h38h420 and 2h250h250) both on the direction of length
and uprightness, pressing the start coil and separate excitation coils in one by one in order.(Attention: the
series excitation coils and separate coils have the shedding kind and cross kind, they shall not be installed
wrong.)

b. assemble the main pole to frame

(a) Put the frame vertically, with the transmission end upwards.

(b) Put the main pole that hitched by a nylon sling into the frame.

(c) Check the position of the main pole assembly. The coil should have no loose. Then tighten screw bolt of
main pole.
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 Chapter 2 Electric Machine

(d) After main pole assembly, check the inner diameter of the main pole iron core, the verticality of the main
pole iron core and the deviation between the main poles. They shall all meet the requirement of the
limitation list.

c. The assembly between accessory pole and iron core: put the accessory pole insulation plate and the frame
into the coil, then, put the core into the frame, finally, put adjust flake and the insulating plate, the coil
should have no loose, otherwise need to use the brass flake or the zinc coated flake embeds tight.

d. Assemble the additional pole to the frame:

(a) Put the leading wire of additional pole into the frame, then, put a 0.5 mm glass board (3240) under core.

(b) Check the position of the accessory pole. The coil should have no loose. Then tighten the accessory pole
screw bolt.

(c) After the accessory pole assembly, check the inner diameter of the accessory pole iron core, the
verticality of the accessory pole iron core and the distance deviation between the main pole and accessory
pole. They shall all meet the requirement of the limitation lists.

e. put the machine base vertically and connect the wire according to the design requirement. The connection
face shall be in good condition. Fix the connection wires and arrange the wires neat.

d2. Inspection and repair of the armature

ķ Check the rotation shaft of armature , and the dimension of shaft should meet the requirement of the
limitation lists.

ĸ Check the insulation of all parts of the armature, there shall be no ageing, over-heated or break down.
There shall be no loose and crack on the weftless taps. There shall be no loose or split on the slot wedge.

Ĺ Measure the insulation resistance to the ground of the armature with 500V meg-ohmmeter, make sure
that the insulation resistance is no less than 5M¡.If the value is lower than the specification, the armature
should be cleaned with the gasoline again, then sweep it to recover the insulation. The armature can be put
into the oven for drying if the insulation resistance is reduced because of humidity.

ĺ Measure the resistance of armature winding from one to fifteen with double bridge and calculate it to the
value at 15ć. The deviation between the value and the specified one in the main technique parameter shall
be over 10%.

Ļ There shall be no lugs, severe burns and scratch on the surface of commutator. Finish turning shall be
carried out to the commutator when wear depth of is over the 0.2 mms or commutator roundness is over the
0.2 mms. After the finish turning, the surface roughness shall be 1.25̚2.5­m, the runout shall be less than
0.03mm. Under cut depth of commutator mica groove is the 1.2f0.2 mms. The slot of the groove shall be
chamfered 0.5h45e. Get rid of the burrs on the chamfer and the mica powder inside the slot and copper
scraps.

ļ if there is tip-off, shrinkage or line off, the welding treatment shall be carried out to the commutator.

Ľ Measure the resistance between each slice of the commutator, the difference between the measured value
and the average value shall be no more than 5%.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

ľ There shall be no shake and crack on the fan of armature. If the fan shakes because of big fit clearance,
the fan shall be dismantled from the armature shaft and repair the fitting face by electro-brush plating to
assure the fitting between the fan and shaft meet the requirement of the limitation lists. There shall be no
crack and deformation on the fan blades. There shall be no tip-off on the welding position. If there are
cracks, welding is allowed for repair. The rivets which are loose shall be retightened.

Ŀ Check if the counterweight of the armature is loose, off or dislocated. The dynamic balance test shall be
carried out to the defective one and welded one. The allowed unbalance is 61 g-cm.

d3. The inspection and repair of the bearing

ķ Check the bearing. There shall be no loose and the rotation shall be flexible and without abnormal sound.

ĸ There shall be no crack, stripping and color change because of overheat on the bearing balls, rollers,
inner and outer tracks.

Ĺ Measure the bearing radial clearance, the value should meet the request of limitation.

ĺ There shall be no cripple, crack, flash and deformation because of overheat on the retainer. The rivet
shall not be broken or loose.

Ļ If the bearing is not in good condition through inspection, it shall be replaced.

d4. The inspection and repair of the end cover and bearing cover

ķ Check the end cover and bearing cover. There shall be no deformation or crack. Welding with low carbon
steel electrode for repair is allowed when there are cracks.

ĸ Check the bearing cover to see if there is any scratch or off roundness. The defective one shall be
repaired or replaced.

d5. The inspection and repair of the brush yoke

ķ check the brush yoke ring of the phenol aldehyde laminated cloth board, there shall be no cracks,
deformation and burns. The defective one shall be repaired or replaced.

ĸ check the connection bolts of the brush yoke, there shall be no loose. The defective one shall be
retightened. When the joints are overheated and the color changes, it shall be removed for sanding and
enameling tin, then install it back to the original position. The breakage of the connection wires insulation
shall be rewrapped and then tie the wire to the brush yoke ring with the ¶2mm wax line.

Ĺ The action of the brush compression mechanism should be flexible, there shall be no crack and damage
on the press finger. The springs of the press finger shall be free from damage and the action shall be flexible.
There shall be no annealing phenomenon.

ĺ Brush holder, brush box shall be free from burns, cracks and deformation. The defective one shall be
replaced.

Ļ The height of brush shall meet the requirement of the limitation list. The brush tail shall not be loose and
the area of broken wire shall not exceed 10% of the original section area. While replacing the brush, same
motor should use same brush of the trademark of same factory.
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 Chapter 2 Electric Machine

ļ The brush in the brush box should move freely. The clearance between brush and brush box and the
brush pressures shall meet the requirement of the limitation list.

d6. Voltage withstanding test of the stator, rotor and brush yoke equipment

Carry out the voltage withstanding test of stator, armature, brush yoke to ground for 1 min with 50Hz,
1125V (all new insulation shall be 1500V) simple AC. There shall be no flashover and breakdown.

e. Assembly

e1. Before assembly, check each component to assure its quality and cleanness.

e2. The motor's nameplate should be legible. The mark on the outlet lines shall be accurate. The connection
lines shall be in order and be free from damage. There shall be no friction between the connection lines. The
reduction of effective conduction area shall not exceed 10%.

e3. New bearing Assembly (when replacing the bearing)

Before assembly, the bearing inner diameter and shaft journal size shall be measured to make sure its fit
interference meet the requirement of the limitation list. First cover the front end inner bearing cover (with
grease) to the shaft, then shrink the sealing ring and small bearing on. Shrink the big bearing inner ring on
the rear end of the rotation shaft. The heat of the bearing shall be even. The temperature is 100-110ć. Use
the oil bath method of heating for 30min. (induction heating method can also be used).

e4. Install the gudgeon pressing plate after the grease is filled to the small bearing. Then use the 00# emery
cloth to pack on the out cycle of the commutator in order to milling the brush after assembling, also can
protect commutator form knock and break

e5. Press the big bearing (without the inner ring) into the bearing housing at the rear end cover. Fill grease to
the inner and outer bearing cover and the big bearing at the rear end. The total amount of the grease shall be
2/3 of the grease chamber. Install the inner and outer bearing cover separately to the two sides of the rear
end covering. Make them align to the location mark. Install the tighten bolts. Then install the rear end cover
entirely to the big bearing inner ring of the rotor.

e6. Install the rotor hanger onto the cone face of the rotation shaft. Install the round nut. Lift the rotor and
move it slowly into the stator. Make the rear end cover rabbet align to the machine base according to the
location mark. Tighten the end cover bolt.

e7. Install the front end cover to the small bearing out ring. After fill the grease to the out bearing cover of
the front end, make it align to the location mark. Install the bolt to connect the inner and outer bearing cover.
Make the front end rabbet align to the machine base, tighten the end cover bolts and then tighten the bolts of
bearing cover.

e8.Put the brush into the brush box and press the press finger. Measure the brush pressure. Adjust the
working surface distance between the brush box and the commutator, and the distance between the brush
box and commutator riser. They shall meet the requirement of the limitation list.

e9.The running armature. There shall be no block or inflexibility. Whet the brush at the same time, the
contact surface reach 100%. Draw out the emery cloth.

e10. Check and adjust the neutral line of the brush yoke equipment.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

e11. Connect the outlet line S2 and the commutating pole and brush yoke connecting wire.

e12. Check and assure the grease cup is good, and install the air inlet mask and air outlet mask.

f. Test

f1. Measure the cold condition grounding insulation of every winding and brush yoke device and the
insulation between them. The value shall not be less than 5M¡

f2.Idle run test: According to the working direction run the machine as motor at no-load, increase the current
of separate excitation windings(T1-T2) to 8A,then increase gradually the voltage of the motor unto 110V,
and then reduce gradually the separate excitation current againˊGradually raise the rotation speed to
2730r/min, keep running 1h. During the running, the rotation should be balanced, smooth, and without
abnormal noiseˊThe temperature rise of bearings should trend to be stable and not exceed 55k (At bearing
shield not exceed 40k). Check the contact area between the brush and commutator after the idle test, the
value shall not be less than 75%.

f3.Measurement for the radial TIR(Total-Indicates-Runout) of the commutator: After the idle run test, the
radial TIR of the commutator should not be more than 0.06mmˊ

f4. Overspeed test: Renew the rotor wrapped with weftless taps. Keep run for 2mins at the rotation speed of
3280r/min. there shall be no mechanical damage or permanent deformation that affects the normal running
of the motor.

f5. Grounding insulation dielectric strength test

Apply 50Hz, 1125V (1500V if the insulation is all new changed) simple alternating current to every winding
and brush yoke device for 1min grounding voltage withstanding test. There shall be no breakdown or
flashover.

g. Install the transmission flange

Pre-install the flange. Check the contact area between the flange and the shaft journal. The value shall not
be less than 75% and the contact shall be even. The flange shall be shrunk on. Heat the flange to 180ć in
the oven or oil bath and shrink it onto the shaft. Use the retainer for locating to make sure the pressing-in
travel length shall be 0.9~1.3mm (the operation can refer to the flange installation of main generator).
Tighten the gudgeon nut. Install the anti-loose gasket after it is cooled. Measure the end face runout of the
out side face. The value shall be less than 0.15.

3.5 Main Parts List

NO. Name Code Qty. Manufacturer
1 Locking plate ZF8-000-001 1
2 Pressing plate ZF8-000-002 1 CSR Xiangfan Electric Motor
Co.,Ltd.
3 Front bearing cover ZF8-000-003 1
4 Oil seal of the front end ZF8-000-004 1
5 Inner cover of the front bearing ZF8-000-005 1
6 Rear end cover ZF8-000-008 1
7 Rear bearing cover ZF8-000-009 1

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 Chapter 2 Electric Machine

NO. Name Code Qty. Manufacturer

8 Terminal box cover plate ZF8-000-012 1
9 Air inlet mask assembly ZF8-010-000 1
10 Air Outlet mask assembly ZF8-020-000 1
11 Terminal box ZF8-030-000 1
12 Armature assembly ZF8-100-000 1
13 Counterbalance ZF8-100-001 Some
14 Oil seal of rear end ZF8-100-005 1
15 Core of armature ZF8-110-000 1
16 Rotation shaft ZF8-110-001 1
17 Commutator ZF8-111-000 1
18 Armature coil ZF8-140-000 38
19 Equalizing wire ZF8-160-000 38
20 Stator assembly ZF8-200-000 1
21 Commutating pole bolt ZF8-200-006 8
22 the line board ZF8-200-008 2
23 Commutating pole line A ZF8-200-009 2
24 Main pole bolt ZF8-200-011 12
25 Commutating pole line B ZF8-200-014 1
26 Outlet line T ZF8-200-100 2
27 Outlet line Q1 ZF8-200-200 1
28 Outlet line Q2 ZF8-200-300 1
29 Outlet line S2 ZF8-200-400 1
30 Outlet line H1 ZF8-200-500 1 CSR Xiangfan Electric Motor Co.,
Ltd.
Commutating pole-brush yoke ZF8-200-600
31 1
connecting line
32 Main pole assembly ZF8-210-000 1
33 Main pole core ZF8-211-000 4
34 Separate excitation coil A (Openings) ZF8-212-000 1
35 Series excitation coil A(Openings) ZF8-213-000 1
36 Main pole assembly ZF8-220-000 1
37 Separate excitation coil A (Intersect) ZF8-222-000 1
38 Series coil(Intersect) ZF8-223-000 1
39 Main pole ZF8-230-000 1
Separate excitation windings ZF8-232-000
40 1
B(Openings)
41 Series coil B(Openings) ZF8-233-000 1
42 Main pole ZF8-240-000 1
43 Separate excitation windings B(Intersect) ZF8-242-000 1
44 Series coil B (Intersect) ZF8-243-000 1
45 Commutating pole assembly B ZF8-250-000 2
46 Commutating pole coil B ZF8-250-100 2
47 Commutating pole core ZF8-250-200 4
48 Commutating pole assembly A ZF8-260-000 2

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

NO. Name Code Qty. Manufacturer

49 Commutating pole coil A ZF8-260-100 2
50 Machine base ZF8-290-000 1
51 Front end cover ZF8-300-001 1
52 Brush yoke assembly ZF8-310-000 1
D104 or NY28 Brush ZF8-310-002 Shanghai Morgan Carbon Co.,
53 12
LTD
54 The commutator end bearing 6312C4 1 Wa Fangdian Bearing Factory,and
Dalian Bearing Factory
55 The transmission end bearing NU317C4 1
Lubricating grease for locomotive motor
56 L-XEGEB2 Some Tianjin Tanggu Chemical Plants.
bearing

4 Inductor Exciter
4.1 Operating principle and structure
JGL405B inductor exciter is a 3-phase asynchronous AC generator (Fig. 2-10), the 3-phase AC power
generated by which will be used as exciting power supply of JF204D synchronous main generator after
bridge rectification.

Both excitation winding and armature winding of motor are mounted on the stator. No winding, electric
brush or collecting ring is required on the rotor.

After the excitation winding is excited by DC, when the rotor is rotating at a uniform speed, due to the
periodical change of air gap permeance in the tooth space of rotor core, the magnetic flux produced by
exciting magnetic pole will change periodically in the valid layer of stator core, then alternating
electromotive force will occur in the 3-phase armature winding.

The motor is of protected axial self-ventilation structure. The centrifugal fan absorbs cooling air via the air
intake port on the end cover of shaft extension end and the air intake port of the base and discharges via the
air discharge port on the base of non-transmission end. 6313/C3 deep groove ball bearing is mounted at the
non-transmission end of the motor, SKF NU313ECM/C3 (or NU313MC3E of NSK) cylinder solid roller
bearing is installed at the transmission end.

Base, end cover and fan of motor are welding structure.

4.1.1 Stator
Stator core is made through pressing with pressing ring and end plate from a complete wafer punched by
high-quality cold rolled silicon sheet of 0.5mm thick, and then pressed and fixed on the base.

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 Chapter 2 Electric Machine

Fig. 2-10 JGL405B Type Inductor Exciter

1-bolt M10h65; 2-washer 10; 3-front bearing cover; 4-screw M6h8; 5-washer 6; 6-buffer; 7-bolt M12h35; 8-
washer M12; 9-end cover; 10-oil cup M10h1; 11-retainer ring65; 12-bearing 6313C3; 13-sealing ring; 14-inner
bearing cover; 15-fan; 16-rotor assembling; 17-stator assembling;18-lower shield; 19-upper shield; 20-bearing
NU313ECM/C3 or NU313MC3E; 21-mesh enclosure; 22-rear bearing cover; 23-bolt M10h65; 24-screw M8h12;
25-washer 8; 26-washer 8; 27-terminal box.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

There are four parallel branches in the armature winding; Single layer chain soft winding is adopted as coil.
Armature winding and excitation winding are embedded in the stator core. The mark of outgoing feeder end
of winding is indicated by label plate fixed on the wiring plate: The line end marks of armature winding
and neutral line leading-out line are respective U, V, W and N; the marks of leading-out line of excitation
winding are L1 and L2.

Refer to Fig. 2-11 for Schematic Diagram for Wiring of Winding.

Rotor is composed of rotating shaft, rotor core and fan, etc. Rotor core is made through pressing of high-
quality cold rolled silicon sheet of 0.5mm thick. There are 12 skewed tooth distributed on the surface evenly.
Iron oxide red alkyd prime coat C06-1 is coated on the surface of iron core. There is no tooth groove or
winding on the rotor.

Fig. 2-11 The Elementary diagram of the windings in the inductor exciter JGL405B

4.1.2 Rotor
Rotor is composed of rotating shaft, rotor core and fan, etc. Rotor core is made through pressing of high-
quality cold rolled silicon sheet of 0.5mm thick. There are 12 skewed tooth distributed on the surface evenly.
Iron oxide red alkyd prime coat C06-1 is coated on the surface of iron core. There is tooth groove on the
rotor, but no windings.

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 Chapter 2 Electric Machine

4.2 The main technical parameters

Type JGL405B Working system continuous
Rated capacity 41kVA Number of phases 3
Rated voltage 77V Cooling mode Axial self-ventilation
Rated current 297A Exiting mode Separate exciting
Rated rotary speed 2696r/min Rated exciting voltage 59.2V
Rated frequency 539.2Hz Rated exciting current 5.47A
Rated power factor 0.95 Efficiency 88.8%
Wiring mode of stator Y (with neutral line) Rotary direction of motor Clockwise (from the
transmission end)
Insulation class F Weight of motor 355kg
Resistance of excitation 7.486¡(at 15ć) Length of air gap 0.7 mm
winding
Resistance of armature 0.00794¡(at 15ć)
winding

4.3 The original dimension and limitation list

Limit
No. Description Original shape
Medium repair Forbidden
1 Air gap on one side 0.7 0.7

2 Diameter of rotor shaft at the bearing installation ij65 ij65

Inside diameter of mounting hole at the external ring

3 ij140 ij140
of bearing on the end cover
Cylindricity of inside diameter of mounting hole at
4 ˘0.02 ˘0.02
the external ring of bearing on the end cover
Non-
transmission 0.003~0.035
Interference of fitting between the end
5
inner ring and axis of bearing
transmission
0.003~0.035
end
Clearance of fitting between the Non-
external ring of bearing and the transmission -0.014~0.035 0~0.05
6 bearing hole of end cover end
transmission
-0.014~0.035 0~0.05
end
Radial original clearance space of bearing at the non-
7 0.023~0.043 0.05
transmission end
Radial original clearance space of bearing at the
8 0.06~0.09 0.12
transmission end
Runout of shaft extension cone facing to the bearing
9 ˘0.03 0.06
step

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

4.4 Inspection and Repair Process

4.4.1Special equipment, tools and measuring tools

a. Equipments: Idle running test bench, voltage withstanding machine, drying oven, dynamic balancing
machine, bearing heater.

b. Tools: Special Puller for flange, gravity center lifting tools for rotor, bearing extractor, rotor storage rack.

c. Measuring tools: double bridge, universal meter, 500V meg-ohmmeter, micrometer caliper of inside
diameter, micrometer of external diameter.

4.4.2 Main technological process

a. Preparation before disassembling

a1. Carry out the visual inspection of the condition of each component of motor. Check if there is
deformation or damage on the case, base and coupler and whether each connection is fine.

a2. Measure the insulation resistance with 500V meg-ohmmeter.

a3. Measure the resistances of excitation winding and armature winding with double bridge.

a4. Check if there is irregular noise with the bearing and the condition of temperature rise during the
running of motor.

b. Disassembly

b1. Remove the flange at the transmission end: Unfasten the pressing nut until three threads from the shaft
end; remove the ring flange with special puller for flange (remove flange without key groove with hydraulic
pump); remove the pressing nut and remove the transmission flange and key.

b2. Remove the bearing: Before disassembling the front and rear bearing covers, mark them well for
convenient mark aligning and locating in assembling; remove the M10 bolt on the front and rear bearing
covers and then remove the front and rear bearing covers; remove the mounting bolt between the front and
rear end covers and the base and pack out the front and rear end covers from the M12 cone screw holes with
two mounting bolts and then remove the end covers; knock the bearings off from the rear end cover with
copper rod (non containing internal ring of bearing); Pay attention to press the bearing with uniform forces
while knocking.

b3. Separation of stator and rotor: Align the gravity center lifting tools for rotor with the shaft head at the
front end of upper rotor; screw on two M10 bolts and fasten; the lifting position should be consistent with
the gravity center of rotor, then lift the rotor and place it on the rotor storage rack; dismantle the lifting tools.

b4. If it is necessary to replace the bearing, remove the inner rings and sealing rings of the front bearing and
rear bearing with bearing extractor; then remove the inner bearing cover.

c. Cleaning after disassembly

c1. Lift the stator, rotor, end cover, etc. to the sweeping room respectively and sweep them with 0.6Mpa dry
compressed air.
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c2. Clean the inside of stator with gasoline or cleaning agent and then dry it through blowing with dry
compressed air.

c3. Clean the front and rear end cover, bearing cover, etc.

c4. Clean the bearing with gasoline and clean through blowing with compressed air.

d. Inspection and repair

d1. Inspection and repair of stator

ķCheck the insulation of each winding, which should be undamaged and aging free. The connectors of
each winding shall be free from cracks and be firmly welded; the connecting lines of motor shall be in order
and the broken strands of leading-out line shall not exceed 10% of the original section area; poorly welded
position shall be cleared and welded again with No. 1 tin.

ĸSlot wedge of each winding shall not be loose.

ĹCheck to confirm the iron core is not loose: If it is loose, insert thin wedge made of insulating material
between the press ring and cramp according to actual condition and cement with epoxy resin so as to make
the iron core solid and tight.

ĺThe body shall be free from cracks or defects. Welding repair is allowed for cracks.

ĻMeasure the insulation resistances of excitation winding and armature winding to the ground and the
resistance between them with 500V meg-ohmmeter, which shall not be lower than 5 Mȍ. If they are lower
than the specified values, re-clean them with gasoline and sweep completely until insulation is recovered. If
the motor is affected with damp, which cause the lowering of insulation resistance, the stator can be put into
the drying oven for drying.

ļMeasure the resistances of excitation winding and armature winding with double bridge and convert them
into values at 15ć, then compare them with the regulated values (refer to II, main technical parameters),
the difference between them shall not exceed ±10%, besides, the difference between the resistance of each
phase of armature winding shall be lower than 4% of the arithmetic mean of numerical value of 3-phase
resistance.

ĽConduct withstand voltage test to ground for armature winding and excitation winding for 1 min with
50Hz, 1125V simple AC power (plus 1500V for new insulation), no breakdown or flashover shall occur.
Warning: Withstand voltage test must be conducted on rubber ground and the operator must be apart from the work parts for
at least 2m.

d2. Inspection and repair of the rotor

ķ Scratch on the surface of the rotor journal which is not exceeding 15% is allowed

ĸ If the wear and tear of journal is too large, conduct chrome plating and then recover the dimension of
original shape through processing with machine tool.

Ĺ Check the fan and counter balance, there shall be no loose. The blade of fan shall be free from crack or
deformation. If the fan is loose, corresponding fittings shall be treated so as to satisfy the requirement of
fitting.

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d3. Inspection and repair of the bearing

ķ Check to confirm the bearing is not loose and the rotation is flexible without irregular noise.

ĸThe bearing ball, roller, inner and outer ring ball track shall be free from cracks, stripping or overheat
discoloration.

ĹIf the bearing is loose, measure its radial clearance and replace the unqualified ones.

ĺThe retainer shall be free from crippling, cracks, flap edge or overheat deformation; The rivet shall be
free from fracture or loosing.

ĻIf it is found that the status of bearing is poor in inspection, it shall be replaced.

d4. Inspection and repair of the end cover and bearing cover

ķCheck to confirm the end cover is free from deformation or crack. Welding repair is allowed for cracks.

ĸCheck to confirm the bearing cover is free from pull, scratch, out of round, etc. The defective ones shall
be repaired or replaced.

e. Assembly

e1. Assembling of new bearing

ķ Measure the dimension of inner ring and shaft diameter of bearing, its interference of fitting shall satisfy
the requirement for limit.

ĸ Cover the inner bearing covers at both ends with lubricating grease on the shaft, then put the sealing
rings and inner rings of bearing at both ends on the heater of bearing until 120ć and slip on corresponding
journals of the rotor.
Warning: It is forbidden to heat the parts of bearing with flame unless it is determined that the bearing is discarded.

ĹAfter replacing the front end bearing, the retaining ring at the shaft head must be mounted.

e2. Blow the dusts off on stator and rotor with dry compressed air.

e3. Lift the rotor into the stator with gravity center lifting tools for rotor.

e4. Press the rear bearing (NU313ECM/C3 or NU313MC3E)(not containing inner ring) into the rear cover.

e5. Add lubricating grease to the bearing at both ends and inner and outer covers of bearing. The volume
shall be controlled within two third of oil cavity of bearing.

e6. Cover the rear end cover on the shaft and push the bearing into the inner ring of bearing. After the
position of mounting is aligned, fasten the mounting bolt.

e7. Align the inner hole of front end cover with the outer ring of bearing and push it in. After the position of
mounting is aligned, fasten the mounting bolt.

e8. Mount the front and rear bearing covers, align the end cover, inner cover of bearing and bolt hole on the
outer cover of bearing, screw on mounting bolt and fasten.

e9. Check to confirm the oil cup is fine and install protective shields on both ends.

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e10. Install the transmission flange: Pre-install the flange in advance and check it to confirm the contact
surface between the flange and the journal is not less than 75% and the contact is even. For shaft head with
key groove, measure the width of key groove and fabricate key again, the width of key shall be larger than
the width of groove by 0.01~ 0.03. Flanges without key groove must be hot fixed in the following
procedures, firstly, heat it in the dry oven or oil bath until 180ć, then fix on the shaft and locate it with
retainer so as to guarantee the pressing-in distance to be 0.8~1.1(refer to the mounting for flange of main
generator for detailed operations), then fasten the nut at the shaft head. Measure to confirm the end face
runout at the outer side of flange is not higher than 0.15.

e11. The motor should be clean and orderly with clear name plate and correct marks on leading out line.

f. Test

f1. Measure the cold state insulation resistance of excitation winding and armature winding to the ground
and that between them with 500V meg-ohmmeter, which shall not be lower than 5 Mȍ.

f2. Idle running test: After the motor unit is assembled, run it at the rated rotary speed for 1h and check the
performance of motor, the temperature rise of bearing shall comply with the technical requirements.

f3. Withstand voltage test: Supply the motor and ground with 50Hz, 1125V sine AC power (plus 1500V for
new insulation) for 1 min, no breakdown or flashover is allowed.

f4. The motor should run stably and freely with no abnormal noise.

g. Record the information of inspection and test of the motor in details.

4.5 Main Parts List

No Description Code Q’ty. Manufacturer
1 Bolt M10×65 GB/T 5782-2000 6 Standard
2 Washer 10 GB/T 93-1987 6
3 Front bearing cover QD2-000-008 1 Yongji Motor Works, Qi
Factory
4 screw M6×8 GB/T 946-1988 26
Standard
5 Washer 6 GB/T 93-1987 18
6 Baffle QD2-000-007 1 Yongji Motor Works,
7 Bolt M12×35 GB/T 5783-2000 12
Standard
8 Washer 12 GB/T 93-1987 12
9 End cover QD2-400-000 2 Yongji Motor Works and
Qi Factory
10 Oil cup M10×1 GB 1152-89 1 Standard component to be
purchased
11 Retaining ring 65 GB 894.1-86 1
12 Bearing 6313/C3 1 Dalian Bearing Plant
13 Seal ring ZF1-000-004 2 Yongji Motor Works
14 Inner bearing cover QD2-000-003 2 Yongji Motor Works and
Qi Factory
15 Fan QD2-140-000 1
16 Assembly of rotor QD2-100-000 1
17 Assembly of stator QD4B-200-000 1 Yongji Motor Works,

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No Description Code Q’ty. Manufacturer

18 Lower protective shield QD2-020-000 2
19 Upper protective shield QD2-010-000 2
20 Bearing NU313ECM/C3/NU313MC3E 1 SKF/ NSK
21 Mesh enclosure QD2-000-004 1 Yongji Motor Works
22 Rear bearing cover QD2-000-002 1 Yongji Motor Works and
Qi Factory
23 Bolt M10×65 GB/T 5782-2000 6
24 Screw M8×12 GB/T 67-2000 2 Standard
25 Washer 8 GB/T 93-1987 2
26 Washer 8 GB/T 97.1-1985 2
27 Outgoing feeder box QD2-030-000 1 Yongji Motor Works and
Qis Factory
28 Key QD2-000-001 1
29 Ring key QD2-110-005 2
30 Safety ring QD2-110-006 1
31 Insulating sleeve QD2-200-002 3
32 Slot wedge QD2-200-005 96 Yongji Motor Works
33 Wiring board QD2-200-602 1
34 Flange plate QD2-400-001 2 Yongji Motor Works, Qi
Factory
35 Bearing sleeve QD2-400-002 2
36 Gusset QD2-400-003 12
37 Plate QD2-400-004 2
38 Motor bearing grease L-XEGEB2 Tianjin Tanggu Chemical
Plants

5 Air compressor motor

5.1 Function
ZTP-180CG motor is a DC motor that is special for
locomotive air compressor. It provides power for the
compressor.

5.2 Structure
This motor is four poles DC motor. There are 4 main
poles and 4 auxiliary poles in stator part. Octagon
motor seat is welded by pressed steel plates. There is
an observing hole cover near the commutator end on
the seat to prevent the foreign material from entering Fig 2-12 ZTP-180CG motor figuration
the motor. It is only allowed to open the observing 1. Motor 2.axile bush 3.tightening screw
cover when observing the spark and carrying out
maintenance to brush or brush rod. There are four feet

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welded under the motor seat in order to locate the motor. There are 4 lifting hooks used for lifting the motor,
and make sure that 4 lifting hooks are simultaneously weighted. This motor adopts self ventilation structure.
Structure of the fan is cast aluminum blades with steel sheath and blades are backward inclining. The
number of blades is 13. Motor main pole coil adopts flatwise double layers and no radian structure, while
auxiliary pole coil adopts edgewise structure. Main pole and auxiliary pole coils are fixed on motor seat by
2 M12 screws.

There is one bearing on both two end covers of the motor. The one at commutator end is 6310C3, while the
other one at transmission end is 6313C3. Both are lubricated by No. 3 lithium grease. Both two covers have
a M10 u 1 oil cup.

There is an outlet box on the motor. Marks of the wire are A1ǃB2. A1stands for armature head; B2 stands
for auxiliary pole winding end.

Armature has front and rear racks. Armature stampings are made of 0.5mm silicon steel by punching. The
type of armature winding is single winding, and the commutator whose material is plastic adopts inner steel
ring tightening structure.

The baffle ring of commutator has balance slot to install balance block if necessary. It adopts the method of
reducing weight to correct dynamic balance at fan end.

The motor has 4 independent brush rods, each of which is located by M12 bolt on front cover. Each one has
3 16×25×40 brushes. Trademark of the brushes is D214.

5.3 Motor disassembly and assembly

5.3.1 Motor disassembly

Clean the dirt on the out of the motor. Get the brushes out of brush box. Loosen off the 4 M8 screws on
front bearing cover, and remove front bearing cover. Place the motor vertically with the transmission end
upwards. Then loosen off the 4 M8 screws of back bearing cover. Dismantle the back bearing cover. Lift the
armature with special lifting ring carefully. Pay attention not to bump the commutator. Loosen off the round
screw. Then dismantle the bearing at commutator end, front inner shaft seal and front inner bearing cover.

Turn over the motor to make the auxiliary end upwards. Remove the wires which connect brush rack and
commutating pole, and the outlet wires which connect outlet box. Mark the front cover and motor seat and
remove the front cover.

Dismantle the joint of outlet wire and low weld pole, and then demount main poles and auxiliary poles,
marking shall be made before demounting.

5.3.2 Motor assembly

5.3.2.1 Before assembly, check whether the motor components are clean, and if the oil quantity of the
bearing is proper.

5.3.2.2 Stator assembly˖Assemble the main poles and auxiliary poles according to the mark, and then
connect the wires between poles and the outlet wire. This axis of main pole should be vertical to motor seat.

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

Distance between main poles and auxiliary poles shall be equal.

5.3.2.3 Main assembly˖Mount front inner oil seal, front inner bearing cover and bearing onto the axle.
Front inner oil seal and bearing inner ring adopt the way of shrinkage fit. Tighten the round nut, and buckle
the anti-loose cramp. Mount the front cover assembly according to the mark on motor seat. Connect the
connecting wires and outlet wires on brush rack. Then turn over the motor to make the transmission end
upwards. Lift armature commutator downwards into the stator with special lifting ring. Make sure that the 4
M8 screw holes of front inner bearing cover and front cover aim at each other. Then tighten the bolts. Mount
back cover with back inner bearing cover, bearing outer ring and back bearing cover onto motor seat. Place
the motor horizontally. Mount the front bearing cover and the brushes. Make sure armature can rotate
flexibly.

5.4 Maintenance

5.4.1 Maintenance for commutator

Commutator is the core of DC motor. If maintenance is not properly done, failures are likely to happen.
Frequent maintenance is very necessary. Check and clean it once a week at least.

5.4.1.1 when check the surface of commutator, attention shall be paid to˖

5.4.1.1.1 Observe the surface of commutator˖The trace which leaved by brushes should be even and
lustrous, forming a commutator pellicle whose color is tint, deep color, or even fuscous. As long as there is
not the phenomena of uneven abrasion, partial black and serious lackluster, it shall be considered to be
normal.

5.4.1.1.2 Check the undercut depth of the mica between the commutator bars: Depth is 1.5+0.2mm, the angle
of the chamfer at the two sides of the commutator bar is 0.5×45q.

5.4.1.2 Maintenance method of commutator˖

5.4.1.2.1 Blow off the powdered carbon on commutator surface with high pressure wind. If there is oil dirt
or slight burn, clean with cotton cloth with alcohol.

5.4.1.2.2 If there is obvious burn and cleaning with cotton cloth does not have effect, put a piece of 00# glass
cloth on the surface of commutator closely for cleaning when the motor is idling fast (If possible press a
piece of wood with the same radian on the surface of commutator ). The cleaning time shall not be too long.
The elimination of the burn shall be the limit. Then blow it with high pressure wind. It is forbidden to use
emery cloth when clean the surface of commutator.

5.4.1.2.3 If there is too much abrasion or burn and affect normal operation of the motor, the motor shall be
disassembled for the finish smoothing of the commutator. The roughness of the commutator surface shall
not be less than Ra1.6 during the smoothing. The runout of the commutator surface to the bearing inner ring
of the two ends shall be no more than 0.02mm.

5.4.1.2.4 If the undercut depth of the mica between the commutator bars is less than 1mm, the undercutting
shall be redone. The undercutting can be done on the planning machine or be done by hand with saw blade.
The two sides of the commutator bar shall be chamfered of 0.5×45q after undercutting.

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5.4.2 Maintenance of brush rod rack

5.4.2.1 Brush rod rack which is cast in colophony is an insulating component for the insulation of brush box
to the ground. Keep its surface clean and remove the dirt such as powdered carbon.

5.4.2.2 Check if the rotation of the press finger of the brush holder is flexible, if there is rust corrosion on
the press finger spring, and if the spring pressure on the brush lies in the specified range of 7.84r0.98N.

5.4.2.3 Brush should be agile from top to bottom in brush box, but not too loose to shake from side to side.
If there is abrasion between brush and the surface of commutator, forming two or even more interfaces, that
is to say the cooperation of brush and brush box is too loose. Then it’s necessary to find out the reason and
handle it in time.

5.4.2.4 The contact area of brush and the surface of commutator should not be less than 75% of the whole
area of brush, otherwise it shall be grinded. The glass cloth shall be used for the grinding. It is forbidden to
use emery cloth. It is better to use the special grinding tools for the brush grinding. If the grinding is done
manually, pay attention to make the paper tightly pressed on the surface of the commutator.

5.4.2.5 When brush reaches its abrasion limit or there are severe faults such as cracks or brush cord loose,
the brush shall be replaced. The new one should be grinded according to the above requirement.

5.4.2.6 Neutral position of the whole brush rack is adjusted and fixed.

In order to avoid changing neutral position and ensure the motor quality, it is better not to dismount the
components such as brush box, brush rod rack and so on. When it is necessary, the neutral position shall be
adjusted after disassembly.

5.4.3 Maintenance of bearing

5.4.3.1 Check operation condition of bearings frequently. If there is abnormal noise or the bearing is too hot,
find out the reason and solve it in time.

5.4.3.2 Make sure that bearings are lubricated well when the motor is running normally. Generally, every
2000 hours operation, 10-20g shall be filled by oil filler.

5.4.3.3 After cleaning, fill lubricating grease to the bearings on both ends of motor. Quantity of lubricating
grease shall be 1/3 of the bearing room. Trademark of lubricating grease is NO.3 lithium grease.

5.5 Motor using standard

5.5.1 Allowed increasing temperature of motor components
Allowed increasing
Motor parts Insulation rank Measure method
temperature
Armature winding F Resistivity method 135 K
Main pole winding F Resistivity method 150 K
Auxiliary pole winding F Resistivity method 150 K
Commutator Temperature method 100 K
Bearing Temperature method 50 K

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5.5.2 The insulated resistance of motor should be examined periodically. And cold condition insulated
resistance shall not be less than 5Mȍ.

5.5.3 Control in motor physical dimensions

5.5.3.1 Diameter of the commutator working surface should not be less than 144mm.

5.5.3.2 Distance between brush box and commutator surface is 2.5±0.5mm.The unparallel degree should not
be more than 1mm.

5.5.3.3 Distance between brush side face and hoist piece is 5-7mm.

5.5.3.4 Clearance between brush and brush box (unit: mm)

Direction Design value Condemn limit
Brush thickness 0.09-0.28 0.4
Brush width 0.12-0.31 0.8

5.5.3.5 Condemn limit of brush height is 25mm.

5.6 Safety technology

5.6.1 It is forbidden to contact electrified part of the motor.

5.6.2 It is forbidden to blow the inner part of the motor with high pressure wind when it is electrified.

5.6.3 It is forbidden to lift finish machining part of the motor such as working surface of commutator, axle
extension etc. with steel rope.

5.7 Motor idle test

Input low voltage to the motor and turn higher slowly. Run steadily for 15 minutes respectively at the speed
of 500 rpm, 1000 rpm, 2000 rpm, and 3000 rpm in order to check temperature rising situation and whether
there is abnormal noise.

5.8 Checking tool:

No Description Tool Sort
Sleeve spanner
Dismantling and tightening of all sorts of
1 ring spanner Common
bolts.
Adjustable spanner
2 Dismantling of the bearing Wheel puller Special
Dismantling of the bearing inner ring and
3 Inductive heater Special
seal ring .
Cleaning of the commutator surface mica
4 Angle reamer Special
slots.
5 Cleaning of the commutator surface Brush Common
6 Illumination Electric flashlight Common
7 Fill oil into bearing room Grease gun Common

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6 The Blower Motor for Braking Resistor

The type of the blower motor for braking resistor is
ZTPˉ63H4, the figuration is following Fig.2-13.

6.1 Operating Principle and

Structure
While the exciting winding of the stator and
armature winding of rotator is supplied with the
direct current, under the action of stator field, the
armature winding will move along the direction of
electromagnetic force and run the rotator, which can
drive the cooling fan, finally, the cooling air is Fig. 2-13 ZTP-63H4 Motor

supplied for the braking resistor unit.

ZTP-63H4 motor is quadrupole series excitation direct current traction motor. In order to start directly, the
tab and segment of the commutator are in an one-piece structure, the commutator and armature are welded
by the argon arc (TIG). There is a guard band for the observation window that is at the commutator side,
open the band, some work, such as replacing the brush, maintenance for commutator and brush yoke system,
observing the commutator spark in the test, can be conveniently done. The structure is shown in Fig.2-14.

Fig. 2-14 The structure of ZTP-63H4

1-Bearing 6309˗2-The front outer bearing cover˗3-Bolt M8h48˗4-Washer 8˗5-The front
inner bearing cover˗6-Bolt M8h50˗7-Washer 8˗8-The front end shield˗9-Back plate˗10-
Brush yoke˗11-The stator˗12-The armature˗13-The back end shield˗14-The back outer
bearing cover˗15-Bearing 6310˗16-The back inner bearing cover˗17-Bond˗18-Bolt M8h
55˗19-Bolt M10h30˗20-Washer 10˗

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6.1.1 Stator
The stator consists of the frame, 4 main poles and 4 commutating poles, and each pole is fixed on the frame
by the spring washer and 2 M10 bolts with class 8.8. The lamination structure is adopted for the main pole
iron core, and the integrity structure made of the flat steel is for the commutating pole iron cores. Both coil
windings adopt the H class wires lapped by skin touch imines film, and the specification is 3.55h6.3, there
are 20 turns for the commutating pole, and 14 for the main pole. The poles connecting wires are caped and
cold pressed, then lapped by the insulation, after the space between the coil and iron core are filled by the
polyester felt, adjust the coil height through the backup plate,
and then dip them in the lacquer to make them be a one-piece
structure, it can enhance the reliability.

The elementary diagram of the stator is shown in Fig.2-15.

6.1.2 The Armature

The armature consists of iron core, winding, commutator, rotor
axes, fore and after bracket etc. The iron core is made of the
pressed silicon steel plate with the thickness of 0.5mm, the
external diameter of the armature is 195mm, and it has 27 slots.
The iron core insulation end plate and the brackets are directly
Fig. 2-15
pressed on the rotor axle, which is made of 42 CrMo alloy
The elementary diagram of the stator
steel. The simplex wave windings are used for the armature,
each armature has 27 coils, and each coil has 5 units, and each
unit is made of 2 conductors in parallel connection, the
conductor is massed of the line named 2-1.16h4.7
SBMB20/180-1Y3F1, and be dressed on the complex
insulating material, the conductor will be put in the slot after
do some insulation for the slot, finally, it will be dipped in the
lacquer. The commutator looks like a arched swallowtail, and
it is made of 135 commutator segments and mica plates, the
permissible wear in the radial direction for each side is 6.5mm,
the insulation grade is H. The two flanks of the commutator
are sealed with epoxy resin; it can advance the performance of
air proof and humidity resistant. The armature coil and Fig. 2-16 The wiring Figure
commutator riser are welded through argon arc, it can provide of the armature
good electric specification and mechanical strength.
The wiring diagram is shown in Fig.2-16.

6.1.3 The end shield

The front and back end shields and bearing covers are used for supporting and sealing. The pie iron casting
end cover is installed on both sides of the motor which enhance the mechanical strength of the whole motor.
Both of the two bearing are single row centripetal ball bearings. The bearing at the commutator side is type
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of 6309, and at the transmission side is type of 6310. The locomotive motor bearing grease is used for this
motor, and the adding quantity should be two thirds of the whole oil storage space in the motor. The
polyester felt is filled between the coil and pole body. There is no foot for the frame, and no flange for the
end cover, the position setting is through the rabbet on the out dummy club of the frame, the motor is fixed
in the air duct of the blower. The open type is used for the front and rear end cover, and the motor has no fan,
it can be cooled by the blower’s air.

6.1.4 The brush yoke system

The brush yoke is fixed on the front end
cover through the back plate and two
bolts type of M8h45, so it is
convenient to adjust the brush yoke
through screwing the bolts. The brush
yoke has four brush holders. The radial Fig. 2-17 The wiring diagram of motor
constant pressure type is adopted for the
brush holder; the spring pressure is correctly controlled in the manufacture, so it needs not to be adjusted in
the future. The brush box is made of die-casting brass H62, and the brush is D374N electric graphite carbon
brush, which dimensions are 12.5mmh25mmh40mm. The wiring diagram of the motor is shown in Fig.2-
17.

6.2 Main technical parameters

Motor Model ZTP-63H4
Rated power (kW) 30
Rated Voltage (V) 260
Rated Current (A) 136
Specified Speed(r/min) 3500
The Highest Speed (r/min) 4000
Insulation grade H/H
Level of Protection IP21
Main pole winding resistance(ȍˈat 20ć) 0.0201¡
Accessory pole winding resistance(ȍˈat 20ć) 0.0227¡
Armature Winding resistance(ȍˈat 20ć, 1ˉ34sheet) 0.0369¡
Install type IMB1Ċ
Cooling type ICĊ1

6.3 Inspection and Repair Process

6.3.1 Special Equipments, fixtures and measuring Tools

a. Equipments: Idle run test bed, withstand voltage machine, oven, bearing heater

b. fixtures: special flange puller, special rotor sling, bearing puller, the rotor storage rack

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

c. Measuring tools: The double bridge, universal meter, 500V megohmmeter, bore dial indicator, out side
micrometer.

6.3.2 Main Technological Process

a. Disassembly

a1. Remove all the link lines of the motor

a2. Remove the bolts of the motor’s installation ring, and take the motor out of the wind tube.

a3. Loosen the bolts of the end cover and bearing cover at the commutator side, remove the outer bearing
cover.

a4. Take out the brush from the brush holder, and remove the link lines of the brush pole.

a5. Dismount the end cover, brush holder stud seat, brush holder stud, brush holder and brush at the
commutator side.

a6. Remove the bolts of end cover at the axle extend end, and take out the armature and end cover from the
stator carefully, be carefully not to damage the winding.

a7. Put the armature and the end cover on the bracket, and well pack the armature, and then remove the bolts
of the bearing cover at the axle extend end, finally, take down the bearing outer cover and end cover.

a8. If the bearing needs to be replaced, take out the bearings under the help of bearing puller.

b. Inspection and Repair

b1. The commutator surface should be smooth with no mechanical damage or burnings. If it has light
burnings, please polish it lightly on the running commutator with the 00# glass emery cloth, if the burning is
serious, please use the thick emery cloth first, and then the 00# glass emery cloth to polish it. If there are
some obvious asperity, unroundness or some recess, lathe turning need to be done. The surface roughness
should be Ra0.8. After the lathe turning, please make the depth of the mica cutting to be 1.5mm and the edge
rounding at both sides should be 0.5h45e, finally, clear up the burrs and scraps.

b2. The inspection and repair of the rest components can refer to the relative parts of the start motor.

c.Assembly

c1. Put the two bearing inner covers on the axles, and shrink the bearing on the axles. Pay attention, it is 309
type bearing at the commutator end and 310 type bearing at the transmission end.

c2. The assembly is in the reversing order of the disassembly, it can also be installed vertically, the sequence
is as follow: First, fix the front end shield on the frame, then turn the frame to be vertical with the back end
upside, and put the rotor in it under the help of the special sling, next step, make the screw holes of the
bearing cover, end shield and bearing inner cover at the back side to be in a line, then screw down the
screws. Second, turn over the the frame, install the front bearing cover, make the screw holes of the bearing
cover, end shield and bearing inner cover at the front side to be in a line, then screw down the screws.
Finally, adjust the brush location according to the marked sign, and adjust the pressure of the brush to be
range of 0.025 to 0.035Mpa. Make sure that there is some suitable clearance (no more than 0.15mm)
between the brush and brush box, the brush with height less than 15mm should be discarded.
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d.Test

d1. Measure the cold DC resistance of each winding, and the value should be in the specified scope.

d2. Measure the cold insulation resistance among the winding, brush yoke and groud with 1000V
megohmmeter, and the value should be no less than 5M¡.

d3. Idle run test: the motor should run for an hour at the speed of 3500r/min in the working direction, the
bearing temperature rise should be less than 55K (the temperature rise of the bearing cover should be less
than 40K), it should run stably and freely without abnormal noise in the whole test, after the test, check the
contact area between the brush and commutator, and the value should be no less than 75%.

d4. Overspeed Test: Rebind the rotor and let it run continuously for 2min at the speed of 4375r/min. No
mechanical damage or permanent deformation, which may affect the normal running of the electric motor, is
allowed.

d5. Ground Insulation Dielectric Strength Test: Supply the sine alternate current with 50 Hz, 1125 V (the
voltage should be 3210 V if all the insulation parts are renewed) to each winding and brush yoke about 1
min for the ground withstand voltage test, there should be no breakdown or flashover.

6.4 The limit of inspection and repair

Limit
NO. Description Original Shape
Depot Repair Forbid
Along brush thickness
0.092-0.262 0.35 0.5
clearance between direction (rotation direction)
1
brush and brush box Along Brush width direction
0.11~0.314 0.8 1.0
(axial direction)
2 Height of the brush 4.0 17

Distance between brush box bottom surface and >4

3 3f0.5 f1
commutator working face ˘2
4 Brush Pressure kPa 25~35 ˘20

5 The diameter of commutator working face +1 ¶137

¶150 0
0
6 The depth of commutator mica ¶15 -0.5 0.8 0.5
Runout of the commutator working surface after
7 0-0.03 0.06 0.1
assembly

7 The Other Microminiature Motors

7.1 The main technical parameters

Power Voltage Current Rotating speed Excitation
Name Type (r/min)
(KW) (V) (A) Type
Start-up lubricating oil Shunt
ZTPˉ41 4.5 96 57.8 2200
pump motor excitation

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Power Voltage Current Rotating speed Excitation

Name Type (r/min)
(KW) (V) (A) Type
Fuel pump motor Shunt
ZTPˉ12 1.1 110 13 3000
excitation
Car body blower Shunt
JFJ-A11 0.308 95-115 3.5 3000
motor excitation
Fan motor in the Shunt
LGFˉ40 0.04 110 1250
driver’s cab excitation

7.2 The basic technical requirements

7.2.1 The inner and outside of the motors should be clean and the nameplate should be in good condition,
the signs of the leadout lines should also be right.

7.2.2 There shall be no crack, breakage or deformation on the body, end shield, fan and belt pulley. The
connecting fitting should be in good fastening condition.

7.2.3 There shall be no crack, burning loss or deformation on the brush yoke parts, the brush pressure shall
be even.

7.2.4 The mark of the brush in one motor should be same, and the height should be more than two thirds of
the original size, the brush should be moved freely with no abnormal, the contact area of the brush and
commutator should be more than 75% of their faces.

7.2.5 There should be no burning loss, pulling damage or sagging on the commutator, and it need to be lathe
turning if the abrasion depth is more than 0.2mm, after the lathe turning, the surface roughness should be
1.25 to 2.5­m.

7.2.6 The edge rounding and the carving depth of the mica groove should meet the limit requirement.

7.2.7 The wires of the motors should be in good condition, and the insulation shall have no damage, the
effective conducting area should be more than 90% of the original value.

7.2.8 Measure the cold condition insulation resistance among the winding, brush yoke system and ground,
the value should be no less than 5 M¡.

7.2.9 Measure the winding resistance and convert into the value at 15 ć, the error between it and the
original value should be no more than 10%.

7.2.10 Withstand voltage test: supply the motor and ground with 50Hz, 1000V AC simple alternating
current for 1 min, no breakdown or flashover is allowed.

7.2.11The motors should run stably and freely, the bearing should also be in good condition and its
temperature rise should be no more than 30 ć.

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 Chapter 3 Silicon Rectification and Dynamic Braking Device

Chapter 3
Silicon Rectification and Dynamic
Braking Device

1 Main silicon Rectifier Cabinet and Rectifying Tube

Main rectifier cabinet is the rectifying device of main circuit of DF 8BI diesel locomotive. It converts three-
phase AC generated by main synchronous generator into pulsating DC for the operation of traction motors.

This device adopts the Copper heat sink for high power components and the independent ventilation mode.

It main function: three phase full wave rectifying of main circuit in traction condition.

1.1 Main technical parameters

Type TGZ30
Nominal power 5200KW
Maximum valve-side AC voltage 770V
Maximum DC output voltage 1000V
Nominal DC output current 5600A
Maximum transient DC output current 8000A˄15min˅
Main circuit connection three phase full wave rectifying bridge (Fig.1)
Semiconductor component packages 12pics
Semiconductor component combination 1S×2P×6A
Type of rectifying diode ZPx3000ˉ30
Commutating capacitor CBB80,1ȝˢ,800˲ac ǂ
Way of cooling Forced air cooling, average wind speed•6m/s, lowest point
wind speed •5m/s
Dimensions 740×900×1040
Weight 400kg

1.2 Main circuit connection

Main circuit connection of the rectifier (Fig.2): Connection way of main circuit of rectifier is three
phase full-wave rectifying bridge. Three phase AC generated by the main generator is connected
to the valve-side (input side) of the rectifier which is located at the top left of the rectifier device and
the AC is led out through the copper busbar. Output line (DC side) is at the front and rear side of the
rectifier bottom and the DC is led out through the copper busbar. Over voltage protection resistor-

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capacitor of components are installed on the RC board, which forms a wind channel with
phenolic plastic pole.

Fig.1 Main circuit

Fig. 2 Main circuit connection

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1.3 Configuration, installation and dismantle of the rectifier

The rectifier (Fig.3 and Fig.4) mainly consists of framework, insulation pole, RC board, compressed
components of rectifying tube, copper busbar and door. All the fasteners have protection layer and anti-loose
measures. Electric clearance of main circuit shall not be less than 30mm and creepage distance shall not be
less than 40mm. Damping measures will be taken during the components installation. The ventilation of the
components is forced air ventilation cooling. Inlet air goes from the top of the cabinet, then goes out from
the bottom of the cabinet to cool the traction motor and at last exhausts from the locomotive.

The arrangement of the rectifying tube components in the cabinet is: 2 rows (front and rear), 2 lines (left
and right) and 3 layers (upper, middle and lower). AC input line is connected at the top and DC output line
is connected at the bottom. The corridor side is positive and the middle side is negative.

There is a T-shaped installation carrier at the two ends of rectifying tube components. T-shaped carrier has
rubber damping pads, the installation guide groove which is pushed to the pole. A plate is pressed outside
for fixing. When dismantling the components, disconnect the copper busbar and remove the fixing bolts on
the panel first, then the rectifying tube components can be taken out. Copper busbar shall be removed if it
blocks the components.

Framework, insulation pole and RC board forms a vertical air cooling channel, in which the rectifying tube
components are sealed. There are 12 rectifying tube components in the cabinet, and the arrangement is: 2
rows (front and rear), 2 lines (left and right) and 3 layers (up, middle and down). Frame consists of
framework and insulation pole. There is horizontal groove on the insulation pole, supporting the
components.


Fig. 3 shape of the rectifier cabinet


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 Fig. 4 Rectifier
1 Framework 2 Insulation pole 3 Rectifying tube
 component assembly 4 RC board 5 Door 6 Door lock 

Rectifying tube assembly (Fig. 5) is composed of rectifying tube, heat sink, insulating component, T shape
plate, which have been assembled together on a special machine. T shape plate has horizontal guideway.
During assembly, the plate can be used to guide and support the rectifying tube components. It also has
rubber pads on it.

RC board (Fig. 6) has resistor and capacitor, which can absorb the over voltage of rectifying tube. 

2 4

1
2
1 3 3
4
 
 1 Rubber pad 2 T shape splint 1 RC board 2 Capacitor
3 Heat sink 4 Rectifying diode 3 Resistor 4 Tin plate
Fig. 5 Rectifying diode package Fig.6 Assembly of RC board

During installation, first, insert the rectifying tube components along the vertical groove of the insulation
pole on the framework; next, install the RC board and connect the copper busbar.

Notes: * The rectifying tube components can’t be opened, because the tube has special requirements on the
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assembled components.

* Surface of connector shall be clean and fasteners shall be tightly fastened.

1.4 Operation, repair and maintenance

1.4.1 Check if the bolts and busbar are tightly connected and if there is black spots resulted from overheat.

1.4.2 Check if the ventilator’s operation is normal (average wind speed at the surface of heat sink is 6m/s,
lowest wind speed should not be less than 5m/s); if the wind channel relay’s operation is normal.

1.4.3 Check and see if there is foreign body in the wind channel and on the top of rectifier cabinet that may
affect air circulation and insulation.

1.4.4 Check and see if there is dust on the copper busbar and supporting insulation. Rectifier should be kept
clean.

1.4.5 Periodical maintenance

1.4.5.1 General inspection: use kȍof universal meter to measure the resistance of cathode and anode of
rectifying tube. If the resistance is too small or the value is zero, it means that the component has been
degraded or has been brokendown. As for the degraded component, dismantle it from the cabinet and judge
if it can be used or not by measuring it with a reverse test probe.

1.4.5.2 Dust cleaning: use a high voltage blower, brush or a dust catcher to clean the wind channel of the
rectifier, supporting insulator, busbar, and etc. ǂ

1.4.5.3 Check and see if the fasteners have been loose or if there are any cracks on them; if busbar has
turned black due to overheat. All the bolts of connectors should be fastened. ǂ

1.4.5.4 Use a 2.5kV Meg-ohmmeter to test the insulation value of main circuit and control circuits as well
the cabinet of the rectifier, the value should be no less than 5Mȍ, no breakthrough or flashover should occur
within 1 minute when imposing on 4.5kV power-frequency voltage.

1.4.6 Intermediate maintenance

1.4.6.1 When the repetitive peak reverse voltage VRRM of rectifier is 3000˲, repetitive peak reverse
current ˥RRM should not surpass 80mA˄25ć˅. Difference between commutating capacitor value and
rated value should not surpass 10ˁ by measuring with a resistance-capacitance bridge.

1.4.6.2 Wash or clean the dirt and dust on the semiconductor heat sink, surface of core and porcelain ring,
insulation hose of bolts, insulation pad, supporting insulator, copper busbar, etc.

1.4.6.3 Check and conduct insulation test on rectifier. Testing results should be consistent with the
specifications of intermediate maintenance.

1.4.7 Component replacing

1.4.7.1 When a component is damaged, replace it with the spare parts supplied by the original manufacturer.
The technical specifications of the spare parts should meet the requirements of technical conditions.

1.4.7.2 Check the component and see if the polarity of component is correct after replacing. Check if the
replaced component can be conducted.
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1.5 Limitations
1.5.1 Rectifying tube VRRM/IRRM 3000V / • 80mA˄25ć˅ǂ

1.5.2 Commutating capacitance Surpass the rated value ±ˍˌˁ ǂ

1.5.3 Insulation resistor ˘3Mȍǂ

1.5.4 Voltage resistance ˘3.5kVǂ

1.5.5 Trip of fasteners slides and spring pads can not be reseted.

1.5.6 Insulating parts have been burnt out or carbonized.

1.5.7 Insulating lead has been naked or insulating layer has cracks.

1.6 List of components

Rectifying tube RC board module (Fig.6) Code˖ZS3312000
RC board Code˖ZS3312002
Capacitor Code˖W53802806100
Resistor Code˖W41003011200
Tin chip Code˖ZS3312001
Insulator Code˖ZS179A0004
Insulation pole (left) Code˖ZS517A0100
Insulation pole (middle) Code˖ZS517A0200
Insulation pole (right) Code˖ZS517A0300
Door lock Code˖MTST0122/18
Rectifier tube assembly module Code: ZS331Vi

1.7 Structure and main technical parameters of main rectifier

1.7.1 Structure of main rectifier

2 Excitation Rectification cabinet and Rectifying Tube

Excitation rectifier is the excitation circuit rectify device for DF8BI. Its main function is the three-phase full-
wave rectifying of excitation circuit. It converts the three-phase AC power generated by the inductor exciter
to pulsating DC power for excitation winding of the synchronous main motor to create magnetic field.

2.1 Structure and main technical parameters of rectifier

2.1.1 Structure

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

The excitation cabinet of DF8BI diesel locomotive is mainly composed of cabinet frame, press plate,
coupling plate, RC assemblage, rubber pads, rectifying components etc. The front and side of the rectifier
body has ventage to ensure fine radiation.

Rectifying tube module is located on the centre of the cabinet by 3 rows, each pressed 2 rectifying
components. AC wires are connected from the bottom of the rectifier, and DC wires the lower part. The
front and back of the cabinet are both divided into right side and left side.

Rectifying tube module, press-packed with the aluminum heat sink, has installation screws at both ends.
Epoxy board holds the bottom and fixes the top and side of the tube module. When dismantling and
replacing components, take away the hood first, disconnect wires and then remove the epoxy board bolts,
and finally take out the module.

Protective layers and anti-loose measures are applied to all the fasteners. Clearance of the main circuit of the
rectifier shall be at least 10mm, and creepage distance shall be no less than 15mm. The arrangement of the
components in the rectifier makes the natural ventilation available for the component and heat sink. Cooling
air flows from the bottom, the front and back of the cabinet, and hot air exhausts from the top to the
locomotive.

Aluminum heat sink (matched with two-sided cooling components) and natural ventilation is adopted in the
rectifier. High reliability and certain safety margin are considered.

Main circuit connection of excitation rectifier cabinet: Three-phase full-wave rectifying bridge is adopted in
the connection of main circuit. Three-phase AC output by exciter is connected to the valve side (input side)
of the excitation rectifier. The AC is led out by the cables at the middle and bottom of the cabinet. Output
wires (at both DC sides) are at the left and right side of the excitation rectifier bottom. The DC is led out by
cables. Over voltage protection RC is installed on the RC panel, which is fixed on the upside. The structure
is shown as fig. 3-4.

Fig 3-4 outside view of TGZ33-360/100 type excitation rectifier

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2.1.2 Main technical parameters

Type TGZ33-360/100
Nominal power 36kW
Maximum valve-side voltage 80V
Maximum DC output voltage 100+20%V
Nominal rectifying current 360˝
Maximum short-time rectifying current 400˝(5 minutes)
Type of rectifying circuit Three-phase bridge rectifying
Type of rectifying component ZP81500-12
Quantity of the semiconductor on the device 6
Combination mode of components 1S×1P×6A
Type of cooling Natural air cooling
Installation dimension 540mm×509mm
Dimension of rectifier 700 mm×300mm×500mm
Weight 60kg

2.2 Structure and main technical parameters of silicon rectifier

tube

2.2.1 Structure
The excitation rectifier cabinet of DF8BI diesel locomotive adopts ZP81500-12 type rectifying components.
The rectifying tube is placed between the two heat sinks and fastened with four bolts through two spring
plates. The heat produced by the tube chip is exhausted through the outer surface of the heat sink. The prism
pillar of the heat sink, the 8 variable-thickness cooling fins, and the conducting board connected to the
external are molded in onepiece. The heat sink is cast with ultra-pure aluminum precision casting process.
The surface of the cooling fin is passivating treated.

2.2.2 Main technical parameters

Type ZP81500-12
Nominal mean forward current IF (AV) 1500A
Repetitive peak reverse voltage URRM 1200V
Surge current IFSM 21000A(10ms)
Peak forward voltage UFM İ1.2V
Repetitive peak reverse current IRRM İ120mA(175ć)
Nominal junction temperature TJM 175ć

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2.3 Maintenance method

2.3.1 Basic technical requirements

a. Check if the bolts are tight. The conducting wire for connection shall be free of breakdown, overheating
and burn damage. Check the insulation piece for deterioration and burn damage.

b. Clean the dirt on the cabinet, components heat sink and the surface of the ceramic rings with 0.6 MPa
dried compressed air.

c. Clean the components, heat sink, and protective RC.

d. The rectifying components and protective RC should be tested and meet the technical requirements.
When replacing the rectifying components, the components which have the same or similar parameters shall
be adopted and attention shall be paid to the conformity of the polarity.

e. Test the grounding insulation resistance of the electrified parts of the excitation rectifier cabinet with
500V mega-ohmmeter. The value should be no less than 2M¡(humidity no higher than 85%).

2.3.2 Main equipments, fixtures, measuring tools and materials for

inspection and repairing
a. Equipments: forced draft electric drying oven, voltage endurance tester, ultrasonic cleaning machine,
diode performance test bench and air duster.

b. Fixtures: Hanger, Pneumatic Wrench, Socket Wrench with 28 sets, Service Electric Clamping Tool.

c. Measuring tools: 500V mega-ohmmeter, universal meter, capacitance meter, calculator.

d. Materials: blade cloth, absolute alcohol, cleaning lotion, fuse.

2.3.2 Main technical process

a. Disassembly

Ł Loose the fixing screws on the press plate of the components.

ł Loose the fasteners between the connection wires and the copper busbar, take out the components and
the rubber ring on the components and plates, mark the bridge arm components before removal for the
convenience of re-installation accordingly.

b. Cleaning

Ł Lift the excitation rectifier cabinet to the air dusting room, clean the outer and inner part of the cabinet
with 0.6MPa compressed air.

ł Clean the copper busbar and the inner part of the cabinet first with brush, and then wipe clean manually
with wet blade cloth dipping absolute alcohol.

Ń Clean and clear the semiconductors cooling fins, the surface of the ceramic rings of the tube chip, the
bolt insulation sleeve, insulation washer and supporting insulator.

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ń Components set cleaning

ķ Clean all the components once with pressurized clean water of 0.2MPa~0.6MPa.

ĸ Clean clear the components and press plate with 77-1 cleaning lotion, metal cleaning lotion:
Water=3:100.

a) Dip the components into ultrasonic cleaning machine, and take out the components after 20~30 minutes
cleaning.

b) Flush for 1~2 minute with clean water and hang for water drop.

c. Drying

Put the cleaned modules in places of ventilation. After the outer layer has dried, put the component into the
forced draft electric drying oven for drying for 4~6 hours, with the temperature between 75f5ć. Open the
door of the oven every 10 minutes.

d. Visual inspection of the components set

Ł Check the rectifying components, heat sink, press plate and fixing bolt for no signs of cracking, burn
damage and severe deformation. Fasteners are sufficient with fine fastening.

ł Check the insulation hose and RC components for no signs of cracking or burn damage.

Ń Check visually the resistance for no signs of cracking, the outer layer of enamel for no signs of peeling
or overheating melting. The capacitor should not crack or loose; the conducting wire of the RC components
should not be damaged and should be soldered firmly. Check if the fasteners are sufficient with fine fixing
condition.

ń The nameplate of the components should be clear, with no damage or peeling.

e. Check the press plates and fasteners. The press plates and fasteners should be sufficient and should not be
damaged.

f. Replace the rubber pads with new ones.

g. Maintenance of the body of the rectifier cabinet

Ł The parts of the cabinet should have no dilapidation or severe deformation, and there shall be no solder
cracks on the framework. The bolts fastened position should not be loose.

ł Check the copper busbar for no signs of cracking, loose or deformation. When surface oxidation or light
denudation appears, polish the surface with “00”type metallographic sand paper.

Ń Check the insulation washers for no signs of cracking or breakage; Check the fastening condition. When
the insulation washer is broken, nylon pad or phenolic aldehyde pad processed according to the original
shape can be used for replacement.

ń The cabinet shell should not be deformed. Refit to be flat if deformation happens.

Ņ Check and fasten the hanging rings.

h. RC assembly inspection and repair

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ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

Ł Connect the two ends of the capacitor with conducting wire to make it discharge.

ł Replace the RC mounting brackets that is damaged, deteriorated or deformed.

Ń Replace capacitor that has shell damage and resistance and capacitor that has obvious burn damage or
discoloring.

ń Measure the resistance with universal meter Rh1, the value should be among 12f5%¡. Check the
resistances for sign of ceramic ring breakage, enamel overheating melting, and peeling of the enamel of
connector, open circuit, short circuit and resistance value that exceeds the stipulated value. If any, replace
with qualified resistance of same specification(RX20-30W-12¡).

Ņ Measure the capacitor with capacitance meter, the value should be no less than 0.95­F. Otherwise,
replace with qualified capacitor of same specification (CBB61,1­ˢ,500˲ac).

i. Test of the rectifying tube

On the diode performance test bench,

Ł Under normal temperature and rated maximum junction temperature of 175ć, the rectifying tube is
electrified with 1200V repetitive peak reverse voltage, and the repetitive peak reverse current IRRM should be
no larger than 120mA. Record the data.

ł Under normal temperature and rated maximum junction temperature of 175ć, adjust the mean forward
current IF that flows through the rectifying tube to 1500A and test. The peak forward voltage UFM should be
no larger than 1.2V. Record the data.

Ń Discard the diodes that do not satisfy test Ł and ł.

j. Assembly

Ł The rectifying components (rectifying tube assembly) should be clean; The heat sink should not have
crack. Otherwise, replace.

ł Mount the rectifying components on the excitation rectifier cabinet according to the assembly record
and position of bridge arms.

Ń Pay special attention to the right mounting of the polarity. Knocking the components into the excitation
rectifier cabinet with hammer is not allowed.

ń When fixing the press plate, fasten evenly to the plate of both sides of components; The aluminum heat
sink does not trip. Keep proper electric distance.

k. Insulating strength test

Ł Short connect all the AC, DC busbar with fuse or conducting wire.

ł Measure the grounding insulation resistance of the electrified parts of the excitation rectifier cabinet
with 500V mega-ohmmeter. The value should be no less than 2M¡.

Ń The withstand voltage test can only carried out when the insulation resistance of the excitation rectifier
cabinet has been tested to be qualified.
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ń Lift the excitation rectifier cabinet to the withstand voltage test bench. The operator shall wear
insulating gloves and stand on the insulating felt, and electrify the frame of the excitation rectifier cabinet
with 50HZ, AC 1200V for 1minute. No puncture or flashover happens.

Ņ Remove the temporary fuse or conducting wire among all the AC, DC busbar for short circuit.

l. Preparatory work before delivery

Ł Check the excitation rectifier cabinet for no dirt; Ensure the firmness of the nuts.

ł Mount the cabinet cover and fasten the screws.

Ń Fill the maintenance memo of the excitation rectifier cabinet.

2.4 Components easy to be damaged

Symbol Name Material Note
R Resistance RX20-30W-12ȍ 795 Company, Xianyang
C Kejiaxin Capacitor Research
Capacitor CBB61,1ȝˢ,500˲ac
Institute, Beijing
CSR Times Electric Co., Ltd,
Rectifying diode ZP81500-12
Zhuzhou

3 Braking Resistance Device

Model DF8BI Diesel Locomotive has one pair of model TZZ11B˄I˅ braking resistance device with
horizontal structure, which shall be used as pair in the locomotive. The two devices to be used in pair are
basically same, and the difference is that the top cover assembly of one of devices shall be mounted by
rotating of 180e, which make the two devices located on the locomotive with opposite position.

3.1 Structure
Each braking resistance device includes the resistance cabinet assembly, underframe assembly, transition
duct assembly, flange, impeller, motor installation barrel assembly, air intake barrel assembly, induced hood
assembly, and etc. Each resistance cabinet has three sets of resistance units, which are identified as Z1Z2,
Z3Z4, and Z5Z6 on the cover plate accordingly, among them Z1Z2 and Z3Z4 are definitely same which are
composed of four 0.248¡ resistances that are connected with bus bars; while Z5Z6 is composed of three
0.248¡ resistances and one 0.337¡ resistance. The value of tap resistance (Z5Z7) that connects with the
motor of blower is 0.428¡. There are two kinds of width of resistance band, one width is 115mm, and the
other is 87mm.

The outline sketch of model TZZ11BG braking resistance device is shown in Fig. 3-4.

The braking resistance device will use forced ventilation, and the motor of ventilator is model ZTP-63H4.
The braking resistance device can be used for the self-load test of locomotive.

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3.2 Working Principle

Resistance braking uses the reversible principle of DC motor. When the locomotive applies the resistance
braking, firstly the traction motor is changed from the series motor to separately excited generator through
the working condition alteration switch, which will convert the kinetic energy of the train into the electric
energy, then the electric energy will be supplied to the braking resistances and motor of ventilator, and
finally the heating energy produced by braking resistance will be spread into the air through the ventilator.

Model TZZQQBG braking resistance devices are shown in Fig. 3-4A and B.

The braking resistance device will use forced ventilation, and the motor of ventilator is model ZTP-63H4.
The braking resistance device can be used for the self-load test of locomotive.

Model DF8BI Locomotive uses Class I braking, and the wiring diagram is shown in Fig. 3-5. The control and
adjustment of exciter current and braking current will be realized by the microcomputer LCS32.

3.3 Main Technical Data

Maximum Voltage: 960V
Rated Current: 730A
Cold Status (20ć) Unit Resistance Value: 0.992(+4/-2) % (Without blower)
1.081(+4/-2) % (With blower)
Maximum Self-load Power (Each Resistance Cabinet): 1750kW
Local Maximum Temperature under rated working condition: Not greater than 640ć
Withstand Voltage between Resistance Units and Against Ground: 4450V (Main Frequency)
Cooling Air Volume: No less than 10m3/S

3.4 Maintenance Method

3.4.1 Basic Requirements

a. Remove the dust and oil inside and outside of braking resistance cabinet.

b. Check if the fixation between the braking resistance band and ceramic element is firmed, check if there is
free of foreign materials between resistance bands (or if there is short-circuit between resistance bands), and
it shall settle it immediately if it is abnormal.

c. The resistance bands shall be free of crack, deformation, local overheat, and off-color, and the distance
between layers shall be even and shall be no less than of 3.5mm.

d. Check if it is loose of fasteners of each part, if there is crack, and it shall be settled immediately if the
problem is found.

e. Measure the resistance values of each resistance section under normal temperature, which shall not
exceed f5% of the specified values above.

f. Use 1000V meg-ohmmeter to check the cold status insulation resistances of each unit of resistance against
the earth, and the value shall no less than 5M¡.

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Fig. 3-4A: Resistance Cabinet of TZZ11B˄I˅

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Fig. 3-4B: TZZ11B(I) fanner

Fig. 3-5C: Resistance Braking Diagram

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g. Apply 4450 main frequency AC into the live parts that are insulated each other and against the earth, and
last for 1min, and it shall be free of breakdown and flashover.

3.4.2 Special Equipments, Fixtures, Measuring Tools, and Materials

a. Equipments: Withstand Voltage Tester, Sweeping Equipment.

b. Fixtures: Hanger, Pneumatic Wrench, Socket Wrench with 28 sets, Service Electric Clamping Tool.

c. Measuring tools: 1000V Meg-ohmmeter, Universal Meter.

d. Materials: Blade Cloth, Absolute Alcohol.

3.4.3 Main Technical Processes

a. Dismantlement of Braking Resistance Device

Remove the connection bolts between the transition duct and installation barrel of motor;

Dismantle the installation barrel of motor and air intake barrel (this two will not be separated) from the base;

Dismantle the lead of motor of ventilator from the ceramic bottle, and remove the clamping of press plate
from the rib;

Lift the installation barrel of motor and air intake barrel assembly, turnover and place them in the vertical
position, and the installation barrel of motor shall be in the top position. Remove the installation bolts of
motor of ventilator, and lift the Model ZTP-63H4 motor.

Disassembly of Resistance Cabinet:

During disassembly period, remove the bus bars on the top of resistance cabinet in sequence, and remove
the press plates A, B, (C) in sequence. Install the M8 eyebolts by using of the M8 screw holes of any two
ceramic bottles in the diagonal position of elements, and the resistance elements A, B or C can be lifted out
in sequence. If the part and component are free of damage, it only needs cleaning and inspection; and if the
part and component are damaged, the part and component shall be replaced and cleaned. After inspection, it
shall check the insulation resistance value and withstand voltage value of each resistance unit as per the
relative regulations.

Disassembly of Resistance Elements

I: Firstly disassemble the press plate and bus bar, and loose the nut of square steel, and withdraw the square
steel, remove the ceramic clamp and resistance band.

II: Carry out banding job and make marks. Each element is composed of four pieces of resistance bands. It
is not allowed to mix with other elements, especially with the resistance elements B and C.

The resistance cabinet body, transition duct and base will not be disassembled.

b. Sweeping

Use 0.6Mpa dry compressed air to sweep the elements, and use clean cloth to wipe.

Use brush, blade cloth and alcohol to wipe the ceramic elements and remove the dust.

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Use brush, blade cloth and alcohol to wipe the outside terminate plate and remove dust.

c. Inspection and Repair

The resistance elements shall be free of short-circuit, broken circuit, crack, deformation, overheat, and off-
color, there is free of foreign materials between resistance bands, and the distance between layers shall be
even and shall be no less than 3.5mm. The measuring resistance value shall be converted into 20ć, which
shall meet the specified values shown in the table below, and the allowance is f5%.
Model Z1Z2, Z3Z4 Z5Z6 Z5Z7
TZZ11B(I) 0.992¡ 1.081¡ 0.428¡

The connector shall be firmed, and the damage area shall be no greater than 5%.

The ceramic elements shall be complete, be free from damage and crack.

The installation bracket of resistance element shall be firmed and be free from crack.

The outside terminate plate shall be free from severe overheat and off-color, and burning loss, the wiring
side shall be firmed, and the application of bolt is good.

d. Assembly

Install firmly the serviced motor of ventilator on the braking resistance cabinet.

e. Test

Use 1000V Meg-ohmmeter to measure the resistance values between resistance units and the insulation
resistance against the earth, which shall not less than 5M¡.

Withstand Voltage Test: Apply AC main frequency 4450V into the live parts and against the earth, which
shall be free of breakdown and flashover within 1min.

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Chapter 4
Locomotive Electric Apparatus

1 General Introduction
1.1 Basic complexion

1.1.1 Function
According to the instructions sent by (engine) drivers and the change of each system’s state, operating the
relevant circuit’s on-and-off, by automatic or remote control, to implement the design requirement.

1.1.2 Classification
1.1.2.1 According to working character˖controllingǃoperating ǃprotecting electric apparatus.

1.1.2.2 According to configuration state˖contactorǃrelay and other electric apparatus.

1.1.2.3 According to the method of action˖electro-pneumaticǃelectromagnetic and manual operating

electric apparatus.

1.2 Characteristic
Besides obeying the TB/T 1333-96 ljThe Basic Technical Condition of Locomotive Electric ApparatusNJ,
according to the running condition, locomotive electric apparatus should also meet various special
requirements of the locomotive circuit. The main characteristics are as following:

1.2.1 High vibration resistance and impact resistance;

1.2.2 Long electric and mechanical life;

1.2.3 Working in high altitude circumstance;

1.2.4 Reaching all kinds of operating requirements while working in certain ambient temperature;

1.2.5 Reaching all kinds of operating requirements while working in certain ambient humidity;

1.2.6 Surfaces have high decay resistance.

1.2.7 The rated air pressure of air-actuated apparatus, magnet valves and electric-pneumatic driving
apparatus is 500kPa. The minimum action air pressure is 375kPa, and the maximum is 650kPa.

1.2.8 The rated action voltage is 110V DC. The maximum action voltage is 121V DC, and the minimum is
77V DC.

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1.2.9 The electric apparatus, used in special condition, should also meet the particular requirements of the
relevant electrician specialized standard. This will be defined by the technical condition.

1.2.10 The structure is compact, the power wastage is small and the weight is light. Compact structureǃlow
consumed powerǃlight in weight.

1.2.11 It is simple and convenient to maintain and repair or overhaul.

The electric apparatus that adopted in DF8BI locomotive mainly include various contactors, relays,
changeover switches and master controller, which are for locomotive controlling; various relays, protectors,
resistors, capacitors, transformers, switches, fuses, lamps, sockets, plugs, terminal strips, terminal boxes,
sensors and copper busbars etc., which are for locomotive protecting.

When the locomotive is in medium maintenance/repair, partial electric apparatus, like various resistors,
capacitors, transformers, switches, fuses, sockets, plugs, spools, trunkings, terminal boxes, terminal strips,
partial sensors and copper busbars, are left on the locomotive. And the introduction and repair method of
these devices see Chapter one.

2 Contactor
Contactor is a kind of automatic transfer electric apparatus, which is used to switch/turn on and cut off the
main circuit, auxiliary circuit and other control circuit frequently. Its characteristic is as following:
automatic control from a long-distance, high operating frequency, large making and breaking current.

DF8BI diesel locomotive adopts contactor group and electric-magnetic contactor.

2.1 Contactor group

DF8BI type locomotive adopts one contactor group used to control the single stage field weakening of the
traction motors. Its code name in the electric schematic diagram is 10KM and its type/model is T661E.

This contactor group is an electric pneumatic driven apparatus. When the electric pneumatic valve is
electrified, the wind path will put through. Then the compress air will enter into one side of the contactor
group’s cylinder, and push the piston and connecting rod to drive the square shaft of the same side to rotate.
The square shaft’s rotation makes the moving contact and the fixed contact closed, meanwhile, the auxiliary
contact rotates and closes. When the electric pneumatic valve power is cut off, the antagonistic spring inside
the air cylinder will turn off the main contactor, and drive the auxiliary contact cam to make the auxiliary
contact disjointed.

2.1.1 Structure and figure

Two symmetrical electric pneumatic valves control the two right-and-left cylinder gearings. And the
connecting rod, which driven by drive rod, drive one square shaft respectively. Each side axis fixes up three
moveable contact brackets abreast, and each moveable contact bracket installs moveable contact and contact
spring.3 moving contact brackets are fixed in each square shaft in parallel, and each bracket equips moving
contact and contact spring. On the top of the square shaft there is a moving rod which can drive the auxiliary
contact assembly.

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The configuration is in Fig. 4-1.

Fig.4-1 T661E Configuration

2.1.2 Specification
Main contact
Rated insulation voltage 770V
Rated current 400A
Breaking voltage 10V
Quantity Two poles, each one has three couples of contacts
End pressure ı49N
Tip break 16~19mm
Over travel ı10mm
Auxiliary contact
Rated voltage 110V
Rated current 1A
Quantity Each pole has 2NO and 1NC
End pressure ı0.98N
Tip break ı4mm
Over travel ı0.5mm
Drive system
Rated air pressure 500kPa
Minimum operating air pressure 375̚650 kPa
Electric pneumatic valve Rated voltage 110V

2.1.3 method of inspection and repair

2.1.3.1 Basic technical requirement

2.1.3.1.1 Every assembly dimension should accord with the table of limits.

2.1.3.1.2 The three contacts on the same shaft should act synchronously, flexible and reliable.
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2.1.3.1.3 Crack, distortion, overheats and burns are not permitted. The thickness of the contact should not be
less than two-thirds of the original one (when in medium repair).

2.1.3.2 Main equipment and tool

It includes Calipers, 500V and 1000V meg-ohmmeter, universal meter, common electrician tools, equipment
for blowing and sweeping, gasoline, sandpaper and butter.

2.1.3.3 Main process engineering

2.1.3.3.1 Disassembly

2.1.3.3.1.1 Driving system

2.1.3.3.1.1.1 Remove the mounting bolts of the electric pneumatic valve and take out the electric pneumatic
valve and the rubber gasket.

2.1.3.3.1.1.2 Pull the splint pin out of the connecting moveable pole /connecting rod, and then draw out the
pole pin.

2.1.3.3.1.1.3 Screw out the mounting bolts of the wind cylinder; discharge the wind cylinder’s assembly and
gaskets.

2.1.3.3.1.1.4 Disassemble the wind cylinder groupware.

2.1.3.3.1.2 Contact system

2.1.3.3.1.2.1 Screw out the mounting bolts between the moving contacts and the flexible braided wires.

2.1.3.3.1.2.2 Take out the main contact spring.

2.1.3.3.1.2.3 Loosen the main contact’s bolts and take them out.

2.1.3.3.1.2.4 If the moving contact assembly has crack or defect, it should be changed.

2.1.3.3.1.2.5 Loosen the fixed contact's bolts and take them out.

2.1.3.3.2 Cleanout

Clean out all parts that were disassembled by gasoline, and then blow them by compress air. At last, wipe
them off by cloth.

2.1.3.3.3 Inspection and repair

2.1.3.3.3.1 Driving system

2.1.3.3.3.1.1 No serious crack or sand holes should be existed in the air cylinder. If the crack is tiny, repair
welding is permitted.

2.1.3.3.3.1.2 The inner wall of the air cylinder should not have any scratches.

2.1.3.3.3.1.3 The leather bowl of the air cylinder should have no aging .crack or distortion, or replace it.

2.1.3.3.3.1.4 The piston rod should have no rupture or severe pull, and the screw thread of it have no
damage.

2.1.3.3.3.1.5Inspect the antagonistic spring that it has no rupture or severe distortion and the dimension
accord with the demand.
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2.1.3.3.3.1.6 The square shaft connecting rod should have no rupture, severe abrasion or distortion and be
firmly fixed with rod things.
2.1.3.3.3.2 Contact system
2.1.3.3.3.2.1 The main contacts should have no burning loss but have smooth surface, after
finished/processed, it should accord with the demand.
2.1.3.3.3.2.2 The main contact spring should have no crack or severe distortion, and the free height
shouldaccord with the demand..
2.1.3.3.3.2.3 The spring seat/base and cap should have no breakage.
2.1.3.3.3.2.4 The moving contact assembly should have no crack, distortion or burning loss and be firmly
fixed with each other.
2.1.3.3.3.2.5 The installation matching surface of the contacts should be smooth and have no oxide layer.
2.1.3.3.3.2.6 The flexible braided wire should have no loosening; the connecting end/terminal should not
change color due to oxidizing.
2.1.3.3.3.2.7 The plastic bushing of the flexible braided wires should have no breakage, severe aging or
burning loss.
2.1.3.3.3.3 Bed frame assembly
2.1.3.3.3.3.1 Each rod has no rupture or loosening.
2.1.3.3.3.3.2 Each insulator has no breakdown, burning loss or rupture.
2.1.3.3.3.3.3 If the fastenings have breakage or omission, they should be changed and made up.
2.1.3.3.3.4 Assembly
Assemble it according to the opposite order of disassembly, and notice: When assembling, it could operate
according to the reverse order of the disassembly. But pay attention to the followings:
2.1.3.3.3.4.1 The contacts of the same group should have the same radius or thickness.
2.1.3.3.3.4.2 Each rotation part should be spread with some butter for lubricating.
2.1.3.3.3.4.3 Spread the inner wall of the wind cylinder with some butter.
2.1.3.3.3.5 Tune-up test
2.1.3.3.3.5.1 Adjustment
2.1.3.3.3.5.1.1 The adjustment manner of the main contacts’ tip break and over travel:
2.1.3.3.3.5.1.1.1 Change the thickness of the main contacts.
2.1.3.3.3.5.1.1.2 Change the extended length of the piston rod.
2.1.3.3.3.5.1.2 The adjustment of the main contacts’ assembly deviation:
2.1.3.3.3.5.1.2.1 Adjust the moving contacts’ mounting position with the square shaft and the fixed contacts’
mounting position.
2.1.3.3.3.5.1.2.2 If the assembly deviation of the three couple contacts in the square shaft does not accord
with the demand, loosen the supporting plates which are on the side of the square shaft. The deviation could
be adjusted by adding gaskets on one side of the space between supporting plates and the under frame then
reducing the gaskets on the other side. Note that the square shaft should have 0.2~1.0mm axial swaying
allowance.

2.1.3.3.3.5.1.2.3 Adjust the mounting position of the contact bracket.

2.1.3.3.3.5.1.3 The contact’s end pressure can be changed by regulating the pretightening force of the
contact spring.

2.1.3.3.3.5.1.4 Putting through the wind path, the three couple contacts of the same square shaft should act
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synchronically. If not, it can be reached by regulating the adjusting screw which is in the moving contact
bracket.

2.1.3.3.3.5.1 Inspection and measure

2.1.3.3.3.5.1.1 Measure the tip break, over travel, end pressure of the main contacts. All these should accord
with the technical demand.

2.1.3.3.3.5.1.2 The assembly deviation of the moving and fixed contact should accord with the technical
demand.

2.1.3.3.3.5.1.3 Putting through the wind path, by using light transmission method or carbon paper, make
sure that the contact wire length of the main contact is not less than 75% of the moving contact width.

2.1.3.3.3.5.1.4 Putting through the 0.37Mpa wind path, the contactor should act reliably. Putting through the
0.63Mpa wind path, there should be no leak in the electric pneumatic valve and the wind cylinder.

2.1.3.3.3.5.1.5 The insulation resistance between the main contacts, between the main contact and the
auxiliary contact, and between the main contacts and the ground must be over 10 M¡measured by 1000V
meg-ohmmeter.

2.1.3.3.3.5.1.6 The insulation resistance between the auxiliary contacts, and between the auxiliary contacts
and ground must be over 10 M¹measured by 500V meg-ohmmeter.

2.1.3.3.3.5.1.7After repairing or replacing the insulator, the withstand voltage test should be done. There
should be no breakdown or flashover if we carry out an industrial frequency alternating current for 1 min
between the live parts and between live parts and the ground.
Main contact to ground Between main contacts Main to auxiliary Auxiliary to ground
3000V 3000V 1100V 1100V

(6) Record after inspection and repair

2.1.4 Vulnerable parts

No. Name Drawing number Made by/Remark
1 Moving contact 4Q2-300-001 Xi’an railway signal factory
2 Fixed contact 4Q2A-400-000 Xi’an railway signal factory
3 Rubber Piston ring 3Q51-050-003-1 Xi’an railway signal factory
4 Sealing ring/plate 3Q7-000-008 Xi’an railway signal factory
5 Sealing ring/plate 4Q2-100-002 Xi’an railway signal factory

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2.2 DC electromagnetic Contactor

The "ON/OFF" of the DC magnetic contactor's main and auxiliary contacts is controlled by power's
"ON/OFF" of its coil. This can control the whole circuit.

The DC electric magnetic contactors mounted in DF8BI are made in Xi’an Schaltbau Electric Corp., Ltd. Six
of them are S140 of 40A, one is S195, four are S1001 and seven are S1100. All of these contactors adopt
S847 series quick action switches that have achieved the dust-proof grade of IP60, except the S195
contactor adopts the sealing standard of IP40.

S847 series quick action switches adopt the building block design and contact forcibly break-off mechanism.
These switches can be safely off even their contact joints are burnt together due to short circuit. This
function can avoid the danger caused by spring's failure. The friction-type action of the contact is more
suitable to the low current and the load current of the contact can reach 10A. The contact status can be
easily observed through the transparent shell, and various action devices can be interchanged.

2.2.1 DC S140 series Contactor

There are six S140A-2-110V-B contactors in the locomotive to control the fuel pump motor (4KM), the
starting generator (5KM1)'s excitation, the starting generator (5KM2)'s excitation while it is in failure, the
exciter's excitation (7KM1, 2) and the car body ventilator (11KM) respectively.

2.2.1.1 Structure and dimension

DC electromagnetic contactor is mainly composed of electromagnetic mechanism, main contacts, arc

control device and auxiliary contacts. The magnetic circuit coil contains self-induced over voltage
suppressor, and also operating indicator which can show the operating status of the contactor.

The S140A DC contactor's figure is in Fig. 4-2, its dimension is in Fig. 4-3, and its wiring diagram is in Fig.
4-4. The figure of the main contact S008 series and the auxiliary contact S847 series is in Fig. 4-5.

2.2.1.2 Main Technical Parameters

Rated voltage:
Rated voltage of main contact 110V
Rated voltage of auxiliary contact 110V
Rated voltage of controlling power 110V
Pick-up voltage İ77V
Release voltage ı5.5V
Rated current
Rated current of main contact 25A (P5)
Continuous current of auxiliary contact 1A
Coil parameters
Wire type QZ-1
Wire diameter ¶0.21
Turns 132000
Fig. 4-2 S140A DC Contactor
Resistance 740¡(20ć)

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Delay time (coil with suppressor)

Delay time of pick-up İ90ms
Delay time of release İ40ms

Fig. 4-3 Structure of S140A-type DC Contactor

1- Wiring bolts M4 of coil; 2-S847 auxiliary contactor; 3-S008 P6 (5) contact; 4-Installation bolts M3 of auxiliary contact; 5-
Installation bolts M5 of main contact; 6-Base; 7– suppressor; 8–Yoke/Heel piece; 9-Coil; 10-Guide bar; 11-Spring; 12-Bracket; 13-
Cam; 14– Locking plate; 15-Iron core; 16-Stopper; 17-Armature; 18-Spring seat; 19-Rotor plate.

2.2.1.3 Repair method

2.2.1.3.1 Basic technical requirements

2.2.1.3.1.1 The contactor should be cleaned up and be installed accurately. It should also have high
insulating property and complete spare parts.

2.2.1.3.1.2 Under the normal temperature environment the contactor's pick-up voltage should not be more
than 77V and the release voltage not less than 5.5V. The release voltage of the active contactor should not be
more than 33V while the diesel engine is starting.

2.2.1.3.1.3 Moving parts like armature should act flexibly without clamping stagnation.

2.2.1.3.1.4 Add some #6 engine oil (GB11121) to the rotating parts of the contactor.

2.2.1.3.1.5 While replacing the main contact, make sure that the external-lines' polarity should conform to
the polarity that signed in contacts and no iron impurity adsorbed on contacts. Otherwise it will lead to
clamping stagnation and burning loss.

2.2.1.3.1.6 The insulation resistance of live parts which should be insulated from each other, must be more
than 10M¡ (by 500V Meg-Ohmmeter). After overhauling, the dielectric strength test should be conducted.

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There should be no breakdown or flashover if we carry out a sine alternating current of 50Hz/110V for 1
min between live parts of the contactor and between live parts and the ground.

Fig. 4-4 Wiring Diagram of S140A DC Contactors

S008 P6 (P5) S847

Fig. 4-5 Contactor Outline

2.2.1.3.2 Main equipments and tools

Test bench, contact resistance meter, test instrument of coil turns short circuit, universal meter, 500V meg-
ohmmeter, AC withstand voltage tester, ruler, feeler gauge, brush and common electric tools.

2.2.1.3.3 Maintenance & repair processes

2.2.1.3.3.1 Dismounting and cleaning

2.2.1.3.3.1.1 Dismount the main contacts and auxiliary contacts from contactor.

2.2.1.3.3.1.2 Dismount the coil suppressor.

2.2.1.3.3.1.3 Dismount the rotor plate, guide bar and springs.

2.2.1.3.3.1.4 Dismount the coil, iron core, and armature

2.2.1.3.3.1.5 Brush every part clean in absolute alcohol or gasoline.

2.2.1.3.3.2 Overhauling
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2.2.1.3.3.2.1 Every component is mounted correctly, and every part of it is intact and the insulation has high
insulating property.

2.2.1.3.3.2.2 No fastener is absent and in poor condition.

2.2.1.3.3.2.3 The aberration between the measured coil resistance and the nominal value should be withinf
10% . No short circuit happened between turns when the coil is tested by the coil short-circuit admeasuring
apparatus.

2.2.1.3.3.2.4 A spring shouldn't be broken or bent when it is pressed and rebound and has good elasticity. In
free state, no obvious distortion or rust in it, or replace it by new one.

2.2.1.3.3.2.5 The mounting rivets firmly fastened.

2.2.1.3.3.2.6 No crack, distortion, overheats or burning loss is in the moving and fixed contacts of the main
contact, and the contact surface shouldn't be dress or burnished. The roller wheel of the moving contact
should be flexible, and drop some #6 gasoline to the rolling axle. The conductive contact surface between
the moving contact and terminal screw should be smooth and without burning loss. Since the arc contact
surface between the bridge arm and terminal screw is coated by special lubricant, don't wash it with any
solvent. The binding posts on the static contact should be fixed reliably, and no one of them could be
loosened or absent. The fixed contact with a deep abrasion over 0.4mm in its surface should be replaced.

2.2.1.3.3.2.7 The auxiliary contact should act flexibly and reliably and without buring loss. The auxiliary
contact is maintenance-free. The whole auxiliary contacts should be replaced in case of serious electrical
erosion or inflexible operation. The switch Bakelite and positioning roller should have no crack, looseness,
serious abrasion or pull.

2.2.1.3.3.2.8 The nameplate and marks of the contactor should be complete, intact, clear and accurate.

2.2.1.3.3.3 Assembly

2.2.1.3.3.3.1 The spring should be fully placed into the spring seat and the guide bar should be vertical to
the yoke. After the contactor picking up, the guide bar should be on the same straight line with the spring
seat. When rotor plate is acting, the spring and the spring guide bar should operate flexibly and there should
have no abrasion or peculiar noise between them. In case of an allophone, the spring position should be
adjusted by rotation to eliminate the allophone. If there is peculiar noise, it can be eliminated by rotating to
adjust the spring position

2.2.1.3.3.3.2 The moving parts like armature iron should operate flexibly without any seizure. The gap/left-
right clearance between the rotor plate and the long journal of the yoke should be more than 0.5mm,
otherwise, it may lead to mechanical blocking and seizure. If this still cannot meet the requirement, we can
dismount the base to adjust the positioning plate, so as to guarantee the suitable position of the rotation plate
and flexible operation of the armature iron.

2.2.1.3.3.3.3 The two ends of the coil are equipped with the suppresser for controlling the induced
electromotive force, and the operating indicator light. While inspecting make sure that the polarity of the
power source is correct. The wiring should be “positive pole to left and negative pole to right”. If the
indicator light does not act when the power is put through, it should be inspected immediately and the
suppresser shall be replace.

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2.2.1.3.3.3.4 No iron impurity should be absorbed in the surface of S008 and S847 contacts which are anti-
arc by permanent magnet. Pay attention to the polarity in wiring, the positive terminal should be connected
to the current input end while the negative terminal to the current output ends.

2.2.1.3.3.4 Debug

2.2.1.3.3.4.1 As switching on the contact of the contactor, the gap between the roller and cam should be ı
0.5mm; as switching off, clearance between contacts should be 6.0f0.8mm. In case of no operation
for/action of the auxiliary contact, the gap between roller and cam should be ı0.1mm; in case of
operation/action, the clearance between roller and the limit position should be ı0.8mm.

Insert a 0.5mm-thick tuck ruler feeler into the gap between the yoke and the rotor plate (Fig. 4-6 A), and
insert another one between the iron core and armature stoppers (Fig. 4-6 B). Keep it in this state and operate
the contactor, all the auxiliary contacts should be working reliably.

2.2.1.3.3.4.2 The pick-up and release voltage of the contactor should be in the regulated range. If it can't
reach the requirement, adjust the spring force by changing the quantity of gaskets between the guide bar and
spring. See Fig. 4-7.

Fig. 4-6 Sketch map of contact move inspection Fig. 4-7 Position

2.2.1.3.3.4.3 Measured by the contact resistance detector, the

main contact's resistance should be less than 100m¡ and the
auxiliary contact S847 should be less than 200m¡. If the
auxiliary contact's resistance exceeds the standard, adopt wiring
as Fig. 4-8. That is, shunt the inductive load of 1A current (time
constant is about 20~50ms) to clean the contact surface oxide
by arc light.

2.2.1.3.3.4.4 Contactor insulation should meet the following Fig. 4-8 Circuit to eliminate surface oxide

requirement:

2.2.1.3.3.4.4.1 Resistance between live parts, as well as the live parts to and the earth, should be no less than
10M¡ (500V Meg-Ohmmeter).

2.2.1.3.3.4.4.2 After the repair or overhaul, the insulation dielectric strength test should be conducted. There
should be no puncture or flashover phenomena if we carry out the sine alternating current of 50HZ/1100V
between live parts of contactor and between live parts and the earth for 1 min.

2.2.1.3.3.5 After the repair or overhaul, fill in the overhaul record in terms of relevant regulation.

2.2.1.3.4 Wearing parts

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No. Name DWG No. Remarks

1 Rotation Rotor plate XS600· 06·00 Xi’an Schaltbau
2 Roller assembly XS413· 03·00 Xi’an Schaltbau
3 Spring XS600· 00·04 Xi’an Schaltbau
4 Inhibitor Suppressor assembly XS600· 08·00 Xi’an Schaltbau
5 stopper XS600· 00·15 Xi’an Schaltbau
6 Cam switch S008 P5 Xi’an Schaltbau

2.2.2 S195 Contactor

There is only one S195SE-80V-B DC contactor in the locomotive for
controlling the motor circuit of starter fuel pump (coded as 3KM).

2.2.2.1 Structure and contour

The structure and contour of S195 DC contactors are shown in Fig. 4-9
and Fig. 4-10.

2.2.2.2 Main Technical Parameters

Rated voltage
Rated voltage of contact 110V
Rated power control voltage 80V
Rated current of contact 250A
Coil power İ25W
Fig. 4-9 S195 Contactor
Continuous operating time 100%

2.2.2.3 Overhaul method

Refer to relevant contents of S140 DC contactors

Fig. 4-10 Structure of S185 Contactors

1. Arc-control device, 2. Installation screw, 3. Auxiliary contact S847, 4. Operation rod, 5. Installation screw of
auxiliary contact, 6. Wiring screw M8 of primary contactor, 7. Outlet of arc-control device, 8. Wiring support, 9.
Inhibitor, 10. Coil, 11. Casing, 12. Yoke, 13. Coil lead piece.

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2.2.3 S1001 Series DC Contactors

There is one S1001/06-PB-44-80V-B DC contactor in the locomotive for controlling the starting circuit of
diesel engine (coded as 6KM), three S001/06-PB-33-110V-B
DC contactors for controlling the exciting circuit of main
generator (coded as 8KM1) and for controlling the motor
circuit of air compressor (coded as 9KM1, 2). The two kinds
of contactors all belong to S1001 series DC contactors.

2.2.3.1 Structure and contour

Shell structure of S1001/06-PB(PC) series DC contactors is

shown in Fig. 4-11, 4-12; the contour structure of auxiliary
contact S847 is shown in Fig. 4-5.

2.2.3.2 Main Parameters

Main circuit Fig. 4-11 S1001/06-PB (PC) DC Contactor

Pole quantity Single
Rated operation voltage 110V

Fig. 4-12 Structure of S1001/06-PB (PC) Series DC Contactor

1.Right-side planks; 2. Operate frame, 3. Contact parts; 4. Yoke; 5. Cover, 6. Coil; 7. Dynamic iron core; 8.locking sleeve; 9. Joint
bolt; 10. Sleeve, 11. Spring clip support 2,12. Upper copper bars; 13. Manual plectrum; 14. Convex piece; 15. Spring 1; 16. Spring
2; 17. Spring 3; 18. Connecting shaft; 19. Camshaft; 20. Cam; 21. Left rack; 22. Inside copper bars; 23. Stop pin 1; 24. Manual
handle; 25. Manual shaft; 26. Separator sleeve; 27.stopper; 28. Connecting block; 29. Connecting block insulation sleeve; 30. Quick
switch; 31. Spring clip support 1, 32. Insulation pad; 33. Padding block; 34. Braiding wire; 35. Inhibitor component; 36. Bottom
copper bars; 37. Insulation sleeve 1; 38. Shaft; 39. Shaft; 40. Shaft; 41. Insulation sleeve 2; 42. Mounting pad 3, 43. Main shaft; 44.
Nylon connecting rod; 45. Mounting pad 1, 46. Mounting pad 2.

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Rated operation current 630A

Control circuit

Rated control power voltage 110V S001/06-PB-33-110V-B

80V (S1001/06-PB-44-80V-B)

Operation voltage (0.7~1.25Ue)

Power consumption of coil 40W (S001/06-PB-33-110V-B)

60W (S1001/06-PB-44-80V-B)

2.2.3.3 Repair or overhaul method

2.2.3.3.1 Basic technical requirement

2.2.3.3.1.1 The contactor should be clean and be accurately installed, with good performance of insulation
and intact spare parts.

2.2.3.3.1.2 Complete fastening parts and good fastening performance

2.2.3.3.1.3 Moving parts, like armature iron, should operate flexibly without jam.

2.2.3.3.1.4 Drop some #6 engine oil (GB11121) to the rotating parts of the contactor.

2.2.3.3.1.5 As replacing the main contact of the contactor, attention should be paid to that if the polarity of
the external-lines conforms to the polarity mark on the contact. And there should be no any iron impurity, or
the main contact should be seizures and burns.

2.2.3.3.1.6 The name plate and marks should be complete, intact, clear and accurate.

2.2.3.3.2 Main equipment and tools

Electric apparatus test bench, coil interturn short circuit tester, universal meter, meg-ohmmeter, AC
withstand-voltage tester, ruler, and common electrical tools.

2.2.3.3.3 Overhaul technical process

2.2.3.3.3.1 Cleaning after the decomposition Disassembly and cleaning

2.2.3.3.3.1.1 Dismantle the contactor from the motherboard and take out the connection copper bar. Clean
the appearance of the contactor. Clean the connection copper bar, motherboard and fixed rack for standby.

2.2.3.3.3.1.2 Arc chute (See Fig. 4-13)

2.2.3.3.3.1.2.1 Beat away the 6 tubular rivet caps on the drill machine (no damage to the side plate of the arc
chute) and take out the tubular rivets and screw out the two M5 nuts fixing the polar plates to decompose
the arc chute.

2.2.3.3.3.1.2.2 Check the side plate (No. 3) of arc chute and cover board (No. 4). The ablation depth of the
side plate near the main contact breaking place cannot be more than 2mm, and there should be no crack, or
it should be replaced. The ablation depth of the cover board of the arc chute cannot be more than 2mm, or it
should be replaced. If there is no above phenomenon, clean and wipe up them for standby.

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Fig. 4-13 Anti-arc Structure of S1001/06 Contactor

1. Arc blowout coil component, 2. Magnetic core component, 3. Arc chute side
plate, 4. Arc chute cover board, 5. Polar plate, 6. Adjusting pad 6, 7. Insulation
sleeve 3; 8. Adjusting pad 5, 9. Stop pin 2; 10. Grid blade; 11. Fixed rack, 12.
Connecting rod; 13. Tubular rivet, 14. Permanent magnetic core.

2.2.3.3.3.1.2.3 Check the arc-control grid blade (No.10). Replace it in case of fusion welding and swelling,
or clean and wipe up the surface for standby.

2.2.3.3.3.1.2.4 Check the blowout coil component (No.1). Replace the coil component in case of ablation,
deformation, fusion welding, short-circuit or open circuit, or clean the surface of the blowout coil for
standby. As cleaning the surface, the coil should be protected to avoid the damage.

2.2.3.3.3.1.2.5 Check polar plate (No. 5) and fixed rack (No. 11), and clean the dust;

2.2.3.3.3.1.2.6 Check the banking pin 2 (No.9), and fasten the pin with the epoxy colloid in case of
abnormality.

2.2.3.3.3.1.2.7 Clean the insulation sleeve 3 (No. 7) and replace the adjusting pad 5(No.8);

2.2.3.3.3.1.2.8 Assembly. 1) Put two blowout coil components into a side of arc chute and close another arc
chute; 2) On both sides of the arc chute, equip with adjusting pad II, insulation sleeve, and insert the
permanent magnetic core component. The s pole should be equipped on the side of the banking pin, cover
with the polar plate and penetrate with the connecting bolt. Then the two ends should be fastened by flat pad,
spring cushion and nuts; 3) Insert the grid blades (13 blades in all) in the middle, with a clearance of 9mm,
that is, one blade every a channel, and the bending direction of the blades should be in the same direction; 4)
clasp the cover board, if necessary, the adjusting pad may be added upon the two ends of the cover board.
Fasten the fixed rack, penetrate with the tubular rivets and rivet up the two rivet ends with M4 flat pad.

2.2.3.3.3.1.3 Contactor body

As for S1001/06-PB(PC) Contactor(Fig. 4-12): screw out the locking sleeve, demount the movable iron core
and take out the four M6 long nuts fastening the electromagnet and take down the electromagnet component.
Dismantle the screws connecting the soft connecting wires and bottom copper bar on both sides of and at
the bottom of the side plates, remove the retaining ring on one side of the camshaft, take out the camshaft
and separate the left side plate from the right side plate. Take out the parts inside the side plates and further
decompose them into single part and clean them.
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2.2.3.3.3.2 Overhaul

2.2.3.3.3.2.1 Main contact

Replace the contact if the ablation of the main contact

exceeds the limit in Fig. 4-14.

The surface oxide on the moving contact seat and copper bar
of the moving/fixed contact can be wiped away by the
absolute ethanol. Fig. 4-14 Abrasion Limit of the Primary
Contact
It is required to replace the moving/fixed contacts and the
connection screws (M8h20(GB70-85)). In case the contact resistance exceeds the standard, we can shunt
the inductive load of 1A current (time constant is about 20~50ms) and clean the contact surface oxide by arc
light; in case exceeds again, the contact should be replaced.

2.2.3.3.3.2.2 Coil

The coil should have no looseness, short circuit or external damage. The looseness can be settled by
replacing the mounting pads of the coil support. The permissible error of coil internal resistance upon the
design value should be in the range of f10% as measuring the coil resistance under the ambient
temperature of 20ć. Measured by the coil short-circuit measuring instrument, it should have no interturn
short circuit, or it should be replaced.

2.2.3.3.3.2.3 Left/right side plates

Replace the plates in case of cracks or the limit size of¶12 hole is more than ¶12.5mm.

2.2.3.3.3.2.4 Movable core

It is necessary to replace the movable core and guarantee the flexible glide of the movable core in its
installation position. As adjust the iron core, loosen the four M6 bolts fastening the electromagnet and
appropriately rotate the yoke, and finally screw down the bolts on the premise of ensuring the flexible
operation of main shaft and movable core system

2.2.3.3.3.2.5 Braided wire

The broken wire of the braided wire cannot be more than 5% (3 strands, 1500 wires). Replace it if the
broken wire is more than 3 strands measured by sight.

2.2.3.3.3.2.6 Clean up the up/down copper bars and the movable contact seat for standby.

2.2.3.3.3.2.7 Replace the spring 1(No.15) and spring 2(No.16) if unqualified to the test. When the spring 1
is compressed to 15mm, the spring force is 45f4.5N, and when compressed to 13.8mm, the spring force is
60f6N; when the spring 2 is compressed to 12mm, the spring force is 15f1.5N, and when compressed to
9mm, the spring force is 24f2.4N. Replace spring 3 (No. 17) and Spring 4 (between movable contact seat
and rotation frame)

2.2.3.3.3.2.8 Replace the insulation sleeve 1(No.37), insulation sleeve 2(No.41), nylon screw, nylon nut
(connect the internal copper bars and right-side plate, no show in the diagram), and the sleeve /busher
(No.10).

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2.2.3.3.3.2.9 Check damping washer 1(No.45), damping washer 2(No. 46) and damping washer 3(No. 42),
replace them in case of aging, crack or no inelasticity.

2.2.3.3.3.2.10 Check the spring clip support 1 (No.31) and support 2 (No.11). Replace in case of
unrecoverable distortion.

2.2.3.3.3.2.11 Check the drive parts. Replace the parts in case that the connection hole has cracks or the
limit size of hole diameter is more than ¶5.5mm or the limit size of the hole connecting with the axle
(No.39) is more than ¶12.5mm.

2.2.3.3.3.2.12 Check the suppressor component. Replace it in case of an abnormality.

2.2.3.3.3.2.13 Assembly

Assemble the contactor in the order of small component before big component and internal component
before external component without shortage of parts inside the body. Every connecting joint is firm, the
glide of the movable core is flexible and the rotation of the handle shaft is agile. The assembly process is as
follows:

2.2.3.3.3.2.13.1 Operative frame component

Put the spring 4 in the spring seat of movable joint seat and rotation rack (all in No.2), and align the¶10
holes of the two parts and penetrate them with the rotating shaft (No.38) and position them with the 2.5h22
pin (GB879-86); fasten the braided wire components (No.34) on the movable joint seat by the M8 bolts and
special gaskets; Penetrate shaft (No.40) into the rotation rack and clip the two ends of the rack with the
retaining ring 12 (GB894.1-86); Screw down the main shaft on the drive mechanism after penetrating the
damping washer 3(No.42) into the main shaft; the appropriate screw thread glue should be coated on the
screw thread of the main shaft before it is screwed down on the drive mechanism. Penetrate the square end
of the nylon connecting rod (No.44) into the two¶5 holes of the drive mechanism, plug the pivot, and then
clip them with retaining ring 3.5 (GB896-86) after adding the¶5 flat pad. Penetrate into the rotary rotating
shaft (No.39) after the rotation rack be penetrated into the drive mechanism as shown in the diagram, and
position it with the 2.5h22 pin (GB879-86); Put the movable joint seat into the insulation sleeve 2 (No.41)
and fasten the joint part (No. 3) on the movable joint seat in a right direction.

2.2.3.3.3.2.13.2 Stick the banking pin 1(No.23) to the left side plate with the epoxy colloid

2.2.3.3.3.2.13.3 Penetrate the insulation sleeve 1 (No.37) into the upper copper bars (No.12) and connect the
joint parts (No.3) on the copper bars with M8 screws (no fastening at the beginning), finally put the upper
copper bars and the spring clip support 2 (No. 11) in the left side plate.

2.2.3.3.3.2.13.4 Penetrate the connecting block (No. 28) through the connecting block insulation sleeve
(No.29) and then put the sleeve into the left side plate.

2.2.3.3.3.2.13.5 Install the two separator sleeves (No.26), bottom copper bars (No. 36), spring 3(No. 17)
(maybe including adjusting pad) and two connecting shafts (No.18) in the left side plate in turn.

2.2.3.3.3.2.13.6 Penetrate the manual plectrum (No. 13) into the manual shaft (No.25), and clip them with
retaining ring 10 (GB894.1-86); Penetrate the spring 1 (No. 15) and spring 2 (No. 16) into the shaft of
manual convex piece (No.14) and insert the manual plectrum into the ditch of the convex piece, meanwhile
clip it into the left side plate, but the long end of the manual shaft should be upward.
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2.2.3.3.3.2.13.7 Mount the operative support component in the left side plate, and note that it is necessary to
add the adjusting pads on both sides of the rotary rotating shaft (No.40).

2.2.3.3.3.2.13.8 Check the inside parts in the contactor body and clasp the right side plate in case of no short
of the parts. There should be no seizure for spring, separator sleeve and shaft during the commissure of left
and right side plates, so as to avoid the damage to the side plate. After the commissure, fasten the left/right
side plates with the corresponding screws.

2.2.3.3.3.2.13.9 Put the insulation pad (No.32) and spring clip support 1 (No. 31) in the ditch of side plate
and penetrate into the inside copper bar (No. 22); attention should be paid to that there is a spacer block (No.
33) between the bottom of inside copper bars and the braided wires. Use the M8h20 screws to fasten the
inside copper bars, spacer block, braided wires and bottom copper bars.

2.2.3.3.3.2.13.10 Connect the cam (No.20), spacer sleeve and nylon connecting rod through the camshaft
(No. 19) and use another camshaft to correctly connect the cam and left/right side plates.

2.2.3.3.3.2.13.11Penetrate the yoke(No. 4), which connect the suppressor component, the coil
component(No.6) and the cover board(No. 5) into the main shaft in turn and connect them with left/right
side plates through the connecting bolt (No.9), penetrate stopper (No. 27) and the movable core (No. 7) into
the main shaft, and adjust the yoke to guarantee a flexible glide of the movable core in the sleeve, and screw
down the connecting bolts and lock the movable core with the locking sleeve.

2.2.3.3.3.2.13.12 Fix the left and right brackets (No.21) on the side plates and mount the quick switch (No.
30) on the left/right brackets.

2.2.3.3.3.2.13.13 Penetrate the manual plank (No. 24) into the manual shaft (No. 25), and then fasten it with
the retaining ring 10(GB894.1-86).

2.2.3.3.3.2.13.14 Adjust and screw down the connecting parts on the upper copper bar to guarantee the
clearance between two contacts and the connecting wire length.

2.2.3.3.3.3 Debug

Debug it on the test bench. The clearance between main contacts and over-travel requirement under the
normal temperature is required as following:
Coil Pick up Release Pick up Release
Model
resistance(¡) voltage(V) voltage(V) time(ms) time(ms)

S1001/06-PB(PC)-44-80V-B 108 İ56 24ıUı5.5 İ120 İ50

S1001/06-PB(PC)-33-110V-B 300 İ77 ı5.5 İ120 İ50

Distance between main contacts while contactor breaks 12~16mm

Contact pressure while contactor picks up ı70N

(The pressure is guaranteed by Spring 4. It needn't be checked after Spring 4 replaced)

Distance between main contacts while contactor picks up (3mm to static/fixed contact top) ı0.5mm

Distance of moving contact central line and fixed contact central line while contactor picks up İ0.6mm

Percentage of moving/fixed contact line upon the total length while contactor picks up ı80%

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Examination of auxiliary contact

Min clearance between roller frame and cam while auxiliary contact releases ı0.5mm

(Looseness and droop of roller frame of the auxiliary is excluded as testing the clearance)

Distance between roller frame and the limit position while auxiliary contact picks up ı0.8mm

2.2.3.3.3.4 Test of insulation performance

Under the circumstance of ambient temperature of 20f5ć and relative humidity of 50%~70%, the
insulation resistance between live parts and between the live parts and the earth should be more than 10M¡
(500V Meg-Ohmmeter).

After repair or replace the insulator, the insulation dielectric strength test should be conducted. There should
be no puncture or flashover phenomena if we carry out the power frequency test voltage of 1100V for 1min
between the live parts, which should be insulated from each other, and between the live parts and the earth.

2.2.3.3.3.5 Appearance inspection: The nameplate, positive/negative plates should be clear and the screws
should be complete.

2.2.3.3.3.6 Assemble: Mount the qualified contactor and connection copper bars on the motherboard.

2.2.3.3.3.7 After the repair, fill in the repair record in terms of the regulation.

2.2.3.4 Wearing parts

Model or DWG Quantity /set
No. Name Remarks
No. S1001/06-PB(PC) S1001/06-ES
1 Contact parts XS6690-09-00 2 4 Main contact
2 Spring 3 XS6690-01-18 1 2 Antagonistic spring
Compression spring for
3 Spring 4 XS6690-05-08 1 2
moving contact
4 Adjusting pad 5 XS6690-18-09 1 2
5 Screw GB70-85 2 4 For main contact
6 Sleeve/busher XS6690-01-08 1 2
7 Insulation sleeve 1 XS6690-01-12 1 2
8 Nylon screw XS6690-01-27 1 2
9 Nylon nut XS6690-01-28 1 2
10 Insulation sleeve 2 XS6690-05-03 1 2
11 Movable core XS6690-01-05 1 2
12 Pin 2.5x22 GB879-86 2 4 Standard
13 Retaining ring 3.5 GB896-86 4 8 Standard
14 Quick-action switch S847 W2A2b

2.2.4 S1100 Series DC Contactors

There are seven S1115/10-P-33-110V-B DC contactors in the locomotive. The code name is 1KM1̚1KM6
and 2KM . Contactors 1KM1~1KM6 are used for connecting the power supplying circuit of the traction
motors, and the contactor 2KM is used for connecting the excitation circuit of the traction motors on the
condition of dynamic braking.
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2.2.4.1Main technical parameters

1. Main circuit
The number of the pole single
Rated operating voltage (Ue) 1000V
The Max operating voltage (UMmax) 1500V
Rated operating current Ie (DC1/AC1) 1000A
Mechanical life >2X106 ⃵
Electrical life >2X105 ⃵
Rated insulation voltage 5000V
2. Control circuit
Rated voltage of the control power supply (Us) DC 110V
operating voltage (0.7̚1.25) Us
Coil resistance: 288ȍ
Coil power: about 42W
3. Auxiliary contacts
No. and style 3 groups,3NO+3NC
Rated voltage (Ue) DC 110V
Rated current (Ie) 1A
The conventional thermal current (Ith) 10A
The Min reliable working voltage (Umin) DC 12V
The Min reliable working current (Imin) 5mA
4. Protection degree
The whole sets IP00
Auxiliary contacts IP00 (wiring part)
IP60 (S847 contact point)
5. Overall dimensions and the weight
overall dimensions˖ (See Fig. 4-15)
weight˖ About 12kg
6. When the main contacts break, the distance between main contacts not less than 14mm
7. release voltage not less than 5ˁUs
Pick-up voltage not more than 70ˁUs
8.Delay time of pick-up not more than 120 ms
Delay time of release not more than 50ms
2.2.4.2 Intallation and use notices
a. The structure and the mounting dimensions of the 639% DC contactor˄basic type˅
is shown in the Fig. 4-15.

bˊP series contactors are permanent magnet arc-extinguishing, it only can be used in the circuit
which the direction of the current does not change, and pay attention to the wiring polarity of the
main circuit.˄the upper one is positive, and the lower one is negative˅DŽ

c. Attention should be paid to the direction of limit screw during installation of me arc- distinguishing
chamber, the said chamber would be unable to install or be damaged if the direction isn’t correct; When
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install the contactor, make sure that the air-blast direction is upward. And pay attention to the spacing
direction as mounting the arc chute. (It cannot be mounted in the reverse direction)

d. There is a voltage suppressor connected between the two ends of the coil, attention should be paid to the
polarity in wiring (the left is positive, and the right is negative); and there is no need to add other
suppressors outside.

Fig. 4-15 S1115/10-P-33-110V-B DC Contactors

3 Master Controllers, Operating Mode Transfer Switch and

Direction Transfer Switch

3.1 Master Controller

S710Q-B master controller belongs to the command controller for the driver of DF8BI diesel locomotives to
operate the locomotives and their switching. And S710Q-B master controller is the electric equipment to
indirectly control the main circuit through the low-voltage appliance of control circuit. It is used to control
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the operation conditions and driving speed of the locomotive.

The master controller is characterized by compact structure, small volume, light weight, high reliability,
long life, little maintenance or free maintenance. Its contact adopts the advanced contact module from
German Schaltbau Corporation. It has the quick-acting, self-purification and sealing mechanism.

It has the function of displaying the gears at night.

3.1.1 Structure and Contour

The contour structure of S710Q-B master
controller is shown in Fig. 4-16 (260mm
h200mmh150mm), the contact closing
state and wiring of S710D-B master
controller is shown in Fig. 4-17, and the
contour structure of S847 contact is
shown in Fig. 4-5.

In order to avoid the possible

mishandling, interlock structure is set up
between the master handle and the
reverse handle of the master controller.
As the reverse handle is placed at the
gear “0”, the master handle is locked at
the gear “0”. If the reverse handle is at
the gear “back drive” or “front drive”, the
control handle can move to the gear “16”.
If at the gear “back brake” or “front 





 
 

brake”, the control handle can be moved 








 
 

only to the gear “12”. As the master 







 
 

handle is not at the gear “0”, the reverse  

handle is locked.

Fig. 4-16 Structure of S710Q-B master Controllers

3.1.2 Technical Parameters

Contact's characteristics

Contact belongs to a quick-acting and sealing mechanism, with self-purification function and high reliability
of the computer signal.

Operating force on handle

On master handle: İ10N
On reverse handle: İ20N
Protection grade (grade 3 for pollution)
Complete controller IP00
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Contact S847 IP00 (wiring part)

IP60 (contact part)
Inverter input voltage 110VDC
Durability
Mechanical life >1h106
Electrical life >1h105
Weight About 10kg
Wiring way
Contact (in master controller) M3 bolt
External wiring of master controller
Inside master controller (20-core socket) TL02J20ZY
Control console (20-core plug) TL02K20TY

Fig. 4-17 S710Q-B Contact Closing State and Wiring of Master Controllers

3.1.3 Use and Operation

On the panel of the master controller, there are master handle and reverse handle. The master handle has
gears “0-1-2-3-4-5-6-7-8-9-10-11-12-13-14-15-16”, and the reverse handle has five gears: “back brake”,
“back traction”, “0”, “front traction” and “front brake”.

The master handle of the master controller has fixed sites at the gears “0”,“1”, “2”, “3”, “4”, “5”, “6”, “7”,
“8”, “9”, “10”, “11”, “12”, “13”, “14”, “15” and “16”. The reverse handle has fixed site at each gear. The
reverse handle should be leveled off at the corresponding gears.

Lock the control handle as the reverse handle is fixed at the gear “0”; if the reverse handle is at the gear
“back drive” or “front drive”, the control handle can move to gear “16”; and if the reverse handle is at the
gear “back brake” or “front brake”, the control handle can only move to the gear “12”.

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The master handle adopts the fixed mode; and the reverse handle adopts the removable mode (key-lock),
and the reverse handle which can only be plugged in or drawn out at the gear “0”. The reverse handle is also
the control handle of the auxiliary master controller. As a result, the master controller of the complete
locomotive mutually uses one moveable handle (key lock handle), which guarantees that one master
controller is operated during the locomotive drive and the rest three controllers are locked at the gear “0”,
without any disorder of the circuit commands.

As performing the operation, choose the driving direction and working condition by the reverse handle and
then control the locomotive speed by operating the master handle. During the drive, if the driver needs to
change the working condition of the locomotive, it is necessary to put the master handle at the gear “0”
before operating the reverse handle. If the driver needs to conduct the operation in the other end of the
locomotive (or shunting), first of all it is necessary to put the master handle of the master controller at the
gear “0” and draw out the reverse handle from the gear “0” on the local end.

The night display of the gears on the panel of master controller is controlled by the toggle switch of
“instrument light”. As driving at night, switch on the toggle switch of “instrument light” and then the gear of
master controller and the locomotive instrument will shine at the same time.

3.1.4 Overhaul method

3.1.4.1 The nameplate and marks of the master controller should be complete, intact, clear and accurate.

3.1.4.2 The parts of the master controller should be clean and be accurately connected to external socket,
with good performance of insulation and intact spare parts.

3.1.4.3 Complete fastening parts and good fastening performance

3.1.4.4 The operation of the control handle should be flexible among the gears, without mechanical jam and
stands between two neighboring gears.

3.1.4.5 The operation of the control handle should be flexible among the gears, without mechanical seizure
and stands between two neighboring gears. At the gear “0”, the handle can be demounted smoothly.

3.1.4.6 Lock the control handle as the reverse handle is fixed at the gear “0”; if the reverse handle is at the
gear “back drive” or “front drive”, the control handle can move to gear “16”; and if the reverse handle is at
the gear “back brake” or “front brake”, the control handle can only move to the gear “12”.

3.1.4.7 The contact closing state and wiring of the master controller should coincide with the regulation in
Fig. 4-18.

3.1.4.8 The α6 engine oil (GB11121) should be feed to all rotating parts of the master controller and the
lubricants should be feed to the mechanical interlock component.

3.1.4.9 The master controller's insulation should comply with the following requirements:

3.1.4.9.1 There are electrical elements in the flaring device of the master controller. As performing the
insulation test and dielectric strength test, the investor input terminal and output terminal should be
insulated to avoid the damage to the flaring device.

3.1.4.9.2 Resistance between live parts, which should be insulated from each other, and between the live
parts and the earth should be no less than 10M¡ (500V Meg-Ohmmeter).
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3.1.4.9.3 After the repair or overhaul, the insulation dielectric strength test should be conducted. There
should be no puncture or flashover phenomena if we carry out the sine alternating current of 50Hz/1100V
for 1min between the live parts of the contactor and between the live parts and the earth.

3.1.4.10 Contact overhaul of the master controller should comply with the following requirements:

3.1.4.10.1 Check the operating flexibility and reliability of the contact inside and roller frame (including the
rolling of the roller); or, a little of 6# engine oil (GB11121) should be feed to the rotating parts of the contact
roller core and roller frame core to increase the flexibility of the contact operation.

3.1.4.10.2 The S847 contacts used in the master controller belong to the self-purification and quick-acting
switch, with free maintenance. In case of a serious burn and operating inflexibility, the contact should be
replaced. As being replaced, attention should be paid to contact models and the installation direction of the
contact rollers.

3.1.4.10.3 Check the contact resistance of the S847 contact with the low-resistance tester (for instance
GOODWILL GOM-801G), and the measuring current should be no less than 1A. The contact resistance of
the contact should be less than 200 m¡. In case of a higher contact resistance, the wiring can refer to Fig.
4-9, and we can shunt the inductive load of 1A current (time constant is about 20~50ms) and clean the
contact surface oxide by arc light to reduce the contact resistance.

3.1.4.11 Under the normal operation (no load), the input voltage of TGNˉ110A inverter is 110V DC and
output voltage 200V AC f20VAC. In case of no output voltage, the inverter is damaged and should be
replaced. The input terminal and output terminal of the inverter cannot be reverse connected as being
replaced.

3.1.4.12 Flaring instrument of the master controller belongs to the electroluminescent (EL) instrument, with
no heat and free maintenance. In case of damage to the EL clip, the EL clip it should be replaced. Note that
if one of the EL clips doesn’t work, the other clips would not work either, because the EL clips are
connected in parallel with the output terminal of the inverter.

3.1.4.13 In case of dismantling or separating the master controller owing to mechanical troubles, attention
should be paid to the followings:

There is a mechanical interlock relationship between the control cam component and the reverse cam
component of the master controller, so the marks should be made, and the dismantling must be performed in
terms of the contact closing diagram.

The front/back position of the spring clip component near the control handle and the reserve handle can
adjust the gap between the control linkage plate and reverse linkage plate. And we should guarantee an even
gap among the linkage plates and a flexible rotation of controlling & reverse handles, without mechanical
seizure.

The gradient of the spring clip component near the control and the reserve handles can adjust the operating
force of control & reverse handles. Under the reliable operation of the master controller, the two handles
should be characterized with a convenient and flexible operation.

Don’t randomly disassemble the rectified or fixed cam component near control and reverse handles.

In order to guarantee the correct external wiring of the master controller, attention should be paid to the

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external wiring during the overhaul and dismantling:

Inside master controller 20-core socket TL02J20ZY

Control console 20-core plug TL02K20TY

3.2 Operation mode changeover switch and direction

changeover switch
DF8BI adopts one operation mode changeover switch and one direction changeover switch. The operation
mode changeover switch is used for the conversion between locomotive traction and resistance braking. And
the direction changeover switch is used for the conversion between forward moving and backward moving
of locomotive. Both changeover switches are nationalized appliances imported from GE technology. The
model is T829 and T830, and the code name on the electric schematic diagram is 2QP and 1QP. And they
have the same structure and parameters.

3.2.1 Configuration and figure

Fig.4-22 T829, Operation mode changeover switch and T830 direction

changeover switch

Fig.4-22 is the configuration of T829 operation mode changeover switch and T830 direction changeover
switch. The main contact locates in the middle of the device, which adopt the type of axis of rotation
configuration. /which adopts the rotation axis mechanism. The contact bracket around the steel side axis,
there has two roundness supports on the contact. While the contact move to the left side, the underside
spring will produce pressure; while the contact move to the right side, the upside spring will produce
pressure.

The rotation axis is separated into six layers. Each direction changeover switch or operation mode
changeover switch has twenty-four couple’s main contacts, which can control six traction motors
synchronously.

The auxiliary contact system has eight groups aggregately, which locate under the device, and four of them
are double-throw contacts with middle contact.

The cylinder drive system locate under the device, it adopt the cylinder that has two positions. The cylinder
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drives by using the gear and it adopts two-position drive cylinder which is rack-and-pinion drive the
cylinder uses two electric pneumatic valves to control the conversion of the two positions. The leather bowl
adopts the durable material. Its mechanism/mechanical life can achieve over 1 million time. It adopts
orientating spring to control the orientation, while wind pressure minishes or loses voltage, it can still
orientate reliably.

The device has a neutral position, and it can be switched to the position through the handle to disconnect all
the main contacts while overhaul.

Both the operation mode changeover switch and the direction changeover switch have no arc-control
mechanism, so they cannot break while loaded. It means that they can switch only when the main handle is
at “0” gear, or it will lead severe burning to them. If serious enough/What is more, it will damage the
traction motors.

3.2.2 Specification
Main contact
Rated voltage 1000V
Rated current 1000A
Quantity 12 groups
Pressure 155~200N
Tip break 18~20mm(3Q53)
17.5~20.5mm(3Q51)
Overdrive 4.3~8.8mm(3Q53)
5.5~7mm(3Q51)
Contact wire ı29.5mm
Auxiliary contact
Rated voltage 110V
Rated current 0.5A
Quantity 8 sets
Pressure ı3.3N
Tip break ı25mm
Over travel 3~4.8 mm
Drive part
Rated air pressure 500kPa
Operating wind pressure range 375kPa̚650 kPa
Rated voltage of electric pneumatic valve 110V
Cylinder piston stroke 82f0.5mm
Diameter of cylinder 57mm

3.2.3 Examine and repair

3.2.3.1 Basic technical demand

3.2.3.1.1 Each part should not crack and the fasteners should not become flexible.

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3.2.3.1.2 Each insulator of the live part should be up to demand and have no crack, burning loss or
carbonization.

3.2.3.1.3 The wind cylinder should not leak, the wind path should be smooth, and the leather bowl should
not crack or distort.

3.2.3.1.4 After put through the 0.375Mpa wind path, the change-over switch should act reliably. Put through
the 0.65MPa wind path, and then inspect the cylinder by soap liquid to make sure that there is no leakage of
the cylinder contact surface and the mounting base of the electric pneumatic valve.

3.2.3.1.5 While the main contact is at working state, the length of the contact wire should exceed seventy
five percent.

3.2.3.2 Main equipment and instrument

It includes sleeve, spanner, screwdriver, brush, ruler, 500V and 1000V meg-ohmmeter, T Z instrument.

3.2.3.3 Main technical process

3.2.3.3.1 The inspect before disjoint Examination before disassembly

Blow and clear the change over switch by 0.6Mpa dry compressed air, to get rid of the surface dust.

3.2.3.3.1.1 Clean up the switch parts by brush and clean cloth, especially the dust and the oil dirt on the
surface of the insulator.

3.2.3.3.1.2 Check the appearance and pay attention to the main contact to see if it has burning loss or the
connecting cord overheats.

3.2.3.3.2 Disassembly

3.2.3.3.2.1 The disassembly of the air operated component

3.2.3.3.2.1.1 Take out the fastening bolts of the left and the right electric pneumatic valves, and then take
out the rubber mats, which on the valve and the valve seat.

3.2.3.3.2.1.2 Mimeograph market on the connecting location of the left and right wind cylinder lid, then can
install it rightly. Make the mark on the joint surface of the left and right wind cylinder lids to enable
assembly as the original position.

3.2.3.3.2.1.3 Open up the air cylinder lid.

3.2.3.3.2.2 The disassembly of the main contact component
3.2.3.3.2.2.1 Remove the bolts of the main contact groupware.
3.2.3.3.2.2.2 Take out the main contact groupware.
3.2.3.3.3 Examination and repair
3.2.3.3.3.1 The examination and repair of the moving and fixed contacts

3.2.3.3.3.1.1 The surface of the moving and fixed contacts should not be scratched and burned. When it has
light burn, you can e repair it by filing with smooth file. Note: Cannot polish the main contact by emery
paper.

3.2.3.3.3.1.2 The thickness of the moving and fixed contacts should not exceed the limit, or else must

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exchange it or replace them.

3.2.3.3.3.1.3 The contacts should be installed reliably.

3.2.3.3.3.1.4 The retainer spring of the moving contact should be all right and have no distortion. The spring
seat should be well.
3.2.3.3.3.2 The inspect of the insulating parts

3.2.3.3.3.2.1 The insulator of the contact groupware should have no crack or carbonization which caused by
overheating.

3.2.3.3.3.2.2 The insulating bushing should not crack or become loose, or else must change it or stick it by
glue.
3.2.3.3.3.3 The overhaul of the auxiliary contact groupware

3.2.3.3.3.3.1 The soleplate of the auxiliary contact should not crack or overheat, or else must change it.

3.2.3.3.3.3.2 The auxiliary contact should not burn, melt and or overheat. If it has light burn, please repair it
by file and change it when it is severe.

3.2.3.3.3.3.3 The flexible connecting cord of the auxiliary contact should be all right and do not overheat.
The broken strands should not exceed ten percent, or else change it them.

3.2.3.3.3.3.4 The terminal of the auxiliary contact flexible connecting cord should not overheat.

3.2.3.3.3.4 The overhaul of the wind operated parts

3.2.3.3.3.4.1 The wind cylinder body and the cylinder lid should not crack, the connecting surface should be
flat and do not bend or distort. If the cylinder body has slag pinhole, please weld and repair it from outside,
then file and repair it by file.
3.2.3.3.3.4.2 If the fixing seat of the electric pneumatic valve is not flat, please file and repair it by fine file.

3.2.3.3.3.4.3 The leather bowl of the wind cylinder should not deteriorate or crack. The leather bowl and the
inside wall of the wind cylinder should match well, or else replace it.
3.2.3.3.4 Installation Assembly

The assembling should be conducted in the opposite order of the disassembling and pay attention to the
following items while assembling:
3.2.3.3.4.1 The air operated parts

3.2.3.3.4.1.1 Before the cylinder assembly, ensure the leather bowl lubricant by dropping #13 compressor
oil to the inside wall of the cylinder.

3.2.3.3.4.1.2 The leather bowl adopts the durable material, so its life can be over 1 million times. In medium
maintenance, change it or not according to its state.

3.2.3.3.4.1.3 Inspect the gear and the rack of the drive cylinder to see if they are all right and if the spring is
well.
3.2.3.3.4.2 Main contact parts

3.2.3.3.4.2.1 While install the fixed contacts which on the same axis, please choose the contacts that have
the similar dimension to assemble.
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3.2.3.3.4.2.2 Add some lubricating oil to the spring seat and the spring axis of the contact properly. Make
sure that while the main contact closes, it can reach the destination naturally.

3.2.3.3.4.2.3Poke the rotation axis by the handle, then inspect the connecting surface of the contact and the
length of the flexible connecting cord to see if they are suitable.

3.2.3.3.4.2.4 While assembling, remember to spread some conductive coating on the main contact to
guarantee good conductivity.

3.2.3.3.5 Adjust experimentation Turn-up test

3.2.3.3.5.1 Air operated parts

3.2.3.3.5.1.1 Under the 0.375 Mpa air pressure, the changeover switch should work reliably.

3.2.3.3.5.1.2 Under the 0.65 Mpa air pressure; there should be no leak in the connecting surface of the air
cylinder and the mounting base of the electric pneumatic valve measured by soap liquid.

3.2.3.3.5.2 The examination of the main contact interface:

The contact wire length of the main contact should exceed seventy five percent of the main contact. Put
through the wind path, then examine the contacting situation by the following three methods:

3.2.3.3.5.2.1 Put a carbon paper between the two contacts, then close the changeover switch, and inspect the
percentage of the marking.

3.2.3.3.5.2.2 After the contacts close, measure the contact resistance by TZ instrument.

3.2.3.3.5.2.3 Examine it by light transmitting method.

3.2.3.3.6 The measurement of the insulation

3.2.3.3.6.1 The insulation resistance between main contacts and between main contacts and the earth should
not be less than 10M¡ measured by 1000V meg-ohmmeter.

3.2.3.3.6.2 The insulation resistance between auxiliary contacts and between auxiliary contacts and the earth
should not be less than 10M¡ measured by 500V meg-ohmmeter.

3.2.3.3.7 Withstand voltage test

If the device or insulator have changed or repaired, the withstand voltage test should be conducted. While
testing, there should be no breakdown or flashover if we carry out the power frequency AC voltage of
3000V for 1 min between each part of the device and between each part and the earth.

3.3.4 Vulnerable parts

No Description Drawing number Manufacturer
1 Sealing ring 3Q51-000-006 Xi’an railway signal factory
2 Spring 3Q51-000-018 Yongji electric machine factory
3 Mat 3Q51-000-019 Yongji electric machine factory
4 Piston ring 3Q51-010-003-1 Yongji electric machine factory
5 Contact assembly 3Q51-080-000 Yongji electric machine factory

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4 Relay
There are one earth-fault relay for the ground protection of main circuit, one over current relay for the over
current protection of main circuit, and one differential relay for the protection of resistance braking blower
motor in the DF8BI locomotive. In addition, 5 intermediate relays are used.

4.1 Grounding fault relay

Grounding fault relay is used for the ground protection of the main circuit.

While the alternator bears the symmetrical load, the neutral point (electric) potential of the Y-type armature
winding is zero, and it can be regarded as the comparative point of the main circuit ground protection which
combined the rectification circuit of the diode bridge and the coil of the earth fault relay (code name: KE)
make up the earth detecting circuit. there is always potential difference between the earth point and the
neutral point of the armature winding to enable the coil of earth fault relay have current. While the current
reaches 0.5A, the earth fault relay acts. And the normally closed contacts break, the normally open contacts
pick up, then the diesel engine unloads and sends out the indicating signal.

4.1.1 Construction and figuration

The figuration of earth-fault relay shows in Fig. 4-23 and
the structure shows in Fig. 4-24. The earth fault relay
mainly consists of contacts (actuating mechanism of
relay), electro-magnetic mechanism (measuring
mechanism of relay) and mounting base. And this relay
has no self-locking mechanism.

4.1.2 Specification
Contact
Rated voltage 110V DC
Rated current 5A DC
Tip break ı3mm
Pressure ı0.98N Fig.4-23 5Q17 and 5Q6D relay

Over travel ı1.2mm

Quantity 1NC+1NO
Coil
Diameter of wire 0.4mm
Resistance 66f5%¡
Turn 3750
Action current 500f37.5mA
Overall dimension 220h100h130mm
Installation size 2-¶10(190h160mm)

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4.1.3 Maintenance method

4.1.3.1 Basic technical demand

4.1.3.1.1 Each part should be clear, and have no break or damage.

4.1.3.1.2 It should work flexible and reliable. Its locking equipment should work well.

4.1.3.1.3 The operating value and each parameter of the contact should accord with the demand of the limit
table and the main technical parameter.

Fig. 4-24 Earth-fault relay

1-spring;2-lock bar;3-support;4-moveable groupware;5-static groupware;6-coil;7-iron core;8-base

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4.1.3.1.4 Insulation

4.1.3.1.4.1 The insulation resistance between the coil and earth, and between the coil contacts measured by
1000V meg-ohmmeter should be no less than 10 M¡.

4.1.3.1.4.2 The insulation resistance between the contact and earth measured by 500V meg-ohmmeter
should be no less than 10M¡.

4.1.3.1.4 Withstand voltage test

There should be no breakdown or flashover when taking the withstand voltage test with AC power
frequency for 1 min.

Following is the Experimental voltage: The testing voltage is as following:

Between Coil and earth Between Coil and contact Between Contact and earth Between contacts
3000V 3000V 1100V 1100V

4.1.3.2 The main equipment and tool

There are appliance test-bed, withstand voltage equipment, universal meter, 500V meg-ohmmeter, 1000V
meg-ohmmeter, common electrician tools.

4.1.3.3 Main technical process

4.1.3.3.1 Disassembly

4.1.3.3.1.1 Dismount the contact wire and recover springs.

4.1.3.3.1.2 Dismount the bracket bearing and the contact assembly, and then take out the bracket assembly.

4.1.3.3.1.3 Dismount the coil and the fastening screws of the press plate, and then take out the press plate
and the coil assembly.

4.1.3.3.2 Cleanout

Clean up each part by brush, alcohol and cotton cloth.

4.1.3.3.3 Overhaul

4.1.3.3.3.1 Contact system

4.1.3.3.3.1.1 There should be no rupture, burn or serious overheat distortion in the movableǃfixed contacts
and contact's accessory (the support patch of fixed ǃmovable contact poles). The contact should not be
peeled off or broken off. And the normal burnt can be recovered through sanding by metallographic sand
paper. The contact should be fixed firmly, or change it.

4.1.3.3.3.1.2 Measure the thickness of the contact, the moveable contact should be no less than 1.5mm and
the fixed contact should be no less than 1mm.

4.1.3.3.3.1.3 The bracket of the fixed contact, the insulator bracket of the moveable contact and the
connecting terminal should have no rupture, burning or looseness.

4.1.3.3.3.1.4 The contact spring should not break. The spring should be straight under free state and check it
by hand to make sure it is good.

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4.1.3.3.3.1.5 The wire and the sleeve should have no crack, aging or burning loss. The core of the wire
should have no rupture of strands. Connected and welded firmly with terminals.

4.1.3.3.3.2 Electromagnetic mechanism

4.1.3.3.3.2.1 Coil

4.1.3.3.3.2.1.1 Screw out the support chip of the armature, and then take out the armature assembly

4.1.3.3.3.2.1.2 Screw out the fastening bolts of the coils assembly, and then take out the coil assembly,
insulating mat and the iron core.

4.1.3.3.3.2.2 Frame yoke, armature iron, bracket and iron core should not rupture or shatter. Frame yoke and
iron core should be fixed firmly. The bracket and the armature iron should rivet up reliably.

4.1.3.3.3.2.3 If the brass gaskets which under the moving iron core break off or shatter, it must be changed
or repaired by welding.

4.1.3.3.3.2.4 The adjusting bolt and the bracket bearing should not shatter, and have good regulating
function. Inspect the clearance which between the bracket bearing and the hole to make sure it is no more
than 0.4mm.

4.1.3.3.3.3 Locking device

4.1.3.3.3.3.1 Each welding part should not rupture or fray badly. The unblock rod and the locking rod or the
stop catch and the back plane should not become loose.

4.1.3.3.3.3.2 The edge of the locking piece and the working end surface of the locking rod should be smooth.
If it has burr or serious abrasion, repair it by filing or change it.

4.1.3.3.3.4 Others

4.1.3.3.3.4.1 The antagonistic spring should not be broken. It should not be bent or distorted in free state. It
should have a good elasticity.

4.1.3.3.3.4.2 The pothook, spring base and the adjusting bolts should have no damage and have a good
adjusting function. The adjusting function should be well.

4.1.3.3.3.4.3 The fixed bent plate of bolts should have no rupture, damage or looseness.

4.1.3.3.3.4.4 The insulation insulating base and the lining board should not rupture, carbonize or distort. If
there is partial burn, scrape it, and spread insulating paint on it and then drying it.

4.1.3.3.3.4.5 The nameplate should not have no damage, and its label should be clear.

4.1.3.3.4 Assembly

Assemble it according to the opposite order of the disassembly. The clearance between the static iron core
and, the hole of the coil bracket, should be even.

4.1.3.3.5 Turn-up test

4.1.3.3.5.1 Ways and Method

Put the relay on the test-bed/test stand. And connect the wiring according to the Fig. 4-25. Then take the
turn-up test by controlling the switch on or off.
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4.1.3.3.5.2 Parameter adjustment

4.1.3.3.5.2.1 Adjust the bearing bolts and

inspect the bracket to make sure the
transversal variable is 0.2~0.5mm.

4.1.3.3.5.2.2 Contact (part)

4.1.3.3.5.2.2.1 By adjusting the extended Fig.4-25 Wiring diagram

length of the fixed contact bolt and the
magnet gap of the iron core can regulate the tip break, over travel and pressure of the contact. The bigger
the over-travel is, the greater the pressure is.

4.1.3.3.5.2.2.1.1 The normally open contact

While the relay releases, adjust the extended length of the screw, then inspect the tip break of the contact to
see if it exceeds 3mm. Press the movable iron core, inspect the over travel of the contact to see if it exceeds
1.2mm.

4.1.3.3.5.2.2.1.2 The normally closed contact

While the relay picks up, adjust the extended length of the screw, then inspect the tip break of the contact to
see if it exceeds 3mm. Release the iron core slowly, the contact’s moving distance, which is from the contact
just connecting to each other to the locking piece just falling on the catch angle iron, is that we call over
travel. And this over travel should exceed 1.2mm. Its measuring manner is the same as the normally open
contact.

4.1.3.3.5.2.2.2 If the demand can be reached by only adjusting screws, do not adjust the iron core. If the iron
core needs to be adjusted, it’s necessary to fasten all the locking screws equably after the adjustment, to
make sure the clearance between locking nuts and armature is 0.02~1.0mm

4.1.3.3.5.3 Test

Carry out the operation test according to the adjusting manner. Adjust all the technical index /data; each
measured parameter should be up to demand. Meanwhile inspect the locking device to to make sure it works
well.

4.1.3.3.5.4 After the test, strengthen the fasteners of the adjusting part. After proof it to right, mark it by
lacquering. After inspection, make the mark of lacquering.

4.1.3.3.6 The measuring test of insulation resistance and withstand voltage test are showed in basic technical
requirement.

4.1.3.3.7 After overhaul, fill in the maintenance records.

4.1.4 Vulnerable parts

No Description Drawing number Manufacturer
1 Moveable contact groupware Xi’an railway signal factory
2 Contact support groupware Xi’an railway signal factory
3 Tension Spring Xi’an railway signal factory

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4.2 Over-current relay

There is one over-current relay (code name: KC) on the locomotive, which is used to monitor the looping
fire of the traction motors, the short circuit of the silicon rectifier component and the over current of the
alternator. When the DC current of the main circuit reaches 7600A, the current that pass through the coil of
over-current relay will reach 7.6A. Then the relay acts and makes the diesel engine unload, meanwhile
sends out an indicating signal.

4.2.1 Construction and figuration

Fig.4-26 is the figuration of the over-current relay. The over-current relay mainly consists of contacts
(actuating mechanism), electromagnetic mechanism (measuring mechanism) and the mounting base
assembly. And this relay has no self-locking mechanism.

4.2.2 Specification
Contact
Rated voltage 110V
Rated current 5A
Clearance ı3mm
Pressure ı0.98N
Over travel ı1.2mm
Quantity 1NC+1NO
Coil
Diameter of wire 2.24mm
Resistance 0.066r5%¡
Turn 132
Action current 7.6r0.3A
The left and right movable clearance of the armature 0.2~0.5 mm
The assembling deviation of the movable and fixed contacts İ1 mm
Outline dimension 220h100h130mm
Installation size across corners, 2-¶10(190h160mm)

4.2.3 Examine and repair

4.2.3.1 The main equipment and tool

The appliance test-bed, universal meter, bridge, meg-ohmmeter (500V), common electrician tools, and so on.

4.2.3.2 Main technical process

4.2.3.2.1 Clear and examine it before disassembling

4.2.3.2.1.1 Clean up the dust and the oil stain of the relay by brush and rag.

4.2.3.2.1.2 Inspect the coil and every part. If it becomes flexible loose or being damaged, repair or change it.
If there is looseness or damage, repair or change it.
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Fig.4-26 configuration
1-Spring groupware; 2-Support; 3-Reed hook; 4-Moveable groupware; 5-coil;6-Iron core; 7-base.

4.2.3.2.1.3 Inspect the connecting terminal of coil to make sure there is no looseness or sealing off.
Otherwise, repair it by sticking epoxy resin or weld it again. If the thread of the terminal is not good, change
it.

4.2.3.2.1.4 Measure the resistance of the coil by bridge(scope:0.066r5%¡). The coil resistance measured
by bridge should be within the range of (0.066r5%)¡.

4.2.3.2.2 Disassembly and overhaul

4.2.3.2.2.1 Disassembly

4.2.3.2.2.1.1 Unpack the contact tie line and the antagonistic spring.

4.2.3.2.2.1.2 Screw out the screw of the bracket and the contact component, and then take out the bracket
component.

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4.2.3.2.2.1.2 Screw out the coil, the pressure plate, and the fastening bolts, and then take out the pressure
plate and the coil component.

4.2.3.2.2.2 Cleanout

Clean and wipe each part by brush, alcohol and rag.

4.2.3.2.2.3 Examine and repair

4.2.3.2.2.3.1 There should have no rupture, burning loss or serious overheat distortion of the fixed contacts
and the contact component. The contact should not peel off or break off. If it burned slightly, polish it by
Ā0ā# metallographic sand paper, then clean it by using cloth dipped in alcohol.

4.2.3.2.2.3.2 The thickness of the movable contact should be no less than 1.5mm and the thickness of fixed
contact should be no less than 1mm.

4.2.3.2.2.3.3 The insulating bracket of contacts and the connecting terminal should have no rupture, burning
loss or looseness.

4.2.3.2.2.3.4 The contact spring should not break and have no distortion in its free state. And it has a good
elasticity checked by hand.

4.2.3.2.2.3.5 Check that wire and sheath have no breakage, aging or burning loss. The wire core and the
terminal are in good welding property. And the broken strands of core should be no less than 5%, or weld
them again.

4.2.3.2.2.3.6 Check that outside insulator of coil component has no damage, dilatation, breakdown or
burning loss.

4.2.3.2.2.3.7 No open or short circuit in the coil inspected by universal meter. The resistance measured by
bridge should accord the technical demand.

4.2.3.2.2.3.8 Check that the connecting terminal of coil has no looseness, damage or burning loss and the
thread section of it works well.

4.2.3.2.2.3.9 If it needs to change the connecting terminal of the coil, note that keep a distance of over
10mm between the two connecting terminals while welding. First envelop the terminal by insulating
varnished silk, and then reel it thickly by cotton wax wire. At last, dip it in varnish and drying it.

4.2.3.2.2.3.10 Check that the yoke, iron core, bracket and armature have no rupture or damage. The yoke,
iron core are installed firmly, and the bracket and armature are riveted reliably.

4.2.3.2.2.3.11 Check that the antimagnetic washer, which under the movable iron core, should not break off.
If it is damaged, replace it or repair it by welding.

4.2.3.2.2.3.12 The adjusting screw and bracket should have no damage. The function is good and the fit
clearance accords the demand.

4.2.3.2.2.3.13 Each rod of the locking mechanism should have no rupture or serious abrasion. The
unblocking rod and the locking rod or the stop catch and the back plane should not have looseness. If the
edge of the locking piece has burr, repair it by sanding. If the working end surface of locking bar is abraded
seriously, repair it by filing.

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4.2.3.2.2.3.14 The antagonistic spring should not break, distort in its free state and have a good elasticity.

4.2.3.2.2.3.15 The antagonistic spring, pothook, spring base and adjusting bolts should have no damage and
have a good adjusting/regulating function.

4.2.3.2.2.3.16 The fixed bent plate of the antagonistic spring bolts should have no rupture or looseness, and
should be riveted up reliably.

4.2.3.2.2.3.17 The insulating base and the lining board should have no crack or burning loss. Replace it
when severely distorted. If there is partial burn, scrape it and spread insulating paint on it and then drying it.

4.2.3.2.2.3.18 The nameplate of the device should not shatter or break off. Its label should be clear and be
installed firmly.

4.2.3.2.3 Assembly

Assemble it accords to the opposite order of the disassembling. While assemble it pay attention to the
following particulars:

4.2.3.2.3.1 The left and right movable clearance of the armature iron should accord with the range demand
of 0.2~0.5mm.

4.2.3.2.3.2 The contacts must be lined up, and the deviation of the assembly should not exceed 1mm.

4.2.3.2.3.3 The tip break and the over travel between contacts should accord the dimension limits.

4.2.3.2.4 Debug

4.2.3.2.4.1 The action current: is 7.6r0.3A. Its act should be exact and flexible. It should act correctly and
flexibly and its locking mechanism should act reliably.

4.2.3.2.4.2 If the pick-up value is too small, increase the pre-tightening force of the spring or shift up the
movable iron core. If the pick-up value is too large, the regulating means is on the contrary.

4.2.3.2.4.3 Notes

4.2.3.2.4.3.1 Consideration should be given to every aspect when adjusting. Don’t make the air gap too
small or the extension spring in a loose state.

4.2.3.2.4.3.2 The position after adjustment should be suitable. Don’t lead to filing the locking rod in order to
enable the self-locking.

4.2.3.2.4.3.3 The three locating screws, which on the locking nuts, should be loosened or fastened
synchronously to avoid the leaning of the iron core. After adjusting, fasten the nuts and check it again.
When achieve the demands, make the mark of lacquering.

4.2.3.2.5 Insulation test

4.2.3.2.5.1 The insulation resistance between the contact and earth measured by 500V meg-ohmmeter
should exceed 10M¡.

4.2.3.2.5.2 There should be no breakdown or flashover if we carry out the withstand voltage test with
1100V/50Hz sine alternating current for 1 min between the live parts and between live parts and the earth.

4.2.3.2.6 Fill in the maintenance records.

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4.2.4 Vulnerable parts

No Description Drawing number Manufacturer
1 Moveable contact groupware --- Xi’an railway signal factory
2 Fixed contact groupware --- Xi’an railway signal factory
3 Extension Spring --- Xi’an railway signal factory
4 The contact spring blade part --- Xi’an railway signal factory

4.3 Wind speed relay

There is one differential relay (code name: 2KP) on the locomotive. It is regarded to protect the cooling
blower circuit of the braking resistor when the locomotive is at the resistance braking. When the unbalanced
current differential of the two blowers reach 33A, the relay acts. And the alternator’s excitation and the
resistance brake will be shut off.

4.3.1 Specification
Contact
Rated voltage 110V
Rated current 5A
Clearance ˚3mm
Pressure ˚1N
Over travel ˚1.2mm
Quantity 1NC+1NO
Coil
Rated current 101A
Rated voltage 770V
Action current 33f3A

4.3.2 Structure
Fig. 4-27 is the configuration of the differential
relay. The differential relay adopts the
electromagnetic mechanism of solenoid type. This
relay mainly consists of two coils which are reeled
crossly/contrarily (measuring mechanism), the
electromagnetic mechanism (actuating mechanism)
and mounting base. The contact system has 1 NC
and 1NO. Fig. 4-27 5Q20A differential relay

4.3.3 Examine and repair

4.3.3.1 The main equipment and tool

The electric apparatus test-bed, universal meter, bridge, Meg-ohmmeter (500V), common electrician tools
and so on.
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4.3.3.2 The main technical process

4.3.3.2.1 The clearing and examination before disassemble

4.3.3.2.1.1 Clear the dust and the oil stain of the relay by brush and rag.

4.3.3.2.1.2 Inspect the coil to see if it becomes loose and inspect each part to see if it disrepairs. Repair or
change the parts that don’t accord the demands.

4.3.3.2.1.3 Inspect the connecting terminal of coil to make sure there is no looseness or sealing off.
Otherwise, repair it by sticking epoxy resin or weld it again. If the thread of the terminal is not good, change
it.

4.3.3.2.2 Disassemble and overhaul

4.3.3.2.2.1 Disassemble

4.3.3.2.2.1.1 Unpack the connecting wire of the contact and the antagonistic spring.

4.3.3.2.2.1.2 Screw out the bolts of the bracket and the contact component, and then take out the bracket
component.

4.3.3.2.2.1.3 Screw out the coil, the pressure plate and the fastening bolts, and then take out the pressure
plate and the coil component.

4.3.3.2.2.2 Cleanout

Clean and wipe each part by brush, alcohol and rag.

4.3.3.2.2.3 Examine and repair

4.3.3.2.2.3.1 There should have no rupture, burning loss or serious overheat distortion of the movable/fixed
contacts and the contact component. The contact should not peel off or break off. If it burned slightly, polish
it by Ā0ā# emerge paper metallographic sand paper, then clean it by cloth dipped in alcohol.

4.3.3.2.2.3.2 Inspect the thickness of the contact, the movable contact should exceed 1.5mm, and the fixed
contact should exceed1mm.

4.3.3.2.2.3.3 The insulating bracket of contacts and the connecting terminal should have no rupture, burning
loss or looseness.

4.3.3.2.2.3.4 The contact spring should not break and have no distortion in its free state. And it has a good
elasticity checked by hand.

4.3.3.2.2.3.5 Check that wire and sheath have no breakage, aging or burning loss. The wire core and the
terminal are in good welding property. And the broken strands of core should be no less than 5%, or weld
them again.

4.3.3.2.2.3.6 Check that outside insulator of coil component has no damage, dilatation, breakdown or
burning loss.

4.3.3.2.2.3.7 Inspect the coil by universal meter to make sure there is no open or short circuit. The resistance
measured by bridge should accord the technical demand.

4.3.3.2.2.3.8 Check that the connecting terminal of coil has no looseness, damage or burning loss and the

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thread section of it should work well.

4.3.3.2.2.3.9 If it need to change the coil connecting terminal, note that keep a distance of over 10 mm
between the two connecting terminals while welding. First envelop the terminal by insulating varnished silk,
and then reel it thickly by cotton wax wire. At last, dip it in varnish and drying it.

4.3.3.2.2.3.10 Check that the yoke, iron core, bracket and armature have no rupture or damage. The yoke,
iron core are installed firmly, and the bracket and armature are riveted reliably.

4.3.3.2.2.3.11 Check that the antimagnetic washer, which under the movable iron core, should not break off.
If it is damaged, replace it or repair it by welding.

4.3.3.2.2.3.12 The adjusting screw and bracket should have no damage. The function is good and the fit
clearance accords the demand.

4.3.3.2.2.3.13 The antagonistic spring should not break, distort in its free state and have a good elasticity.

4.3.3.2.2.3.14 The antagonistic spring, pothook, spring base and adjusting bolts should have no damage and
have a good adjusting/regulating function.

4.3.3.2.2.3.15 The fixed bent plate of the antagonistic spring bolts should have no rupture or looseness, and
should be riveted up reliably.

4.3.3.2.2.3.16 The insulating base and the lining board should have no crack or burning loss. Replace it
when severely distorted. If there is partial burn, scrape it and spread insulating paint on it and then drying it.

4.3.3.2.2.3.17 The nameplate of the device should not shatter or break off. Its label should be clear, and be
installed firmly.

4.3.3.2.3 Assembly

Assemble it accords to the opposite order of the disassembly. While assemble it must pay attention to the
following proceeding:

4.3.3.2.3.1 The left and right movable clearance of the armature iron should accord with the range demand
of 0.2~0.5mm.

4.3.3.2.3.2 The movable contact and the fixed contact should be lined up. The deviation of the assembly
should not exceed 1mm.

4.3.3.2.3.3 The tip break and the over travel of the contact should accord with the dimension limits.

4.3.3.2.4 Debug

4.3.3.2.4.1The action current: is 33r3A. Its action should be exact and flexible.

4.3.3.2.4.2 Debug method: while the pick-up value is too small, then can increase the pretightening force of
the spring or shift up the movable iron core. While the pick-up value is too great /large, the adjusting
method is opposite.

4.3.3.2.4.3 Notes

4.3.3.2.4.3.1 Consideration should be given to every aspect when adjusting. Don’t make the air gap too
small or the extension spring in a loose state.

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4.3.3.2.4.3.2 The position after adjustment should be suitable.

4.3.3.2.4.3.3 The three locating screws, which on the locking nuts, should be loosened or fastened
synchronously to avoid the leaning of the iron core. After adjusting, fasten the nuts and check it again.
When achieve the demands, make the mark of lacquering.

4.3.3.2.5 Insulation test

4.3.3.2.5.1 The insulation resistance between the contact and earth measured by 500V meg-ohmmeter
should exceed 10M¡.

4.3.3.2.5.2 There should be no breakdown or flashover if we carry out the withstand voltage test with
1100V/50Hz sine alternating current for 1 min between the live parts and between live parts and the earth.

4.3.3.2.6 Fill in the maintenance records.

4.3.4 Vulnerable parts

No Description Drawing number Manufacturer
1 The moveable contact groupware --- Xi’an railway signal factory
2 The static contact groupware --- Xi’an railway signal factory

4.4 Intermediate relay

There are several intermediate relays on the locomotive used
for the intermediate delivering and amplifying of the signal.
The coil part of the magnetic flux equips self-induced voltage
suppressor and indicating light to indicate the working state of
the relay. In order to increase the breaking current of contactˈ
permanent magnetic blowout device should be adopted.

The intermediate relay used on the locomotive is Schaltbau

electric appliance, Type S141A-110V-B.

4.4.1 Structure and frame

The structural profile of S141A intermediate relay refers to Fig.
4-28; the installation dimension refers to Fig 4-29; the wiring Fig. 4-28 S141A type Intermediate Relay

diagram refers to Fig. 4-30; the structural profile of S847 auxiliary contact terminal refers to Fig. 4-6.

4.4.2 Main technical specifications

Rated voltage
Rated voltage of contact terminal (Ue): 110V
Rated control source voltage (Us): 110V
Picking-up voltage ”66V
Release voltage •5.5V

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Fig. 4-29: Structural profile of Type S141A intermediate relay

1. Coil connection screw M4, 2. S847 contact; 3. Screw M3 for mounting contact; 4. Bracket plate; 5. Base; 6.
Suppressor; 7. Iron yoke; 8. Coil; 9. Pilot rod; 10. Bracket; 11. Spring; 12. Cam; 13. Positioning plate; 14. Iron core; 15.
Armature; 16. Stopper; 17. Spring seat; 18. Turning plate;

Rated current
Rated operating current: 1A
Conventional thermal current: 10A
Coil specification
Wire type: QZ-1 type
Wire diameter: ) 0.21
Turn: 13200
Resistance: 740: (20ć)
Delay time (coil with suppressor)
Delay time of pick-up: d100ms
Delay time of release: d100ms
Life
Mechanical life: > 1×106 times
Electrical life: > 1×105 times
Weight about 1.6kg
Wire connection mode
Contact M3 screw
Coil M4 screw

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Fig. 4-30 S141A wiring diagram

4.4.3 Repair and maintenance

4.4.3.1 Main equipment and tools

Electric apparatus test-bed, universal meter, withstand voltage tester, meg-ohmmeter and electrician’s
common electrician tools and so on.

4.4.3.2 Main technical process

4.4.3.2.1 Disassembly and clean

All parts of intermediate relay should be kept clean, well-insulated, and be installed correctly with all spare
parts intact.

4.4.3.2.2 Maintenance and assembly

All fastening parts should be intact and well fastened.

4.4.3.2.2.1 Spring should be fully put into the spring seat, and the guide rod should be vertical to iron yoke;
after the intermediate relay picks up, the guide rod and spring seat should be in a straight line. When the
rotor plate is actuated, the spring and its guide rod should move flexibly, having no friction or abnormal
noise. If abnormal noise is heard, the spring can be turned to a certain position to eliminate such
phenomenon.

4.4.3.2.2.2 Moving parts, such as armature, should be actuated agilely without jam. The gap between the
rotor plate and the neck of iron yoke should be more than 0.5mm, or there may be occurrence of mechanical
blockage. If the gap does not meet the requirement, the base can be removed, and the location of locating
plate can be adjusted, to make the rotor plate at its proper position and the armature move agilely.

4.4.3.2.2.3 There is no crack in the cam base and the rivets are not loose.

4.4.3.2.2.4 The maintenance of the contact terminals of the intermediate relay should meet the following
requirements:

When the relay releases, the distance between contact’s roller and its limit position should not be less than

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0.8mm. After the relay is picked up, the gap between the roller and the cam should not be less than 0.1mm.
After a long-time use of contact, the roller rack may be loose and droop. This looseness should be excluded
when checking the gap between roller and cam.

4.4.3.2.2.5 A suppressor is connected in parallel to both ends of coil to suppress the induced EMF, and there
is an indicating lamp. Attention should be paid to the polarity correctness of controlling power source. The
correct wire connection method is “left positive, right negative”. If the indicating lamp doesn’t light up after
energizing, the suppressor should be checked and replaced in time.

4.4.3.2.2.6 The nameplate and labels should be complete, clear and correct.

4.4.3.2.3 Debug

4.4.3.2.3.1 The deviation between the value of coil resistance and its nominal value (740:, 20ć) should not
be more than 10%.

4.4.3.2.3.2 The pick-up and release voltage of intermediate relay should be checked regularly. At normal
working temperature (20ć), the pick-up voltage should not be more than 66V, and the release voltage
should not be less than 5.5V. If the requirement cannot be satisfied, increase or decrease the shims between
the guide rod and the spring to adjust the spring force.

4.4.3.2.3.3 The insulation should be in accord with the following requirements:

The insulation resistance between two live parts mutually insulated, as well as live part and ground, should
not be less than 10M:. (Measured with 500V meg-ohmmeter)

The insulation dielectric strength test should be conducted after repair. There should be no breakdown or
flashover if we carry out the sine alternating current of 50Hz/1100V for 1 min between the live parts and
between live parts and the ground.

4.4.3.2.3. When the contact resistance of the contact is measured with contact resistance tester, S847 should
be lower than 200mȍ. In case that the contact resistance of the contact exceeds the standard, the wire should
be connected as Fig. 4-8 specifies by the means of disconnecting the inductive current load of about 1A
(time constant of 20~50ms) so as to clean out the oxide on the surface with the arc.

4.4.3.2.4 After repair, maintenance record should be filled out as specified.

4.4.4 Vulnerable parts

No Name Drawing No manufacturer
1 rotor plate XS701· 01·00 Xi’an Schaltbau
2 Roller XS413· 03·00 Xi’an Schaltbau
3 Spring XS600· 00·04 Xi’an Schaltbau
4 Suppressor XS600· 08·00 Xi’an Schaltbau
5 Stopper XS600· 00·15 Xi’an Schaltbau

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5 differential manometers
When the pressure of the diesel engine crankcase inside exceeds a
certain value, the high pressure may cause the crankcase
bang/explosion. The locomotive installs a CY-3 difference-show
differential manometer (20KP). One end of the U tube is
connected to the atmosphere, and the other end is connected to the
diesel engine crankcase through the steel tube. When the pressure
inside the diesel engine crankcase overruns 600Pa, the salt
solution liquid level inside U tube would go up. Two needles
touch the liquid level then get conducted through the salt solution.
Meanwhile, it gives a switching value signal to the EXP, and then
EXP controls the diesel engine to stop work for avoiding the
explosion accident.

5.1 Cconfiguration
The differential manometer is a U type organic glass tube, inside
of which there is red salt solution. The two metal needles inside
the U tube are upon the liquid level and don’t connect to each
other. The figure is shown as Fig. 4-31.

5.2 Examine and repair Fig 4-31 pressure gauge

5.2.1 Disassemble
5.2.1.1 Screw out the pipe joint; take out the wire, connecting terminals and air vent pipe joint.

5.2.1.2 Screw out the liquid stopper, land let out the conducting liquid.

5.2.1.3 Clean the liquid stopper by cleaner and then wash them by water.

5.2.2 Examine and repair

5.2.2.1 Check that the organic glass should have no crack or damage; have good clarity; be installed firmly
and reliably; and the nameplate is clear and installed well.

5.2.2.2 The liquid stopper must be well without leaking.

5.2.2.3 The tube joint should be connected to pressure gauge well and the sealing is good after fastening.

5.2.2.4 The touch needle should have no erosion, burning, bend, rupture, break or crack; the base of touch
needle should have no crack; the connecting terminal should be connected well; and the needles should be
parallel and the clearance between each other should be no less than 1.5mm.

5.2.2.5 After installing the touch needles, the needle points must be at the red location of the stop-work area,
and the distance error couldn't be more than r1.2mm, and two touch needles are of the same length.

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5.2.2.6 The outgoing lines of touch needle terminal must be tightened reliably with intact sheath, and can
prevent short circuit.

5.2.2.7 The cover of touch needle terminal must be perfect and installed tightly.

5.2.2.8 The air vent joint should have no crack, damage and the outlet should be upward after fastening and
sealing well.

5.2.3 Test
5.2.3.1 Before adding conductive liquid, checking the insulation between two touch needles with 500V
million- ohmmeter, it must be more than 1M¡.

5.2.3.2 Check the liquid stopper has good sealing by adding the salt solution.

5.2.3.3 Raise the pressure of the connecter between U tube and crankcase by rubber pipette bulb, observe
the state of the liquid surface, and check that the interface to atmosphere should be smooth.

5.2.3.4 Connect the signal lamp (low-voltage) with the outgoing lines in series and put through the power
supply, raise the pressure of the tube joint near the crankcase slowly by rubber pipette bulb to make the
liquid level up to the stop-work area (30mm). When the two touch needles connect through liquid, the signal
lamp will light up.

5.2.3.4 After meeting the request, open the stopper, let out the liquid, clean and dry it, and then put into
storehouse for standby.

5.2.4 Fill in the maintenance records.

6 Toggle switch and pedal switch

6.1 Toggle switch

The toggle switch is featured with flexible operation, high reliability and long service life. The contact
adopts the advanced contact module imported from Schaltbau GmbH (Germany) with protective class of
IP00, compactness, lightweight, convenient installation and large breaking capacity. The toggle switch can
be adapted to different loads through different contact terminals. It is up to such technical standards as
TB1333-96 Basic Technical Specifications of Locomotive Electrical Device.

Schaltbau LS Series and PS Series toggle switches and S126D S008P5 interlock switch (1SK) are used in
the switch assembly on the driver control panel desk of DF8BI locomotive. And 2SK is the toggle switch for
PS3 0/3, 3SK1-2 for PS3-9/7, 4SK1-3 for PS3-0/3, 5SK1-3 for PST3-20/19, 6SK1-3 for PS5-20/19(ĉ),
7SK for LS5-13/5-P5×2(O), 8SK for PS3 9/7 (T), and 9SK for LS3-0/3-P5(ĉ).

LS Series adopt S007a and S008P5 cam switches. PS Series adopt S847 quick-action switches.

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6.1.1 Structure and figure of toggle switch and contact terminals

Fig. 4-32 refers to structure of LX3 a/b toggle switch; Fig. 4-33 refers to structure of LX5 a/b toggle switch;
Fig. 4-34 refers to outlines of contacts of S007a and S008P5 cam-operated switches; Fig. 4-19 refers to
outline of S847 snap-action switch.

Fig. 4-32 LX3 a/b' s structure

1-Contact S007a;2-Contact S008P5;3-Handle;4-Pin;5-Bolt M5.

6.1.2 Main technical specifications

6.1.2.1 Rated Voltage of Cam-operated S008P5 Switch:

Rated Voltage (Ue): DC 110 V

6.1.2.2 Rated current of S847W2A2b Snap-action Switch (Contact):

Rated Voltage (Ie) DC 25 V

Rated Thermal Current (Ith): DC 15A

Rated Current (Ie): DC 1A

Protection grade IP00

Life

Mechnical life >1h106

Electrical life >1h105

Connection mode M5 screw

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Fig 4-33 The structure of toggle switch LX5 a/b

1ˉcontact S007a˗2-contact S008P5˗3ˉ5-position torque˗4ˉspring
pin˗5ˉM5screwDŽ

S008P5 (P6) S007a

Fig 4-34 Contact outline

6.1.3 Maintenance
6.1.3.1 Basic Technical Requirements

6.1.3.1.1 The components should be complete, clean and have no damage, dust or oil stain.

6.1.3.1.2 The fastening pieces of components should be complete, installed reliably and act well.

6.1.3.1.3 The movable parts such as torque should work properly, and have no looseness.

6.1.3.1.4 Switches are in good function.

6.1.3.1.5 Each insulation piece should have no aging, crack, burning or breakdown.

6.1.3.1.6 The switch with lock is unlocked with key, it must work flexibly, and contacted well.

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6.1.3.2 The main equipment and tools

Sweeping tools, universal meter, 500V meg-ohmmeter, contact resistance tester, AC withstand voltage tester
and common electrician tools

6.1.3.3 Main technical process

6.1.3.3.1 Disassembly

6.1.3.3.1.1 Loosen the screws on the pressure plate of the toggle switch in the switch cabinet and
disassemble the switch parts (including the Lock Switch).

6.1.3.3.1.2 Disassembly the plate of the mounting bracket on the support saddle.

6.1.3.3.1.3 Take down the rotating mounting and take off the positioning key locating pin, break down the
movable and fixed contact, handle parts and take out the bakelite parts, pressing spring, antagonistic spring
and positioning roller etc.

6.1.3.3.2 Sweeping and cleaning

6.1.3.3.2.1 Sweep the disassembled parts with air pressure of 0.4MPa~0.6MPa

6.1.3.3.2.2 Clean the inner side of the installing plate, name plate and toggle switch (incluing the lock) with
absolut alcohol,brush and rag.

6.1.3.3.3 Maintance

6.1.3.3.3.1 During inpection of torque switches, the movable and fixed contacts should have no crack,
distortion, overheat or burning, the contact surface should be flat and smooth. The rollers of the movable
contact should roll flexibly and add some # 6 engine oil to the roller shaft. The conductive surface between
the movable contact and connecting bolts should be smooth without burning. Special lubricant should be put
to the circular contact surface between the rotating bridges and the connecting bolts. Cleaning to the surface
with any liquid solvent should be forbiddened. It’s not permitted to wash the surface by any solvent. If the
wearing depth of the movable and fixed contact surface is more than 0.4mm, the contact should be replaced.

6.1.3.3.3.2 The fixed contact has post heads which should be complete, installed reliably and tight.

6.1.3.3.3.3 Press spring and antagonistic spring should not be broken, bent and in case of any obvious
distortion or corrision in its free state, the spring should be replaced.

6.1.3.3.3.4 The fixed lock should be opened conviently and the on-off circuit should be reliable..

6.1.3.3.3.5 Bakelite parts, positioning rollers, rotating mounting parts and troque parts should be free of any
brokens, looseness, serious corrision, or strains. The working face should be smooth without any edges and
the locating pin should have no looseness or crack.

6.1.3.3.3.6 Installing plate and specification plate should be flat without any distortion, brokens crack or
defect. In case of any distortion, adjustments should be done to repair them; In case of crack or defect,
replace them. Name plates of the specification plates should be free of any damages and with clear signs.
The intalling bracket should be well fastened.

6.1.3.4 Assembly

Assembly should be on the reverse sequence of disassembly.

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6.1.3.4.1 All fastening parts should be intact and be fastened well.

6.1.3.4.2 Movable parts, such as armature, should be actuated agilely without jam

6.1.3.4.3 The spring bracket of contact should fall on the respective groove of the conrreponding movable
contact and the notch of the bracket should be parallel to the side of contact, otherwise the control of torque
switch will be out of use.

6.1.3.4.4 The locating pin should be well installaed unless the torque locating will not be relaible.

6.1.3.4.5 When the contact doesn’t act, the space between roller and cam of LS contact should not be less
than 0.3mm (with reference to Fig 4-35);while for PS, the space should not be less than 0.2mm; If the
clearance doesn’t reach, check whether the abrasion of the movable contact exceeds the limit or the torque
doesn’t fully act due to the jam caused by foreign matter (LS series); check whether the roller bracket of
contact loosen or droop. After the contact picks up, the contact tip break of LS series is 5.5±0.5mm; for PS
series is 1~3mm; and the distance between torque and plate should be more than 0.5mm.(reference to Fig 4-
36)

6.1.3.4.6 While connecting wires to the contact, note that if the connection polarity accords with the rule of
“up positive, down negative”, which means the current input is connected to the positive terminal as the
current output is connected to the negative terminal. In addition, the movable and fixed contacts should not
absorb foreign material.

6.1.3.5 Test

6.1.3.5.1 The contact resistance of contact measured by contact resistance tester should be less than 100mȍ.

6.1.3.5.2 The insulation resistance between two live parts mutually insulated, as well as live part and ground,
should not be less than 10M:. (Measured with 500V meg-ohmmeter)

6.1.3.5.3 Conduct insulation’s dielectric strength test after repair. There should be no breakdown or
flashover when we carry out the withstand voltage test with 1100V/50Hz sine alternating current for 1 min
between the live parts and between live parts and the earth.

6.1.3.6 After repair, fill in the maintenance records.

6.1.4 Vulnerable parts

6.1.4.1 LS3 0/3 Toggle Switch
No Name Type Drawing No
1 L series 3-position toggle cam --- XS831· 01·02B
2 Cam Switch S007a XS406· 00·00
3 Cam Switch S008 P5 XS404· 00·00

6.1.4.2 LS5 20/19 Toggle Switch

No Name Type Drawing No
1 L series 5-position toggle cam --- XS840· 01·02L
2 Cam Switch S007a XS406· 00·00

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6.2 S126D Lock Switch

S126D lock switch has equipped mechanical interlock mechanism which ensures the safe operation of the
control circuit.

6.2.1 Structure and figure of S126D lock Switch

6.2.2 Main technical specifications

Rated Voltage
Rated Voltage for Contact 110V DC
Rated current
Rated Current for Contact 40A DC (P6)
25A DC (P5)
1.5A DC (S007a)
Conventional Thermal Current of contact (Ith) 15A DC (S007a)
Protection Class (Pollution Class 3) IP00
Working Life
Mechanical Life >1×106
Electrical Life >1×105
Connection
Contact M6 Screw (S008P6)
M5 screw(S008P5ǃS007a)

6.2.3 Maintenance
6.2.3.1 The lock switch should keep clean, be insulated and fastened well with all spare parts intact.

6.2.3.2 All fastening parts should be intact and fastened in well conditions.

6.2.3.3The insulation of switch should be in conformity with the following specifications.

6.2.3.3.1 The insulation resistance between two live parts mutually insulated, as well as live part and ground
should not be less than 10M:. (Measured with 500V meg-ohmmeter)

6.2.3.3.2 Insulation’s dielectric strength test should be conducted after repair. There should be no breakdown
or flashover when we carry out the withstand voltage test with 1100V/50Hz sine alternating current for 1
min between the live parts and between live parts and the earth.

6.2.3.4 Maintenance of the contacts should be according to maintenance of toggle switch.

6.3 Paddle Switch

Schaltbau S293 S3 paddle switch, the code of which is 7SA1-2, is installed in the locomotive used to
control the sanding and horn circuit.

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Fig 4-37 S126D's structure

1-Contact S008 P5(P6)/S007a; 2-Bolt M5; 3-Lock; 4-Key; 5-Bolt M5 Screw(S008P5,S007a)

Fig 4-38 Paddle Switch S293 S3

Fig 4-39 Switch S293 S3

Fig.4-40 S804b's structure 1-Lock Nut;2-Limit nail;3-Up Cover;4-Cap;5-cover;6-connect
port;7-bottom;8-contactS804b;9-Horizontal Axial
1-Contact 2-Bolt M3.

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Characters of S293 S3 paddle switch: compact structure, flexible operation, and quick-acting
contact, act reliable and long life. The housing is airproof and dustproof.

6.3.1 Structure and Frame

Structure of paddle switch refers to Fig 4-39, and contact terminal S804b refers to Fig 4-3340

6.3.2 Technical specifications

Rated Voltage
Rated Voltage for contact 110V
Rated Current
Rated Current for contact 1A
Conventional Thermal Currrent for contact 10A
Qty of contacts 1 open, 1 closed /1 NO+ 1 NC
Torque less than 35N

6.3.3 Overhaul method

6.3.3.1 Paddle switch should keep clean, be insulated and installed well with all spare parts intact.

6.3.3.2 All fastening parts should be intact and fastened in well conditions.

6.3.3.3 Moving parts, such as caps, should be actuated agilely without jam.

6.3.3.4 The contact is designed free of maintenance and fixed to the bottom case by two M3 screws which
can keep it from outside pollution and interference Open the lock nuts and covers to check whether contact
work reliably or not and whether there is any burn. In case serious burns or inflexible working occurs, the
contact should be replaced completely. The connection lines should not touch the middle horizontal axis in
case of any reduction of insulation.

6.3.3.5 Attentions should be given to the up and down over stroke of the paddle switch during the repair.
The up stroke should be not /not be less than 5mm as contacts break while the down stroke should not be
less than 2.5mm as contacts pick up. In case of failure to this requirement, the two set screws should be
adjusted with removal of the lock nuts of the up cover till the screws meet the satisfaction. Please pay
attention that the two set screws should be at the same height. As for the measurements of up and down
excess of stroke, please refer to Fig 4-41.

6.3.3.6 The insulation of paddle switch should conform to the following requirements:
6.3.3.6.1 The insulation resistance between two live parts mutually insulated, as well as live part
and ground should not be less than 10M:. (Measured with 500V meg-ohmmeter)
6.3.3.6.2 Insulation’s dielectric strength test should be conducted after repair. There should be no
breakdown or flashover when we carry out the withstand voltage test with 1100V/50Hz sine
alternating current for 1 min between the live parts and between live parts and the earth.

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Fig 4ˉ41 Up and down stroke measurements for S293 S3 Paddle Switch

6.3.4 Vulnerable parts

Item Name Specifications Drawing No.
1 Spring maintaining plate --- XS750-00-02
2 Snap Switch S804b 1-1523-272169

7 The locomotive head lamp

The LW-800(1) halogen tungsten head lighting adopts a new type efficient halogen tungsten lamp for light
source and paraboloid reflector with short focal length and high performance. It has no trigger, and the
dimming resistor is running with the lamp which could light up as electrified. It has good stability and
excellent color rendering capability, which wouldn’t change the real color of the object, and it can help to
identify the barrier quickly without disturbing the signal along the route. At the same time it is suitable to
work under the fog due to the wide illuminating surface and the even illumination which can reduce the
glare effect. The lamp should be put horizontal and can be regulated stably and reliably. When adjusting the
focus forward and backward, the lamp isn’t likely to break.

7.1 Technical parameter

Type LW-800(1)
Type of light source LJQ110-800
Power voltage 110V DC
Total power 800W
Range 600m
Valid scattering angle 5e
Lamps dimension 260mmh240mmh440mm

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7.2 Configuration
Gen tungsten head lighting consists of lampǃreflector and lamp
body. The figure is shown as Fig. 4-42.

7.2.1 Lamp

The bulb is high efficient halogen tungsten lamp with quartz

glass shell.

7.2.2 Reflector

The reflector is parabolic glass with new type with membrane

outside.

7.2.3 Lamp body

The lamp body constitutes of bottom plateǃpitching regulating Fig.4-42 LW-800(1) Head lamp

mechanismǃconnecting terminalǃbracketǃregulating
resistorǃlamp bracket and focusing mechanism.

7.3 Examine and repair method

7.3.1 Repair equipmentǃfixturesǃmeasuring tools and material

Blowing equipmentǃcommon locksmith toolsǃ500V meg-ohmmeterǃcottonǃabsolute alcohol and the

test bench of head lamp.

7.3.2 Main technical process

7.3.2.1 Examination and repair

7.3.2.1.1 Blowing the dust with 0.2Mpa compress air, and cleaning every surface of the head lamp with
tender cloth that prevent anything would scrape the reflector.

7.3.2.1.2 Check the lamp bracketǃreflectorǃlamp, and insure that there is no breakdown, corrosion or
damage.

7.3.2.1.3 The connecting wire of the terminal post, terminal and dimming resistor should have no
discoloration, burning or rupture.

7.3.2.1.4 Check that every part and bottom plate have no rupture or burning, and the outgoing lines have no
damage or looseness.

7.3.2.2 Insulation measurement:

Measuring everyone that has electric with 500V meg-ohmmeter, insure them all bigger than 5 meg-ohms.
The insulation resistance between every live part and the ground should be more than 5 M¡ measured by
500V meg-ohmmeter.

7.3.2.3 Light regulation

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7.3.2.3.1 Regulation of horizontal direction

Screw off the 4 mounting bolts of the bottom plate, and rotate the lamp slowly till the brightest lighting is
gathered at the track center. At last screw down the bolts.

7.3.2.3.2 Pitching regulation

Screw off the locating screws in the middle of the lamp bottom plate, and rotate the focusing button till the
brightest lighting is gathered at the 200m in front of the track. At last screw down the locating screws and
the bolts of the lamp bracket.

7.3.2.3.3 Focus regulation

Under the dark environment, light up the head lamp, irradiate the white screen which is 15mm away; rotate
the focusing button till the lightness is gathered as the bright facular of ž500mm and thus regulating is over.
(After regulating, the distance between the front surface of the sliding block and the end surface of the
reflector hole is about 7~10mm)

8 The electric equipment repair limit of DF8BI locomotive

The electric equipment repair limit of DF8BI locomotive

Limit
No. Appellation Shape
Mid Repair Prohibit
2 Operation mode transfer switchǃ direction transfer switch
2.1 Movable contact finger thickness 17.5 ı16.5 <16.3
Main contact line length The contact line length of main
2.2 ı29.5 ı29.5 <29.5
contact
2.3 Main contact pressure (N) 155~200 155~200 <150
2.4 Exceed distance Over stroke 5.5~7.0 ı3.0 <1.8
2.5 Auxiliary contact tip break ı25 ı25 ˉ
2.6 Auxiliary contact over stroke 3.0~4.8 ı3.0 ˉ
2.7 Auxiliary contact pressure (N) ı3.3 ı3.0 ˉ
3 earth fault relayǃover-current relay
3.1 Contact tip break ı3 ı3 ˉ
3.2 Contact over stroke ı1.2 ı1.2 ˉ
3.3 Contact pressure (N) ı1.0 ı1.0 ˉ
3.4 Movable contact thickness 2.0 1.5 ˉ
3.5 Fixed contact thickness 1.5 1.0 ˉ
4 Schaltbau S140 DC contactor
4.1 Main contact moving-fixed surface wear thickness ˉ <0.4
4.2 tip break when main contact break 6.0f0.8 6.0f0.8 ˉ
Distance between roller and cam when main contact pick
4.3 ı0.5 ı0.5 ˉ
up

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Limit
No. Appellation Shape
Mid Repair Prohibit
Trolley limit location exceed distance when Distance
4.4 between roller and limit position when auxiliary contact ı0.8 ı0.8 ˉ
acts
Distance between roller and cam when auxiliary contact
4.5 ı0.1 ı0.1 ˉ
doesn’t act
5 Schaltbau S141 series intermediate relay
Distance between roller and limit position when relay
5.1 ı0.8 ı0.8 ˉ
releases
5.2 Distance between roller and cam when relay picks up ı0.1 ı0.1 ˉ
6 Schaltbau TKS series master control
6.1 Distance between roller and cam when contact doesn’t act ı0.5 ı0.5 ˉ
7 Schaltbau toggle switch
7.1 Contact tip break when toggle switch breaks 5.5f0.5 5.5f0.5 ˉ
Distance between roller and cam when toggle switch picks
7.2 ı0.3 ı0.3 ˉ
up
7.3 Contact top cap exceed distance when button acts ı1.0 ı1.0 ˉ
Distance between contact and top pole when button doesn’t
7.4 ı0.3 ı0.3 ˉ
act
8 Schaltbau S293 S3 paddle switch
8.1 Up stroke ı5.0 ı5.0 ˉ
8.2 Down stroke ı2.5 ı2.5 ˉ

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Chapter 5
Semiconductor device

1 PRS series protection device

PRS series protection device is suitable for DC circuits with relatively large inductive load which could
limit the self-induced EMF created by inductive load when disconnecting power supply. It is competent to
suppress the high-voltage electromagnetic interference of the locomotive circuit and extend the contact
service life of DC contactors. The protection device of this series can be mainly divided into two types,
PRS-80 (160) and PRS-80C.

PRS-80 (160) protection device shall be connected in parallel to the two terminals of inductive load while
working to limit the self-induced EMF created by inductive load when disconnecting power supply. It is a
device integrating fly-wheel diode, short-circuit protection, over voltage protection and blown fuse
indicating in together, which could suppress the high-voltage electromagnetic interference of the locomotive
circuit and increase the contact service life of DC contactors. The main protection objects are starting
contactor (6KM) and excitation contactor (8KM) on diesel locomotive.

When using PRS - 80C series protection device, it should be connected in parallel to the two ends of contact
requiring protection, and the arcing of contacts can be suppressed when the contacts are breaking. It is a
device integrating RC protection, short-circuit fuse breaking protection, and over voltage protection together,
which could suppress the high-voltage electromagnetic interference of the locomotive circuit and increase
the contact service life of DC contactors. The main protection objects are DC contactors which are turning
on and off frequently, such as contactors used for air compressors (9KM1~2) on locomotives.

1.1 PRS-80 (160) protection device

1.1.1 Principle
For the DC inductive load, larger self-induced EMF may be created across the two terminals of inductive
load L when disconnecting the power supply. The self-induced EMF created at this time has bad effect on
the contact of the contactor KM and the circuit in the case that no any protection device is connected. PRS
protection device shall be connected in parallel across the two terminals of inductive load L, connecting the
positive terminal of PRS to the current-input side of inductive load L, and the negative terminal to the
current-output side. When disconnecting the power source, the self-induced EMF created across the two
terminals of inductive load L shall be released through diode V and fuse FU in the PRS protector, to
suppress the occurrence of the self-induced EMF created by large capacity of inductive load L, which could
reduce the high-voltage electromagnetic disturbance in the circuits of locomotives, and extend the service
life of contact KM for DC contactor. With feature of time delay burn out, the fuse FU in PRS protection
device can withstand large impulse current within short time. In the case of relatively large current
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occurring in the circuit for a long time, the fuse FU will burn out, to ensure the safety of circuits and electric
appliances. After the fusant burns out, the leads of blown fuse indicator burns out, and the indicator pops up,
giving out alarm for checking and replacing. The resistor-capacitor RC may act as over-voltage protector.

1.1.2 Configuration and wiring principle

Shapes of PRS-160 (80) protection device are shown in Fig. 5-3 and Fig. 5-4. Wiring diagram and
schematic circuit diagram of PRS-160 (80) protection device are shown in Fig. 5-5 and Fig. 5-6.

Fig. 5-3 Shape of PRS-160 Fig. 5-4 Shape of PRS-80

Fig. 5-5 Wiring Diagram Fig. 5-6 Schematic Circuit Diagram

1.1.3 Main technical parameters

Item PRS-160 Protector for 6 KM starting PRS-80 Protector for 8 KM excitation
contactor contactor
Repetitive reverse voltage URRM ı1500V ı1500V
Mean forward current IF 160A 80A
Protective current for burning out IeR 600A (1S) 1200A (0.2S) 300A(1S) 600A(0.2S)
Surge current 680~720A(voltage drop 1.15~1.25V) 680~720A(voltage drop 1.65~1.75V)

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1.1.4 Cautious
a. For external wiring, the positive and negative polarity should not be reversed. The correct wiring should
be: connecting positive terminal parallel to the current-input side of inductive L, and the negative terminal
parallel to the current-output side.

b. The cross-section of outward connecting wire of the PRS-80 protectors should be no less than 3mm2. The
cross-section of outward connecting wire of the PRS-160 protectors should be no less than 4.5mm2. The
bolts for outward wire connection should be M8.

c. The height of blown fuse indicator should be the same as that of cover plate under normal circumstance.
It shows that the protector is damaged from breakdown if the blown fuse indicator pops up 3mm higher than
the cover plate. It is necessary to replace it for ensuring the reliable operation of main contact.

1.1.5 Repair and maintenance

a. Ensure that the blown fuse indicator of PRS protection device is not jammed.

b. All fasteners should be complete, well fixed and fastened with intact components.

c. Reverse withstand voltage test: connecting the positive wiring terminal to the positive polarity of power
source, and the negative wiring terminal to the negative polarity of power source. It should withstand 1500V
DC voltage without breakdown and flashover within 1 minute. (As there is absorber circuit inside, the
testing voltage shall rise at a slow speed; otherwise high drain current may cause false alarm.)

d. Surge current test:

Since the diode in the protector is reversely connected, the positive wiring terminal of the protector must
connect to the negative terminal of test instrument, the negative wiring terminal of the protector to the
positive terminal of test instrument during the test. The measured values should conform to the values listed
below:

Surge current test values

Model Surge current (A) Forward voltage drop
PRS-160 680~720 1.15~1.25
PRS-80 680~720 1.65~1.75

DBC018-TM thyristor tester for measuring the on state peak voltage may be applied as the test instrument.

e. When the electrical cabinet is under withstand voltage test, both terminals of PRS should be short-
circuited.

f. Fill out repair and maintenance record.

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1.2 PRS-80C protection device

1.2.1 Operating principle

When the power supply is connected and 9KM1-2 contactors are disconnected, the capacitor installed in the
PRS - 80 C protection devices begins to be charged. Although the charging current is comparatively high,
the charging duration is short (less than 5 ms). Hence, the malfunction of 6MA motor will not occur.
During the long-time connection to the power supply, the current passing through 6MA motor is about
10mA, the temperature of protection device will basically not go high.

When the 9KM1-2 contactors are closed, the capacitor cannot discharge to the main circuit due to blackout
of the diode. There is a discharging circuit in the inner part of PRS. After discharging for 5s, the terminal
voltage of capacitor can be decreased to less than 5% Ue.

When the 9KM1-2 contactors are again breaking again, the capacitor will absorb the arc energy created
during the breaking of the contacts due to the fact that there is a PRS-80C protection device connected in
parallel to the main contacts of 9KM contactor, making the galvanic corrosion of the contacts to be greatly
reduced, hence increasing greatly the service life
of contacts.

When fault occurs in some parts of the circuit, the

fuse installed in the protective device will clear the
fault part, and the normal operation will not be
influenced.

1.2.2 Structure and wiring

principle
Shape of PRS-80C protection device is shown in
Fig. 5-7. Wiring diagram and schematic circuit
diagram are shown in Fig. 5-8 and Fig. 5-9. Fig. 5-7 Shape of PRS-80C protection device

Fig. 5-8 Wiring Diagram Fig.5-9 Schematic Circuit Diagram

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1.2.3 Main technical parameters

Rated operating voltage Ue DC110V
Capacitance of capacitor ı2200uF
Average forward current of diode IF 80A
Peak forward current of diode 400 A
Discharging time of capacitor (external) <5s
Discharging time of capacitor (internal) <180s

1.2.4 Repair and maintenance

a. Ensure that the fuse blown fuse indicator of PRS protection device is not blocked.

b. All fasteners should be complete, well fixed and fastened with intact components.

c. The capacitance between the “TEST” end and the negative end shall be measured with a capacitance
meter and the total capacitance shall be no less than 2500­F.

d. In case that the shell is deformed, the capacitance value is lower than specified value, or the diode is
damaged etc, it shall be replaced in time.

e. For outward wire connection, the positive and negative polarity should not be reversed. The correct
wiring should be: connecting positive terminal parallel to the positive end of the contact of the contactor,
and the negative terminal parallel to the negative end.

f. The cross-section of outward connecting wire of the PRS-80C protector should be no less than 3mm2. The
bolts for outward wire connection should be M8.

g. Fill out repair and maintenance record.

2 Voltage Regulator

2.1 Summarize
TPZ9A voltage adjuster can adjust the output voltage of
the auxiliary generator to be 110Vf2V automatically.
It also owns the perfect over-voltage and under-voltage
protecting function. When the output voltage is higher
than 125V+2V caused by auxiliary generator fault, the
device can stop working automatically and self-lock. At
the same time make the external circuit turn to the fault
excitation state. When the auxiliary voltage feedback
disconnects the device, adjusts the pulse of switching tube
Fig. 5-10 Profile of voltage adjuster
automatically and ensure the auxiliary generator output
not to be over-voltage.

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2.2 Technical specification

Boundary dimension: 320h290h100(lengthhwidthhheight)mm, Fig. 5ˉ10 shows the contour of
voltage regulator.

Redundancy: the auxiliary generator control device is designed according to single piece. One locomotive
owns two devices, cold backup.

External interface: the connector assembly adopts the TY48K20TY and TY48J20ZY type electric connector
produced by Luoyang aeronautic electrical equipment factory. The pin definition of panel 20-core socket
(TY48J20ZY) is as follows:
Pin Number Wire number Pin definition
1 FQ Feedback of auxiliary generator voltage
2 FQ Feedback of auxiliary generator voltage
3 QDKZ Air compressor startup control
4 QGZX Air compressor startup realization
5 CK1 Normal open contactor 1
6 CK1 Normal open contactor 1
7 CK2 Normal open contactor 2
8 CK2 Normal open contactor 2
9 CB1 Normal close contactor 1
10 CB2 Normal close contactor 2
11 GD High end of exciting voltage
12 GD High end of exciting voltage
14 DD Low end of exciting voltage
15 DD Low end of exciting voltage
17 COM GND
18 COM GND

2.3 The principle of voltage regulator

The voltage regulator samples the output voltage of auxiliary generator and compares it with the control
base voltage of auxiliary generator to control the magnetic current of auxiliary generator. It guarantees the
auxiliary generator output voltage to be steady in range of 110Vf2V. When the fault of auxiliary generator
makes the output voltage to be higher than 125V+2V, the device will stop working automatically and self-
lock. At the same time makes the external circuit turn to fault excitation state. When the auxiliary voltage
feedback breaks the device, adjusts the pulse of switching tube automatically and ensures the auxiliary
output not to be over-voltage.

2.4 Installation
The voltage regulator is installed on the frame horizontally. It is fastened with M6 screw. Connect the
external wire and plug in, turn on the panel switch and the device begins to work. The panel potentiometer
is applied into adjusting the 110V output voltage.

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2.5 Overhaul method

2.5.1 Basic technical requirement

a. All connecting wires shouldn’t be short, insulation ageing or deteriorative. Among which the broken
strand of multi-strand wire should not exceed 10%.

b. All the wiring should be bound reliably. The printing circuit board should not be broken, corrosion or
loose.

c. Every component should not be loose. The soldering joint should have no corrosion, cold welding or false
welding.

d. The plug and socket should not be broken and crack.

e. The performance and parameters of every component should accord with the requirement.

f. When test it with generator, the output voltage of generator should be stabilized at the range of 110f2V
and have no obvious fluctuation if the rotating speed and load change.

g. Adjust the potentiometer R23 of printed board. Viz, adjust the over-voltage protecting value of 125V.

2.5.2 Main instruments and tools

a. Voltage adjuster test bench and constant temperature oven.

b. Oscilloscope.

c. Digital frequency meter

d. Transistor characteristic graphic instrument

e. Integrated block test tester (the test board according to different model)

f. Universal meter, capacitance meter

g. Electric soldering iron (two pieces: 25W inner-heat type and tin-extracting type), tweezers, brush, cutting
nipper, screwdriver, open wrench, scissors, soldering tin etc common Electro-technical tools.

h. Alcohol for cleaning

i. All measuring instruments and shell of electric soldering iron must be grounding lest to damage the
integrated circuit.

2.5.3 Main technical process

a. The test before overhaul

b. Remove the voltage regulator from the locomotive and put it on the test bench. Observe whether its
working state is good or not and what fault it has. Confirm the major test part according to the forecasting
record.

c. Disassemble the printed circuit board

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d. Observational check and maintenance

(1)Wipe off the dust and oil stain with brush or cloth. And blow it clean with 0.6MPa compressed air.

(2)If any component is loose, please fasten it.

(3)If there is corrosion at soldering joint of component please weld it again.

(4)Check the connecting wire

ķThe wire should not be broken. If the soldering joint of multi-strand wire breaks more than 10%, it should
be welded again. If the broken strand rate exceeds 10%, the wire should be replaced.

ĸIf there are overheat, colour-change or ageing phenomena in wire insulating layer and the soldering joint
is eroded badly, the wire should be replaced. The bad joints should be cleared.

(5)Check the quality of every component

ķIf the component doesn’t accord with the requirement, such as: overheat, colour-change, crack, it should
be replaced.

ĸWhen weld transistor, the action must be quick and accurate. What’s more the heat emitting measure must
be adopted. The corrosive soldering flux must be forbidden. The soldering flux must be cleaned with
alcohol or silk cloth after welding.

(6)The soldering joint on the circuit board should be smooth, firm and heave 2mm or so. The cold welding
or short should be forbidden. The metal foil should not be separated from board base.

(7)If there is damage and crack in plug and socket please replace them. The finger touch should not have
burning loss and color changing. Its flexibility is normal.

(8)The new components must be tested and sifted before using them. The measured parameters must reach
the corresponding standard and accord with the performance requirements of electrical equipment.

d. Test

(1)Short the each joint of external subassembly of voltage regulator and measure the shell insulating
resistance with 500V meg-ohmmeter. The resistance should not be less than 10 M¡.

(2)Put the voltage regulator on the test bench and put through the plug. Adjust the resistance of panel
potentiometer to the maximum and startup the DC assembly unit. Then the voltage regulator enters the
working state. The generator should display voltage value.

ķIncrease the rotating speed of generator (viz. motor rotating speed) to 1078 r/min. Adjust the panel
potentiometer to raise the voltage to 110V rated voltage. Screw down the locking nut. Increase the generator
rotating speed gradually and observe the changing state of voltage. When the rotating speed boosts to 2695
r/min, the voltage should be stabilized in the range of 110f2V and there is no obvious fluctuation. Adjust
the panel potentiometer, as the printed circuit board potentiometer R23 boosts to the voltage stably to 125f
2V, the over-voltage relay should act.

ĸIf fault occurs during test, the cause should be examined. Clear the fault and repeat the test.

ĹThe test should be done in normal temperature and high temperature conditions respectively. The
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performance should accord with the regulated requirement. The high temperature test will be done after
putting the voltage regulator into the constant temperature oven (the temperature is 70f2ć, allowable
module working state) for an hour.

ĺAfter testing qualifiedly on test bench the voltage regulator must be taken to the locomotive to do loading
test. When blow at 0 position, the voltage regulator should work normally.

ĻThe locking nut of adjusting potentiometer should be locked after adjustment. Then Test its performance
again. If the testing result accords with the requirement dot a lacquer label on locking nut.

e. Fill out the overhaul record.

3 Voltage Boosting Modules

3.1 Summarize
DC/DC voltage boosting and filtering module is a voltage boosting and filtering device that is researched
specially for settling the power-fail down problem of microcomputer and display, which is caused by the
unstable voltage when diesel engine of diesel locomotive startup. It applies into all DF type diesel
locomotives. When diesel engine starts, motor starts, and air compressor starts while locomotive diesel
engine or locomotive works normally, it would cause the power supply voltage of control system to
fluctuate in large range. The voltage boosting and filtering module can control the voltage of working power
supply stably through automatic adjustment. It can avoid the power-fail down of control system and ensure
the normal working.

3.2 Technical specification

3.2.1Boundary dimension: 239×126×44 (length × width × height) mm, Fig. 5-11 shows the contour of
voltage boosting and filtering module.

Fig. 5-11 Contour drawing of voltage boosting (and filtering) module

3.2.2Redundance: the voltage boosting and filtering module is designed according to double pieces, hot
backups.

3.2.3External interface: The connecting assembly adopts the LYP21ZJ9U and LYP21TK9UQ type electric
connector. The pin definition of panel 5-core socket (LYP21ZJ9U) is as follows:
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Pin number Wire number Pin definition

1 OUTG 110V output ground
2 ING 110V input ground
3 OUT+ 110V output
4 IN+ 110V input
5 PB Mask

3.2.4 Load characteristic

Input voltage: DC 30V ~ 97V ˗ 97V ~ 140V
Output voltage: DC 92V ~ 97V ˗ (97V ~ 140V)-3V
Output current: DC 0.1A ~ 1A

3.2.5 Voltage stabilizing performance

The allowable output current of this module is 1A. When the input voltage is less than 97V, the voltage
boosting and filtering function of this module works and makes the output voltage to be (92V ~ 97V). When
the input voltage is more than 97V, the voltage boosting function stops working and the module is used as a
power supply filter. The differential voltage of input and output voltage is less than 3V.

3.3 Operating principle of voltage boosting and filtering

module
Figure 5-12 shows the block diagram of voltage boosting and filtering module.

Energy storage Rectifying circuit

Vin+ Vout+

Current
First Filter circuit

Auxiliary power supply

Voltage sampling

transformer
Second filter
Chopping control

Chopping tube

Vin
Vout-

Fig. 5-12 Functional block diagram of voltage boosting and filtering module

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The voltage boosting and filtering module mainly consists of first filter, auxiliary power supply, energy
storage inductor, chopping control circuit, current transformer, chopping circuit, rectifying circuit, voltage
sampling circuit and second filter. The first filter is parallel connected between the anode and cathode of
input port of power supply. It filters the input voltage. The auxiliary power supply is parallel connected
between the anode and cathode of input port of power supply. It provides power for other circuit. The
energy storage inductor and rectifying circuit constitute the first series branch. It is connected between the
anode of input port and output port of power supply. The chopping tube and current transformer constitute
the second series branch. It is parallel connected between the middle point of above first series branch and
cathode of input port of power supply. Chopping control circuit includes a control integrated circuit, which
connects with the output port of auxiliary power supply. The current inducing signal of current transformer
is connected to the current signal input port of this control integrated circuit. The output port of the control
signal is connected to the control port of above chopping tube. The voltage sampling circuit is parallel
connected between the anode and cathode of power supply output port. It samples the output power supply.
The output port of sampling signal is connected to the voltage signal input port of control integrated circuit
of chopping control circuit. The second filter is parallel connected between the anode and cathode of power
supply output port. It filters the output voltage.

3.4 Operating Specification

After fastening the voltage boosting and filtering module with M7 screws, put through the external wire and
plug in. Then turn on the panel switch and make the module work. The panel indicating lamp1 and lamp 2
are both on to show that the inside circuit works normally. If the indicating lamp1 or indicating lamp2
illuminates and turns off orderly, it means that the inside hot backup circuit goes wrong. At this time the
module can still work normally. But it needs overhauling.

3.5 Overhaul method

3.5.1 Basic technical requirement

a. All connecting wires shouldn’t be short, insulation ageing and deteriorative.

b. All the wiring should be bound reliably. The printing circuit board should not be broken, corroded and
loose.

c. Every component should not be loose. The soldering joint should have no corrosion, cold soldering or
false soldering.

d. The plug and socket should not be broken and should not have crack.

e. The performance and parameters of every component should accord with the requirement.

3.5.2Main instruments and tools

a. Voltage boosting module test console and constant temperature oven

b. Oscillograph

c. Digital frequency meter

d. Transistor characteristic graphic instrument

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e. Integrated block tester (the test board according to different model)

f. Universal meter, capacitance meter

g. Electric soldering iron (two pieces: 25W inner-heat type and tin-extracting type), tweezers, brush, cutting
nipper, screwdriver, open wrench, scissors, soldering tin etc common Electro-technical tools.

h. Alcohol for cleaning

i. All measuring instrument and shell of electric soldering iron must be grounding lest to damage the
integrated circuit.

3.5.3Main technical process

a. The test before overhaul

Remove the voltage-boosting from the locomotive and put it on the test bench. Observe whether its working
state is good or not and what fault it has. Confirm the major test part according to the forecasting record.

b. Disassemble the printed circuit board

c. Observational check and maintenance

(1)Wipe off the dust and oil stain with brush or cloth. And blow it clean with 0.6MPa compressed air.

(2)If the component is loose, please fasten it.

(3)If there is corrosion in soldering joint of component please weld it again.

(4)Check the connecting wire

ķThe wire should not be broken. If the soldering joint of multi-strand wire breaks more than 10%, it should
be welded again. If the broken strand rate exceeds 10%, the wire should be replaced.

ĸIf there are overheat, colour-change or ageing phenomena in wire insulating layer and the soldering joint
is eroded badly, the wire should be replaced. The bad joints should be cleared.

(5)Check the quality of every component

ķIf the component doesn’t accord with the requirement, such as: overheat, colour-change, crack, it should
be replaced.

ĸWhen weld transistor, the action must be quick and accurate. What’s more the heat emitting measure must
be adopted. The corrosive soldering flux must be forbidden. The soldering flux must be cleaned with
alcohol or silk cloth after welding.

(6)The soldering joint on the circuit board should be smooth, firm and heave 2mm or so. The cold joint or
short should be forbidden. The metal foil should not be separated from board base.

(7)If there is damage and crack in plug and socket, please replace them. The finger touch should not have
burning loss and change color. Its flexibility should be normal.

(8)The new components must be tested and sifted before using them. The measured parameters must reach
the corresponding standard and accord with the performance requirements of electrical equipment.

d. Test

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(1)Short the each joint of external subassembly of voltage boosting and filtering module and measure the
shell insulating resistance with 500V meg-ohmmeter. The resistance should not be less than 10 M¡.

(2)Put the voltage-boosting module on the test bench and put through the plug. Turn on the panel switch and
make the module to work. If the panel indicating lamp1 and indicating lamp2 are both on, it shows that the
internal circuit works normally.

e. Fill out the overhaul record.

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Chapter 6
Ammeter Module, Anemometer Module,
Sensors and Battery

1 The ammeter module

1.1 Summarize
ZDZ1-5 Multi-functional Indicator Module (Ammeter Module) consists of locomotive double-needle
speedometer (Speedometer, mounted by users), electric measuring double-needle indicator (Indicator, mode
YDS-2), state-indicator light and other parts. It is mounted on the locomotive control panel to display the
running parameters, equipment operating state and other relative information to the operator. Its modular
structure makes the installation very convenient, clear display and high reliability.

1.2 Function
1.2.1 Measure and display the current-speed of the running train and limited-speed of section.
1.2.2 Measure the running parameters of the locomotive equipment such as voltage and current.
1.2.3 Display the working state of the equipment, such as operating state and malfunction state.

1.3 Transmitting mode

Adopt analog transmitting.

1.4 Main technical parameters

The technical condition of the ammeter module includes the synthetic parameter and the technical condition
of the double-needle speedometer, electric measuring double-needle indicator, state-indicator light and
others parts.

1.4.1 Synthetic parameters of the ammeter module

Working voltage DC 110V(1±20ˁ)
Lighting voltage DC 110V(1±20ˁ)
Signal voltage DC 110V(1±20ˁ)
Maximum power 12W
Insulation resistance no less than 5M:
Voltage endurance 1000V, 1min
Apply environment - 25ć~+50ć˗relative humidity: İ 95ˁ
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Outer magnetic field interference 0.4kA/m

Mechanical performance vibration 10m/s2 (tri-direction)
impact: 30m/s2 (longitudinal)
Protect capability dust-proof

1.4.2 Main technical parameters of double-needle speedometer

Measuring range 0~120km/h
Input signal 0~20mA
Accuracy class 1.5
It conforms to the TB/T1334-93 technical standard for the analog electric measuring indicator.

1.4.3 Main technical parameter of double-needle indicator

Accuracy class˖ 1.5
Damping˖ Not exceed 4s

It conforms to the TB/T1334-93 technical standard for the analog electric measuring indicator.

1.4.4 Main technical parameter of state-indicator light

The state-indicator light adopts a LED luminescent tube with two optional colors (red and green). Each light
can indicate the working state of the locomotive with Chinese characters and figure. The brightness of the
light can be adjusted manually, and it also has self-checking function.

Main technical parameter of the state-indicator light:

Brightness adjustment includes five shifts of ultra-bright, hypo-ultra-bright, medium-bright, hypo-medium-

bright and bright (Manually).

It conforms to the TB/T3021 technical standard for the electronic device of railway locomotive and rolling
stock.

1.5 Circuit principle diagram

S1 S1 Delay circuit Control circuit

S3 Self-checking circuit
DC DC/DC DC

Control signal
Input circuit

Driving circuit Display circuit

S1ǃS2 is adjusting manually button for brightness of light, S3 is the self-checking button.
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The electric ammeter module includes

1.5.1 The ammeter installation board

It is mainly used to install the speedometer, double-needle meter and indicators; they are fixed on the
driver’s control platform via the meter installation board.

1.5.2 ‫ ג‬Control voltage/charge-discharge current” , ‫ ג‬main voltage

and main current‫ ד‬meter
It is a general electromagnetic double-needle meter for locomotive, the control voltage meter’s (150V) full
scale stimulus value is 150V, the charge-discharge current meter’s (f100A) full scale stimulus value is ˉ
75mV~ˇ75mV,main voltage meter’s (1000V) stimulus value is 5mA,The main current meter’s (8000A)
stimulus value is 8A. The positive terminal of the connection line is “1” or “5”˗ The negative terminal of
the connection line is “3”or “7”. The underside of the meter is the lighting source of 110V. This meter
adopts the field lighting, which is soft and uniform, is beneficial to the user’s eyes.

1.5.3 Indicator lights

When powered on, all indicator lights flicker automatically (if control signal has been connected, the lights
will be constantly on) and self-check, the power indicator light I, II and auto-light turn on. When some
input the control signal, the corresponding lights turn on.

Brightness adjustment: In this mode, press the Ƹ button, it turns to be brighter, and it shields to be medium-
bright after it is pressed three times; Press the ͪ button, it becomes dimmer, and it shields to be medium-
bright after it is pressed three times. It has five shifts: ultra-bright, hypo-ultra-bright, medium-bright, hypo-
medium-bright and bright.

Self-check button˖Press “self-check” button, all indicator lights flicker (if control signal has been
connected, the lights will be constantly on), start self-check. Test if the circuit or indicator light is normal or
not.

1.5.4 Speedometer
This speedometer adopts the EGZ 3/8 model, 0~160Km/h, the exciting value is 0~20mA, the internal
illumination adopts the DC110V,0~106Km,the mileage accumulation adopts the double-needle wide scale
meter, the external needle is for the speed limit, the inner pointer needle is for the actual speed, the mileage
counting signal is the DC110V 15mA(the pulse time length is ı150ms).

1.6 Outline and Definition of connection

Outline dimension is 340mm×250mm×135mm, mounting hole: 4-I5.5, frontispiece has ž10.5h90edeep

holes. The background color of the module panel is black. The installing dimension is 325mmh180mm.

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Outline of ammeter module refers to Fig. 6-1, back view refers to Fig. 6-2, and definition of the meeting of
the estate display refers to Fig. 6-3.

Signal plug
Fix bolt

Speedometer fix bolt instrument fix bolt

Fig. 6-1 Outline of ammeter module

Corresponding position (A~X) of the panel to the core NO.(2dǃ4dǃ6dĂĂ24dǃ2zǃ4zǃ6zĂĂ

24z)32d: power +ǃcontrol signal; 32z˖power -ǃcontrol signal.

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A B C D E F G H I J K L

M N O P Q R S T U V W X

Estate light
Fig. 6-3 definition of the meeting of the estate display

Resistor

Input current Splitter Input voltage

Light voltage

Fig. 6-4 Voltmeter and ammeter wiring

See figure 6-4, the voltmeter (5mA) and relevant multiplicator (accessory) should be used in pair; the
voltmeter should be series connected with the multiplicator.

See figure 6-4, the ammeter (75mV) and corresponding current divider (accessory) should be used in pair.
The ammeter should be parallel connected with the current divider.

Note:

a) The wires which used in 75mV ammeter checking has the overall resistance value of 15:±0.05:˗

b) The voltmeter with input value 150V adopts inner attached resistor, the voltage value can be input
directly according to the input value of the scaling panel.

c) The ammeter with input value 8A adopts inner attached current divider; the current value can be input
directly according to the input value of the scaling panel.

d) The needle of bidirectional ammeter moves up when post 1(5) connected with 3(7), whereas it moves
down.

1.7 Maintenance and Note

1.7.1 Maintenance
The module including state-indicator lights should be checked before installing onto the locomotives or
every 6~12 months after installation (include indication light).

When abnormities occur, the module should be maintained or replaced immediately.

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Take off four M3 screws on the cover of lights, three M3 screws on the PCB, then the lights could be pulled
out and replaced, make sure that the small dots( + pole) should be the same direction when reinstall it.

The control board can be pulled out for repairing after taking off four M3 screws on the back cover.

When take off all the M3 screws around the box, the speedometer, ammeters and light-adjusting PCB could
be pulled out for maintenance, be careful not to damage the illuminating wires in reinstallation.

1.7.2 Notes
1.7.2.1 The connector plugs of the 48-core and 9-core speedometer must be firmly screwed. The fastening
screws of the 48-core plugs are the spare parts (M2.5h12).

1.7.2.2 Place the front side of the module on a soft object like a thick sponge; avoid to be scratched by hard
stuff. When install onto the panel, first fix the upper two bolts then the lower two, when disassemble firstly
remove the lower two then the upper two.

1.7.2.3 All the plugs should be firmly covered by sleeves to prevent from inter-short circuit.

1.7.2.4 Be careful not to damage the illuminating wires of the indicator and speedometer, while installing
the cabinet of ammeter module.

1.7.2.5 If the nuts or screws are found in the box, please get them out immediately to avoid the damage to
other components and circuits. When disassemble the module, firstly take off the four screws on the back
cover, and then pull out the PCB and other nuts and screws.

1.7.2.6 Don’t exceed the measuring range, though it has the 120% anti-overload ability.

1.7.2.7 Pay attention to the wiring, the diameter of the lead is less than 2mm (including sleeve), recommend
use wiring of 0.5mm2, and prevent from moisture and corrosion.

1.7.2.8 If accuracy is getting down or malfunction occurs, please find the reason, and it can be reused only
after repaired and proved to be qualified.

1.8 Examine and repair method

1.8.1 Basic technology requirements

1.8.1.1 The indicated value error should not surpass the basic error tolerance.

1.8.1.2 The variation of the indicated value should not surpass the absolute value of the basic error.

1.8.1.3 The zero displacement should not be more than 1/2 of the basic error.

1.8.1.4 The basic error of the locomotive speedometer with sensor should be the result measured together
with the corresponding sensors.

1.8.1.5 The surface should be clear; the pointer should be flat and point at the zero position (adjustable).

1.8.1.6 The insulation resistance between the indicator, circuit of the accessory and the housing should be
measured with a 500V-mega-ohm meter, the resistance should not be less than 1M¡ under the normal
temperature.

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1.8.2 Equipment, working tools, measurement tools and materials

1.8.2.1 Equipment: Magnetizer and demagnetizer, AC regulator, DC regulator, standard millivoltmeter,
ammeter test-bed, speedometer test-bed.

1.8.2.2 Working tools: Forceps, screw drivers for watch repair, punching pin, natural whetstone, 100mm
adjustable wrench, moving coil protection fork, 25W electric iron, 60- times magnifying glass.

1.8.2.3 Measurement tools: 500V mega-ohmmeter, universal meter.

1.8.2.4 Materials: Edge cloth, absolute alcohol or gasoline, wool brush, willow sticker and red nail polish.

1.8.3 Main technical process

1.8.3.1 External appearance check.

1.8.3.1.1 The meter shell should be tight and without cracks which affect the sealing and observation, the
rubber gasket should not be aging.

1.8.3.1.2 The dial should be clean, the scale and number should be clear.

1.8.3.1.3 Slightly shake the meter; no element loosing, falling off and the hand should not be blocked.

1.8.3.1.4 The balance of the needle should be good; the scale Zero should be adjustable.

1.8.3.1.5 The connection column and the thread should not be damaged.

1.8.3.2 Power –on testing

1.8.3.2.1 Connect the meter (including meter and sensor) to the circuit in the test-bed, let the needle stably
move up to the highest scale, then shield to Zero stably. Record the readings at each point (evenly select 3-4
points).

1.8.3.2.2 Check the indicated value over error, the variation error and zero scale error.

1.8.3.2.3 If the needle is stuck, slow-moving or jumping.

1.8.3.2.4 Check the lighting and insulation.

1.8.3.2.5 For the locomotive speedometer, if the over error is found, open the second sealed cover on the
back of the meter, adjust the two internal potentiometers, the upper one is the inner pointer, the lower one is
the external pointer, when the adjustment is finished, restore the sealed cover.

1.8.3.3 Disassemble

When the meter fails and should be disassembled, we can dismantle the corresponding meter from the
ammeter module.

1.8.3.3.1 Disassemble the voltage meter and current meter

1.8.3.3.1.1 Remove the bolts on the side cover, take out the base, and weld off the down-lead of the upper
and lower hairspring.

1.8.3.3.1.2 Loose the fixture screw and take out the meter movement component.

1.8.3.3.1.3 Put the protection fork into the clearance between the magnets, loose two screws of the magnetic
core support.
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1.8.3.3.1.4 Hold the protection fork and gently take out the magnetic core moving coil, weld off the upper
and low hairspring.

1.8.3.3.1.5 Loose the upper and lower bearing buffer nut, take out the moving coil bearing, spring gasket,
zero adjustment plate and hair spring welding plate.

1.8.3.3.1.6 Take the moving coil pointer component from the magnetic core and place the magnetic core
into the magnet yoke to prevent the demagnetization.

1.8.3.3.2 Locomotive speedometer disassemble

1.8.3.3.2.1 Loose two installation screws of the meter head, take the meter head out.

1.8.3.3.2.2 Loose four installation screws of the meter, demount the surface glass and remove the meter dial.

1.8.3.3.2.3 Disconnect all meter head connections and take out the meter movement components.

1.8.3.3.2.4 Weld off the upper and lower hair springs, remove the hair spring support, and take out the
moving coil and pointer combination components.

1.8.3.4 Cleaning

1.8.3.4.1 Clean the bearing by the cotton bar with alcohol, and get rid of the dirty matters in the holes with a
willow sticker.

1.8.3.4.2 Clean other components with the alcohol or gasoline.

1.8.3.4.3 When the dial face is dirty, clean it with a wool brush or rubber.

1.8.3.5 Examine and repair

1.8.3.5.1 Inspect the shaft head and bearing with a 60-times magnifying glass, if they have defects or are
worn-out, replace them with new ones.

1.8.3.5.2 Inspect the welding point, if the connection is off or the wire is damaged.

1.8.3.5.3 The scales on the dial should be clear, if they are not clear, remark them or replace the dial with a
new one.

1.8.3.5.4 If the rotator is demagnetized, charge the magnet.

1.8.3.5.5 There are lighting diodes on the back part of the ammeter, the specification is of DC110V, if they
are damaged, take them out from the back part and replace them.

Maintainance of the speedometer and ammeters:

Problem Cause Solution
1.The core sensitivity declines
1.Adjust the potentiometer
2.The contact point (soldering point) resistance
2.Reinstall or re-weld
Large deviation increased
3.Replace or adjust components
3.Varying component value
4.Adjust the bearing
4.Bearing slacks
1. The needle is not at its mechanical zero
1. reset Zero position
Needles can’t return to zero position
2. Adjust hairspring
position, or stuck 2. Distorted hairspring
3. Clean up burr of the core
3. Stuck needle

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Problem Cause Solution

Large balance deviation Balance system has been broken Revise the balance
Instable indication Bad weld Check and re-weld the slack components
The needle does not move
Test the short circuit and open circuit Eliminate short circuit and open circuit
after power on
Only move slight after power Short circuit of the shunt resistance Replace the shunt resistance
on Part circuit is short Eliminate short circuit and open circuit

1.8.3.5.7 Brightness adjustment circuit˖

Problem Cause Solution and Remark
1. 32d connector core is ˇ, and 32z is ˉ
No power supply indicator-
Check the wiring and polarity and the voltage 2. Signal and polarity depending on the
light and state indicator-light
value. nameplate
after power-on
3. 15V output power supply
One power supply broke
Only one power supply light Replace the power or indicator light
Power indicator light broke
1. Check the voltage of the D8 3 pin of the
1. D8 3 pin output one pulse signal
circuit
No self-check after power- 2. The picking-up voltage of relay is 12V
2. Check the voltage of the relay and if it could
on 3. D8 and the relay start working(self-
pick up
check),when voltage of D7 10 pin is 15V
3. Check the voltage of the D7 10 pin
1. Check the voltage of the light if there’s 1. The voltage of the light should between
Some indicator lights don’t voltage, light is broken. 1V to 15V
light when power-on and
self- check 2. If there’s no voltage, the IC and input 2. It’s more possible that the IC or input
isolation module is broken circuit broke
1. Connect according to the wiring diagram
No corresponding indicator 1. Check signal line 2. Check the voltage and polarity of signal
light for working signal 2. Corresponding isolation module is broken line
3. Replace the isolation module
All indicator lights turn on Isolation module damage of this route
1. Replace the isolation module
when one route is supplied There is short circuit between this route and
the signal voltage 2. Check circuit
self-check circuit
Self-check after power-on, 1. The three buttons are all normally
1. Self-check button is broken
but can’t self-check opened contacts.
manually 2. D7 IC has been broken
2. Replace the damaged components
D5, V3 and V4 is broken
D6 is broken 1. button: light turn to be brighter
Brightness can’t be adjusted There are rosin joint, short circuit or open 2. ͪbutton: light turn to be dimmer
circuit 3. Replace the damaged components
The button is broken

1.8.3.6 Assembly

When the replace the grease of the bearing, Assemble it in reversed process when disassemble it.

1.8.3.7 Testing

1.8.3.7.1 The insulation resistance between the indicator, circuit of the accessory and the housing should be
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measured with a 500V meg-ohmmeter; the resistance should not be less than 1Mȍ under the normal
temperature.

1.8.3.7.2 Connect the meter (with complete meter head and sensor) to the circuit in the test-bed, let the
pointer stably move up to the highest scale, then shield to Zero stably. Record the readings at each point
(evenly select 3-4 points).

1.8.3.7.3 If the pointer is stuck, slow-moving or jumping.

1.8.3.7.4 The linear error should be adjusted by adopting the demagnetization or magnetization methods.

1.8.3.7.5 The non-linear error should be corrected by adjusting the shaft head, the bearing position, the
moving coil shaping and iron core clearance.

1.8.3.7.6 The lighting should be excellent.

1.8.3.8 When the meter is qualified after the inspection, seal it with a stamp and paste a verification date.

1.8.3.9 Install the repaired meter on the ammeter module.

1.8.3.10 Fill in the maintenance record.

2 Anemometer modules

2.1 General introduction

ZDY1-5 audio pressure indicator combination module consists of double-needle pressure gauge (YYS3-
100Z)ǃdigisplay pressure gauge (the type is TXY4), It is installed on the control panel of locomotives,
used to display the running parameters and other relative information to the operator.

The double-needle pressure indicator is mainly used to measure the pressure of the hydraulic-system and the
cylinders. It could simultaneously measure two same or different pressures (the different value of the two
should not exceed the upper 1/3 of the measuring range). It adopts internal annular LED illumination.

The axial configuration of the indicator can be converted to radial configuration. The hose-connection and
bolt-fasten ensure a firm contact between the indicator and the installing panel, and also makes the console
of the locomotive good looking.

The digisplay pressure gauge is used for measuring the working reservoir pressure of the locomotive.

2.2 Main technical parameter

2.2.1 Main technical parameters

Measuring range˖ 0̚1200kPaǃ0̚1600kPa˗
Accuracy class˖ 1.5
Working temperature˖ 25ć̚+50ćˈrelative humidity : not exceed 80%
Temperature influenceġthe additive deviation is less than 0.4%/10ć when the operating temperature is 20
ć±5ć
Connecting mode: hose-connecting
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Illumination voltage˖ DC 110V˗

Mechanism performanceġ Vibration 10m/s2 (tri-direction), impact: 30m/s2 (longitudinal) conforms to
the GB1226-86,1227-86 technical standard for pressure indicator

2.2.2 Main technical parameters of the numerical manometer:

Working voltage˖ DC 110V(1±20%)˗
Input signal˖ 0̚10mA
Display range˖ (0.0̚10.0)×100kPa˗
Accuracy class˖ ±1 bit (last bit)˗Matching accuracy with the sensor is 2.5
Output voltage˖ DC 24±5%˗
Input impedance˖ 50:±10%˗
Working temperature˖ 25ć̚+50ćˈrelative humidity: not exceed 80%
Mechanism performanceġ Vibration 10m/s2 (tri-direction) impact: 30m/s2 (longitudinal)

2.3 Outlineǃmountingǃhole dimension and weight

a. Outline dimension: (W×H×D) 280mm×250mm×180mm˗
b. Mounting dimension: (W×H) 265mm×180mm
Hole dimension (W×H) 250mm×240mm,
mounting hole size is 4-I5.5(deep hole).
c. Weight: 5kg
Fig. 6-5 is the outline of anemometer module.

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2.4 Configration and connection

2.4.1 Double-needle pressure indicator connecting method

It is jointed by hose and nuts. Seal washer (supplied by factory) should be used between the pressure meter,
bent sub and the nut. The outer joint screw thread of bent sub is: M16×1.5(external thread).

2.4.2 Illuminating wiring

Connect the illuminating pole to the power supply. Note: connect pole“ˇ”to anode, pole“ˉ”connect to
cathode. The voltage conforms to request.

2.5 Maintenance and Note

The double-needle pressure indicator should be measured every 6-12 months, in order to keep its accuracy.

In case abnormal situation occurs, maintenance and replacement should be done at once. The foreside cover
can be opened. Unscrewing the three M3 screws on the front cover, it can be taken down, and the screws
should be carefully and equably released.

The double-needle pressure indicator can be removed after the three M3 screws on backside have been
released.

2.5.2 Notes
2.5.2.1 The installation ambient temperature should be between -25ć~+50ć, and the relative humidity
should not exceed 80%. The indicator should be at the same level with the sampling point for measuring,
otherwise the additive deviation should be considered.

2.5.2.2 When used for measuring of stable pressure, the 1/3~2/3 of the measuring range could be used; For
variable pressure, the used range should not exceed the upper 1/2 of the measuring range; for instant
measurement, the nether 3/4 of the measuring range would be available.

2.5.2.3 Place the front side of the module on a soft object like a thick sponge, and avoid to be scratched by
hard stuff. When installed onto the panel, first fix the upper two bolts then the lower two, when
disassembled first remove the lower two than the upper two.

2.5.2.4 All the plugs should be firmly covered by sleeves for soldering to prevent from inter-short circuit,
and the soldering time should not be too long.

2.5.2.5 The storage environment of the double-needle pressure indicator should be kept ventilated and dry,
and the temperature should between 0~40ć, relative humidity should be 85%, and be keep away from
corrosive gas and other harmful substance.

2.5.2.6 If accuracy is getting down and the needle flutters or instable indicating occurs, please find the
reason, and it can be reused only after repaired and proved to be qualified.

2.5.2.7 Pay attention to the polarity of illuminating wiring, and avoid corrosive and humidity.

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2.6 Examine and repair method

2.6.1 Basic technology requirements

2.6.1.1 The indicated value tolerance should not exceed the basic tolerance.

2.6.1.2 The variation of the indicated value should not surpass the absolute value of the basic.

2.6.1.3 The zero displacement should not be more than 1/2 of the basic error.

2.6.1.4 The basic tolerance of the locomotive speedometer with sensor should be the result measured
together with the corresponding sensors.

2.6.1.5 The surface should be clear; the pointer should be flat and point at the zero position (adjustable).

2.6.1.6 The insulation resistances between the indicator, circuit of the accessory and the housing should be
measured with a 500V-mega-ohm meter, the resistance should not be less than 1M¡ in the normal
temperature.

2.6.2 Examine and repair equipment, tools and materials

2.6.2.1 Equipments˖Magnetizer and demagnetizer, DC regulator, standard millivoltmeter, electrical

manometer test-bed and piston manometer.

2.6.2.2 Working tools˖forceps, screw drivers for watch repair, punching pin, natural whetstone, 100mm
adjustable wrench, moving coil protection fork, 25W electric iron, 60- times magnifying glass.

2.6.2.3 Measurement tools˖500V meg-ohmmeter, universal meter

2.6.2.4 Materials˖Edge cloth, absolute alcohol or gasoline, wool brush, willow sticker and red nail polish.

2.6.3 Main technical process

2.6.3.1 External appearance check.

2.6.3.1.1 The shell of meter should be tight, no cracks to the seal and observation, the rubber gasket should
not be aging.

2.6.3.1.2 The dial should be clean, the scale and number should be clear.

2.6.3.1.3 Slightly shake the meter; no element loosing, falling off and the pointer should not be blocked.

2.6.3.1.4 The balance of the pointer should be excellent; the scale Zero should be adjustable.

2.6.3.1.5 The connection column and the thread should not be damaged.

2.6.3.2 Powered action test

2.6.3.2.1 Connect the meter (include the sensors) to the circuit in the test-bed. Let the pointer stably move
up to the highest scale, then shield to Zero stably. Record the readings at each point (evenly select 3-4
points).

2.6.3.2.2 Check the indicated value over error, the variation error and zero scale error.

2.6.3.2.3 Check whether the pointer is blocked, slow-moving or jumping.

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2.6.3.2.4 Check the lighting and insulation.

2.6.3.3 Disassembling

If the meter fails and must be disassembled, dismount the meter from the anemometer module. Open the
meter covers and take the components such as the meter head out.

2.6.3.4 Cleaning

2.6.3.4.1 Clean the bearing with the alcohol cotton, and get rid of the rubbish in the holes with a willow
sticker.

2.6.3.4.2 If the dial face were dirty, clean it with a wool brush or eraser.

2.6.3.5 Examining and repair

2.6.3.5.1 Inspect the shaft head and bearing with a 60-times magnifying glass, if they are in defects or worn-
out, replace them with new ones.

2.6.3.5.2 Inspect the welding point to find if the connection is off or the lead is damaged.

2.6.3.5.3 The scales on the dial should be clear, if they are not clear, refigure them or replace the dial with a
new one.

2.6.3.5.4 Maintenance to the double-needle pressure indicator:

Problem Cause Solution
Small angle between the crank and the connecting
Fast-slow Rotate the gear set to increase the angle
rod
Big angle between the crank and the connecting
Slow-fast Rotate the gear set to reduce the angle
rod
Great measuring Grind the transmission units or change the
Friction or looseness of the transmission units
deviation dimension of them
Repair the central gear and the fan-shape
The central gear and the fan-shape gear can’t gear;
firmly engage because of the wearing or dust; Grind the connecting rod to make it more
Partial bouncing and the
tapping bouncing of the The connecting rod is blocked; flexible;
needle The hairspring touched the fan-shape gear; Adjust the position of the hairspring;
The central gear touched the soleplate. Reinforce the roundness demand to the
machining.
The transmission ratio of the connecting rod and
the fan-shape gear is not suitably adjusted; Adjust the transmission ratio or change the
Different indicating The dial plate and the central gear are not length of the connecting rod;
deviation concentric; Adjust the center;
The tube-spring is fatigued and creep for lasting Replace the tube-spring.
pressure.
Adjust the hairspring;
The hairspring is too loose or tight;
Examine the device and the tube-spring, and
Leaking oil;
The needle can’t shield plug up each solder point;
The connecting rod is too short;
to the “0” position Lengthen the connecting rod;
The engaging position is not correct;
Change the engaging position ;
The needle is not at “0” originally.
Re-fix the needle.

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2.6.3.6 Assembly

Assemble it in reversed process of disassembling.

2.6.3.7 Test

2.6.3.7.1 Measure the insulation resistance between the indicator, circuit of the accessory and the housing
with a 500V-mega-ohm meter, the value should not be less than 1Mȍ in the normal temperature.

2.6.3.7.2 Connect the meter (include the sensors) to the circuit in the test-bed. Let the pointer stably move
up to the highest scale, then shield to Zero stably. Record the readings at each point (evenly select 3-4
points).

2.6.3.7.3 Check whether the pointer is blocked, slow-moving or jumping.

2.6.3.7.4 The lighting should be excellent.

2.6.3.8 When the meter is qualified after the test, seal stamp and paste date of check.

2.6.3.9 Install the repaired meter on the ammeter module.

2.6.3.10 Fill in the maintenance record.

3 Sensors

Symbol in the
No Type Model Test position
circuits
Output voltage of the main rectifier
1 SCM voltage TQG11G SCM5
cubicle
Armature current of No.1 traction
2 LEM current NA1000-T 1SC1
motor
Armature current of No.2 traction
3 LEM current NA1000-T 1SC2
motor
Armature current of No.3 traction
4 LEM current NA1000-T 1SC3
motor
Armature current of No.4 traction
5 LEM current NA1000-T 1SC4
motor
Armature current of No.5 traction
6 LEM current NA1000-T 1SC5
motor
Armature current of No.6 traction
7 LEM current NA1000-T 1SC6
motor
Magnetic field current of traction
8 LEM current NA1000-T 1SC7
motors
Magnetic field current of main
9 SCM current TQG10-75 SCM1
generator
Magnetic field current of excitation
10 SCM current TQG10-75 SCM2
motor
11 SCM current TQG17A Electric inject loading signal SCM3
Rotating speed of No.1 traction
12 Magnetoelectricity Frequency TQG2B 1SR1
motor
Rotating speed of No.2 traction
13 Magnetoelectricity Frequency TQG2B 1SR2
motor

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Rotating speed of No.3 traction

14 Magnetoelectricity Frequency TQG2B 1SR3
motor
Rotating speed of No.4 traction
15 Magnetoelectricity Frequency TQG2B 1SR4
motor
Rotating speed of No.5 traction
16 Magnetoelectricity Frequency TQG2B 1SR5
motor
Rotating speed of No.6 traction
17 Magnetoelectricity Frequency TQG2B 1SR6
motor
Rotating speed of No.1 cooling fun
18 Magnetoelectricity Frequency TO3 4SR1
motor
Rotating speed of No.2 cooling fun
19 Magnetoelectricity Frequency TO3 4SR2
motor
20 Magnetoelectricity Frequency TO3 Rotating speed of diesel 4SR3
Rotating speed of main generator
21 Magnetoelectricity Frequency TO3A 2SR1
fanner
22 Magnetoelectricity Frequency TO3A Rotating speed of front fanner 2SR2
23 Magnetoelectricity Frequency TO3A Rotating speed of back fanner 2SR3
Thermal resistance temperature High temperature water intake
24 Y921 ST1
temperature
25 Thermal resistance temperature Y921 Cooling water outlet temperature ST2
Thermal resistance temperature Heat exchanger outlet water
26 Y921 ST3
temperature
27 Thermal resistance temperature Y921 Oil intake temperature ST4
28 Thermal resistance temperature Y921 Oil outlet temperature ST5
Thermal resistance temperature High temperature water outlet
29 Y921 ST6
temperature
30 Thermal resistance temperature Y921 Cooling water intake temperature ST7
31 Thermal resistance temperature Y921 Environment temperature ST8
32 Liquid pressure TQG14G Oil intake pressure 1BP1
33 Liquid pressure TQG14G Oil outlet pressure 1BP2
Oil intake pressure of front
34 Liquid pressure TQG14G 1BP3
turbocharger
Oil intake pressure of rear
35 Liquid pressure TQG14G 1BP4
turbocharger
36 Liquid pressure TQG14G Oil intake pressure of oil-filter 1BP5
37 Liquid pressure TQG14G Fuel pump outlet pressure 1BP6
38 Liquid pressure TQG14G Fuel system end pressure 1BP7
39 Liquid pressure TQG14G Front brake cylinder pressure 1BP8
40 Liquid pressure TQG14G rear brake cylinder pressure 1BP9
41 Liquid pressure TQG14G Control reservoir pressure 1BP10

3.1 LEM current sensor

LEM sensor is a kind of examine equipment that examine voltage and current by detecting magnetic flux
density with Hall generator. It is a magnetic balance Hall sensor.

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3.1.1 Principle of work of the Hall component

Hall component can turn the change of magnetic flux into the change of voltage. Under the effect of
magnetic field, the magnetic field air gap produced by magnetizer can make the Hall component, through
which the control current passes, produce Hall voltage; this is the principle of work of the Hall sensor.
When neglect the non-equipotential Hall voltage, we think the magnetic flux density and the control current
is perpendicular. So:

VH=KgBgIc
note: VHˉ Hall voltage˗
Kˉ Hall generator sensitivity coefficient(mV/mAgT)˗
Icˉ Control current(mA)˗
Bˉ Magnetic flux density(T).

Magnetic flux density B is generated by measured current and in direct proportion to the current. So, Hall
voltage VH is in direct proportion to the current.

Using Hall component, magnetizer and amplification circuit, Hall sensor can turn primary input signal into
isolated output signal, this is the principle of work of the Hall sensor.

NA1000ˉT type current sensor is a detecting equipment that can detect all kinds of current by detecting
magnetic flux density with Hall generator. It can measure high DC, AC and ripple current by isolating them.
Its measuring accuracy is high, the linearity and stability is
good, and overloading capacity is strong, and it cannot be
disturbed by other magnetoelectricity. NA1000ˉT current
sensor figure is showed as Fig. 6-6.

The sensor is composed of primary circuit, magnetic circuit

(including Hall component in magnetic field gap), secondary
circuit and electronic circuit, which is installed in the
fireproofing plastic shell. Its frame is symmetry. There are
double air gap in the magnetic circuit and two Hall generators
symmetrically inside. The secondary circuit has static screen Fig. 6-6 Sensor NA1000ˉT
and double parallel circuit signal processing function, so it can
avoid being disturbed by other magnetoelectricity. In addition to this, the sensor is enclosed by silicone
rubber sealant, so its electric insulation and vibration resistance property and good. The sensor can absorb
shock voltage and avoid the damage caused by mistaken polarity connection of the power supply.

3.1.2 Technical parameter

Rated measure current 1000A rms
Range 0~f1800A
Overloading ability 1500A 3min/h
Rated measure output 200mA rms
Accuracy f1%
di/dt >50A/­s

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Power voltage f15V(f10%)~f24V(f10%)

Secondary current expend 60mA+measure output current
Withstand voltage primary side circuit to secondary, ground and static screen layer˖
6kVrms/50Hz/1min
Work temperature ˉ25~70ć
Storage temperature ˉ40~85ć
Weight 3f0.5kg
Shape size 230mm×132mm×153.5mm

3.1.3 Mounting and use

Connect in series the sensor’s primary side to the measured circuit, and give it right power. When current
passes through the primary side, measure the output M, the output value is output current signal is. When
measured current is DC and its direction is same with the direction of the arrowhead on the sensor, the
direction of the measured output current is from M to 0 and M is positive. Otherwise M is negative. Fig. 6-7
is connection mode.

The connection about output plugs

and outside signal of sensor are
showed in the following sketch map:

Terminal 1 is to +, terminal 2 is to -,
terminal 3 is to M and terminal 4 is
to E.
Fig. 6-7 NA1000ˉT Current sensor connections
Note:

+ is sensor's power positive, and connect ˇ15V power voltage

- is sensor's power negative, connect -15V power voltage

M is output of sensor; connect with user’s current meter or measures sampling resistance Rm then connects
to the 0 point of power supply.

E is the output of sensor's static screen, and it connects to ground of user’s system. If the system doesn’t
have “ground”, it connects to the negative terminal of the power supply.

Rm is sampling resistance, from whose two terminals measured signal can be got.

3.1.4 Warning
3.1.4.1 The core over-magnetization and remanence shall be avoided. Core over-magnetization may be
resulted from the opening of secondary winding or power, which can affect the measurement precision.

3.1.4.2 Loading expiation of inductance and capacitance: When there are inductance and capacitance in
secondary loading resistance, it will affect the response time.

3.1.4.3 The value of loading resistance should be within the limit value. It is ignored the magnetic field
disturbance produced by the conductor whose rated current is one or two times of that of the primary side at

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the distance of (5~10cm).When some strong magnetic field disturbance exists, the direction or position of
installation should be changed for reducing the influence.

3.1.4.4 Reduce the disturbance of outer magnetic field.

3.1.4.5 Try to make the rated value of measured signal be same as the rated valued of sensor.

3.1.4.6 Take and put carefully, protect from mechanical or electric damnify.

3.1.4.7 Keep the connecting terminal of sensor clean, no oil dirt, and dust; ensure the wire and terminal in
good connection.

3.1.5 Overhaul and repair

3.1.5.1 Check if the wire connection is correct and if the connection components are reliable. The shell body
shall be free from damage and crack.

3.1.5.2 When no signal input, switch on power and make the output become loop. Measure the output signal
by universal meter. The signal should not 0.4mA.

3.1.5.2.1 If the out-of-tolerance of output signal exceeds 1mA, it is say that some component is defects in
the sensor.

3.1.5.2.2 If the output signal value is within the rated range, cut off the power and monitor the output signal.
If the output signal doesn’t change or be 0 constantly, it is say that the output loop in sensor is (secondary
winding, Hall component); if the output is changed, it is say the sensor is ok.

3.1.5.2.3 If the output signal exceeds the tolerance, but it is not over 1mA, cut off the power and monitor the
output signal. If the output signal doesn’t change, it is say that the output loop in sensor is broken
(secondary winding, Hall component); if the output changes, it is say the sensor is ok and the out-of-
tolerance is evocable by magnetization. It doesn’t affect the performance of sensor.

3.1.5.3 If the sensor is judged to be in good condition, let it work and monitor the output. The output data
should accord with the technical requirements.

3.1.5.4 If the accuracy is in 1%, it is say that sensor is ok.

3.1.5.5 If the output doesn’t change with the change of input, it is say that primary side of sensor is broken
or the signal can not enter the inner terminal of sensor. Check the down-lead. If the down-lead is ok, it is say
that the sensor is fault.

3.1.5.6 If the accuracy of output is out-of-tolerance, check the accuracy of the testing instrument whether
the accuracy accord with the requirement or not, if ok, it is say that sensor is broken-down.

3.2 SCM sensor

3.2.1 Structure and function

SCM sensor is a circuit board of signal transformation; it can isolate the main circuit and LCS32 system in
locomotive and detect the current and voltage signals, which can be transformed to the signal that is
required by LCS32. Fig. 6-8 is connection mode.

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There are 4 SCM boards totally in the locomotive, two

are current sensor of TQG10-75, one is current sensor
of TQG17A, one is voltage sensor of TQG11G.They
are defined as SCM1, SCM2, SCM3, SCM5 according
to the installation order.

SCM1, SCM2 respectively turn the main generator

excitation currentǃexciter excitation current into
0~10V DC signal, the input signal is from the diverter
of excitation circuit. Fig. 6-8 Sensor of SCM

SCM3 board can turn electrc injecting loading signal of

0~20mA into voltage signal of 0~4.88V.

SCM5 board can measure the DC output voltage of main silicon rectifier. Its input signal is the DC output
voltage of main silicon rectifier. It can turn the DC output voltage of main silicon rectifier of 0~1000V into
DC signal 0~4.88V.l

3.2.2 Adjustment and test of the current sensor of TQG10-75

At room temperature, DC of 0-75mV
is input between binding post 2 and 3
of TB2 or DC of 0-18.3V between
binding post 1 and 3 of TB2 , all the
outputs of TB1 are 0-4.88V, its
linearity is in range of f0.3%, and
the connection of testing device is
showing as following figure:

Process and measure of the

adjustment:

3.2.2.1 Zeroing: Short-circuit Fig. 6-9 Current sensor TQG10-75

terminals 2 and 3 of the TB2,
measure the output of terminal 1 and 6 of TB1 by the position of 200mV of the digital universal meter of
41/2, and then adjust potentiometer of P2 on the
SCM board, make the output be close to 0mV as
near as possible.

3.2.2.2 Adjusting full range˖Cut off one terminal of

R3, and input 75f0.01mV between terminal 2 and
3 of TB2, monitor the input by digital universal
meter and keep the value be static, measure the
output voltage between terminal 1 and 6 of TB1, and
then adjust potentiometer of P1, make the output be
4.88f0.01V. Fig. 6-10 Sensor of TQG11G

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3.2.2.3 Testing the linearity: Choose 6-8 values of the input between 0 and 75mV, observe the output value,
the total linearity should be in range of f0.3%.

3.2.2.4 Connect the precise adjustable regulated power supply according to the connection figure, take out
the potentiometer and weld the resistance on the SCM board, and the zero point and full range of the
module are adjusted well, they can’t be adjusted any more. Input DC of 0-18.3V between binding post 1 and
3 of TB2, Choose 6-8 values of full range ,test the output voltage between binding post 1 and 6 of TB6, the
total linearity should be in range of f0.3%. If the full precision can’t satisfy the requirement, the value of
R3 must be adjusted newly to satisfy the requirement.

3.2.3 Voltage sensor of TQG11G

Fig. 6-10 and Fig. 6-11 are connection mode. The
debug method as follow:

3.2.3.1 Zeroing˖Short circuit terminals IN+ and IN-

of the T2, then connect the test equipment and power
supply well according to the following Fig. 6-10,
measure the output of terminal 1 and 5 of T1 by the
stall of 200mV of the digital universal meter of 41/2,
and then adjust potentiometer of P3 on the SCM Fig. 6-11 Sensor of TQG11G
board, make the output be close to 0mV as near as possible,

3.2.3.2 Adjusting full range˖Input power DC of 1000f1V between terminal IN+ and IN- of T2, monitor
the input by digital universal meter and keep the value be static, measure the output voltage between
terminal 1 and 5 of T1, and then adjust potentiometer of P1, make the output be 4.88f0.01V,

3.2.3.3 Testing the linearity: Choose 6-8 points of the input between 0 and 1000V, observe the output value,
the total linearity should be in range of f0.3%.

3.2.3.4 Examining and repair methods

3.2.3.4.1 Detect and adjust the sensors according to the adjusting methods, when the adjustment is over, seal
potentiometer by paint to avoid being loose,

3.2.3.4.2 Periodical inspect whether the wire pressing screws on each connection terminal is loose or not.

3.2.3.4.3 Don’t screw the potentiometers of zeroing and full ranging at will.

3.2.3.4.4 Purge the circuit board surface frequently, and keep the surface clean.

3.2.4 TQG2B speed sensor

TQG2B speed sensor is used according to electromagnetic induction theory, when the addendum of
measured iron gear(m˙2.5,¢˙20ez˙68,the space between addendum and the tip of sensor is 1.2mm)
rotates by the tip of sensor, the loop on the magnetic circuit gets voltage. It will be amplified and plastic by
electronic circuit, and is output in the form of square wave pulse, so the rotating speed can be measured by
measuring the number of the pulse.

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3.2.4.1 Technical parameter

Measure range 18~5000r/min
Loading resistance 10k¡
Isolation dielectric strength 500V 50Hz 1min
Isolation resistance 10M¡
Working temperature -25~70ć
Shock 40Hz 2.3mm
Shockproof 100m/s2

3.2.4.2 Fixing size

The figure and fixing size TQG2B speed

sensor is showed on Fig. 6-12

3.2.4.3 Instruction

Tip protection of the speed sensor has been

considered before delivery. When fixed, take
Fig. 6-12 TQG2B speed sensor
down the end cover, when the sensor is not
used, the cover shall be put on. The distance between sensors should be over 100mm. The tips of sensor are
forbidden to touch each other. Otherwise sensor will fail.

3.2.4.4 Checking and repair

3.2.4.4.1 Check and repair electric connector pin, they should not be curve.

3.2.4.4.2 Measure the sensor output A and B resistance by universal meter. If the resistance is about 3.5k¡,
the sensor is ok.

3.2.5 TO3 magnetoelectric sensor

TO3, TO3A sensors are magnetoelectric sensors without source and their parameters are same except the
different length fixed in different place. T03 is used for measuring cooling fan speed and T03A used for
measuring ventilator speed.

The sensor is used of magnet steel and its surface can build a magnetic field. Once the magnetic resistance
changes, corresponding output AC voltage signals will be induced from the inside coil of the sensor, in this
way the sensor measures the speed.
3.2.5.1 Technical parameter
Loop resistance About 500¡

Measure condition Send signal gear 60

Material Steel Q235

Modulus 2

Sensor end face to addendum 1mm

Division value as followed

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Speed r/min 10 20 50 100 200 500 1000 2000

Output voltage(virtual value)ı 50mV 100mV 250mV 500mV 1V 2.5V 5V 10V

3.2.5.2 Figure and size

TO3 magnetoelectric sensor’s figure and size are showed as Fig. 6-13

Fig. 6-13 Figure size of TO3 sensor

1ˉSteel screwed tube 2ˉCopper nut 3ˉMagnetic head 4ˉSocket 5ˉPin
6ˉShielded wire

The casing of TO3 is

the stainless steel tube of M16X1. The front end face is made of pure iron of ž5, and the interior is
packaged by epoxy resin. The outgoing wires adopt circuit connector X12K4P of navigation, and the socket
part that is lathed in circle connects to the threaded pipe of stainless steel.

3.2.5.3 Mounting and use

In order to make the sensor induce out AC voltage signals, the magnetizer gear which is used for
offering rotating signal to the sensor is fixed on the end of cam shaft of engine, and the distance
between the top of gear and the end face of sensor is about 1mm, less the distance is, larger the
output signals will be received.
3.2.5.4 Checking and repair
3.2.5.4.1 Overhaul the aero plug and contact pin, they should not be curve.

3.2.5.4.2 Measure the internal resistance of sensor coil by universal meter, when the resistance is about 500
¡, the sensor is in good condition.

3.2.6 Y921 heat-sensitive temperature sensor

3.2.6.1 Main technical parameter
Work temperature range -50~150ć
Plugs environment temperature -40~60ć
Work current 1mA
Insulation resistance ı 20M¡

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Division value as followed

Temperature(ć) 50 60 70 80 90 100
Rated resistance(k¡) 4.498 3.300 2.441 1.837 1.390 1.067
Tolerance(k¡) f0.034 f0.024 f0.016 f0.011 f0.008 f0.006

3.2.6.2 Conformation and theory

Y921 heat-sensitive temperature

sensor consists of nozzle,
pressure inlet, socket, heat-
sensitive sensor and plugs.
Nozzle and pressure inlet are
soldered together, heat-sensitive
component is fixed in nozzle to
feel the temperature, and its Fig. 6-14 Y921 Sensor
resistance changes with the
change of temperature. Heat-
sensitive sensor connects with socket by brass wires then the signal enters EXP through plugs and wires.

3.2.6.3 Mounting and use

3.2.6.3.1 Sensor and measured medium are fixed countercurrent, at least 90e, and the work part should be
in the place where the speed of measured medium is highest in the pipe center.

3.2.6.3.2 The length that sensor nozzle puts in measured medium should be in 20mm~30mm from velocity
of flow center.

3.2.6.3.3 Wires size is of 1mm2~1.5mm2.

3.2.6.3.4 The sensor wires should not be dipped in oil, water or other liquid to prevent from affecting
measure precision, and should be fixed in less vibration place and add protect vibration shim.

3.2.6.4 Checking and repair

3.2.6.4.1 Check plugs and socket to keep clean and dry. Prevent short circuit to affect measure precision.

3.2.6.4.2 Check and repair nozzle, they should not be curve to mangle sensor.

3.2.6.4.3 Check plugs connection, then check two pins inside, they should not be curve to mangle sensor.

3.2.6.4.4 Measure the resistance between two pins of sensor by universal meter, and the resistance should be
3k¡~10k¡.

3.2.7 TQG14G pressure sensor

TQG14G pressure sensor is used in measure all kinds of no crystal liquid medium which is in static state.

3.2.7.1 Main technical parameter

Measure arrange 0~1000kPa
Output voltage 0~2V
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 Chapter 6 Ammeter Module, Anemometer Module, Sensors and Battery

Overload ability 3000kPa/1min

Transmit mode Four-wire system
Power voltage 24Vf10%
Basic tolerance limit f1%
Current consumption 20mA
Loading ability ı1k¡
Pressurization 1500V, 50Hz, 1min Fig. 6-15 TQG14G sensor
Work temperature ˉ25~85ć

3.2.7.2 Working theory

TQG14G pressure sensor adopts stainless

steel isolation transduce head, when the
outside pressure acts on the sensitive area of
sensor and the sensor is electrified by
constant current. With the silicon voltage
resistance effect, the electric signal will be
output, then turn the signal into 0~2V DC
voltage signal. Because it adopts output
phase retrieval technique and temperature
retrieval technique, its output characteristic is good.

3.2.7.3 Adjustment of sensor

In order to ensure the measure precision, the system showed in Fig6-15 is utilized to adjust sensor, the
number of the adjusted points should not be less than 5. If the value of output is too big when 0 voltage, user
can adjust the potentiometer of interior circuit to make the value of output is within 5mV when 0 voltage.

3.2.7.4 Warning

3.2.7.4.1 Try to fix sensors perpendicularly steadily hard, use tools when loading and unloading.

3.2.7.4.2 The sensor can not be used to measure caustic acid, alkaline liquid or gas.

3.2.7.4.3 Avoid oil and water in the plugs and socket when using, in order to prevent bad insulation or short
circuit.

3.2.7.4.4 Sensor should be adjusted timely (once about 6 months).

4. Storage battery

4.1 Application
The super-high rate alkaline rechargeable battery with high capacity is specially designed as staring power
source for diesel locomotives. It can be used at the ambient temperature from -10ć to +55ć.

4.2 Basic parameters

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The outline dimension of battery frame:

490h355h365

Type: GNC210ˈ

dimension of single battery: 165h105h

350

Capacity: discharge rate ı210Ah in 5

hours;

single battery voltage: 1.2V

4.3 Construction of
batteries

4.3.l Construction of cells

The cell is consisted of sintered positive
plate and negative plates which contain
active materials and these plates are
connected with terminals by nuts and
firmly Packaged in a

Semitransparent plastic container which

has high mechanical strength.

On the cover of cell, there is a hole for filling the electrolyte and the positive and negative poles are sealed
by rubber O-ring to seal electrolyte. The vent is usually screwed with vented plastic gas-plug. When filling
electrolyte into the cell, the plug should be opened. (See Fig.l)

4.3.2 Construction of the batteries

Put 8˄or6˅ cells into an insulating,
corrosion resistant firm container , and
connect the cells in with elastic copper
connector coated with nickel, undulant
elastic collars and nuts.

On the sides of the container, there are

square windows for ventilation and heat
release. (See Fig.2)

*1& *1&
Fig .2

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4.4 Battery operating theory

When the battery is charged, the electrical energy is transformed into chemical energy, reversibly, the
chemical energy turns into electrical energy when discharged. The overall reaction is as following:

charge
2Ni(OH)2 + Cd(OH)2 2NiOOH +Cd+2H2O
discharge

It can be seen from the formula, the electrolyte level increases during charge and decreases during discharge.

4.5 Main electrical performance

4.5.l Discharge performance

Because the internal resistance of the battery is low, it can be discharged at high rate. See Table l

Table 1
Discharge rate Current of discharge (A) End voltage discharge (V) Duration of discharge
Nominal discharge rate 42 1.0 •5h
1 rate discharge 210 0.9 •60 min
5 rate discharge 1050 0.8 •8 min
10 rate discharge 2100 0.8 •2 min

4.5.2 Charge retention

When battery is stored at the ambient temperature of 20 ຿ 5ć for 28 days after charged, it can deliver
more than 75 percent of its nominal capacity.

4.5.3 Mechanical strength

The fully charged battery should not be mechanically damaged when it is shocked for 1000 times at the
frequency of 50̚100 times/min and the acceleration of 39.2 m/S2 (4g), and then vibrated for one hour at
the frequency of 940/min, and the amplitude of 2.5 mm. At the same time, when the battery is discharged at
the current of l C5A to the end voltage of 0.9V, the discharged time should not be less than 54 minutes.

4.5.4 Service life

The service life of battery shall be tested according to IEC standard and shouldn’t be less than 500 cycles.
At the end of life, the remained capacity is not less than 70% of the nominal capacity.

4.5.5 Storage period

After stocking for 3 years, the performance of batteries should conform to the above requirements when

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their capacities are restored (The open circuit voltage is allowed to decrease during the storage period).
During the stocking period, the vent plug should be screwed and layer of Vaseline oil should be coated on
nuts, terminals, and connectors in order to keep them from rust.

4.5.6 Charge performance

Battery can be charged at nominal current of 0.2C5A and a higher current of 0.5C5A, or a lower current of
0.l C5A. Details see clause 9.2.

4.6 Preparation of electrolyte

4.6.1 Water for preparing electrolyte: Water for preparing electrolyte must be distilled water and ion
exchange water. It is prohibited to use tap water and water which is polluted by acid.

4.6.2 Solid electrolyte

Potassium hydroxide for preparing electrolyte may be adopted from the chemical grade product (GB2306-
80 Grade m). LiOH · H2O: The content of lithium hydroxide should not be less than 50%.

4.6.3 Vessels

The vessels for preparing of electrolyte may be of glass, plastic, porcelain, enamel ware or of stainless steel
which can resist acid and alkali.

4.6.4 Implements

Hydrometer (range of l.l0̚1.30), thermometer, graduated cylinder, funnel, plastic scoop platform scale,
stirrer (special-purpose stirrer should be used when preparing a large amount of electrolyte, and plastic rod
or glass rod can be used when preparing a little amount of electrolyte).

4.6.5 Process of electrolyte preparation

4.6.5.1 Weigh the needed amount of potassium hydroxide, lithium hydroxide and water according to the
weight ratio in Table 2.

Table 2

Ambient Temperature Weight ratio for

Density of electrolyte Content of
preparation
3
(ć) (g/cm ) LiOH·H2O(g/1)
(KOH:H2O)
0̚+40 1.20 ೳ 0.01 1:3 20̚30
-20̚0 1.25 ೳ 0.01 1:2 20̚30

4.6.5.2 In preparation of electrolyte, one should put on goggles, rubber gloves, rubber overshoes and
working clothes to protect his skin from being harmed by alkali. If his skin is touched by alkali, he must
wash it off with 3% boric acid solution at once.

4.6.5.3 When preparing electrolyte, firstly, put water into the vessel, then slowly add potassium hydroxide
into water and constantly agitate them (it is prohibited to put water into alkali) to make the alkali dissolve in
water on the thoroughly. Finally, add lithium hydroxide which has been dissolved in water on the electric
stove. In the whole process, the electrolyte should not contact with copper, iron or aluminum (Note: at
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beginning, the electrolyte solution is hot, so cover the vessel for cooling and keeping away from impurities).

4.6.5.4 Adjust the density of electrolyte

When the temperature is dropped to 20 ೳ 5ć, the density of the fully dissolved electrolyte should meet the
requirements in Table 2. Add water when the density is higher; and add suitable potassium hydroxide when
density is lower.

4.6.5.5 The up-to standard electrolyte should be stood for 4̚6 hours before using.

4.6.6 The storage of electrolyte

The electrolyte is easy to absorb carbon dioxide, and to produce the harmful carbonate, that makes the
battery’s capacity decrease. So the unused electrolyte must be well covered to prevent any other things or
metals dropping into it.

4.6.7 In operation, the electrolyte density is calculated by the following equation when temperature of the
electrolyte changes.

DT = D20- 0.0005 (T-20)

Where, T: temperature of electrolyte
Dr : Tć vs. electrolyte density
D20: 20ć vs. electrolyte density

4.7 Checking and storage

4.7.1 The finished batteries are packed for delivery after draining out the electrolyte in discharged state.
They must be Inspected carefully when accept them. Contact with the manufacturer when something wrong
is found.

4.7.2 Short time storage

The battery which is prepared to use or which is stored within one year can be stored with electrolyte.
Adjust the level of the electrolyte and screw the vent plug before storing. The batteries should be stored in a
dry, acid-less and well-ventilated room where the temperature is 25 ຿ 10ć.Inspect the storage condition at
regular intervals. Correct it if something wrong happens.

4.7.3 Long-term storage

Batteries for long-term storage should be stored after draining out the electrolyte in a discharged state.
Screw the vent and clean the batteries. Coat a layer of Vaseline oil on metal collars, nuts and terminal. The
storage condition is as same as clause 7.2.

4.8 Preparation before operation

4.8.l Inspection

4.8.1.l Inspect the new batteries or the stored batteries before operation. Seek it out if somewhere is wrong
such as wrong poles installation.

4.8.1.2 If the metal wares rust, clean them with cleanser and coat a layer of Vaseline oil on them. Tighten the

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connectors if they are loose.

4.8.2 Filling of electrolyte

Clean the qualified batteries, open the vent, fill the electrolyte into batteries with funnel or rubber tube.
Adjust the level of electrolyte after standing for two hours. Screw the vent when the electrolyte level is up to
the maximum line.

4.9 Charge
4.9.1 The positive terminal of the battery is connected with the positive post of the charger while the
negative terminal of the battery is connected with the negative post of the charger. Open the vent, plug
before charge and tighten it after charge.

4.9.2 Constant current charge

4.9.2.l Normal charge rate: charge at rate of 42A for 8 hours.

4.9.2.2 Supplemental charge rate

Battery which has been stored for 15 to 30 days in charged state should carry out supplemental charge with
constant current of 42C5A for 2 hours and a half before using.

4.9.2.3 Float charge rate: Float charge can be carried out on moving train. The batteries should be charged at
normal charge rate before float charge. The charge voltage is 1.38̚1.42 V/cell.

4.9.3 The optimal ambient temperature for charging is 25 ຿ 5ć. It is better to charge at a place with good
ventilation and without flame and fire. It should stop charging or decrease the charge current when the
temperature of electrolyte is over 45ć. Charge again when the temperature is right. When the ambient
temperature is lower than 5ć, it will decrease the efficiency of charge. It is better to charge at normal
temperature and to use at low temperature.

4.9.4 Process of charge

If charging voltages of some cells are low during charge and the voltage is still lower than 1.40V after
charging for 6 hours; The voltage rises at the beginning and decreases lower than 1.40V with continuous
charge, or the open-circuit voltage of charged battery decreases very fast during stand period, the open-
circuit voltage is lower than 1.20V after standing for seven days. If the above cases occur, that means there
is fine short-circuit in cells, such cells must be changed. If not, that will affect the performance of batteries.

4.9.5 It is not allowed to contact the positive and negative terminals with metal instrument simultaneously.

4.9.6 The alkaline electrolyte on the cover terminals, and connectors of the batteries should be cleaned up.
Tighten the nuts if they are loose.

4.9.7 Charge before installed on train

4.9.7.l The new batteries whose storage time are not longer than half a year can be charged according to
9.2.1.

4.9.7.2 The batteries which have been stored more than half a year should be activated for l~5 cycles before
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using. Discharge the battery at constant current of 42A to l.0 V/cell according to clause 9.2.l (Over-
discharge is prohibited). Once discharge duration time is five hours or more than five hours, that will be
regarded as fully activated.

4.10 Daily maintenance.

4.10.l Batteries should be kept clean and dry. Clean them with pure water if there’s carbonate crystals (white
deposits) on the vent or around the terminal. The metal wares should not be rusty. Clean the batteries if there
is greasy dirt on the surface.

4.10.2 The vent should be kept unblocked to ensure that the gas that generates during charge and discharge
can exhaust smoothly, that the electrolyte could not flow out, and that dust and other things could not fall
into the electrolyte.

4.10.3 After the storage battery construction locomotive circulate, should usually check whether all tight
firmware conjunctions are firm or not.

4.10.4 Check the voltage of batteries in operating. If short-circuit battery is found (If the terminal voltage is
0v), replace it.

4.10.5 Inspection and adjustment of electrolyte level.

4.10.5.l Replenishment of water

While the vehicle is in motion, the battery’s electrolyte level should be kept between the specified
indicating lines. It is not allowed that the level is below the MINIMUM line. The electrolyte level should be
inspected once every month (For the high temperature region, the electrolyte level should be inspected once
every 10 days). Replenish with distilled water if necessary. After replenishing, the level should be as high as
the upper indicating line. While replenishing, the operator should be careful not to add the water out of or
between the batteries. If the water flows on the appearance of the battery, clean it immediately to keep the
battery from short-circuit. After replenishing, tighten the plug.

4.10.5.2 Adjustment of electrolyte density

While in operation, the electrolyte density of batteries should be inspected every half a year. The density
should be l.17-1.23 (at 0̚40ć) and l.23-1.27 (at -20̚0ć).Absorb electrolyte from batteries and measure
its density. If the density is low, add electrolyte with high density. If the density is high, add distilled water
in order to meet the required density.

4.11 Periodic maintenance

4.11.1 Batteries should be checked and maintained every l year.

4.11.2 Check-up of electrolyte.

4.11.2.l Measurement of density of electrolyte

Screw off the battery’s plug, extract 10̚15 ml electrolyte from the battery (measure 3 to 5 batteries
normally).If the density is not in accordance with specifications, regulate it as specified in clause l0.5.2.

4.11.2.2 Measurement of CO32- content in the electrolyte.

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In the course of operation and storage, the electrolyte will absorb the CO2 from the air; and form into
carbonate. The carbonate will increase the internal resistance and affect the battery performance, so it’s
necessary to check up the content of K2CO3 in the electrolyte. If the following cases occur, the electrolyte
should be replaced:

(1) The carbonate content exceeds or approaches 50g/l.

(2) Battery’s charge efficiency drops dramatically.

(3) Discharge voltage decreases and charge voltage increases.

(4) The electrolyte temperature is very high during charge and discharge.

4.11.2.3 Replacing methods of electrolyte

Firstly discharge the batteries to 1.0V/cell at the constant current of 42A. Then screw off the hexagon nut
and take away the corrugated collar and connecting plate, take out the cell and screw off the plug. Place the
battery, upside down and pour out all electrolytes. Fill in new electrolyte immediately, clean the battery case,
and connect them again. That will be ready for using.

4.11.3 Capacity recovery and check-up

If the battery is in float charge state for along time, it will cause the cell’s capacity non-uniform. In order to
ensure that the battery can work in a good condition and extend its service life, the battery should be carried
out a capacity recovery per year.

4.11.3.1 Cycles: Don’t charge the batteries after dismounted from the locomotives. Discharge them to
0V/cell at a current of 42A. Then charge according to clause 9.2.1 at the ambient temperature of 20 ೳ 5
ć.After that, discharge to l.0V/cell at a constant current of 42A after standing for 0.5-1 hour.

4.11.3.2 Check-up of capacity

Charge the batteries as specified in clause 9.2.1 at the temperature of 20±5ć, stand them for 0.5-l hour, and
then discharge to l.0 V/cell at current of 0.2C5A.

Discharge capacity (Ah) =discharge current (A) ×discharge duration time (h)

Capacity inspection is allowable to carry out 5 times, if any one time reaches the standard, the inspection
can be stopped. After 5 times inspection, if the capacity can’t reach 70% of nominal capacity, the battery
should be replaced.

4.11.4 Cleaning of batteries

Batteries should be kept clean. If the metal parts become rust, remove the rust and paste with Vaseline oil.

4.11.5 Check the terminals, nuts and connectors. Tighten them if they are loose.

4.11.6 Batteries should be charged according to clause 9.2.l before mounted on the locomotives.

4.12 Overhaul
Overhaul of batteries can be carried out with the locomotives.

4.12.1 Discharge of batteries

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Take off the batteries from locomotives, and discharge them with constant current of 42A to 1.0V/cell.

4.12.2 Disassembling

Firstly, unscrew the nuts, connectors and undulant elastic collars; then take out ceils from the battery
container.

4.12.3 Check electrolyte, see clause 11.2

4.12.4 Checking and cleaning of cells

4.12.4.1 The recovery of capacity, see clause 11.3

Replace the unqualified cells or short-circuit cells with new cells.

4.12.4.2 Check the container and the cover. If some metal wares or plastic wares are destroyed, change new
one.

4.12.4.3 Cleaning of batteries

Clean the disassembled batteries in hot water with metalloid soft brush, and dry them in air.

4.12.4.4 Cleaning of container and frame

Clean the container and frame in water with cloth or soft brush, and dry in air. wipe the rust off and coat a
layer of Vaseline oil or paint in the same color.

4.12.5 Assembling

Put the cleaned batteries into container; connect with connectors, and tighten with undulant elastic collars
and nuts.

4.13 Transportation and storage

4.13.1 Batteries can be carried by any transportation in discharged state. Don’t put the battery upside down,
and batteries should be prevented from raining, sunshine and violent shocking.

4.13.2 Short-term storage. See clause 7.2

4.13.3 Long-term storage see clause 7.3

4.14 Main troubles and trouble shootings

NO. Troubles Causes Troubles shooting
l. Over-discharged 1.Charge the battery and check again.
The voltage of
2. There isn’t any electrolyte in the 2.Fill in electrolyte and charge the battery.
1 discharged battery
battery Adjust the electrolyte density.
is 0v
3. Internal short-circuit 3.Replace the short-circuit cell.
1.The charge/discharge mode is not 1. Use the correct charge/discharge mode
correct. 2. Replace the short-circuit cells
2.Internal fines short circuit 3. Add enough electrolytes and adjust electrolyte
The capacity
2 3. The amount of electrolyte isn’t density, then charge it.
decreases
enough, the electrodes are emerged. 4. Replace the electrolyte
4. The carbonate contented in the 5. Regulate the charge ambient temperature to 20
electrolyte is too high. 5. The ambient
຿ 5ć.
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NO. Troubles Causes Troubles shooting

temperature is too low or too high. 6. Replace the fault cells.
6. Capacity of some cells is lower than 7. Check and rectify the instruments.
70% of its rated capacity
8. Adjust electrolyte to specified requirement.
7. Instruments are not properly used.
8. The electrolyte density doesn’t
conform to the specification.
1. The electrolyte level is too high l. Regulate the electrolyte level
The while charge. 2. Check the cover and container of cells.
3 Electrolyte 2. The cover or container of cells is Replace them if they are damaged
leakage damaged, or the sealing is not tight. 3. Tighten the nuts. Replace the damaged washed
damaged or sealing ring.
The voltage of cells There is not electrolyte in cells Add electrolyte and regulate its level
4 is too high at initial
charge
The charging l. There is fine short-circuit in cells. l. Replace the fault cells
voltage of cell is 2. The temperature of electrolyte is too 2. Decrease the temperature of electrolyte
5
lower than 1.40V high while charging.
while charging.
Bubbles appear There are organic impurities in the Replace the electrolyte
6 from the inside of electrolyte
battery.
l. The vent plug is blocked l. Wash the vent plug with hot water or replace
Cell container new one
7 2. Wrong operation cause the electrodes
swells.
swelled 2. If necessary, replace the cell.
The battery is over charged seriously or Replenish with distilled water and adjust
operated at high temperature. electrolyte level, improve the ventilation of the
Electrolyte charging room. Perform correct charging
8 consumes too mechanism.
quickly.
Inspect the charge voltage and adjust it if
necessary.
There is acidic gas in operation. The Clean the metal parts and paste Vaseline oil. It’s
Metal parts become humidity is too high. Or the layer of not
9 nickel-plating is damaged
rust. Allowed to acidic substance in them, is acidic
substance in the charging room.
Cells and The terminal nut is loose Tighten the nut
10 connectors generate
heat abnormally.
The working l. Some cells are short-circuit l. Replace the cells
current doesn’t 2. The terminal nut is loose 2. Tighten the nut
11 conform to the
requirement under
normal condition.

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 Chapter 7 Microcomputer Control System

Chapter 7
Microcomputer Control System

DF8BI type diesel locomotive microcomputer control system is a multi-processor network control system. It
realizes some functions of locomotive, such as: multiple-connection control, logic control, traction
characteristic control, dynamic braking characteristic control, anti-slip/anti-slide protection, fault
diagnosis and processing. The microcomputer control system is divided into two-level structure:
locomotive control level (LCS32) and human-computer interface level (IDU1,2). The locomotive
control level system takes charge of managing, harmonizing every control part of locomotive. It
realizes the control of traction, braking, anti-slip/anti-slide, self-load characteristic and the logic
control, fault diagnosis and processing of locomotive. The human-computer interface realizes the
human-computer conversation. The control command and state data of locomotive are transmitted
through LonWorks network (double channel) between multiple-connection locomotives, or
between locomotive control level and human-computer interface level.

The locomotive level microcomputer control system adopts LCS32 slot-box structure. The slot-box
adopts bus-bar bus structure. There are 20 standard slots in the slot-box. All the subassemblies
are connected to the motherboard bus through the connectors. The external wire is connected to
the slot-box through the external socket installed on the motherboard. It adopts wire-wrap
connection between external socket and subassembly. The microcomputer control system mainly
adopts the 32 bit micro-processor MC68332 and extended with some external subassemblies
such as digital I/O, analog I/O, frequency processing, chopping control etc and LonWorks
communication network card with redundant structure. LCS32 adopts LonWorks bus to
communicate with IDU1, IDU2 and LCS32, IDU1, IDU2 of another locomotive.

LCS321, LCS322 are cold backup for each other. IDU1 and IDU2 are connected to ATX machine
case through RS485 serial bus and receive shaft temperature information from the alarm of shaft
temperature of local locomotive. Then send those information to another locomotive IDU1, IDU2
through LonWorks bus. LCS32 takes charge of managing and harmonizing the working of every
locomotive control subcomponents. It is the main device of control system.

1 Microcomputer Control box

1.1 Summarize
Locomotive microcomputer control device adopts double cold backup. It is equipped with two
microcomputer cases that have same software and hardware. Normally one microcomputer case is
electrified and works, and the other one is not electrified and acts as a cold backup. If one set of
microcomputer control system goes bad it can switch to the other system through switching the
microcomputer A/B changeover switch on the driver operating table to ensure the normal operation of

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locomotive. But must pay attention: Must shut off the power supply of microcomputer before switching.
The power operation is forbidden.

The main functions of this microcomputer control device are as follows:

zLocomotive multiple-connection control function
zLocomotive logic control function
zLocomotive traction characteristic control function
zLocomotive dynamic brake characteristic control function
zLocomotive self-load characteristic control function
zLocomotive anti-slip/anti-slide protecting function
zDiesel engine constant power control function
zProtect locomotive, diesel engine, electric etc system.
zComplete the fault diagnosis, record and display function of each system of locomotive
zControl function of LonWorks network communication.

1.2 Physical Parameters

Dimension: 534mm (length)×1030mm (height)×305mm (depth)

Device weight: about 90kg

Installing requirement: Panel, LCS32 case is separated from car body with slab rubber.

Installing method: the panel and the bottom of LCS32 case are fastened on the ebonite base in electric
cabinet. The panel is fastened with four M8×20 screws and the bottom of LCS32 case is fastened with four
M8×80 screws.

Figure 7-1 shows the contour and installing drawing of microcomputer control device.

1.3 Electric Parameters

Digital input signal: 0̚30V is logic “0”
65̚110V is logic “1”
Switch output driving current: 1A
Excitation choppin g driv ing cu rrent: 6A
Analog signal: high voltage channel is 0~110V
low voltage channel is 0̚10V
Frequency signal: 10̚10000HZ
Rated input voltage: DC 110V
Allowable range of input voltage: DC 77̚137.5V
Power supply parameters in LCS32 case:5V±0.5% 5A
±15V±1.5% 2.2A

1.4 Electric Structure

Each set of control device has one panel (refer to figure 7-2), two LCS32 cases (refer to figure 7-3 and
figure 7-4) and one set of wire bunch (refer to figure 7-5).

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Figure 7-1 Contour and installing drawing of microcomputer control device

At the bottom of the LCS32 case is the fan-cooling device. The locomotive microcomputer adopts the
redundant structure of cold backup with double microcomputer cases. The power supply changeover switch
is placed on the operating bench in driving cab. It is convenient for drivers to switch between the working
microcomputer case and backup microcomputer case, which improves the reliability of locomotive
microcomputer device greatly.

Inside the LCS32 case there are 20 standard slots, of which 13 subassemblies (belong to 8 sorts) are used.
The position and name of subassembly are listed in below table and figure 7-6.
Symbol Figure number Name Qty Slot number
Switching power supply
17FE200A1 ZS308-300-00 1 3# slot
subassembly
17FE840C1 ZS851-570-000 Digital output subassembly 3 6,7,8# slot
17FE830A1 ZS456-330-000 Digital input subassembly 3 9,10,11# slot
17FE850B1 ZS456-350C-000 Analog processing subassembly 2 12,13# slot
17FE111A1 ZS706-21-00 Switching control subassembly 1 15# slot
17FE820A1 ZS456-320A-000 Frequency serial port subassembly 1 16# slot
17FE188A1 ZS403ˉ26-00 LonWorks communication 1 18#slot
17FE810A1 ZS456-310A-000 CPU subassembly 1 19#slot
Total 13

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56-core Socket


Front side of panel˄D˅

grounding bus-bars

wire-binding rack


back side of panel˄E˅
Figure 7-2 Panel

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Fuses of three fans

respectively

fan switch

fan case (three fans

front side of microcomputer case˄D˅
inside)


fan power supply socket


side of microcomputer case˄E˅
Figure 7-3 LCS32 microcomputer case

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Inside of microcomputer caseďaĐ

Inside of microcomputer caseďEĐ

Figure 4 inside of LCS32 microcomputer case

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209
power supply
connected to

connected to
62-core plug

62-core plug


upper case

lower case
plug of fan

CPU subassembly



)
(



$






)
(



$


LonWorks communication
Frequency serial port
subassembly



)
(



$




Signal switching subassembly



)
(



$



Figure 7-6 Detail drawing of subassembly position


Analog quantity processing subassembly



)
(



%


Digital quantity input

Figure 5 wire bunch

subassembly



)
(



$




Digital quantity output subassembly



)
(



&


Switching power supply subassembly



)
(



$


ELECTRIC MOTOR AND ELECTRIC APPARATUS MANUAL

Whole drawing˄D˅

Partial Drawing˄E˅
FigureLCS32 case and its subassemblies

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1.5 Illustration of Subassembly

1.5.1 Switching power supply Subassembly (17FE200A1)

Provide working power supply for microcomputer control device. The figure 7-8 shows its contour.

Input: DC 110V

Output:5V˄5A˅˗ +15V˄2.2A˅˗ -15V˄2.2A˅

1.5.2. CPU Subassembly (17FE810A1)

This CPU Subassembly is the core of the whole system. It contains MC68332 and serial communication
control chip. It is shown in figure 7-9.

Figure 7-8 Switching power supply Subassembly 17FE200A1˅

Figure 7-9 CPU subassembly˄17FE810A1˅

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1.5.3. Frequency serial port subassembly (17FE820A1)

It is used for processing 15-channel frequency signal. Figure 7-10 shows its contour. The concrete signals
are as follows:
˄1˅ 1# sensor signal of rotating speed of traction motor
˄2˅ 2# sensor signal of rotating speed of traction motor
˄3˅ 3# sensor signal of rotating speed of traction motor
˄4˅ 4# sensor signal of rotating speed of traction motor
˄5˅ 5# sensor signal of rotating speed of traction motor
˄6˅ 6# sensor signal of rotating speed of traction motor
˄7˅ Sensor signal of rotating speed of front cooling fan
˄8˅ Sensor signal of rotating speed of rear cooling fan
˄9˅ Sensor signal of rotating speed of ventilator of main generator
˄10˅ Rotating speed signal of ventilator of front bogie
˄11˅ Rotating speed signal of ventilator of rear bogie
˄12˅ Sensor signal of rotating speed of front turbocharger
˄13˅ Sensor signal of rotating speed of rear turbocharger
˄14˅ Input of standby frequency signal 1
˄15˅ Input of standby frequency signal 2

Figure 7-10 Frequency serial port subassemblyď17FE820A1Đ

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1.5.4. Digital input subassembly (17FE830A1)

There are 32 digital input channels on one digital input subassembly. Totally there are 96 channels on three
subassemblies. Figure 7-11 shows its contour. The concrete signals are as follows:
˄1˅ A/B position signal of microcomputer communication
˄2˅ Switch signal of the other locomotive startup lubrication pump
˄3˅ Startup signal of diesel engine of local locomotive
˄4˅ Startup signal of the other locomotive diesel engine
˄5˅ Shut down signal of local locomotive diesel engine
˄6˅ Shut down signal of the other locomotive diesel engine
˄7˅ Switching signal of fuel pump
˄8˅ Closing signal of contactor of fuel pump
˄9˅ Switching signal of local locomotive startup lubricating pump
˄10˅ Closing signal of startup contactor of lubricating pump
˄11˅ Closing signal of startup contactor of lubricating pump
˄12˅ “ˌ”position signal
˄13˅ Master controller coding A signal
˄14˅ Master controller coding B signal
˄15˅ Master controller coding C signal
˄16˅ Master controller coding D signal
˄17˅ 75MPA startup signal of air compressor
˄18˅ Sanding signal
˄19˅ Low level of cooling water signal of water tank
˄20˅ Over-pressure signal of crankcase
˄21˅ Interlocking signal of crank shaft
˄22˅ Acting signal of oil pressure relay of front turbocharger
˄23˅ Acting signal of oil pressure relay of rear turbocharger
˄24˅ Standby
˄25˅ Switching signal of local locomotive auxiliary generate
˄26˅ Switching signal of the other locomotive auxiliary generate
˄27˅ Closing signal of auxiliary exciting contactor
˄28˅ fixed generating signal of local locomotive
˄29˅ fixed generating signal of the other locomotive
˄30˅ Closing signal of fixed generating contactor
˄31˅ Over-voltage signal of auxiliary generator
˄32˅ Tractive operating mode signal
˄33˅ Braking operating mode signal
˄34˅ Self-load operating mode signal

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˄35˅ Test operating mode signal

˄36˅ Locomotive control signal
˄37˅ 70MPA startup signal of air compressor
˄38˅ Closing signal of locomotive control safety
˄39˅ Closing signal of machine control relay
˄40˅ Forward signal
˄41˅ Backward signal
˄42˅ Closing signal of contactor
˄43˅ Closing signal of excitation contactor of exciter
˄44˅ Closing signal of brake contactor
˄45˅ Low air pressure of reservoir signal
˄46˅ 1# closing signal of electromagnetic contactor
˄47˅ 2# closing signal of electromagnetic contactor
˄48˅ 3# closing signal of electromagnetic contactor
˄49˅ 4# closing signal of electromagnetic contactor
˄50˅ 5# closing signal of electromagnetic contactor
˄51˅ 6# closing signal of electromagnetic contactor
˄52˅ Operating mode switch signal 1
˄53˅ Operating mode switch signal 2
˄54˅ Direction switch signal 1
˄55˅ Direction switch signal 2
˄56˅ Acting signal of over-current relay
˄57˅ Acting signal of grounding relay
˄58˅ Acting signal of relay of current difference of dynamic brake motor
˄59˅ Dead man signal
˄60˅ Low pressure signal of brake pipe
˄61˅ Fault excitation input
˄62˅ Shunting operating mode signal
˄63˅ Shield signal of closing magnetic field weakening contactor
˄64˅ Shield signal of contactor closing of air compressor 1
˄65˅ Shield signal of contactor closing of air compressor 2
˄66˅ Separating signal of dynamic braking
˄67˅ ̚˄96˅Standby digital input 1̚27

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Figure 7-11 Digital input subassembly˄17FE830A1˅

1.5.5. Digital output subassembly (17FE840C1)

There are 12 digital output channels on one digital output subassembly. Totally there are 36 channels on
three subassemblies. In addition there is one excitation chopping output channel. Figure 7-12 shows its
contour.

The concrete 36 digital output signals are as follows:

Drive of alarm indicating lamp of microcomputer (normally OFF)
Drive of shut down of diesel engine
Drive of Sanding (sanding indicating lamp)
Drive of locomotive control relay
Drive of forward direction switch
Drive of Backward direction switch
Drive of changeover switch drive of tractive operating mode
Drive of changeover switch drive of braking operating mode
Drive of braking contactor
Drive of 1# electromagnetic contactor
Drive of 2# electromagnetic contactor
Drive of 3# electromagnetic contactor
Drive of 4# electromagnetic contactor
Drive of 5# electromagnetic contactor
Drive of 6# electromagnetic contactor
Drive of excitation contactor
Drive of excitation contactor

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Drive of magnetic field weakening contactor

Drive of air compressor 1 contactor
Drive of air compressor 2 contactor
Drive of auxiliary exciting contactor
Drive of fixed generator contactor
Drive of lubricating pump contactor
Drive of grounding relay cutting
Drive of startup contactor
Drive of master controller position A
Drive of master controller position B
Drive of master controller position C
Drive of master controller position D
Drive of diesel engine idle
Drive of emergency braking vent valve
Dead man alarm bell drive
Drive of stepper motor A phase
Drive of stepper motor B phase
Drive of stepper motor C phase
Drive of shutter
Digital output standby 1
Digital output standby 2
Digital output standby 3
Digital output standby 4

Figure 7-12 Digital quantity output subassembly˄17FE840C1˅

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1.5.6. Analog quantity processing subassembly (17FE850B1)

There are 21 input signals of temperature and pressure, among which there are 10 signals of temperatureˈ
and 11 of pressure. Figure 7-13 shows its contour. The concrete definition is as follows:
(1) Temperature input of inlet of high temperature water system
(2) Temperature input of outlet of middle cold water system
(3) Water temperature input of heat exchanger outlet
(4) Temperature input of lubrication oil inlet
(5) Temperature input of lubrication oil outlet
(6) Temperature input of outlet of high temperature water system
(7) Temperature input of inlet of middle cold water system
(8) Ambient temperature input
(9) Standby temperature 1 input
(10) Standby temperature 2 input
(11) Input of diesel lubrication oil inlet pressure
(12) Input of diesel lubrication oil outlet pressure
(13) Input of inlet of front turbocharger lubrication oil pressure
(14) Input of inlet of rear turbocharger lubrication oil pressure
(15) Input of inlet of lubrication oil filter pressure
(16) Input of outlet of fuel pump pressure
(17) Input of fuel system end pressure
(18) Input of front bogie brake cylinder pressure
(19) Input of rear bogie brake cylinder pressure
(20) Input of control air cylinder pressure
(21) Standby pressure input

There are 12 10V low voltage analog input signals. They are as follows:
(1) current signal of 1#traction motor
(2) current signal of 2# traction motor
(3) current signal of 3#traction motor
(4) current signal of 4# traction motor
(5) current signal of 5# traction motor
(6) current signal of 6# traction motor
(7) current magnetic field signal of traction motor
(8) Output voltage signal of main rectifier
(9) Excitation current signal of main generator
(10) Excitation current signal of exciter
(11) LCS˄electric spray˅signal input
(12) Output current of main generator (before rectifying)

The number of standby 10V low voltage analog input signal is 5. They are as follows:
(1) Input of standby analog signal 1
(2) Input of standby analog signal 2
(3) Input of standby analog signal 3

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(4) Input of standby analog signal 4

(5) Input of standby analog signal 5

The number of 110V high voltage analog input signal is 7. They are as follows:
(1) Auxiliary generate voltage
(2) Input of standby analog signal 1 (110V Positive)
(3) Input of standby analog signal 2 (110V Positive)
(4) Input of standby analog signal 3 (110V Positive)
(5) Input of standby analog signal 4 (110V Positive)
(6) Input of standby analog signal 5 (110V Positive)
(7) Input of standby analog signal 6 (110V Positive)

Figure 7-13 Analog quantity processing subassembly˄17FE850B1˅

1.5.7. LonWorks communicating subassembly (17FE188A1)

The LonWorks network consists of communication subassembly in microcomputer cabinet, communication
board in display, network wire for connecting every component. There are 8 LEDs (light emitting diode) on
the network communication subassembly in microcomputer cabinet. The LEDs are divided into two groups
from middle. Each group with four LEDs indicates the working state of one network channel. Figure 7-14
shows its contour.

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Figure 7-14 LonWorks communication subassemblyď17FE188A1Đ

1.5.8. Switching control subassembly (17FE111A1)

This subassembly is used for realizing the cold backup with double set of microcomputer. It switches part of
sensor input signals (mainly the resistance type temperature signal and current type signal) through the
operating /cutting of relay. At the same time it transforms the signal and sends it to the analog quantity
processing subassembly. Figure 7-15 shows its contour.

Figure 7-15 Switching control subassembly (17FE111A1)

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1.6. Microcomputer operating principle block diagram

Figure 7-16 LCS32 microcomputer operating principle block diagram

1.7 Operating Precautions

1.7.1. Under normal circumstancesˈ the changeover switch of microcomputer control power supply on
driver operating bench must be placed at A or B position;

1.7.2. The following switches must be shut off before connecting or disconnecting N101-N107 plugs in
LCS32 case:

1) Microcomputer power supply switch;

2) Locomotive control switch.

1.7.3. The following precautionary measure must be adopted when replace subassemblies:

1) Forbid to pull out any subassemblies when it is working;

2) Must touch grounding shell with your hands firstly before pulling out the subassembly

3) The removed subassemblies must be put into the electrostatic shielding package.

4) Must wear grounding bracelet before touching the components.

1.8. Fault judging and processing

1.8.1. Two LCS32 microcomputer cases can be switched through the microcomputer A/B group power
supply changeover switch on operating bench in driver’s cab. If one microcomputer control box works
abnormally the other box must be switched to work firstly. But must pay attention: Must shut off the power
supply of microcomputer before switching. The switch operation with power is forbidden.

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1.8.2. If the microcomputer case doesn’t work after switching on the general control switch. We can check
the testing jack (refer to the right figure) on power supply subassembly (3# slot) in LCS32 box. Check
whether the power supply accords with the index of 5V±0.15Vǃ±15V±0.30V. If it is microcomputer power
supply subassembly (17FE200A1) that goes wrong, it must be
replaced.

1.8.3. If the power supply works normally while the microcomputer

doesn’t work completely, it probably is CPU that goes wrong. This
problem can be solved through replacing the standby subassembly
(17FE810A1, refer to right figure). Pay attention: Program software
well when replacing CPU subassembly.

1.8.4. If one display screen in locomotive displays abnormally ˈthe

display screen should be replaced. If all display screens display
abnormally and can’t be communicated with, the network maybe goes
wrong. The user should replace the LonWorks network subassembly
(17FE188A1, refer to right figure). If it still works abnormally, the
display screen maybe goes wrong. Replace it

1.8.5. If some relay installed in locomotive controlled by

microcomputer (for example: sanding drive relay, magnetic field
weakening relay, etc) works abnormally continuously the relay and its
wire must be checked firstly. After confirming that the relay is good,
you can replace the digital output subassembly (17FE840C1, refer to
right figure).

1.8.6. If some signals, such as: inlet and outlet temperature of

lubrication oil, pressure signal are displayed abnormally continuously
but the analog quantity is actually normal. The corresponding sensor
and its wire must be checked firstly. If no fault exists please replace
the analog quantity input subassembly (17FE850B1, refer to right
figure).

1.8.7. If the locomotive works abnormally because of the abnormal

rotating speed of diesel engine, please check the corresponding sensor
and its circuit that is relevant to rotating speed of diesel engine. On the
premise that they are all normal you can replace the frequency input
subassembly (17FE820A1, refer to the right figure).

1.8.8. If the LED2 of LonWorks network subassembly (17FE188A1)

is constantly on, it indicates that the first channel hardware of network
subassembly goes wrong. If the LED6 is constantly on it indicates that
the second channel hardware of network subassembly goes wrong. If
LED2 and LED6 are both off it indicates that the first and second
channel network subassemblies work normally.

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But from the application of microcomputer control device, the fault caused by control device itself almost
occurs. The external sensors and their circuit are often the cause of most faults. If a fault occurs please
check the corresponding external sensor, relay, contactor and their circuit firstly. After confirming that they
are all normal then consider to replace the subassemblies.

1.9 Simple checking method

The off-board test of power supply subassembly: Connect the 55c core of external plug of subassembly to
110V+. Connect the 47c core to 110V-. The corresponding voltage must be produced on following terminals:

1c core: +5V 3c core: common 5V ground

5c core˖-15V 6c core: +15V

7c core: common 15V ground

In the locomotive, open the cover of microcomputer case, check the testing jack +5V, ±15V with universal
meter and observe whether they are normal or not.

1.10 Environmental conditions

Altitude ”2500m

Working temperature -25ć̚+75ć

Air humidity ”100%

Inclination ˘10°

Anti-vibration: Adapt to vertical, horizontal and perpendicular three directions.

1̚50HZˈ˘10m/s2

Anti-impact ˘30m/s2

It must be installed in the car body that is waterproof, snow-proof and wind-proof.

1.11 External interface of microcomputer control device

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N101:
A/B position signal of microcomputer Switching signal of startup lubricating pump
A1: A2:
communication of trail engine
Startup signal of local locomotive diesel Startup signal of trail locomotive diesel
A3: A4:
engine engine
Coast down signal of local locomotive diesel Coast down signal of trail locomotive diesel
B1: B2:
engine engine
B3: Switching signal of fuel pump B4: Closing signal of fuel pump contactor
Switching signal of local locomotive startup
C1: C2: Closing signal of startup lubrication pump contactor
lubrication pump
C3: Closing signal of startup contactor C4: “0” position signal
D1: Master controller coding A signal D2: Master controller coding B signal
D3: Master controller coding C signal D4: Master controller coding D signal
E1: 75MPA startup signal of air compressor E2: Sanding signal
E3: Low water level signal of water tank E4: Over-pressure signal of crankcase
F1: Interlocking signal of crank shaft F2:
Acting signal of lubrication oil pressure relay Acting signal of lubrication oil pressure relay
F3: of front turbocharger (if act, the engine can F4: of rear turbocharger (if act, the engine can
stop) stop)
Switching signal of local locomotive auxiliary
G1: Standby G2:
generation
Switching signal of trail locomotive auxiliary Closing signal of auxiliary excitation
G3: G4:
generation contactor
H1: Local locomotive fixed generation signal H2: Trail locomotive fixed generation signal
H3: Closing signal of fixed generation contactor H4: Over-voltage signal of auxiliary generator
J1: Traction operating mode signal J2: Brake operating mode signal
J3: Self-load operating mode signal J4: Test operating mode signal
K1: Locomotive control signal K2: 70MPA startup signal of air compressor
Closing signal of locomotive control
K3: K4: Closing signal of locomotive control relay
protection switch
L1: Forward signal L2: Backward signal
Closing signal of excitation contactor of
L3: Closing signal of excitation contactor L4:
exciter
M1: Closing signal of brake contactor M2: Low pressure of main reservoir signal
M3: 1# closing signal of electromagnetic contactor M4: 2# closing signal of electromagnetic contactor
N1: 3# closing signal of electromagnetic contactor N2: 4# closing signal of electromagnetic contactor
N3: 5# closing signal of electromagnetic contactor N4: 6# closing signal of electromagnetic contactor
P1: Operating mode switch signal 1 P2: Operating mode switch signal 2
P3: Direction switch signal 1 P4: Direction switch signal 2

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N102:
A1: Acting signal of over-current relay A2: Acting signal of grounding relay
Acting signal of relay of rotating speed of
A3: A4: Dead man signal
motor of dynamic brake
B1: Low pressure signal of brake-pipe B2: Fault excitation input
B3: B4:
Drive of alarm indicating lamp of
C1: C2: Shut down drive of diesel engine
microcomputer (always OFF)
C3: Sanding (sanding indicating lamp) drive C4: locomotive control relay drive
D1: Forward direction switch drive D2: Backward direction switch drive
Changeover switch drive of traction Changeover switch drive of brake
D3: D4:
operating mode operating mode
E1: Brake contactor drive E2: 1# Electromagnetic contactor drive
E3: 2# Electromagnetic contactor drive E4: 3# Electromagnetic contactor drive
F1: 4# Electromagnetic contactor drive F2: 5# Electromagnetic contactor drive
F3: 6# Electromagnetic contactor drive F4: Excitation contactor drive
Drive of magnetic field weakening
G1: Excitation contactor drive of exciter G2:
contactor
G3: Drive of air compressor 1 contactor G4: Drive of air compressor 2 contactor
H1: Drive of auxiliary excitation contactor H2: Drive of fixed generate contactor
H3: Drive of lubrication pump contactor H4: drive of grounding relay cut
Drive of master controller gear A
J1: Drive of startup contactor J2:
˄ electric spray˅
Drive of master controller gear B˄ electric
J3: J4:
spray˅
Drive of master controller gear C˄ electric Drive of master controller gear D
K1: K2:
spray˅ ˄ electric spray˅
drive of diesel engine idle ˄ electric
K3: K4:
spray˅
L1: Dead man alarm bell drive L2: Drive of exciter of upper LCS32 box
Exciting drive feedback of upper LCS32
L3: Drive of exciter of lower LCS32 box L4:
box
Exciting drive feedback of lower LCS32
M1: M2: Power supply 110V of upper LCS32 box
box
Other power supply 110V of upper LCS32
M3: M4: Power supply 110V of lower LCS32 box
box
Other power supply 110V of lower LCS32
N1: N2: 110V microcomputer power supply
box
N3: Power supply ground of upper LCS32 box N4: Digital output ground of upper LCS32 box
P1: Digital input ground of upper LCS32 box P2: Power supply GND of lower LCS32 box
P3: Digital output ground of lower LCS32 box P4: Digital input ground of lower LCS32 box

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N103:
1# sensor signal of rotating speed of traction 1# sensor grounding terminal of rotating speed of
A1: A2:
motor traction motor
1# sensor shield of rotating speed of traction 2# sensor signal of rotating speed of traction
A3: A4:
motor motor
2# sensor grounding terminal of rotating speed of 2# sensor shield of rotating speed of traction
B1: B2:
traction motor motor
3# sensor signal of rotating speed of traction 3# sensor grounding terminal of rotating speed of
B3: B4:
motor traction motor
3# sensor shield of rotating speed of traction 4# sensor signal of rotating speed of traction
C1: C2:
motor motor
4# sensor grounding terminal of rotating speed of 4# sensor shield of rotating speed of traction
C3: C4:
traction motor motor
5# sensor signal of rotating speed of traction 5# sensor grounding terminal of rotating speed of
D1: D2:
motor traction motor
5# sensor shield of rotating speed of traction 6# sensor signal of rotating speed of traction
D3: D4:
motor motor
6# sensor grounding terminal of rotating speed of 6# sensor shield of rotating speed of traction
E1: E2:
traction motor motor
Sensor signal of rotating speed of front cooling Sensor grounding terminal of rotating speed of
E3: E4:
fan front cooling fan
Sensor shield of rotating speed of front cooling Sensor signal of rotating speed of rear cooling
F1: F2:
fan fan
Sensor grounding terminal of rotating speed of Sensor shield of rotating speed of rear cooling
F3: F4:
back cooling fan fan
Sensor signal of rotating speed of ventilator of Sensor ground of rotating speed of ventilator of
G1: G2:
primary generator main generator
Sensor shield of rotating speed of ventilator of
G3: G4: Rotating speed signal of ventilator of front bogie
shield generator
Rotating speed grounding terminal of ventilator
H1: H2: Rotating speed shield of ventilator of front bogie
of front bogie
H3: Rotating speed signal of ventilator of rear bogie H4: Rotating speed ground of ventilator of rear bogie
Sensor signal of rotating speed of front
J1: Rotating speed shield of ventilator of rear bogie J2:
turbocharger
Sensor ground of rotating speed of front Sensor shield of rotating speed of front
J3: J4:
turbocharger turbocharger
Sensor signal of rotating speed of rear Sensor ground of rotating speed of rear
K1: K2:
turbocharger turbocharger
Sensor shield of rotating speed of rear
K3: K4: speed sensor signal
turbocharger
L1: Speed sensor signal -15V L2: shield of standby frequency signal 1
L3: Speed sensor signal L4: Speed sensor signal -15V
M1: Shield of standby frequency signal 2 M2: Input of standby frequency signal 3
Grounding terminal of standby frequency signal
M3: M4: shield of standby frequency signal 3
3
N1: Input of LCP high end N2: feedback of LCP high end
Input of standby analog signal 2 110V+ feedback
N3: Input of LCP slide end N4:
of LCP slide end
P1: Input of standby analog signal 3 110V+ P2: Input of standby analog signal 4 110V+
P3: Input of standby analog signal 6 110V+ P4: feedback of standby analog signal 6 110V GND

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N104:
1# positive power supply of traction current
A1: 1# current signal of traction motor A2:
sensor
1# negative power supply of traction motor 1# power supply GND of traction current
A3: A4:
signal sensor
2# positive power supply of traction current
B1: 2# current signal of traction motor B2:
sensor
2# negative power supply of traction motor 2# power supply GND of traction current
B3: B4:
signal sensor
3# positive power supply of traction current
C1: 3# current signal of traction motor C2:
sensor
3# negative power supply of traction motor 3# power supply GND of traction current
C3: C4:
signal sensor
D1: Input of standby analog signal 1 D2:
D3: D4:
E1: Shield of standby analog signal 1 E2: 4# current signal of traction motor
4# positive power supply of traction current 4# negative power supply of traction motor
E3: E4:
sensor signal
4# power supply GND of traction current
F1: F2: 5# current signal of traction motor
sensor
5# positive power supply of traction current 5# negative power supply of traction motor
F3: F4:
sensor signal
5# power supply GND of traction current
G1: G2: 6# current signal of traction motor
sensor
6# positive power supply of traction current 6# negative power supply of traction motor
G3: G4:
sensor signal
6# power supply GND of traction current
H1: H2:
sensor
Positive power supply of magnetic current
H3: Magnetic current signal of traction motor H4:
signal of traction motor
Negative power supply of magnetic current Magnetic current signal GND of traction
J1: J2:
signal of traction motor motor
J3: J4: Output voltage signal of primary rectifier
Positive power supply of output voltage of Negative power supply of output voltage of
K1: K2:
primary rectifier primary rectifier
K3: Output voltage GND of primary rectifier K4:
L1: L2: Excitation current signal of main generator
feedback of exciting current signal of main
L3: L4: Excitation current signal of exciter
generator
M1: M2: Sensor power supply +15V
M3: Sensor power supply -15V M4:
N1: N2:
Output current of main generator (before
N3: N4:
rectifying)
P1: Input of standby analog signal 1 P2: feedback of standby analog signal 1
P3: Auxiliary generator voltage P4: Excitation of auxiliary generator voltage

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N105:
A1: Temperature input of inlet of high temperature A2: Temperature shield of inlet of high
water system temperature water system
A3: Temperature input of outlet of middle cold water Temperature shield of outlet of middle
A4:
system cold water system
B1: Water temperature input of heat exchanger outlet Water temperature shield of heat
B2:
exchanger outlet
B3: Temperature input of lubrication oil inlet Temperature shield of lubrication oil
B4:
inlet
C1: Temperature input of lubrication oil outlet Temperature shield of lubrication oil
C2:
outlet
C3: Temperature input of outlet of high temperature Temperature shield of outlet of high
C4:
water system temperature water system
D1: Temperature input of inlet of middle cold water Temperature shield of inlet of middle
D2:
system cold water system
D3: Ambient temperature input D4: Ambient temperature shield
E1: Input of standby temperature 1 E2: Shield of standby temperature 1
E3: Input of standby temperature 2 E4: Shield of standby temperature 2
F1: Input of diesel lubrication oil inlet pressure Power supply of diesel lubrication oil
F2:
inlet pressure
F3: GND of diesel lubrication oil inlet pressure Shield of diesel lubrication oil inlet
F4:
pressure
G1: Input of diesel lubrication oil outlet pressure Power supply of diesel lubrication oil
G2:
outlet pressure
G3: GND of diesel lubrication oil outlet pressure Shield of diesel lubrication oil outlet
G4:
pressure
H1: Input of inlet of front supercharger lubrication oil Power supply of inlet of front
H2:
pressure supercharger lubrication oil pressure
H3: GND of inlet of front supercharger lubrication oil Shield of inlet of front supercharger
H4:
pressure lubrication oil pressure
J1: Input of inlet of rear turbocharger lubrication oil Power supply of inlet of rear
J2:
pressure turbocharger lubrication oil pressure
J3: GND of inlet of rear turbocharger lubrication oil shield of inlet of back supercharger
pressure J4: lubrication oil pressure
K1: Input of inlet of lubrication oil filter pressure Power supply of inlet of lubrication oil
K2:
filter pressure
K3: GND of inlet of lubrication oil filter pressure Shield of inlet of lubrication oil filter
K4:
pressure
L1: Input of outlet of fuel pump pressure Power supply of outlet of fuel pump
L2:
pressure
L3: GND of outlet of fuel pump pressure L4: Shield of outlet of fuel pump pressure
M1: Input of standby sensor signal M2: Sensor power supply +15V
M3: shield of standby sensor input M4: Shield of standby sensor signal
N1: Input of fuel system end pressure Power supply of fuel system end
N2:
pressure
N3: GND of fuel system end pressure N4: shield of fuel system end pressure
P1: Input of front bogie brake cylinder Power supply of front bogie brake
P2:
cylinder pressure
P3: GND of front bogie brake cylinder pressure P4: Shield of front bogie brake cylinder
pressure

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N106:
Pressure input of rear bogie brake Pressure power supply of rear bogie
A1: A2:
cylinder brake cylinder
Pressure GND of rear bogie brake Pressure shield of rear bogie brake
A3: A4:
cylinder cylinder
B1: Standby pressure input B2: Standby pressure power supply
B3: Standby pressure GND B4: Standby pressure shield
Pressure power supply of control air
C1: Pressure input of control air cylinder C2:
cylinder
C3: Pressure GND of control air cylinder C4: Pressure shield of control air cylinder
D1: Input of standby analog signal 5 D2: Sensor power supply +15V
D3: Shield of standby analog signal 5 D4: Standby pressure sensor shield 2
E1: Sensor power supply +15V E2: Standby pressure sensor shield 3
E3: Input of standby analog signal 6 E4: Shield of standby analog signal 6
Sensor +15V power supply cutting Sensor +15V power supply cutting
F1: F2:
(out) (out)
Sensor +15V power supply cutting Sensor +15V power supply cutting
F3: F4:
(in) (in)
Sensor -15V power supply cutting Sensor -15V power supply cutting
G1: G2:
(out) (out)
Sensor -15V power supply cutting
G3: Sensor -15V power supply cutting (in) G4:
(in)
H1: H2:
H3: H4:
J1: LCS32 microcomputer TA+ J2: LCS32 microcomputer TA-
J3: Shield J4: LCS32 microcomputer RA+
K1: LCS32 microcomputer RA- K2: Shield
K3: LCS32 microcomputer TB+ K4: LCS32 microcomputer TB-
L1: Shield L2: LCS32 microcomputer RB+
L3: LCS32 microcomputer RB- L4: Shield
LonACOM ˄Connect to locomotive
M1: M2: LonA+
body˅
LonBCOM˄Connect to locomotive
M3: LonA- M4:
body˅
N1: LonB+ N2: LonB-
N3: N4:
P1: P2:
P3: P4:

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N107:
Shield of closing magnetic field
A1: Shunting operating mode signal A2:
weakening contactor
Shield of closing air compressor 1 Shield of closing air compressor 2
A3: A4:
contactor contactor
B1: Separating signal of dynamic brake B2: horn signal
B3: Standby digital input 2 B4: Standby digital input 3
C1: Standby digital input 4 C2: Standby digital input 5
C3: Standby digital input 6 C4: Standby digital input 7
D1: Standby digital input 8 D2: Standby digital input 9
D3: Standby digital input 10 D4: Standby digital input 11
E1: Standby digital input 12 E2: Standby digital input 13
E3: Standby digital input 14 E4: Standby digital input 15
F1: Standby digital input 16 F2: Standby digital input 17
F3: Standby digital input 18 F4: Standby digital input 19
G1: Standby digital input 20 G2: Standby digital input 21
G3: Standby digital input 22 G4: Standby digital input 23
H1: Standby digital input 24 H2: Standby digital input 25
H3: Standby digital input 26 H4: Standby digital input 27
J1: output of stepper motor A phase J2: 3 output of stepper motor B phase
J3: output of stepper motor C phase J4: Shutter drive
K1: K2:
K3: K4:
L1: L2:
L3: L4:
M1: M2:
M3: M4:
N1: N2:
N3: N4:
P1: P2:
P3: P4:

2 Control Software
The control software has some functions such as: realize the multiple-connection control, logic control,
magnetic field weakening control, constant power characteristic control, dynamic brake characteristic
control, anti-slip/anti-slide characteristic control of locomotive, fault diagnosis and protecting function of
diesel engine system, fault diagnosis and protecting function of electric system, displaying function of
display screen etc.

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The control system is divided into four main operating modes: idle, traction, self-loading, dynamic brake.
Figure 7-17 shows the operating mode transition diagram of locomotive control system.

Traction

Power supply
Self-loading
switch Idle

Dynamic brake

Figure 7-17 transition diagram of operating mode

The control system has two running state: single-locomotive and multiple-connection. When LCS32
receives communication information of multiple-connection, the control system runs in multiple-connection
state. Driver sends signal through master controller and corresponding operating switches of local or the
other locomotive. The LCS32 realizes the control of conversion of direction, unloading, loading, traction,
self-loading and dynamic brake according to the operational signal and other logical limited conditions.
When LCS32 receives multiple-connection communication information in specified time, the control
system runs in single-engine state. Driver sends operational signal through local master controller and
corresponding switches.

The locomotive is equipped with a “microcomputer communication A/B position” switch. The switch is
mainly used for setting the address of LonWorks network equipments.

2.1 Constant power characteristic control

(ĉ) Locomotive traction characteristic

When locomotive is in traction operating mode, with different position of diesel engine rotating speed, the
total power, CHEC (Constant Horsepower Excitation Control) power, voltage-limit value, current-limit
value of diesel engine.

The voltage-limit value keeps constant when cut off fault of traction motor. The constant horsepower
decrease 1/6 when cut off one traction motor.

(Ċ) Power loading rate

In order to prevent instantaneous overload of diesel engine and decrease the black smoke when shift main
handle from low gear to high or raise the power from low to high, the power loading rate is restricted under
presetting limit. The power loading rate is different along with different CHEC power.

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(ċ) Power unloading rate

In order to provide smooth power control when shift main handle from high gear to low position the power
unloading rate is restricted under presetting limit. The power unloading rate is different along with different
CHEC power.

(Č) Current increasing rate

The current increasing rate (single traction motor) is restricted under the presetting limit. The smooth
traction motor torque is required to be provided especially when locomotive starts up. The maximal current
increasing rate of single traction motor is regulated: 200 A/s. Otherwise it is restricted by power loading rate.

(č) Current decreasing rate

The current decreasing rate (single traction motor) is restricted under the presetting limit. It is necessary
when reduce the traction motor torqueˈespecially when shift main handle from high gear to low gear ,it
must be provided smoothly. The maximal current decreasing rate of single traction motor is regulated:
250A/s. Otherwise it is restricted by power unloading rate.

(Ď) Voltage increasing rate

In order to provide smooth increase of voltage, the voltage increasing rate of synchronous main generator
must be regulated under the presetting limit. The maximal voltage increasing rate is regulated: 150V/s.
Otherwise it is restricted by the less one between power changing rate and current changing rate.

(ď) Voltage decreasing rate

In order to decrease the voltage of synchronous main generator smoothly when shift main handle from high
gear to low gear, the voltage decreasing rate of synchronous main generator is restricted under the presetting
limit. The maximal voltage decreasing rate is regulated: 300V/s. Otherwise it is restricted by power
unloading rate.

2.2. Dynamic brake characteristic

When locomotive carries out the dynamic brake, the microcomputer system restricts the maximal value of
traction motor magnetic field current and braking resistance current under the permitting limit according to
different gear.

The loading rate of traction motor magnetic field is: 50A/s.

The armature current of traction motor is the current value when motor rotating speed is 2385 r/min (wheel
semi-abrasion, the locomotive velocity is 100km/h). It is got by decreasing linearly from the maximum
when motor rotating speed is 1779 r/min (wheel semi-abrasion, the locomotive velocity is 75km/h).

2.3 Anti-slip/anti-slide control

Adhesion control system is the one that is corresponding to the rotating speed of traction motor. A motor
rotating speed sensor is installed at the end of shaft of commutator of each traction motor to measure the
rotating speed of traction motor. The traction motor will send out 68 pulses when it rotates one circle. The
microcomputer system detects all the rotating signals continuously and compares them. If the speed
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difference exceeds presetting limitˈ the corresponding correcting and protecting measure will be carried
out such as sanding, power-decreasing, unloading etc.

When rotating speed of any one traction motor becomes zero the anti-slip/anti-slide control system will be
shut off automatically.

(ĉ) The anti-slip protection in tractive operating mode

When locomotive is in tractive operating mode and the 8KM contactor coil is electrified ˈ 3 seconds later,
if the rotating speed difference exceeds presetting limit and the current distribution coefficient is larger than
8% it is considered that the locomotive is idle running or going to idle running. In order to ensure that the
rotating speed difference is in the regulated range the microcomputer carries out sanding automatically,
decreases power smoothly in proportion, decreases power rapidly, whole power cutting off etc measure. The
above measures will be carried out gradually according to the severity of idle running. When the power
decreases to the 50% of the corresponding gear power the “Severe of idle running” information is displayed
on the microcomputer display screen. At the same time “microcomputer alarm indicating lamp” illuminates.
Because of the correction of idle running protection the microcomputer will restore the permitting power
after ceasing the idle running. Then “microcomputer alarm indicating lamp” turns off and the locomotive
runs normally.

(Ċ) The sliding protection in dynamic brake operating mode

When locomotive is in dynamic brake operating mode, if the rotating speed difference is exceeds presetting
limit it is considered that the locomotive is sliding or going to be slide. In order to ensure that the rotating
speed difference is in the regulated range the microcomputer carries out sanding automatically, decreases
magnetic field current smoothly in proportion, decreases magnetic field current rapidly, cuts off whole
magnetic field current etc measure. The above measures will be carried out gradually according to the
severity of sliding. When magnetic field current/braking current decreases to 50% of corresponding step
magnetic field current/braking current, “Severe of sliding” information will be displayed on the
microcomputer display screen. At the same time “microcomputer alarm indicating lamp” illuminates.
Because of the correction of sliding protection the microcomputer will restore the permitting magnetic field
current of this gear after ceasing sliding. Then “microcomputer alarm indicating lamp” turns off and the
locomotive runs normally.

2.4 Software setting function

Some control functions of LCS32 will be changed through the IDU1, 2 of local or other locomotive.

1. Through IDU1, 2 of local or other locomotive it can set the running or cutting off of 1#~6# traction
motors.

2. Through IDU1, 2 of local or other locomotive it can set the running or cutting off of grounding
protecting function.

3. Through IDU1, 2 of local or other locomotive it can set the application or cutting off of low pressure
(sensor) protecting function of front or rear turbocharger lubrication oil inlet.

4. Through IDU1, 2 of local or other locomotive it can set the application or cutting off of low pressure
(relay) protecting function of front or rear turbocharger lubrication oil inlet.
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5. Through IDU1, 2 of local or other locomotive it can set the application or cutting off high temperature
protecting function of lubrication oil outlet.

6. Through IDU1, 2 of local or other locomotive it can set the application or cutting off of high
temperature protecting function of diesel engine high-temperature water system outlet.

7. Through IDU1, 2 of local or other locomotive it can set the application or cutting off of adhesive control
function of locomotive.

8. Through IDU1, 2 of local or other locomotive it can set the application or cutting off of locomotive
ventilators (ventilator of main generator, front bogie, rear bogie) protecting function.

2.5 Diagnosis Of fault and protection

Microcomputer detects the voltage, current, frequency signal of locomotive electric system, temperature,
pressure signal and all sorts of input signals of switching quantity (All signals are defined as monitoring
parameters) of diesel engine through sensor continuously. Then compare them with the presented value. If
the computer detects monitoring parameters exceed limit, a piece of fault information is produced and will
be delivered to display screen. The display screen changes its interface into the fault display mode. At the
same time the microcomputer control screen implements corresponding protecting actions according to the
sort and severity of fault such as: alarm (indicating lamp); dead man alarm, record fault; reducing load of
diesel engine; unloading of diesel engine; shutting down diesel engine; emergency brake; record of running
recorder.

If the locomotive fault is eliminated LCS32 will reset the fault according to corresponding resetting
methods based on the different faults.

Automatic — reset when the monitored parameter is less than threshold.

Return to zero automatically—must reset automatically when main handle in zero position.

(ĉ) The content of fault diagnosis and protection

Table 7-1 gives all code and information text of control system faults. It also summarizes some controlling
items that should be completed by LCS32 when fault occurs in locomotive.

In this table symbol “Ɣ” denotes “YES” and “ż” denotes “NO”.

Content of fault diagnosis and protection Table 7-1

Alarm lamp Fault Recorder
Code Fault information text Reset mode
on record record
Shield to zero
0 Over-current of main generator Ɣ Ɣ Ɣ
automatically
Shield to zero
1 Over-voltage of main generator Ɣ Ɣ Ɣ
automatically
Shield to zero
2 Over-current of main generator magnetic field Ɣ Ɣ Ɣ
automatically
Shield to zero
3 #1over-current of traction motor Ɣ Ɣ Ɣ
automatically
Shield to zero
4 #2 over-current of traction motor Ɣ Ɣ Ɣ
automatically

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Alarm lamp Fault Recorder

Code Fault information text Reset mode
on record record
Shield to zero
5 #3 over-current of traction motor Ɣ Ɣ Ɣ
automatically
Shield to zero
6 #4 over-current of traction motor Ɣ Ɣ Ɣ
automatically
Shield to zero
7 #5 over-current of traction motor Ɣ Ɣ Ɣ
automatically
Shield to zero
8 #6 over-current of traction motor Ɣ Ɣ Ɣ
automatically
Shield to zero
9 #1 Over-speed of traction motor Ɣ Ɣ Ɣ
automatically
Shield to zero
10 #2 Over-speed of traction motor Ɣ Ɣ Ɣ
automatically
Shield to zero
11 #3 Over-speed of traction motor Ɣ Ɣ Ɣ
automatically
Shield to zero
12 #4 Over-speed of traction motor Ɣ Ɣ Ɣ
automatically
Shield to zero
13 #5 Over-speed of traction motor Ɣ Ɣ Ɣ
automatically
Shield to zero
14 #6 Over-speed of traction motor Ɣ Ɣ Ɣ
automatically
#1 cutting of traction motor
15 ż Ɣ ż Automatic

16 #2 cutting of traction motor ż Ɣ ż Automatic

17 #3 cutting of traction motor ż Ɣ ż Automatic
18 #4 cutting off of traction motor ż Ɣ ż Automatic
19 #5 cutting off traction motor ż Ɣ ż Automatic
20 #6 cutting off traction motor ż Ɣ ż Automatic
Shield to zero
21 Over-current of braking resistance Ɣ Ɣ Ɣ
automatically
Shield to zero
22 Over-current of traction motor magnetic field Ɣ Ɣ Ɣ
automatically
23 Dead man protection Ɣ Ɣ Ɣ Special
24 Dead man pre-warning Ɣ Ɣ ż Special
25 Monitor emergency Ɣ Ɣ Ɣ Special
26 slip/sliding of wheel pair Ɣ Ɣ Ɣ Automatic
Lubrication oil pressure of front supercharger is
27 Ɣ Ɣ Ɣ Special
low
28 Overpressure of crankcase Ɣ Ɣ Ɣ Special
29 Over-speed of diesel engine Ɣ Ɣ Ɣ Special
Shield to zero
30 Water temperature of diesel engine is high Ɣ Ɣ Ɣ
automatically
Shield to zero
31 Oil temperature of diesel engine is high Ɣ Ɣ Ɣ
automatically
Shield to zero
32 Pressure of main reservoir is low Ɣ Ɣ ż
automatically
Shield to zero
33 Train pipe pressure is low Ɣ Ɣ ż
automatically

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Alarm lamp Fault Recorder

Code Fault information text Reset mode
on record record
34 Over-speed of diesel engine front supercharger Ɣ Ɣ ż Automatic
35 Over-speed of diesel engine rear supercharger Ɣ Ɣ ż Automatic
36 Low lubrication pressure of rear supercharger Ɣ Ɣ Ɣ Special
37 Low pressure of fuel system terminal Ɣ Ɣ ż Automatic
High water temperature of diesel engine and
38 Ɣ Ɣ ż Automatic
power decrease 30%
High lubrication oil temperature of diesel engine
39 — — — —
and power decrease 30%
Relay of front turbocharger lubrication oil
40 Ɣ Ɣ Ɣ Special
pressure acts
Relay of rear turbocharger lubrication oil
41 Ɣ Ɣ Ɣ Special
pressure acts
42 Low water level of diesel engine water tank Ɣ Ɣ ż Automatic
43 Inter-locking of crank shaft ż ż ż Automatic
Shield to zero
44 Offside closing of locomotive control Ɣ Ɣ ż
automatically
45 Illegal setting of locomotive control Ɣ ż ż Automatic
Protection switch of locomotive control doesn’t Shield to zero
46 ż ż ż
close automatically
47 Operating mode signal error Ɣ Ɣ ż Automatic
48 Illegal settings of operating mode handle Ɣ ż ż Automatic
49 Direction signal error Ɣ Ɣ ż Automatic
50 Illegal settings of direction conversion handle Ɣ ż ż Automatic
Shield to zero
51 Fault of operating mode switch Ɣ Ɣ ż
automatically
Shield to zero
52 Fault of direction switch Ɣ Ɣ ż
automatically
Shield to zero
53 Illegal setting of master controller gear Ɣ Ɣ ż
automatically
Shield to zero
54 Illegal direction conversion of locomotive Ɣ Ɣ ż
automatically
Shield to zero
55 Over-current relay acts Ɣ Ɣ Ɣ
automatically
Shield to zero
56 Grounding relay acts Ɣ Ɣ Ɣ
automatically
Shield to zero
57 Wind speed relay acts Ɣ Ɣ Ɣ
automatically
Shield to zero
58 Monitor unload Ɣ Ɣ Ɣ
automatically
Shield to zero
59 Emergency braking Ɣ Ɣ Ɣ
automatically
60 Over-voltage of auxiliary generator Ɣ Ɣ Ɣ Automatic
61 Over-voltage of fixed generator Ɣ Ɣ Ɣ Special
62 Not close-up of fuel pump contactor Ɣ Ɣ ż Automatic
63 Not cut off of fuel pump contactor Ɣ Ɣ ż Automatic
Not close-up of startup lubricating pump
64 Ɣ Ɣ ż Automatic
contactor

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Alarm lamp Fault Recorder

Code Fault information text Reset mode
on record record
65 Not cut off of startup lubricating pump contactor Ɣ Ɣ ż Automatic
66 Not close-up of startup contactor Ɣ Ɣ ż Automatic
67 Not cut off of startup contactor Ɣ Ɣ ż Automatic
68 Not close-up of auxiliary excitation contactor Ɣ Ɣ ż Automatic
69 Not cut off of auxiliary excitation contactor Ɣ Ɣ ż Automatic
70 Not close-up of fixed generator contactor Ɣ Ɣ ż Automatic
71 Not cut off of fixed generator contactor Ɣ Ɣ ż Automatic
72 Not close-up of locomotive control relay Ɣ Ɣ ż Automatic
73 Not cut off of locomotive control relay Ɣ Ɣ ż Automatic
74 Not close-up of excitation contactor Ɣ Ɣ ż Automatic
75 Not cut off of excitation contactor Ɣ Ɣ ż Automatic
76 Not close-up of excitation contactor of exciter Ɣ Ɣ ż Automatic
77 Not cut off of excitation contactor of exciter Ɣ Ɣ ż Automatic
78 Not close-up of braking contactor Ɣ Ɣ ż Automatic
79 Not cut off of braking contactor Ɣ Ɣ ż Automatic
80 1# not close-up of electric magnetic contactor Ɣ Ɣ ż Automatic
81 1# not cut off of electric magnetic contactor Ɣ Ɣ ż Automatic
82 2# not close-up of electric magnetic contactor Ɣ Ɣ ż Automatic
83 2# not cut off of electric magnetic contactor Ɣ Ɣ ż Automatic
84 3# not close-up of electric magnetic contactor Ɣ Ɣ ż Automatic
85 3# not cut off of electric magnetic contactor Ɣ Ɣ ż Automatic
86 4# not close-up of electric magnetic contactor Ɣ Ɣ ż Automatic
87 4# not cut off of electric magnetic contactor Ɣ Ɣ ż Automatic
88 5# not close-up of electric magnetic contactor Ɣ Ɣ ż Automatic
89 5# not cut off of electric magnetic contactor Ɣ Ɣ ż Automatic
90 6# not close-up of electric magnetic contactor Ɣ Ɣ ż Automatic
91 6# not cut off of electric magnetic contactor Ɣ Ɣ ż Automatic
Not close-up of magnetic field weakening
92 Ɣ Ɣ ż Automatic
contactor
Not cut off of magnetic field weakening
93 Ɣ Ɣ ż Automatic
contactor
Overtime of multiple-connection communication Shield to zero
94 ż ż ż
channel A automatically
Shield to zero
95 Setting error of communication A/B ż ż ż
automatically
96 Alarm of fire accident — — — —
97 Fault of ventilator of main generator Ɣ Ɣ ż Automatic
98 Fault of ventilator of front bogie Ɣ Ɣ ż Automatic
99 Fault of ventilator of rear bogie Ɣ Ɣ ż Automatic
Overtime of multiple-connection communication Shield to zero
100 ż ż ż
channel B automatically
101 Short of temperature sensor of oil inlet ż ż ż Automatic
102 Open of temperature sensor of oil inlet ż ż ż Automatic

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Alarm lamp Fault Recorder

Code Fault information text Reset mode
on record record
103 Short circuit of temperature sensor of oil outlet ż ż ż Automatic
104 Open of temperature sensor of oil outlet ż ż ż Automatic
Short circuit of temperature sensor of high
105 ż ż ż Automatic
temperature water system inlet
Open of temperature sensor of high temperature
106 ż ż ż Automatic
water system inlet
Short circuit of temperature sensor of high
107 ż ż ż Automatic
temperature water system outlet
Open of temperature sensor of high temperature
108 ż ż ż Automatic
water system outlet
Short circuit of temperature sensor of middle
109 ż ż ż Automatic
cold water system inlet
Open of temperature sensor of middle cold water
110 ż ż ż Automatic
system inlet
Short circuit of temperature sensor of middle
111 ż ż ż Automatic
cold water system outlet
Open of temperature sensor of middle cold water
112 ż ż ż Automatic
system outlet
Short circuit of water temperature sensor of heat
113 ż ż ż Automatic
exchanger outlet
Open of water temperature sensor of heat
114 ż ż ż Automatic
exchanger outlet
115 Short circuit of ambient temperature sensor ż ż ż Automatic
116 Open of ambient temperature sensor ż ż ż Automatic
117 Not close-up of air compressor 1 contactor Ɣ Ɣ ż Automatic
118 Not cut off of air compressor 1 contactor Ɣ Ɣ ż Automatic
119 Not close-up of air compressor 2 contactor Ɣ Ɣ ż Automatic
120 Not cut off of air compressor 2 contactor Ɣ Ɣ ż Automatic
121 Not close-up of auxiliary generator contactor Ɣ Ɣ ż Automatic
122 Not cut off of auxiliary generator contactor Ɣ Ɣ ż Automatic
123 Electric deficiency of storage battery Ɣ Ɣ ż Automatic

(Ċ) Running recorder

After LCS32 is electrified for 15s and when locomotive fault occurs, partial monitor parameters are
recorded 15s before and the fault occurs and used for analyzing fault. Every fault has 61 frames of data in
the recorder, of which one frame of data is the fault code and occurrence time. The others 60 frames of data
are recorded every 0.5 second. The recorder always records the nearest 10 frames of data about running
information when fault occurs. The content of each frame of data in recorder is showed in table 7-2.

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Frame content of running recorder Table7-2

Code Monitor parameters Unit Explanation
0 Locomotive operating mode Remark 1
1 Locomotive speed km/h —
2 Position of main handle —
3 Diesel engine rotating speed r/min —
4 Basis of main generator power kW —
5 primary rectifier output power kW —
6 Output voltage of primary rectifier V —
7 Output current of primary rectifier A —
8 Excitation current of main generator A —
9 Excitation current of exciter A —
10 Output voltage of exciter V —
11 Voltage of DC auxiliary generator V —

2.6 Fault excitation

When LCS32 is in fault excitation operating mode the microcomputer reserves locomotive logic control
function and reserves all protecting functions simultaneously.

3 Overhaul method of microcomputer control box

3.1 Overhaul device, equipment and tool, measure and material

1. Device: microcomputer control system test bench, constant temperature oven and blowing device.

2. Equipment and tool: oscilloscope, signal generator, integrated block test instrument (the connecting test
board according to different type), transistor characteristic graphic instrument, logic testing pen, pulse-
generating pen, electric soldering iron (two pieces; 25W; inner-heat type and tin-extracting type), hexagonal
socket wrench, screwdriver, scissors, cutting nipper etc common electric tools.

3. Measure: universal meter, capacitance meter

4. Material: silk cloth, absolute alcohol, welding tin, hairbrush

All measuring instruments and shell of electric soldering iron must be grounding well lest to damage the
integrated circuit.

3.2 Main technical procedure

(ĉ) Dismantle and blow

1. Shut off the power supply and pull out all connecting plugs in microcomputer cabinet. Then shield the
plugs retained in the locomotive.

1. Blow the hanged part of microcomputer cabinet with dry compressed air.
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2. Disassemble each circuit board and clean the dust with hairbrush and industrial alcohol.

(Ċ) inspection and repair

1. The shell must not be distorted, cracked. The handle, guiding slot is good and the mark plate should be
clear.

2. All the wire harness should be bound reliably. All connecting wires shouldn’t be short, open, insulation
ageing and heated color-changing phenomenon. Among which the broken strand rate of multi-strand wire
should not exceeds 10%.

3. The integrated circuit board should not be broken, corrosion and loose. The metal foil should not be
separated from board base.

4. Every component should not be loose. The soldering joint should not be corrosion, cold soldering and
false soldering.

5. The switches, plugs and sockets shouldn’t be broken, chapped and loose. The insert pins are not broken
and obvious bent and deformed.

6. Each component should not be color-changing and damaged by heat. The integrated circuit module
should be inserted firmly and reliably.

(ċ) Debug

1. Insert each circuit board into the functional board case correctly according to the position and direction.

2. Install the functional board case into the microcomputer cabinet. Ensure that the connection is correct and
the installation is firm.

3. Put through the fan power supply and the fan should run normally DŽ

(Č) Precautions
1. In order to protect electronic components, the meg-ohmmeter and other high voltage measuring device
can’t be used for testing circuit when overhaul the fault. But we can check it with multi-meter’s R×100,
R×1000 and oscilloscope.

2. When the insulating and withstand voltage test of electronic system is done in the locomotive, all the
connection between microcomputer control box and locomotive electrical system must be cut off.

3. Pulling and inserting of external connecting plugs is forbidden when the microcomputer control box is
being electrified.

4. The Test is carried on at normal temperature and the performance should accord with the regulated
requirement. If necessary the functional board case can be put into the constant temperature oven (at the
temperature of 50±2ć, simulating working condition) and heated for an hour to carry on the high
temperature test.

3.3 Inspection and repair

3.3.1. Test before inspection and repair

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Dismantle the microcomputer control box from locomotive and place it on the test bench. Observe whether
its working state is good or not and what fault occurs. Then know well the actual running condition and
record it.

3.3.2. Disassemble the microcomputer subassemblies

3.3.3. Visual inspection and cleaning

(1) The shell must not be deformed, chapped. The handle, guiding slot is good and clean them with
alcohol. The mark plate should be clean.

(2) Clean the circuit board, plug, and socket with silk cloth or hairbrush soaked with alcohol. Then blow
them clean with ij0.5Mpa compressed air which passes through oil-water separator. If the above
components are damped seriously they must be put into the oven and be dried. (ij60ć).

(3) Check the whole set of circuit. It should satisfy the No 1,2,3,4 of basic technical requirement. The bad
components should be replaced or welded again.

(4) Prepare the new standby electronic components. The new components should be selected through high
temperature test. For the integrated circuit block, its corresponding logic characteristic and other
characteristics should be tested utilizing integrated circuit test board. At the same time observe its input,
output waveform with oscilloscope.

3.3.4. Main faults and their processing of microcomputer control box

(1) Information of time, accumulative total quantity and fault record etc lose on display screen. Processing
method: replace lithium battery on subassembly FE197.

(2) Display screen is invalid or only show the electrifying information. Processing method: check the
identicalness of A/B position of multiple-connection locomotive.

(3) Speed of traction motor is abnormal. Processing method: replace the corresponding subassembly
FE114.

(4) The power of main locomotive generator is low when main handle is at 8~ 16 position. Check the
corresponding circuit or replace the subassembly FE111, FE 850.

(5) The microcomputer control box can’t work normally. Processing method: replace the power supply
subassembly or replace CPU board (FE162).

(6) The locomotive can’t sand normally or can’t sand. It denotes that motor speed sensor or frequency
input board (FE114) goes wrong. Processing method: replace the corresponding motor speed sensor or
frequency input board.

(7) It doesn’t display locomotive speed on display screen or the locomotive slips, slides, decreases power
abnormally. It denotes that motor speed sensor or frequency input board (FE114) goes wrong. Processing
method: replace the corresponding motor speed sensor or frequency input board.

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4 Color display screen

4.1 Operating principle

When color display operates normally it receives the data from locomotive host computer LCS32
continuously and sends it to the buffer. It can display information in Chinese/English and graphical interface
according to the displaying requirement. If need to check other data, select it through pressing keys. The
color display will send different instructions to host computer according to different key pressing. The host
computer will send the required data back to the color display for displaying. So the different data will be
displayed when different function keys are pressed.

4.2 Main technical qualification

4.2.1 The displaying part is 10.4” color TFT LCD. The resolution is 640×480. The backlight is adjustable.

4.2.2 It is equipped with PC104 bus and 386 or more advanced CPU industrial main board. It is also
equipped with parallel port, PC compatible AT keyboard interface, serial port etc.

4.2.3 It owns IC card dumping interface and the corresponding dumping software.

4.2.4 Thin film switching keyboard. The F1~F5 five software functional keys act as the human-computer
input terminal.

4.2.5 It adopts LonWorks bus structure to communicate with locomotive host computer LCS32.
Communicate with power supply system and monitor system with two RS485 interfaces respectively.

4.2.6 It adopts color Chinese/ color English graphical interface. The interface accords with ergonomics
requirements.

4.2.7 Power supply: 65~155V DC 1A

4.2.8 Power consumption: ”25W

4.2.9 Accord with all sorts of testing requirement of TB/T3021-2001ljRailway locomotive electronic
deviceNJ

4.2.10 Contour and installing dimension:

Panel 345 mm×230mm˗

Machine case 300mm×210mm×120mm

Installing dimension 320mm×160mmˈ

4×ĭ5.5/ĭ9×90

4.3. Systemic constitution

Locomotive color TFT display diagnosing device (below “color display” for short) is a terminal device of
locomotive microcomputer. Its structure is divided into five parts: CPU main board, power supply module,
communication module, LCD screen and shell of display. Of which there are thin film keyboard, power
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supply switch etc on panel of shell of

display. There are connecting socket of
power supply and communication cable at
the back cover of machine case. CPU board,
power supply module and communication
module are all fastened on the same base
plate. The figure of the color display is
showed in figure 7-18.

4.4 Operating
explanation
Figure 7-18 Contour drawing of color display
The color display screen displays the
detected data of locomotive according to
the displaying format mentioned in above sections. All the displayed parameters that are referred to (for
example: front bogie, rear bogie, left side, right side) are defined according to the local driver’s cab in
locomotive. The background color of display interface is gray-blue. The color of displaying text and chart
changes according to different data.

As showed in figure 7-19 when press different functional keys to carry on normal display, type of all data
displayed on a screen, protection cutting off, secondary display, switching quantity state and fault display
etc.

Figure 7-19 Operation of color display

4.5 Main technical process

(ĉ) Visual inspection before disassembling

1. Clear the dust, oil stain on the display shell with brush soaked with gasoline. Then clean with clean cloth.

2. Check whether there is crackle or not on organic glass. If it is fuzzed seriously and influences vision the
glass must be replaced.

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3. Check whether the connecting bar, binding post is loose or not. Check whether the screw is stripped,
loose or not. If it is then replace it. If the external wire is of socket type, check whether the power supply
socket, communication socket is broken, loose, off-welding or not. If it is then weld it again or replace it.

4. Check the thin film, touch the button, keyboard gently and feel them.

(Ċ) Dismantle

1. Dismantle the shell screw and open the back cover. Then clean the inside dust with a clean brush.

2. Pull out all wire banks. Check all wire banks whether some one is damaged by heat or not. Check
whether the contact pin is off-welding, broken, bent seriously or not. Check whether the line bank is broken,
damaged or not. Otherwise it must be repaired or replaced.

3. Dismantle the circuit board of power supply communication interface and microcomputer motherboard.
Check whether all the electronic components, integrated components on above two boards are not welded
well, off-soldering, color-changing, burning, broken or not. Otherwise it must be welded again or replaced.

4. Dismantle the LCD screen and clean it. Check whether there is broken pin, loose contact, broken crystal
plane or not. The loose contact should be repaired. The broken pin and broken crystal plane should be
replaced. Take out the backlight tube. If the filament is broken or two ends become black seriously the tube
must be replaced.

5. The power supply switch should contact well. The thin film switch should not be broken and its feeling
should be flexible when touching it.

6. Change the lithium battery.

(ċ) Installation

1. Install the device according to the converse dismantling order. Must pay attention to the installing
position when installing.

(1) The hard fastening is prohibited to avoid that the circuit board and motherboard will be bent and broken.

(2) The LCD screen should be placed gently and fastened with screw diagonally. The strength should be
appropriate.

(3) All the plugs should not be messed up. Be careful of the inserting direction otherwise the components
will be damaged easily.

(4) The spacer, spring washer should be added when fasten the screw. The screw of banding post should be
complete after overhauling.

2. After installing measure the resistance between component and shell with universal meter ×1k gear and
the value of the resistance should exceed 500kȍ. Or measure the grounding resistance with 500V meg-
ohmmeter and value of the grounding resistance should exceed 5Mȍ.

3. Put it on the microcomputer test bench.

(1) Connect data wire of the power supply.

(2) After it is turned on, observe whether the interface of color display screen meet the technological
requirement or not. Press the thin film key and check whether the display can turn page or not.
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(3) It should change obviously when adjusting the brightness.

(4) Adjust all sorts of potentiometers of traction motor rotating speed, current, main generator current,
tractive motor current, voltage, pressure of fuel and lubrication oil, temperature of lubrication oil and
cooling water, supercharger rotating speed, exciter voltage, current, grounding leakage current etc on the
test bench one by one. Observe whether the change of displaying data is the same as the change of bench
output or not.

4. Make the overhauling record well.

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