Maintenance handbook on Tap Changer of AC ELectric Locomotive (2002)

FOREWORD

The proper maintenance of Tap Changer is necessary for

trouble free operation of Electric Locomotive and to avoid

failure enroute. CAMTECH has prepared this handbook to cover

all essential aspects of maintenance of Tap Changer.

The handbook describes various maintenance schedules

along with their periodicity and detailed procedure to be adopted

during repair and overhauling. A very useful compilation of list

of common defects and their remedies is included in the

handbook. The staff in maintenance depots will benefit from

these, which in turn will be reflected in improved reliability and

availability of Electric Locomotives and thus economy in

operation.

CAMTECH, GWALIOR

M.L.GUPTA

21ST MARCH, 2002

EXECUTIVE DIRECTOR

PREFACE

The Tap Changer used in AC electric locomotives is

vital equipment and its proper upkeep and maintenance is

necessary to ensure reliability and availability of AC electric

locomotives. This handbook on "Maintenance of Tap Changer "

has been prepared by CAMTECH with the objective of making

our maintenance personnel aware of correct maintenance and

overhaul techniques to be adopted in field.

It is clarified that this handbook does not supersede any

existing provision laid down in the “Maintenance manual of

electric locomotive” or “AC traction manual” and instructions

issued by Railway Board/ RDSO.

I am sincerely thankful to all officers and staff of electric

loco directorate of RDSO/ LKO for their valuable comments. I

am also thankful to all field personnel who helped us in

preparing this handbook.

Technological upgradation and learning is a continuous

process. Hence feel free to write to us for any addition/

modification in this handbook or if you have any ideas. We shall

highly appreciate your contribution in this direction.

CAMTECH, GWALIOR

RANDHAWA SUHAG

20TH MARCH’ 2002

DIRECTOR

CONTENTS

FOREWORD

PREFACE

vii

CONTENTS

CORRECTION SLIP

xiii

Chapter 1 INTRODUCTION

1.1

The Selector Assembly

1.2

Circuit Breaker

1.3

Operating Principle of GR

1.4

Air Motor MG-2 with Control Unit

1.5

Operating Principle of SMGR

Chapter 2. MAINTENANCE

2.1

Periodic Schedules

2.2

Repairing/Overhauling of GR

2.3

Overhauling of SMGR

2.4

Check Sheet for Overhauling

Chapter 3 STICKING OF SMGR, CAUSES

AND SUGGESTIONS TO AVOID

FAILURE

OF GR/SMGR

3.1

Sticking of SMGR

3.2

Suggestion to avoid Failures of

GR/ SMGR

Annexure-A

List of SMIs / MIS

Annexure -B

List of Spares required For

AOH/IOH

Annexure -C

Kit of Standard Hardware for

Tap Changer

References

CHAPTER 1

INTRODUCTION

The single phase high voltage tap changer is used to notch the

control winding on the high voltage side of the transformer up

and down through 32 steps.

The tap changer is directly built on the transformer, the

selectors and circuit breakers together form a constructional

unit.

The circuit breaker is provided with magnetic blowout,

and supported on two insulated columns . It is mounted on the

oil filled selector casing.

Transformer and selector are separated by oil tight seals

so that during overhauls only the oil from the selector casing

need to be drained.

Tap changer is designed for higher service voltage (25 to

30 kV) and for high switching frequencies. This is equipped

with a circulating pump and a filter for the selector oil. This

device is intended to keep the selector oil clean over long

periods of operations by extracting metallic particles, which may

break off from the control gear.

Since two shaft extensions are available at the selector,

the drive can be built on at the right-hand or left-hand end,

depending on the space available.

1.1

THE SELECTOR ASSEMBLY

The selector assembly consists of following components:

Item

Description

Base frames with covers

Contact plate with connecting pins

Selector housing with covers

Drive shaft with gearing

Notching wheel with contact arm

Bushing and contact rings

Components for fitting air-motor and

Cowling

FIGURE 1.1 SELECTOR ASSEMBLY

Details of figure 1.2

Item

Description

Item

Description

Base frame complete.

Driving shaft with

gearing

1101

Base frame

1401

Driving shaft

1102

Sealing ring

1416

Gearing insert complete.

1103

Base cover

Stepping wheel with

contact arm

1104

Drain plug

1521

Distance tube

1105

gasket

1522

Circlip

1108

Hexagonal bolt

Bushing and contact rings

1109

Spring washer

1601

Bushing, double pole

1110

Cover plate (upper)

1602

Hexagonal bolt

1111

Hexagonal bolt

1603

Spring washer

1112

Spring washer

1607

Carrier plate with guide

sleeve

Contact plate complete

1608

Contact ring, inner

1201

Contact plate

1609

Contact ring, outer

1202

Sealing ring

1613

Hexagonal bolt

1203

Hexagonal bolt

1614

Spring washer

1204

Spring washer

1615

Circlip

1205

Potential contact

Support with circuit

breaker

1208

Contact pin, inner

2101

Support, left

1209

Contact outer

2132

Support, right

Selector housing

with cover

1301

Selector housing

1305

Spring washer

1302

Cover

1311

Oil-drain connection

1303

Gasket

1314

Drain plug

1304

Hexagonal bolt

1.3

OPERATING PRINCIPLE OF GR

The moving contact rollers K1 and K2 in the

selector actuate with the current cut off. Before a roller

leaves the fixed contact, the relevant circuit is interrupted

by the associated circuit breaker. The connections of the

tap changer in the high voltage circuit of the transformer

are shown in figure 1.4 and sequence of movements of

the selector and of the circuit breaker contacts is shown

in fig. 1.5.

23°-I

23-II

23-III

1216

1215

1609

1608

1515-II

1515-I

FIGURE 1.4 CONNECTION OF TAP CHANGER

TO THE TRANSFORMER

When changing over, the resistor R1 carries the

current for a short time together with a circulating

current produced by the tapping winding about to be

switched in or out.

The high-value resistor R2 serves as the

connection between equal potentials, which ensures that

the branches of the circuit being interrupted at the given

potential. The making angles of the contact, as the angle

of rotation of the selector drive shaft, must remain within

a tolerance of ± 3°.

While the rollers remain at the segments 1 and 0,

the breaker I close and take over the service current. A

circulating current then flows through the resistor R1

produced by the tapping winding 0-1 until the breaker II

opens. Finally the disconnected contact roller runs off

segment 0. The tap changer is now at step 1.

The critical angles (referred to the drive shaft)

between the switching sequences at the circuit breakers

and in the selector are designated with the letters x and y.

Deviations in accordance with tolerances indicated must

be taken into account. The maximum permissible

rotational speed at the drive shaft can be determined

from the values of these angles (quoted for new contacts)

and form the time taken for the arc to quench during and

interruption. As the arcing tips of the breaker contacts

piece wear the critical angles and thus also the safety

margins increase. The mechanical method for achieving

the intermittent switching movement is shown in fig.1.6.

1.4

AIR MOTOR MG-2 WITH CONTROL UNIT

The motor is of the four cylinder-reciprocating

type is used to drive tap changer. A pressure reducing

valve, a three- way cock and a pressure gauge to read

between 0 and 10 kg/cm²are connected in series with the

motor. It is advisable to couple a two pole auxiliary

switch with this three-way cock so that when the latter is

closed, the control leads are switched off at the same

time. The electrically operated pneumatic control unit is

connected to the air motor by two connections and one

return line. Depending on the pulses received this unit

allows the motor to run in steps or continuously in either

direction.

Facilities are provided for incorporating one or

several drums for control, indicating and interlock

contacts. The air motor and its control unit is virtually

unaffected by temperature changes, moist air, shock and

vibration. The motor is provided with an enclosure to

protect it against dust etc. The air motor and control unit

is shown in figure 1.7 and figure 1.8 respectively.

1.5

OPERATING PRINCIPLE OF SMGR

The SMGR is controlled by pneumatically damped

movements, which thus saves wear on the mechanical

components of this equipment. The motor operates at a

service pressure between 2.5 and 3.5 kg/cm². Function of Air

Motor is shown in figure 1.9. The crankshaft is held in the

tapping positions by two pistons under pressure via two

connecting rods (e.g. I and III). Each switching process takes

place as a result of the venting of one cylinder and the

simultaneous pressurizing of another one. When the tap

changer

“notches up” the cylinder I is vented and II

pressurized. When the tap changer “notches down” the same

process is repeated in cylinders III and IV.

Details of Figure 1.9 and 1.10

Item

Description

Item

Description

Cylinder I-IV

4517

Journals

Crankshaft

4521

Guide pin

2112

Flywheel

Camshaft

Notching

Planetary gearing

Piston with

5201

Annulus

connecting rod

Air line

5209

Pinion

3120

Three way cock

Valve push rod

3121

Reducing valve

Limit stop

Three way valve

Auxiliary switch drum

I-IV

10°/step

Three way valve

5506

Cam plates 1-14

"UP-Down"

Operating

5514

Auxiliary cam operated

solenoid

switches 1-14

Control cylinder

6101

Gearwheel on crankshaft

Control lever

6103

Intermediate wheel

4502

Toothed segment

6110

Spur gear with indicator

disc

Cyclic distribution (determined by control pulses) over the

four cylinders enables any sequences of switching steps in

either direction. The notching holds the motor at the

tapings when no air pressure is available; this also ensures

that the crankshaft stops in the correct position. Function of

control unit is shown in figure 1.10.

The control unit is designed so that each step of the

driven unit corresponds to two switching steps of 90° each

at the crankshaft. The control pulses to the cylinders are

initiated by the three way valves, which in turn are operated

by camshaft. The camshaft is coupled to the crankshaft

through gearing

(ratio

1:1). The intermediate planetary

gearing can reset the position of the camshaft with respect

to the crankshaft so that the valve positions are changed

over for running in notching up or down. The motor rotates

in the clockwise or counter clockwise direction. External

control commands act upon the solenoid valves and are

transmitted to the control cylinder as pressure pulses. This

causes the lever arm with the toothed segment to rotate

about the pivot either towards the right (notching up) or to

the left

(notching down). The toothed segment engages

with the pinion, which carries the axis of the planet wheel.

When the annulus is stationary, movement of the planet

wheel causes the camshaft to rotate in one or the other

direction by 75° (lead angle). This involves a displacement

relative to the crankshaft, which is maintained as long as

the control command persists. Short control commands are

continued mechanically so that the motor can complete one

entire tap change. The guide pin on the swung out control

lever then runs over a cam on the gearwheel. A mechanical

interlock prevents overrunning the limit position when the

operating mechanism is actuated by hand.

CHAPTER 2

MAINTENANCE

2.1

PERIODIC SCHEDULES

The activities to be carried out during various

periodic schedules are as under:

Indication: "*" work to be done, "-" Work not to be done

S.N

SCHEDULE ACTIVITIES

SMGR

Carry out general inspection and cleaning

Check tightness of connections

Overhaul SMGR

Examine all auxiliary contacts for cracks,

carbonisation, tightness of all connections.

If required, replace by nylon auxiliary

switch.

Clean all auxiliary contacts.

Check and lubricate all the gears and

other parts.

Check all drive parts visually for any

abnormality.

Overhaul control block.

S.N

SCHEDULE ACTIVITIES

Check proper clamping and

strengthening of ZSMGR panel.

10.

Check smooth operation of ZSMS

11.

Ensure locking of SMGR foundation

bolts by plate or lock nut.

12.

Check notching spring, selector lever bolt

SMGR foundation for any cracks.

13.

Check connection tightness of SB and

foundation bolts.

14.

Die penetrant test on crankshaft, SMGR

support bolt and notching spring.

15.

Ensure 100% replacement of " Must

change items".

16.

Leakage testing of SMGR.

17.

Load testing of SMGR along with GR

and CGR on test panel.

18.

Paralleling of SMGR auxiliary cam

switches with spare one.

19.

Check SMGR crank shaft alignment

during overhauling as per Adtranz Jigs

and Fixture.

S.N

SCHEDULE ACTIVITIES

20.

Modification to connection lever of

SMGR for tap changer to avoid air

leakage RDSO/WAM4/58.

21.

Modification to control lever of SMGR

for tap changer - RDSO/WAM4/117.

22.

Application of loctite between the mating

surface of cams shafts and grub screw

and tap holes of tap changer -

RDSO/WAM4/145.

23.

Ensure provision of ceramic filter.

TAP CHANGER

Check condition of RGR and RPGR

Check oil level if less, add up to 40 ° C

Check colour of silica gel and replace/

recondition if necessary.

Check connection of double pole bushing

to CGR1 and 3.

RGR (Other than Lacchman make) IR

valve to be checked (with 1000 V

megger. (Min - 19 MΩ)

Check BDV of oil as per IS: 6772

Check condition of selector (In 2^nd IC)

Check tangential play in moving contact

(2^nd IC)

S.N

SCHEDULE ACTIVITIES

Check DGA, if acetylene contents are

more than 3 PPM then open the GR cover

and check.

GR oil flushing to be done if due.

Check for any oil leakage.

Drain the oil and remove the cover. Clean

with jet and nylon brush.

Check angle setting and contact shorting

Check RPGR value and condition.

Replace all gaskets

Check safety valves and manual drive for

proper functioning. Overhaul safety valve.

Replace top and bottom oil seal.

Maintenance of Tap changer by set of jigs

and fixtures and special tools of M/s

Adtranz only.

19.

Fastening RGR and CGR support plates on

Tap changer assembly RDSO/WAM4/ 52

Modified flexible connection between

RGR & GR - RDSO/WAM4/136.

Provision of canopy on safety valves of

Tap changer RDSO/WAM4/187.

S.N

SCHEDULE ACTIVITIES

Permanent connection of 16th Tap in

place of spring loaded connection.

RDSO/WAM4/192.

23.

Replacement of insulating oil & Silica gel

of Air drier of GR.

24.

100%Replacement of "Must change items"

25.

Check working of safety valves whenever

GR cover open/ canopy provided

26.

Overhaul

CGR

Check Arc Chute for flash mark,

crackness and ensure intactness of latches.

Measure contact pieces dimensions.

Replace if less than 36 mm.

Lubricate mechanical joints/ pins of CGR

assembly.

Check CGR sequence through MOM.

Check CGR to RGR and CGR1 to A34

connection. it shall not be close to

foundation.

Check tightness of contact screw and

foundation screw.

S.N

SCHEDULE ACTIVITIES

Check play of camshaft of CGR assembly

and replace if required.

Check arc horn.

Overhaul.

Use of high temperature grease type

MECKBR-300 for GR.

Check sequence pressure of CGRs as per

SMI 50.

Testing of contact pressure of CGRs as

per SMI 50.

Modification to fixing arrangement for

blow out coil of CGR to ensure locking

of Tap changer. RDSO/WAM4/128.

Provision of latch assembly of CGR arc

chute.

Replacement of contact tips should not

be done ON position.

CIRCUIT BREAKER

Dismantle switching elements (load

switch)

Inspect cams of S 2220.1 ... S 2220.3 for

wear and tear/ functional check.

Clean/inspect arcing chamber S 27 &

arcing horn S 2531.

S.N

SCHEDULE ACTIVITIES

Inspect/replace CGR contacts S 2529 and

S 2530. Tighten Allen bolts with 2.5 Kg-

meter torque.

Clean switching elements and carry out

functional checks with the use of special

tools.

Lubricate contact pivot (S2528) with

high temperature grease.

Tighten Allen key bolts M6, M8 & M12

with torque wrench.

PHGR

Check the working of PHGR

Check visually for any leakage.

Tightness of pipe line clamp as per

RDSO/MODI/114.

Overhaul PHGR and replace rubber

items.

Filter cleaning to be done.

Attend the booking if any.

Provision of modified PHGR.

Ensure support for oil flow indicator as

per RDSO/MODI/162.

S.N

SCHEDULE ACTIVITIES

RGR

Inspect elements for

overheating/cracking.

Inspect insulators for cracks.

Carry out meggar test and measure

resistance value.

After overhauling, carry out tests as

described and record.

2.2

REPAIRING/ OVERHAULING OF "GR"

2.2.1

Removal of Contact Arm

• Lift contact rollers, place hexagonal key and turn

through 90°.

• Remove bolts at bushing and circlip, lift out carrier

plate contact rings.

• Remove circlip and distance tube. Lift out contact

arm with stepping wheel.

2.2.2

Removal of Roller Contacts

Turn roller-lifting gear at bolt to position "On"

with key. Undo lacing and push out insulated tube.

Withdraw outer contact-roller casing (hold roller with

thumb), whereupon contact roller with bearings, roller

guide and pressure springs are now free to drop out.

Remove bolts and push out insulated tube to withdraw

inner contact rollers with contact housing. The fixed and

moving insulation in the selector can now be cleaned.

2.2.2.1 Check for wear

If the tracks on the segments and rails are deeper

than 0.5mm, these parts have to be renewed. The contact

rollers are allowed to wear to a minimum diameter of 17

mm; contact rollers with smaller diameters have to be

changed. When the rollers run correctly, the contact

surface on the segments, rings and contact rollers should

be polished bright.

Check roller guide and bearing for wear renew as

necessary. The roller guide must move freely in the

housing.

2.2.2.2 Refitting contact arm

Before fitting the complete roller housing on the

table plate, ensure that rollers turn easily under pressure

of spring during backward and forward movements. For

the lacing, use good quality hemp string (1 to 2 mm

thick). Before fitting the complete contact arm with

stepping wheel, lift rollers when fitted set "0" position

with checking pin.

2.2.3

Removal and dismantling of gearing

• Remove 3 bolts and withdraw gearing plate with

bearing journal. Do not remove 6 bolts since will this

release oil from transformer.

• Remove threaded pin, circlip and pull out distance

tube.

• Make a note of the number at shims position during

removal of drive wheel so that the original settings

can be retained during reassembly.

• The actuating pins are hardened (HR_c 58 ± 4).

• Renew lantern gear pinion when rollers are

considerably worn. Minimum permissible diameter

15.5 mm. When refitting the reassembled gearing the

wheels should be set to a tapping position with the

aid of the checking pin.

2.2.4 Work on the Selector, which involves draining of

Transformer

• Remove contact pins and renew gaskets.

• Open up side possibly also base covers.

• Loosen connecting terminal.

• Remove special nut in the contact plate (front) and

withdraw pin in direction of terminal.

• Hold connecting terminal with spanner during

loosening or tightening of clamping nuts.

2.2.4.1 Removal of Bearing Flange

• Remove the horizontal shaft first. Remove driving

mechanism.

• Expose shaft extension; i.e. remove gear wheel and

setting device.

• Remove circlips on both sides.

• Unhold journal bearing and withdraw.

• Pull out shaft the right. Remove bolts at bearing

flange and withdraw this flange together with bevel

wheel and coupling tube.

2.2.4.2 Dismantling of Bearing Flange

•

Knock out securing pin, pull out coupling pins and

coupling tube. Release tab washers and withdraw

bevel gear with shaft and ball bearings.

•

Note number of shims. These shims must be

positioned before refitting of ball bearings.

•

During removal and refitting of coupling shaft ensure

that the feather edge of the sealing ring is not

damaged.

•

During renewed of this deal it should be reinserted

with a tube or ring 50/57 mm in diameter.

•

Remove bevel wheel with shaft.

•

Remove contact arm and gearing.

•

Take off lock nut and remove threaded pin.

•

Remove bevel wheel with shaft and ball bearing in a

downward direction. If the sealing ring has to be

taken out of this bearing, the upper bearing flange

requires removal.

2.2.5 Work on Circuit Breaker

2.2.5.1 Removal of Switching Element

• Remove arcing chamber

• Set tap changer so that the rollers upper and lower

are loose. Lift off switching element with insulated

rail.

• When refitting element ensure that the insulated bar

does not become wedged between the connecting

plates and the mating contacts.

• When refitting the contact lever care must be taken

that the individual washers, i.e. plain washer, dished

washer and plain washer, are correctly located.

Ensure that the pin washers are not mixed up since

these are used as shims of varying thickness.

• Renew worn out arc horns. Maintain 0.5 to 1 mm

clearance between contact and arc horn.

• Clean insulated parts with dry, clean rag.

Details of figure 2.1

Item

Description

Item

Description

1316

Rating plate

2122

Hood

1401

Drive shaft

2123

Hexagonal bolt

1601

Double pole Bushing

2124

Spring washer

1602

Hexagonal bolt

2125

Threaded pin

1603

Spring washer

2126

Hexagonal nut

1604

Connection

2127

Spring washer

1605

Hexagonal bolt

2128

Hexagonal bolt

1606

Spring washer

2129

Hexagonal nut

1607

Carrier plate with guide

2130

Tab washer

sleeve

1608

Contact ring inner

2131

Insulated plate, lower

1609

Contact ring outer

2132

Support, right

1620

Hexagonal bolt

2133

Hexagonal bolt

1611

Spring washer

2134

Spring washer

1612

Washer

2135

Connecting angle

1613

Hexagonal bolt

2136

Wire connection

1614

Spring washer

2137

Hexagonal bolt with nut

2101

Support left

2138

Spring washer

2102

Coupling shaft

2139

Connecting link

2103

Bevel wheel

2140

Resistor R2

Item

Description

Item

Description

2104

Securing pin

2142

Hexagonal bolt

2105

Centering

2143

Cap nut

2106

Dust cover

2144

Hexagonal bolt

2107

Clamp

2145

Washer (soft copper)

2108

Self aligning ball

2146

Contact bolt

bearing

2109

Bevel wheel

2147

Contact nut

2110

Securing pin

2148

Hexagonal bolt

2111

Circlip

2149

Spring washer

2112

Lifting link

2150

Connection

2113

Bearing plate, left

2151

Contact bolt

2114

Insulated plate, upper

2152

Contact nut

2115

Connection bar

2153

Spring washer

2116

Hexagonal bolt

2154

Hexagonal bolt

2117

Spring washer

2155

Spring washer

2118

Bearing plate, right

2156

Hexagonal nut

2119

Hexagonal bolt

2157

Connection

2120

Spring washer

2158

Hexagonal bolt

2121

Hexagonal nut

Camshaft

2141

Insulated sleeve

2209

Bevel wheel

• Remove connections between capacitor bushing and

circuit breakers.

• Remove bolts and threaded pin at terminal clamps.

Lift breaker frame from the carrying links.

• Unscrew bearing plate on the right and take off bolts

on top and bottom.

• Remove circlip and withdraw ball bearing as well as

cam plates.

FIGURE 2.2 CAM SHAFT ASSEMBLY

Details of figure 2.2

Item Description

2111 Circlip

2206

Ball bearing

2201 Cam plate I

2207

Circlip

2202 Cam plate II

2208

Shim

2203 Cam plate III

2209

Bevel wheel

2204 Shaft

2210

Securing pin

2205 Circlip

2211

Circlip

• Ensure shims are correctly fitted.

• Now to remove coupling shaft, lift off support and

remove base bolts.

• Knock out pin at upper bevel wheel. Withdraw bevel

wheel and withdraw coupling shaft downwards.

During refitting ensure that the dust cover is

positioned between bevel wheel and ball bearing.

2.2.6

Mounting Tap Changer on the intermediate reservoir

This is sealed from the transformer with an

insulated plate, the bushings having to be oil tight as

well. The reservoir is filled through a connecting pipe to

the transformer, in which a stopcock has to be fitted,

which can be closed when draining the intermediate

reservoir. A vent valve is provided at the highest point of

the reservoir, which remains open during filling until the

oil overflows. The reservoir can be emptied through a

drain cock.

The electrical leads are equipped with plugs,

which can easily be connected with the terminal pins on

the selector.

2.2.6.1 Procedure

• Remove base and side covers also cover plate on

selector frame.

• Lightly and uniformly coat gasket between selector

and transformer with a paste prepared from talcum

powder and a little vaseline to prevent the gasket

sticking to the metallic parts.

• Tighten nuts in the selector frame uniformly.

• At least two, preferably four spring washers should

be placed under the nuts to avoid leakage.

• The plugs of the connecting leads are now fitted in a

straight line to the contact pins of the selector. Push

home connects terminals as far as body of plug. Hold

with open-ended spanner and tighten clamping nuts.

• First make connections for the inner circle and check

them. Fit all covers.

• After filling transformer and intermediate reservoir,

check for leaks.

2.2.6.2 Removal of Drive

A 4-cylinder MG 2-air motor provides the drive

power. If for some reason the drive has to be removed,

the following points should be borne in mind.

• Removal and refitting of the drive should only be

attempted, when both tap changer and drive are in

the “0” position.

• If the front part of this cowling is removed the motor

can be suspended from the eyebolts.

• The drive can be withdrawn complete with the

support.

• Remove bolts. When secure with two securing pins

(diameter 8 and 5 mm, length 28 mm), ensure red

marking at bevel wheels is lined up.

• Separate drive from support (latter remains attached

to rear side of cowling on tap changer).

•

Disconnect air pipe remove nuts and lift off motor.

•

When refitting, motor is placed on the two guide

wedges on support.

•

Before the nuts are tightened the motor can then be

moved in a horizontal direction so that the

engagement of the teeth of the bevel wheel can be

accurately set.

•

The control connections can be brought to the drive

with the aid of plugs or through the stuffing glands.

In the former case the plug is withdrawn as the drive

is removed and the airline unscrewed at the outer

union threads.

•

If the lines enter through stuffing glands, they have

to be disconnected at the inner terminals (cam-type

switches and coils). The airline should be

disconnected and the connecting plate removed from

the cowling. These operations are also to be carried

out if the entire tap changer is removed complete

with drive.

•

Manual operating mechanisms as emergency devices

can be coupled to the free shaft extension or at

various points of the compressed air operating

mechanism.

2.2.7

Taking into Service

•

Remove locking device or slide along shaft.

•

Fill selector housing with clean transformer oil

(about 75 litres at 20°C)

•

Oil level gauge is provided with a scale, which allows

for changes in temperature. The electrical breakdown

strength of oil should attain at least 50 kV/cm for one

minute between 13mm dia. spheres, distance 2.5 mm.

•

Check selector housing and fittings for leaks

•

If necessary retighten nuts and bolts. Repeat this

check after commissioning.

•

Check operation of control system and drive.

•

Before voltage is applied to the tap changer, the

following checks should be carried out:

• The arc chambers must be in position on the

circuit breakers and the locking mechanism

engages.

• The connections between the circuit breakers and

the diverted resistor must be correctly made and

proof against failure. If necessary retighten

terminal bolts.

• Check the resistor R1 (diverted resistor) for faults

which may be the result of damage during

transport. During the first runs check should also

be undertaken to ensure that the resistor is not

being subjected to excessive vibration.

• After filling with oil the tap changer should be

operated over the entire range of steps from 0 to

32 and back before carrying out the voltage

check; this ensures that air bubbles which may be

adhering to parts of the unit rise to the surfaces.

• A check under voltage is not to be attempting

earlier than ½ hour after filling of the selector

with oil.

2.3

OVER HAULING OF SMGR

2.3.1

Removal of Control Unit

• Remove the control leads at the coils and the cam-

operated switches.

• Remove air- line by unscrewing the hollow bolt.

• Unlatch spring-loaded push rod and swing forwards.

Remove bolts of control block and lift off control

unit.

• When refitting the control unit this should be set to

step 0. The motor should also be set so that the red

dot • on the pinion is at the front and when inserting

the control unit engages between the two dots •• on

the gearwheel. Before fitting control unit swing

push-rod forward.

FIGURE 2.3 CONTROL UNIT ASSEMBLY

Details of Figure 2.3

Item Description

5301 Bearing bolt

5309 Push rod

5302 Distance sleeve (short)

5310 Spring

5303 Link

5311 Push rod nut

5304 Distance sleeve (long)

5312 Split pin

5305 Roller (radial ball

5313 Link

bearing)

5306 Pin

5314 Hexagonal nut

5307 Disc

5315 Spring washer

5308 Push rod bolt

2.3.2 Work on Motor

• Disconnect air -line and remove air supply systems

parts. This also exposes the valves.

• Check gaskets and replace as necessary.

• Raise cylinder, remove nuts and eye-nuts from studs

and lift off securing plates.

• Remove and dismantle pistons and connecting rods

as shown in figure 2.4

Details of figure 2.4

Item Description

Piston with

2307 Bearing pin

connecting rod

2301 Circlip

2308 Needle bearing

2302 Thrust ring

2309 Connecting rod

2303 U-section ring

2310 Circlip

2304 Piston skirt

2311 Securing bolts

2305 Circlip

2312 Bearing clamp

2306 Piston

2313 Bearing shells

• Clean cylinder and connecting rod with piston and

relubricate.

• Renew worn U-section rings. The shell bearings of

the connecting rods must not be cleaned with petrol

(gasoline).

• Renew worn bearing shells also being soaked in oil

before fitting.

• The crankshaft is removed together with the flywheel

and the bearing plates. Swing out notching springs at

the notching lever, and then remove nut. Ensure that

the crankshaft is not distorted in the process. Use

screw clamp to pull off the flywheel.

• Replace worn valve push rods and sealing nipples.

Check valve stroke.

2.3.2.1 Dismantling control cylinder

Remove hollow bolts and airlines. Unscrew nuts

at screwed pin. Dismantle components as shown in fig.

2.5. On no account unscrew nuts

4413 and

4415,

otherwise the piston stoke has to be reset after

reassembly. Clean cylinder and piston with clean rag. If

necessary renew sealing ring. Before reassembly lightly

grease cylinder and piston with approved grease.

4418 4417 4416 4109 4408 4406 4404 4403 4405 4402 4401

4414

4413 4415

4407

4410

4419

4420

4422

4421

4412

4411

FIGURE 2.5 CONTROL CYLINDER ASSEMBLY

Details of figure 2.5

Item

Description

Item

Description

4401 Cylinder

4412 Cylinder cover

4402 Sealing ring

4413 Hexagonal nut

4403 Piston

4414 Seal

4404 Sealing ring

4415 Cap

4405 Buffer

4416 Threaded pin

4406 Setting screw

4417 Spring washer

4407 pin

4418 Hexagonal nut

4408 Centering screw

4419 Gasket

4409 pressure ring

4420 Cover

4410 Spring

4421 Allen screw

4411 Cylinder cover with

4422 Spring washer

thread

2.3.2.2 Removal of control lever

Withdraw control unit. Remove circlip and stop

washer. Withdraw lever. When refitting lever, ensure

that the two red dots • • on the toothed segment coincide

with one of the red dots • on pinion. Check clearance of

0.4 to

0.7 mm between guide pin bearing and

intermediate wheel with cam plate.

FIGURE 2.6 CONTROL LEVER ASSEMBLY

Details of figure 2.6

Item

Description

Item

Description

4501

Control lever

4521

Guide pin (1)

4502

Toothed segment

4522

Spring loaded pin

bearing

4503

Nut locked with pin

4523

Spring loaded pin

4504

Lever link

4524

Pressure spring (1)

4505

Needle bearing

4525

Guide pin bearing

support

4506

Needle bearing

4526

Needle bearings (2)

support roller

4507

Lever link complete

4527

Cylinder bolt

4508

Hexagonal bolt

4528

4509

Nut locked with pin

4529

Hexagonal nut

4510

4530

4511

Bearing sleeve

4531

Fitting tool for 4512

4512

Needle bearing

4532

Fitting tool for 4526

Check toothed segment and guide pin for wear

and renew as necessary. Refit with the help of tools. The

components of the control lever are shown in figure 2.6.

2.3.2.3 Removal of camshaft

• Remove circlip, cam plate, key and cover washer.

The shaft extension is then pulled through the ball

bearing.

• Dismantle camshaft. Components of camshaft are

shown in figure 2.7.

• When reassembling camshaft check position of the

cam plates with respect to the key ways.

FIGURE 2.7 CAMSHAFT ASSEMBLY

Details of figure 2.7

Item Description

5101 Shaft

5107 Nut locked with pin

5102 Slotted nut

5108 Circlip

5103 Spring washer

5109 Bearing

5104 Spring plate

5110 Ball bearing

5105 Cam plate (4)

5111 Distance ring

5106 Distance tube

5112 Key

2.3.3

Checks and setting of the solenoid armature strokes

For the operational motor set to step

0 and

proceed as follows:

1. Close pressure line cock.

2. Unlatch push rod for valve of cylinder II and IV.

3. Turn drive with flywheel to step 1 and unlatch push

rods I and III.

4. Open air line and carry out checks or settings of the

solenoids.

5. Close air line.

6. Latch valve push rods I and III and turn drive to step 2.

7. Latch valve push rods II and IV and return drive step 0.

8. Open airline & operate drive Electro- pneumatically.

It is necessary for the various operations to be

carried out in the sequence indicated so that the control

lever, which changes position during actuation of the

valves, can return to the rest position.

2.3.3.1 Armature Setting

• Unscrew nut and unscrew core a few turns. Loosen

nut at setting screw.

• Slide 0.5 mm feeler gauge between push rods.

• Screw in setting screw until slight leak of air occurs

at valve.

• Screw out setting screw until again valve just seals.

• Tighten nut and lock.

2.3.3.2 Core Setting

• Depress push rod in direction of arrow until valve

opens and seals.

• Screw core in until valve vents slightly.

• Unscrew core until valve just seals and then by

another turn (correspondence to an additional 0.5mm

armature stroke).

By following this procedure the minimum

armature stroke and the minimum attraction voltage of

the solenoid is obtained. Check valves of correct

operation and lock nuts with tab washers.

2.3.4

Changing Cam Plates

• Unscrew the carrier plate with the connections after

removing bolts.

• Turn switch drum until slots in cam plates is to the

rear.

• Using 36-mm spanner hold nut locked with pin and

loosen slotted nut with hooked spanner until

sufficient play is obtained.

• Slightly tilt cam plate to be replaced so that it can be

withdrawn from the guide groove of the distance

sleeve. Pull out cam plates towards the front.

2.4

CHECK SHEET FOR OVERHAULING

S.N

ITEM

Standard

Actual

Check complete body,

No crack

contact plate and segment

No damage

etc. for any crack and

damage.

Check bevel wheels for

No wear &

any wear tear.

tear.

Check the bearing

Good.

condition.

Check double pole bushing

No crack.

for any crack and damage.

Check the insulation

100 M.

resistance with 2.5

ohm

kV.Megger between

a) Pole to pole

b)Pole to earth

Replace all rubber items &

To be

oil seal 100%.

Replaced.

Check the height of contact

15.3mm

arm spring under load test

(min.)

of 6.2 kg. as per SMI-8.

Check the contact roller for

No pitting &

any pitting and over

overheating

heating.

Check the contact roller

17mm

diameter.

(min.)

10.

Check radial play between

0.4 mm.

contact roller pin &

bearing.

S.N

ITEM

Standard

Actual

11.

Check play between

Around 0

contact roller housing.

to 5 mm.

12.

Check the wear on contact

0.5 mm

track. If found excessive

deep (Max.)

wear or surface is very

rough, replace them.

13.

Check the gap between

3 to 1mm.

contact segment and

contact plate at back side.

14.

Check the diameter of

15.5

lantern gear pinion rollers.

mm(Min.)

15.

Check the contact roller

Middle ±

position on contact ring.

3mm

16.

Check movement play at

contact arm -

a) Breaker on tapping

10 mm

Position, pin of lantern

(Max.)

gear pinion vertical

Move contact arm to

and fro by hand. The

total deflection should

not exceed the standard

value.

b) Breaker in intermediate

4 mm

position, pin of lantern

(Max.)

gear Horizontal.

The total deflection of

contact arm should not

exceed the standard

value.

S.N

ITEM

Standard

Actual

17.

Check the tightness of the

following with torque

wrenches.

a) Hexagonal bolt on

3.5 M-kg.

selector housing with

moving frame.

b) Special hexagonal bolt

0.5 to 0.6

for fixing insulating

M-kg.

ring inner and outer.

c) Special nut and conical

2.0 to 2.5

nut-part. No. 1214 &

M-kg.

1217.

18.

Check the dielectric

50 kV

strength of oil for 1 minute

with 2.5 mm gap between

13 mm diameter spheres.

19.

Check free operation of

Free

safety valve

20.

Clean the oil indicator &

Above

check oil level.

20° C mark

21.

Making & braking angles

of GR

Inner ring.

Outer ring

S.N

ITEM

Standard

Actual

22.

Check the degree setting of

CGR make and brake

35± 3 - 145± 3

CGR-I

CGR-II

Close Open Close

125± 3 - 145± 3

CGR-III

170± 3 - 190± 3

23.

Check the condition of

Good

potential contact

24.

Replace PHGR filter 100%

Replaced

25.

Replace all rubber 'O' ring

Replaced

of PHGR 100%.

26.

Check the working of

30 to 40

PHGR at 3 Kg/Cm²

strokes per

pressure

minute.

27.

Check for any oil leakage.

No leakage

28.

Check the three way cock

8.5 mm

hole dia. as per SMI-88.

29.

Check the colour of

Blue

silicagel

30.

Any other remarks.

CHAPTER 3

STICKING OF SMGR,CAUSES AND

SUGGESTIONS TO AVOID FAILURES

OF GR/ SMGR

3.1

STICKING OF SMGR

Probable causes for sticking of SMGR may be following.

Guide pin (part No. 4521) stuck up.

Gap between control lever and intermediate gear

exceeds 0.7mm.

Pressure leakage from MG 6/6A and MG 4/5 A

valves.

Improper setting of control block.

Progression and regression time of SMGR

become more/ less ( 9 to 13 seconds)

Lifting valve plunger (part no. 5317) stuck up.

Improper profile of intermediate gear segment/

breakage or crack of segment.

3.1.1

Reasons for guide pin jam

Deposition of dry grease around guide pin.

Deposition of grease in the intermediate gear

segment.

Loss of spring tension or breakage of

compression spring of control lever guide pin.

Rubbing of wearing plate of control lever with

guide pin.

3.1.2

Gap between control lever and intermediate gear

exceeds 0.7mm

Increasing or decreasing play between control

lever and circlip provided on journal pin due to

less or more shim washer (part no. 4515)

Loosening of needle bearing of control lever

provided on journal pin.

Journal pin worn out.

Internal play between intermediate gear and

bearing pin.

Less or more shim washer between intermediate

gear and circlip.

Bending of control lever (part no. 4501)

Pin (part no. 6109) worn out.

Needle bearing

(part no.

6104) worn out at

journal pin end.

Improper fitting of journal pin.

3.1.3

Pressure leakage from MG 6/6A and MG 4/5A valves

Improper setting of valve plunger.

Valve plunger part no. 3209/429 stuck up.

Valve jam due to corrosion.

Improper sitting of push rod and lifting valve

plunger.

Mis-alignment of push rod.

Valve seat defective.

3.1.4

Improper setting of control block

Improper setting of control cylinder affected lead

angle.

Not using proper grease (Bharat MP-2) between

control cylinder and piston as well as increased

greasing interval.

Using inferior quality of 'U' section ring (bucket)

Leakage of air from air coupling in the SMGR.

Pressure settings become less or more through

pressure reducing valve on control panel.

3.2

SUGGESTIONS TO AVOID FAILURES OF GR/

SMGR

Guide pin should be lubricated only by machine

oil H 20/1.

Segments of intermediate gear should be

lubricated only by graphite oil.

Repositioning of wearing plate should be done

when it is rubbing with control lever of guide pin.

Compression spring must be changed during

POH.

Gap between control lever and intermediate gear

segment should be maintained between 0.4 to 0.7

mm. This gap should be checked during every

IA/IB/IC/ schedules.

Air leakage test of SMGR should be performed

in every schedule. The leakage should not be

more than 10% in 10 minutes.

Free movement of valve plunger should be

ensured in every AOH. The valve plunger should

be replaced in every POH.

Gap between adjustable valve screw and bolt

head should be maintained between

0.4 to

0.7mm. This gap should be checked during every

IA/IB/IC schedule.

Plunger should move free in the bearing pin with

strap part no. 5301. The play between spacer and

shim should not be more than 0.2mm.

The setting of control block should be ensured.

10.

Setting of control cylinder should be done as per

instructions of SWT 5013.

11.

Only Bahrain MP-2 or servogem-2 grease should

by used for lubrication of cylinder. Greasing

should be done in every IC schedule.

12.

After changing of 'U' section ring. The plunger

gap should be checked and it should be

maintained within 0.4 to 0.7 mm.

13.

Setting of pressure reducing valve in the control

panel should be checked during every IA/IB/IC

schedules.

14.

Working of inter lock 1-2, 3-4, 5-6, 7-8 at half

notch and interlock 41-42, 43-44, 47-48, 49-50,

53-54, 55-56, 57-58 all '0' close interlock and 61-

62, 83-84 and 89-90 should be checked properly.

15.

Working of interlock of ZSMS switches should

be checked during every IA/IB/IC schedules.

16.

To avoid voltage stress concentration at corner

portion of segment where the roller will into

contact, the sharp edges of inner segment to be

chamfered. This will increase the gap by 1.25mm

17.

Knurlings to be provided on a portion of roller

which travels on insulating ring. This will avoid

dragging and pitting of rollers.

18.

Replace adjusting knob of pressure regulating

valve with metallic knob and check nut.

19.

Carry out Die Penetrant Test on crankshaft,

SMGR support bolt, pnuematic piping and

notching spring during overhauling.

20.

Ensure implementation of various SMI's/ MI's

issued by RDSO as per annexure - A.

21.

Ensure

100% replacement of " Must change

items" during AOH, IOH and POH.

22.

Perform leakage testing of SMGR after

overhauling.

23.

Conduct load testing of SMGR along with GR

and CGR on test panel.

24.

Paralleling of SMGR cam switch.

25.

Align SMGR crankshaft during overhauling as

per adtranz jigs and fixture.

26.

Take measures to prevent burning of notch

repeater.

27.

Perform dielectric test of GR oil in every IC.

Conduct BDV testing with 100 kV motorised

equipment.

28.

Flushing of oil if BDV found less.

29.

Flushing of new tap changer oil after 10,000km

or where more than 25% taps have been changed.

30.

Provide modified PHGR and test on test bench

during AOH/IOH schedules.

31.

Ensure replacement of rubber kit during every

AOH/IOH & POH.

32.

Use set of special tools of M/s Adtranz.

33.

Ensure quality control of CGR contacts, GR

segments, roller, contact ring, insulating ring and

contact plate.

34.

Ensure periodic replacement of insulating oil and

silica gel of air dryer of GR.

35.

Use direct filling arrangement for GR.

36.

Use of high temperature grease type MECK BR-

300 for CGR.

37.

Measure switching angle of contact segment of

GR in AOH, IOH and POH.

38.

Check pneumatic pipe line from EV PHGR to

PHGR for crackness, air leakage from drain

cocks etc. during periodic schedules.

39.

Conduct DGA of tap changer oil in IC.

40.

Plan to replace cast grid RGR with steel punched

grid RGR.

41.

Procure set of two sealing rings for control

cylinder of SMGR in kit from approved sources

only.

42.

Ensure replacement of worn out shaft on

condition basis both top and bottom oil seal

during AOH & IOH.

43.

Clean hollow insulator, bake at 80°C then apply

anti tracking varnish.

44.

Ensure modification of 16th tap connection by

flexible connection.

45.

Check operation of safety valve after fitment of

canopy.

ANNEXURE - A

LIST OF SMI'S/MI'S

S.No.

Title

No.

Breakage of MOM taper pin.

RDSO/ELRS/SMI/17

Malfunctioning of modified

RDSO/ELRS/SMI/18

control lever of TC

Sluggish operation of SMGR

RDSO/ELRS/SMI/20

Breakage of support block of

RDSO/ELRS/SMI/21

auxiliary switch.

Sticking up of tap changer

RDSO/ELRS/SMI/22

between notches

Sticking of control lever guide

RDSO/ELRS/SMI/46

pin.

Adjustment of lead angle of

RDSO/ELRS/SMI/48

control cylinder.

Lubrication to be used for TC.

RDSO/ELRS/SMI/49

Testing of contact pressure of

RDSO/ELRS/SMI/50

CGR 1,2,3

10.

Lubricants to be used for GR

RDSO/ELRS/SMI/80

11.

Roller contact force in GR

RDSO/ELRS/SMI/82

12.

Oil leakage through three way

RDSO/ELRS/SMI/88

cock

S.No.

Title

No.

13.

Tightening

electrical

RDSO/ELRS/SMI/90

connection of CGR.

14.

Journal pin checking and

RDSO/ELRS/SMI/101

procedure for replacement

15.

Lubrication to the groove of

RDSO/ELRS/SMI/105

piston.

16.

Cleaning of GR after 10000

RDSO/ELRS/SMI/106

17.

List of various torque values

RDSO/ELRS/SMI/113

18.

Breakages of needle roller

RDSO/ELRS/SMI/117

bearing

19.

Tightening of connecting

RDSO/ELRS/SMI/118

terminal with nut

20.

Replacement procedure for

RDSO/ELRS/SMI/129

bevel gear

21.

Replacement procedure for air

RDSO/ELRS/SMI/134

motor support

22.

Dismantling instruction &

RDSO/ELRS/SMI/135

fixture details for removal of

pinion of crank shaft of

SMGR

23.

Condition monitoring of GR

RDSO/SMI/138

oil through DGA

24.

Maintenance schedule for GR

RDSO/ELRS/SMI/143

25.

Flashing inside GR

RDSO/ELRS/SMI/144

S.No.

Title

No.

26.

Crank shaft fracture

RDSO/ELRS/SMI/145

27.

Breakage of pin of SMGR

RDSO/ELRS/SMI/146

28.

Support for oil indicator to

RDSO/WAM4/62.

Tap changer

29.

Provision of taper hole to

RDSO/WAM4/69.

accommodate the taper pin in

the manual drive of Tap

changer

30.

Clamping arrangement for

RDSO/WAM4/114

PHGR

31.

Modification

fixing

RDSO/WAM4/128.

arrangement for blow out coil

of CGR to ensure locking of

Tap changer

32.

Modified flexible connection

RDSO/WAM4/136.

between RGR & GR of Tap

changer

33.

Introduction

locktite

RDSO/WAM4/145.

between the mating surface of

cams & cam shaft, grub screw

and taper holes of Tap

Changer

34.

Provision of grub screw

RDSO/WAM4/146.

locking for CG bush & gear

housing assembly of manual

drive for tap changer

S.No.

Title

No.

35.

Modification in insulating

RDSO/WAM4/157.

ring

(1218,

1219) fixing

arrangement

36.

Replacement of cast iron

RDSO/WAM4/161

transition resistance (RGR) by

stainless

steel

transition

resistance in Tap changer

37.

Provision of canopy on safety

RDSO/WAM4/187

valves of Tap changer

38.

Permanent connection of 16th

RDSO/WAM4/192

tap in place of spring loaded

connection

39.

Modification to control circuit

RDSO/WAG5/218

to GR on WAG-5 locos

40.

Modification in the air supply

RDSO/MS/0269

line to ensure effective

operation of the oil pump

(PHGR) fitted with the oil

pump device in the Adtranz

make Tap Changer no. 32.

41.

Measures to prevent burning

RDSO/WAM4/200

of notch repeater used in loco.

ANNEXURE - B

LIST OF SPARES REQUIRED FOR AOH/IOH

AOH KIT

The following components of Tap Changer, No.

(Adtranz make) are to be replaced compulsory by new ones

during AOH Maintenance Schedule.

PART NO.

DRG.NO.

DESCRIPTION

QTY/TC

A. SELECTOR (GR)

S 1519

SWT-435200-P1

Fibre glass cord

S1306.2/

AM-502840-P!

Packing (Oil

S1306.5

level indicator)

S3309

AG- 549697-P1

Gasket (Oil flow

indicator)

B. CIRCUIT BREAKER (CGR)

S1515

AG-546151-R1

Contact Roller

complete

PART NO.

DRG.NO.

DESCRIPTION

QTY/TC

C. OIL FILTRATION UNIT

S3235

SWT-435167-P1

Cup Seal

S3270.3

SWT-435167-P2

Cup Seal

S3221/

SWT-435430-P3

'O' Ring

S3225

S3224/

SWT-435430-P2

'O' Ring

S3252

S3251

SWT-435430-P5

'O' Ring

S3254

SWT-235033-P27

Gasket

0450222008/ HB

Mico Filter Element

D. AIR MOTOR

A1213

SWT-435144-P2

Packing Ring

A2303

SWT-435461-P1

Sealing Ring

A3108

AG- 544441-P2

Gasket

A3111/

AG- 544441-P1

Gasket

A4120/

A4430.19

A4430.4

AM-404742-P1

Packing Ring

A4430.2

AG-413762-P25

Damping Gasket

Note: The above list does not include standard hardware items

(such as Roll pins, circlips, washers, copper washers

etc.) which also need to be changed during AOH.

IOH KIT

The following components of Tap Changer, No.32

(Adtranz make) are to be replaced compulsory by new ones

during IOH Maintenance Schedule

SELECTOR (GR)

PART NO.

DRG.NO.

DESCRIPTION

QTY/TC

S1519

SWT-435200-P1

Fibre Glass

Cord

S1306.2/A

AM-502840-P1

packing (oil

1306.5

level indicator)

S3309

AG-549697-P1

Gasket (oil flow

indicator)

S1303

AG-207812-P1

Gasket

S1320.1

AG-544325-P4

Packing Ring

S1434/

SWT-435381-P1

Oil seal

S1440

S1421

AG-544325-P5

Packing ring

S1218

AM-200095-R2

Insulating ring

(inner)

S1219

AM-200095-R1

Insulating ring

(outer)

10.

S1515

AG-546151-R1

Contact roller

complete

CIRCUIT BREAKER (CGR)

PART NO.

DRG.NO.

DESCRIPTION

QTY/TC

S2529

AG-540123-P1

Contact

OIL FILTRATION UNIT (PHGR Circuit)

PART NO.

DRG.NO.

DESCRIPTION

QTY/TC

S3235

SWT-435167-P1

Cup seal

S3270.3

SWT-435167-P2

Cup seal

S3221/

SWT-435430-P3

'O' ring

S3225

S3224/

SWT-435430-P2

'O' ring

S3252

S3251

SWT-435430-P5

'O' ring

S3254

SWT-235033-P27

Gasket

Mico filter

0450222008/HB

element

CU GASKETS

For oil pipe line, oil flow indicator, oil pump device.

PART NO.

DRG.NO.

DESCRIPTION

QTY/TC

S3290.12

MT-430152-P19

CU Gasket

S3290.14

MT-430152-P18

CU Gasket

S3290.10

MT-430152-P13

CU Gasket

S3290.17

SWT-435491-P13

CU Gasket

S3433

MT-430152-P34

Gasket

S3422/

MT-430152-P23

Gasket

S3406

AIR MOTOR

PART NO.

DRG.NO.

DESCRIPTION

QTY/TC

A1213

SWT-435144-P2

Packing ring

A2303

SWT-435461-P1

Sealing ring

A3108

AG-544441-P2

Gasket

A3111/

A4120

AG-544441-P1

Gasket

A4430.19

A4430.4

AM-404742-P1

Packing ring

A4430.2

AG-413762-P15

Damping Gasket

A2209

SWT-435581-R1

Spring with eyes

Compression

A4540.7

AM-401107-P1

spring

A3209/

Push rod with

AG-544415-P1

A4209

seal

A4206/

AG-544411-P1

Valve nipple

A3206

A1929.1

MT-430189-P471

Roll pin (8/45)

A1929.2

MT-430189-P371

Roll pin (5/45)

S4212

MT-430189-P471

Roll pin (8/45)

S4216

MT-430189-P371

Roll pin (5/45)

S4217

MT-430189-P471

Roll pin (8/45)

S4218

MT-430189-P371

Roll pin (5/45)

ACCESSORIES

C.G. GRID ELEMENT RGR

PART NO.

DRG.NO.

DESCRIPTION

QTY/TC

S3809

KB-473201-P1

Insulating washer

106

S3822.2

B-406533-P2

Micanite tube

S3830.2

SWT-435218-P3

Insulating tube

S3830.3

SWT-435218-P1

Insulating washer

S3830.4

SWT-435218-P2

Insulating washer

S.S. ELEMENT RGR

PART NO.

DRG.NO.

DESCRIPTION

QTY/TC

S4415

KB-473201-P2

Mica washer

141

21/50/2

S4416.2

B-406533-P2

Samica glass tube

S4406.2

SWT-435218-P3

Insulating tube

S4406.3

SWT-435218-P1

Insulating washer

S4406.4

SWT-435218-P2

Insulating washer

Note: The above list does not include standard hardware items

(such as roll pins, circlips, washers, copper washers etc.)

which also need to be changed during IOH.

ANNEXURE - C

KIT OF STANDARD HARDWARE FOR

TAP CHANGER

S.N

PART NO.

DESCRIPTION

DRG.NO.

QTY/KIT

A1906

Hex Screw M8 x 20

MT430106

P2610

A1907/A1936

Belleville spring

MT430151

A6302/A6418

washer dia 9/18

P23

A6509/A6514

S1415/S1460

S1464/S1611

S1614/S2127

S2182/S3450

S3816/S3905

A1908/S2183

Hex Nut 0.8D x M8

MT430108

P 2018

S3449/A6508

A1909

Hex Screw M10 x30

MT430872

P362

A1910/A2109

Belleville spring

MT430151

A4127/S1109

washer dia 11/22

P26

S1112/S1204

S1305/S1403

S1603/S2117

S2120/S2134

S2149/S2155

S3426/S3453

S3710

S.N

PART NO.

DESCRIPTION

DRG.NO.

QTY/KIT

A1912.1

Roll Pin 8 x 28

MT430189

P467

A1912.2/

Roll Pin 5 x 28

MT430189

A4519

P367

A1913

Hex Screw M12x 45

MT430872

P415

A1914/A1941

Belleville spring

MT430151

washer dia 14/28

P28

A1923.2

Hex Nut 1/2" BSP

MT430232

P2004

A1928/A1930

External Circlip A24

MT430201

A2113

P24

A1931

Hex Socket HD.Cap

MT430956

Screw M10 x 40/25

P2209

A1935

Hex Screw M8 x 25

MT430106

P2612

A1937

Hex Screw M6x12

MT430106

P2507

A1938/A1945/

Belleville spring

MT430151

A3110/S3457/

washer dia 7.5/14

P22

S3705/A4102/

A5513/A6306/

A6308/A6503/

A6512

A1939/S3456

Hex Nut 0.8D x M6

MT430151

A6511/S3610

P2017

S3707

S.N

PART NO.

DESCRIPTION

DRG.NO.

QTY/KIT

A1940

Hex Screw M12 x20

MT430106

P2810

A1942

Hex Nut 0.8D x M6

MT430108

P2020

A1944/A5512

Hex Screw M6 x 15

MT430106

A6305

P2508

A1947/

Hex Nut 0.8D x M5

MT430108

A4150.14

P2016

A1948/A4150.8

Belleville spring

MT430151

A4150. 15/

washer dia 6/12

P19

A4150. 22

A5315/ A5516

A6110.4/A6432

A1949/A5314/

Hex Screw M5 x 15

MT430106

A5515/A6328/

P2409

A6431

A2107

Hex BoltM10 x

MT430871

150/32

P380

A2108/S2121

Hex Nut 0.8D x

MT430957

S2129/S2156

M10

P113

A2114

Hex Bolt M10 x

MT430871

160 x 32

P381

A2115

Roll Pin dia 5 x 16

MT430189

P362

A2212.4

Plain Washer dia

MT430828

8.4/15 x 1.5

P2014

S.N

PART NO.

DESCRIPTION

DRG.NO.

QTY/KIT

A2301

External Circlip

MT430201

152

P42

A2314.2/S1405.1

Internal Circlip

MT430202

S1433/S1441

152

P52

S1503/S2111

A3109

Hex Bolt M6 x 70/

MT439005

P270

A3207/A2407

Internal Circlip

MT430202

116

P16

A4101

Hex Bolt M6 x 45/

MT430222

P2514

A4124

Hex Socket HD.

MT430511

Screw M8 x 70/22

P215

A4125/S4517

Belleville spring

MT430190

washer M8 x70/22

P118

A4134/A6502

Hex Bolt M6 x 30/

MT430222

P2511

A4139

Slotted head screw

MT430229

M8 x 25

P2930

A4150.11/

Counter sunk

MT430237

A4150.16

Screw 90° M5 x10

P2713

A4150.21

Hex Screw M5 x10

MT430106

A6110.3

P2406

A4150.32

Hex Nut 0.5D xM6

MT430439

P2012

A4150.7

Hex Screw M5 x12

MT430106

P2407

S.N

PART NO.

DESCRIPTION

DRG.NO.

QTY/KIT

A4430.17

Belleville spring

MT430151

A4430.22

washer dia 6.4/14

P20

S2535/S1529

A4430.18/A4504

Hex Nut 0.8D xM6

MT430957

A4540.11/S1529

P111

A4430.21

Hex Socket HD

MT430956

Cap Screw M6 x12

P2005

A4430.7

Roll Pin 2 x 12

MT430189

A4540.12

P110

A4514/A5404

External Circlip A10

MT430201

A6109/A6403

P10

A4516/ S2410

Hex Socket Hd. Cap

MT430956

S 2530

Screw M8 x 30/22

P2109

A4540.10

Roll Pin 4 x 14

MT430189

P311

A4540.9/A4503

Slotted CH.HD.

MT430229

Screw M6 x 2.0

P2876

A5317.9

Split Pin A2 x 15

MT430405

P2209

A5402/A5523/

External CirclipA17

MT430201

A6111/A6203

P17

A6310/A6408

A5408/A6413

Belleville spring

MT430704

A6107/S3603

washer dia 18/28

A5414

Roll Pin 8 x 25

MT430189

P466

S.N

PART NO.

DESCRIPTION

DRG.NO.

QTY/KIT

A5509/A6327

Belleville spring

MT430704

A6426

washer dia 32/48

P10

A5517

Hex Bolt M8 x 80/

SWT439005

P322

A5521/A6317

Roll Pin 4 x 36

MT430189

A6405

P319

A5524/A6417

Internal Circlip 140

MT430202

A6209/A6309

P40

A6114

Hex Bolt M8 x

MT430222

45/21

P 2614

A6115

Special washer dia

MT430198

8.4 x 15

P17

A6205

Slotted Ch HD

MT430229

Screw M4 x 20

P2676

A6301

Hex Screw M 6 x

MT430872

P2211

A6307

Hex Bolt M6 x

SWT439005

130/18

P278

A6311

Roll Pin dia 6 x 28

MT430189

P417

A6420/S1416

Hex Nut 0.8 D x

MT430957

S1528/S2514

P112

S2525/S3906

A6506/S2160.6

Hex Bolt M6 x

MT430222

35/70

P2512

S1101.2

Helicoil M 10 x 1.5

MT430935

P x 1.5D

P62

S.N

PART NO.

DESCRIPTION

DRG.NO.

QTY/KIT

S1105

Gasket Diameter

MT430152

21/ 25 x 1

P28

S1108/S1304

Hex Screw

MT430872

M10 x 30

P 2362

S1111/S1404

Hex Screw

MT430872

S1427/S1602

M10 x 25

P2361

S2133/S2148

S3714

S1203

Hex Bolt

MT430871

M10 x 55/ 26

P367

S1220/S2160.2

Belleville spring

MT430190

washer dia 6.4/14

P116

S1227/S1436

Roll Pin dia 3 x 25

MT430189

P216

S1230

Roll Pin 3 x 12

MT430189

P210

S1411/S1615

External Circlip

MT430201

S2205/S2220.5

A25

P25

S1414/S1461

Hex Bolt

SWT439005

M8 x 40/22

P 314

S1422

CH HD Screw M5

MT430229

x 10

P2766

S1447

External Circlip

MT430201

A20

P20

S1451

Hex Bolt M8 x 25

MT430872

P2261

S.N

PART NO.

DESCRIPTION

DRG.NO.

QTY/KIT

S1465

External Circlip

MT430201

A55

P 55

S1469

Internal Circlip 142

MT430202

P 42

S1471

Slotted head Grub

MT430440

Screw M5 x 6

P2706

S1480.1/S1481.1

Roll Pin 8 x 45

MT430189

S1929.1/S2104/

P 147

S2100.2/S2210.1

S1480.2/A1481.2

Roll Pin 5 x 46

MT430189

/A1929.2

P371

S2104.2/ S2210.2

S1507

Hex Bolt

SWT439005

M8 x 75/22

P 271

S1510

Hex Bolt

SWT439005

M6 x 80/18

P 272

S1530/S3706

Punched washer

MT430827

S3909

diameter 6.6/12

P2011

S1610/S3903

Hex Screw M8 x16

MT430872

P2259

S2216/S3709

Hex Bolt

MT430871

M10 x 35/26

P363

S2119/S2154

Hex Bolt

MT430871

M10 x 45/25

P365

S2126

Hex lock Nut

MT430439

0.5D x M8

P2013

S.N

PART NO.

DESCRIPTION

DRG.NO.

QTY/KIT

S2128

Hex Bolt

MT430871

M10 x 120/25

P 377

S2145/S2161

CU Gasket

MT430152

S3406

diameter 14/20 x 1

P23

S2153

Belleville spring

MT430190

washer dia 13.5/28

P122

S2164

Roll Pin dia 5 x 20

MT430189

P364

S2184

Punched washer

MT430827

diameter 9/17

P2015

S2185/S3448

Hex Screw M8 x 30

MT430106

P2614

S2404

Hex Bolt M6 x 30

MT430872

P2210

S2406

Hex Socket head

MT430956

cap screw M6 x 30

P2009

S2407

CU Gasket diameter

MT430152

6.5/11.2 x 1

P11

S2408/S2532

Hex Socket head

MT430956

screw M6 x 20

P2007

100

S2409

Punched washer dia

MT430828

6.6/11 x 1.6

P2011

101

S2411

Spring washer

SWT

435227 P1

102

S2413

Hex Socket head

MT430956

screw M12 x 35

P108

S.N

PART NO.

DESCRIPTION

DRG.NO.

QTY/KIT

103

S2604

Socket head cap

MT430956

screw M6 x 25

P2008

104

S2606

Hex Socket Hd Cap

MT430956

Screw M8 x 50/28

P2163

105

S3236

Spring washer B12

MT430197

P218

106

S3303

Gasket dia 16/22

MT430152

P27

107

S3305

Gasket dia 9.7/17

MT430152

P18

108

S3306

Hex Bolt

MT430222

M4 x 40/13

P233

109

S3307

Belleville spring

MT430151

washer dia 5/10

P17

110

S3308

Hex Nut

MT430108

0.8D x M4

P2014

111

S3425

Hex Screw

MT430106

M10 x 30

P2714

112

S3428/S334/

Gasket diameter

MT430152

S3435

22/31.5 x 1

P34

113

S3429

Slotted CH HD

MT430229

Screw M4 x 5

P2660

114

S3430

Spring washer B4

MT430197

P606

115

S3431

Punched washer

MT430827

diameter 4.5/9 x 0.8

P2008

116

S3438/S3464

Gasket diameter

MT430152

11/17 x 1

P19

S.N

PART NO.

DESCRIPTION

DRG.NO.

QTY/KIT

117

S3441/S3611

Hex Screw M6 x20

MT430106

P2510

118

S3451

Hex Bolt

MT430222

M10 x 35/25

P2712

119

S3421/S3452

Hex Nut diameter

MT430108

0.8D x M10

P2019

120

S3454

Punched washer

MT430827

diameter 10.5/22

P2017

121

S3455

Hex Screw M6 x25

MT430106

P2512

122

S3602

Gasket diameter

MT430152

17/34 x 3

P42

123

S3404

Special Nut

MT430232

3/8"BSP

P2003

124

S3609

Belleville Spring

MT430151

washer dia 6.4/14

P21

125

S3704

Hex Screw M6 x35

MT430106

P2515

126

S3814

Hex Screw M8 x20

MT430106

P4610

127

S3818

Hex Screw

MT430872

M12 x 30

P412

128

S3904

Plain washer

MT430445

diameter 8.4/18 x0.5

P2023

129

S3908

Rivet diameter

MT430223

3 x 8

P8563

REFERENCES

Maintenance manual of CLW for electric locomotives.

AC Traction manual.

IRIEEN journals.

Maintenance Schedules issued from Central Railway

Head Quarter, MBCST.

Maintenance Schedules of Northern Railway, GZB,

Western Railway, TKD and Central Railway, JHS.

Suggestions given by RDSO.

Suggestions given by various participants during

seminar.

Maintenance practices studied during visits at various

sheds.

*****