GOVERNMENT OF INDIA - Central Railway · 17-19 8. WAM4/11 4 Clamping arrangement for PHGR 9.7.81...

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GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

VOLUME - III

MODIFICATION SHEETS AND

SPECIAL MAINTENANCE INSTRUCTIONS ON

TAP CHANGER

MAY - 1999

RESEARCH DESIGNS AND STANDARDS ORGANISATION

LUCKNOW - 226 011

LIST OF MODIFICATION SHEETS AS ON MAY 99

2162

EQUIPMENT : TAP CHANGER (N - 32)

SL. No.

MODIFICATION SHEET NO.

DESCRIPTION DATE OF ISSUE

PAGE NO.

1. WAM4/24 Provision of modified tray below tap changer to drain oil (SKEL 2321)

5.5.75 4-5

2. WAM4/45 Modified catch assembly for CGR arc chute (SKEL 2661) 8.7.77 6-8 3. WAM4/52 Fastening RGR and CGR support plates on tap changer

assembly No. 32 (SKEL 2650) 29.8.77 9-11

4. WAM4/58 Modification to connecting air line of SMGR for tap changer No.32 of M/s HBB to avoid air leakage

25.5.78 12

5. WAM4/62 Support for oil flow indicator of tap changer No. 32 (SKEL 2749)

27.1.78 13-14

6. WAM4/69 Provision of taper hole to accommodate the taper pin in the manual drive of tap changer type No. N-32 of M/s HBB make SKEL 2888

3.6.78 15-16

7. WAM4/91 Provision of ducting for safety valve for tap changer type N-32 HBB make

5.2.80

17-19

8. WAM4/114

Clamping arrangement for PHGR 9.7.81 20-21

9. WAM4/117

Modification to control lever of SMGR of tap changer N-32 HBB make

20.8.81 22-24

10. WAM4/124

Modification to special washer used in transition resistance assembly of tap changer No. 32 HBB make SKEL 3456

27.3.82 25-27

11. WAM4/128

Modification to fixing arrangement for blow out coil of CGR to ensure locking of tap changer No. 32 type

15.9.82 28-30

12. WAM4/136

Modified flexible connection (1623) between RGR and GR of tap changer type No. 32 of HBB make

16.3.84 31-33

13. WAM4/145

Introduction of loctite between the mating surface of cams and cam shaft and on GRUB screw and tapped holes of tap changer No. 32 of HBB make

24.6.85 34-36

14. WAM4/146

Provision off grub screws for locking CG bush and gear housing assembly of manual drive for tap changer No. 32 HBB make

24.6.85 37-39

15. WAM4/151

Safety valve operated signalling device and oil duct system of tap changer type No. 32 of HBB make

10.6.86 40-44

16. WAM4/152

Staggery of RGR GRIDS of tap changer No. 32 of HBB make

30.7.87 45-46

17. WAM4/157

Modification in insulating ring (1218, 1219) fixing arrangement

3.11.89 47-49

18. WAM4/161

Replacement of cast iron transition resistance (RGR) by stainless steel transition resistance in tap changer type No. 32 of M/s HBB make

27.5.91 50-54

19. WAM4/187

Provision of canopy on safety valves of tap changer type No. 32 of M/s ABB

4.95 55-57

20. WAM4/192

Permanent connection of 16th gap in place of spring loaded connection

May 1996 58-60

21. ELRS/MS/0292(Rev.`0’)

GR progression and regression valve emergency operation circuit modification in microprocessor based WAG-7 locomotive.

18.07.00 162-163

SL. No.

SMI NO. DESCRIPTION DATE OF ISSUE

PAGE NO.

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22 EL/3.2.30 Modification in the air supply line to nsureeffective operation of the oil pump (PHGR) fitted with the oil pump.

25.10.99 61-63

SPECIAL MAINTENANCE INSTRUCTIONS AS ON MAY 99

SL. No.

SMI NO. DESCRIPTION DATE OF ISSUE

PAGE NO.

1. SMI/17 Breakage of manual driven taper pin 27.5.78 64 2. SMI/18 Malfunctioning of modified control lever (Pt. No. 45) 25.5.78 65-66 3. SMI/20 Sluggish operation of SMGR (Pt. No. 2303) 25.5.78 67 4. SMI/21 Breakage of support block of aux. switches at the fixing

points 14.6.78 68-69

5. SMI/22,24 Sticking of tap changer in between notches /locking of contact screws

14.6.78 70-73

6. SMI/46 Sticking of control lever guide pin 27.3.79 74-75 7. SMI/47 Malfunctioning of reducing valve 11.4.79 76-77 8. SMI/48 Adjustment of lead angle of control cylinder 28.3.79 78-80 9. SMI/49 Lubricants to be used 26.3.79 81 10. SMI/50 Testing of contact pressure of CGR I, II and III 30.3.79 82-84 11. SMI/62

Tightening of electrical connections between GR-CGR-RGR of tap changer type N-32

5.2.80 85-87

12. SMI/63 Flashing of tap changer N-32 25.7.80 88 13. SMI/80 Lubricants to be used for tap changer 12.6.81 89-92 14. SMI/82 Roller contact force in tap changer No. 32 7.7.81 93-94 15. SMI/88 Oil leakage through 3-way cock of tap changer No. 32 29.3.82 95-97 16. SMI/90 Tightening of electrical connector of load switch (tap changer

No. 3) 15.9.82 98-100

17. SMI/101

Method for confirming that the pin nitride and procedure for replacement of journal pin (Pt. No. 451) Tap changer No. 32 type HBB make

29.10.82 101-103

18. SMI/105 Lubrication to groove of piston skirt (Pt. 2304) of Tap changer type No. 32 HBB make

8.4.83 104-105

19. SMI/106

Cleaning of the selector after 10,000 km . run of tap changer No. 32 HBB make

10.6.83 106-107

20. SMI/113

List of various torque values and assembly tools/adopter to be used at various locations in tap changer No. 32 type and air blast circuit breakers (DJ DBTF 30 250 type of HBB make

16.3.84 108-112

21. SMI/117 Breakage of needle bearing roller (Pt. 2311) of tap changer type No. 32 of HBB make

4.4.84 113-114

22. SMI/118

Tightening of connecting terminal (1206) with cut(1207) on contact pins (1208 & 1209) of tap changer No. 32 of HBB make

5.5.84 115-117

23. SMI/129 Replacement procedure for bevel gear 1924/1925 of No. 32 Tap changer of HBB make

29.7.85 118-119

24. SMI/134 Replacement procedure of air motor support 20.10.87 120-122 25. SMI/135 Dismantling instructions and fixture details for the removal of

pinion (Pt. No. 6101) of cranks shaft on (SMGR) 27.10.87 123-125

26. SMI/143 Maintenance schedule for tap changer 27.8.92 126-132 27. SMI/144 Flashing inside the selector of GR check sheets 20.10.92 133-146 28. SMI/145 Crank shaft fracture of SMGR checks sheets 20.10.92 147-156 29. SMI/146 Breakage of journal pin of SMGR check sheets 20.10.92 157-161

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Modification Sheet No. WAM4/24

Title of modification :

Provision of modified steel tray below the tap changer.

Purpose of modification :

The leak out oil from the tap changer drips on the smoothing reactor through the securing bolts of GR causing damage to the smoothing reactor insulation. Therefore, a modified tray is to be provided below the tap changer in order to prevent oil dripping over the smoothing reactor.

Modified Drg. No. : RDSO SKEL 2321

Work to be carried out :

A modified tray for easy draining out of the deposited oil is to be fitted below the tap changer.

Execution of work and material schedule :

CLW has already implemented this modification from 51 locomotive onwards. For the first 50 locos, the modification is to be implemented by the Railways. Modified tray will be supplied by CLW. This modification is to be treated as essential.

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Government of India Ministry of Railways

Research, Designs & Standards Organisation Manak Nagar, Lucknow - 226 011

Ref : EL/3.1.3/E7 Dated : May, 1997

Modification Sheet No. RDSO/WAM4/45

1. Title of modification

Modified catch assembly for CGR arc chute

2. Application to class of loco

WAM4 locomotives

3. Object of modification

The existing CGR arc chute catch assembly, which holds the arch chute plate on to its supports, slips off from the clamp due to vibrations, resulting in the arc chute plate falling off. In order to overcome this problem, it is proposed to braze two lugs (item 5) at the end tips of the existing clamps fixed on the arc chute plates as shown in the drawing.

4. Modification drawing No.

RDSO SK EL 2661

5. Agency for modification

i) Railways - all existing locomotives.

ii) Chittaranjan Locomotive works - locomotives under production.

6. (a) Material required and specification

As per RDSO Drg. No. SK EL 2661

(b) Material rendered surplus

Nil.

7. Work to be carried out

Remove the existing clamp from the arc chute plate. Cut a V-shaped groove as shown in the drawing to accept the modified catch. The passivated zinc coating on the clamp (item 4) should be cleaned and two stop lugs should be brazed at the ends after proper matching as per item 5 of the drawing. The holding catch (item 2) should also be modified as per drawing to match the groove in the clamp.

8. References

RDSO investigations.

9. Distribution

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Secretary (Elec. Traction), Railway Board, New Delhi. General Manager (Electrical)

Central Railway, Bombay VT Eastern Railway, Fairlie Place, Calcutta Northern Railway, Baroda House, New Delhi. South Eastern Railway, Garden Reach, Calcutta Western Railway, Churchgate, Bombay Chittaranjan Locomotive Works, Chittaranjan.

Superintendent (Workshop)

Eastern Railway, Kancharapara. Dy. Chief Elec. Engineer

Central Railway, PCH shop, Bhusaval Eastern Railway, Kancharapara Design, CLW, Chittaranjan.

Sr. Divisional Elec Engineer (TRS) Central Railway, Kalyan Eastern Railway, Asansol/Mughalsarai Northern Railway, Kanpur South Eastern Railway, Tatanagar/Bhilai. Divisional Elec. Engineer (TRS)

Central Railway, Bhusaval Northern Railway, Ghaziabad Western Railway, Vadodara

Dy. Director Inspection (Elec)/RDSO

C/o Chittaranjan Locomotive Works, Chittaranjan.

(B. S. SIDHU)

for Director General (Elec.)

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Ref : EL/3.1.3/E7 Dated : 29th Aug , 1977


1. Title of modification :

Fastening RGR and CGR support plates on tap changer assembly No. 32.

2. Application to class of Locos :

WAM4 locomotives.

Note. Applicable in principle, to all class of ac and ac/dc locomotives where N-32 tap changers are used. This modification may be carried out on locos other than WAM/4 also if failures etc. as mentioned in para 3 below are observed.

3. Object of modification :

Vibrations of high amplitude have been recorded on the tap changer CGR assembly of WAM4 locomotives while running at higher (above 80 kmph) speeds, causing damages to the tap changer assembly electrical connections. It is proposed to make CGR assembly more rigid by providing additional support between CGR and RGR assemblies to reduce the vibrations.

4. Modification drawing :

RDSO SK EL 2650

5. Agency for modification :

1. Railways : WAM4 locomotives

2. Chittaranjan Locomotive Works. Locomotive under production.

6. a) Material required and specification :

RDSO drawing No. SKEL 2650

b) Material rendered surplus :

Existing RGR support plates will be rendered surplus if new plates are manufactured. The existing support plate may however be re-used by welding additional plate to it as shown in the drawing.

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7. Work to be carried out : The existing RGR support plates should be replaced by a modified plates to RDSO drawing. The lifting hook of CGR assembly should be fixed over the CGR support plates. The CGR and RGR support plates on both sides should be connected by a strut. The nuts should be suitably adjusted and tightened to ensure that there is no stress on CGR and RGR supports. All the four support plates shall be protected against corrosion/rusting by two coats of paints. The entire surface of both the struts except the fastening arrangement shall be painted with anti-paint.

8. Reference

9. Distribution :

Secretary (Elec Traction), Railway Board, New Delhi. General Manager (Electrical)

Central Railway, Bombay VT Eastern Railway, Fairlie Place, Calcutta Northern Railway, Baroda House, New Delhi. South Eastern Railway, Garden Reach, Calcutta Western Railway, Churchgate, Bombay Chittaranjan Locomotive Works, Chittaranjan, W. Bengal

Superintendent Workshop Eastern Railway, Kancharapara

Dy. Chief Elec. Engineer Central Railway, POH shop, Bhusaval Eastern Railway, Kancharapara

Dy. Chief Elec. Engineer (Design) Chittaranjan Locomotive Works, Chittaranjan

Senior Divisional Elec Engineer (TRS) Central Railway, Kalyan Eastern Railway, Asansol/Mughalsarai Northern Railway, Kanpur South Eastern Railway, Tatanagar/Bhilai

Divisional Elec Engineer (TRS) Central Railway, Bhusaval Northern Railway, Ghaziabad Western Railway, Baroda (Gujarat)

Dy. Director Inspection (Elec)/RDSO C/o Chittaranjan Locomotive Works, Chittaranjan, W. Bengal.

(S. Malaviya)

for Director General/Elec

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Ref : EL/3.2.30/DC2 Dated : 25May, 1978


1. Title of modification : Modification to connecting air line (1922) of SMGR for tap changer N-32 of M/s HBB to avoid air leakage.

2. Application to class of locomotives :

All locos fitted with N-32 tap changers. 3. Object of modification :

A few cases have been reported by the Railway in which the nipple provided on both ends of air line (1922), a press fit joint, becomes loose resulting in heavy air leakage. To prevent such failures, it is proposed that the joints be brazed.

4. Modification Drawing :

Nil. 5. Agency of implementation :

Railways : On locos in service CLW : On locos under production

6 (a) Material rendered surplus : Rupatum - 43 solder. Rupatum flux. (b) Material to be carried out : Nil 7. Work to be carried out :

Clean both surfaces to be brazed, that is the pipe and nipple with smooth file or emery paper. Heat the pipe and nipple to dull red heat using oxyacetylene flame. Braze the two components together using Rupatum 43 solder and flux.

8. Reference : BBC maintenance manual AM 91001E Drg. No. 6.1-19. 9. Distribution : As per list attached.

DA. One list. (Ramesh Chandra)

for Director General (Elec)

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Ref : EL/3.2.30/DC2 27th January, 1978


1. Title of modification : Support for oil flow indicator of tap changer No.32.

2. Application to class of locomotives : WAM4

Applicable in principle to all electric locomotives in similar locations. 3. Object of modification :

Frequent cracking of oil flow indicator pipe has been reported by the railways. Investigations have shown that the failures due to resonant vibratations at high speeds. In order to minimise such vibrations, it is proposed to secure the oil flow indicator assembly by providing a support from the tap changer body, thereby increasing the resonant frequency.

4. Modification Drawing :

RDSO SKEL 2749 5. Agency of implementation :

Railways : All existing WAM4 locomotives. CLW : Locos under production and future builds

6. (a) Material required and specification : Two fixing clamps and support plate etc. as per drg.No.SKEL.2749.

(b) Material rendered surplus: Nil 7. Work to be carried out :

The support should be fabricated and assembled as per RDSO drawing No.SK.EL.2749 and fixed on the graduator cover. The oil flow indicator should be secured by two clamps as shown.

8. Reference : Nil 9. Distribution : As per enclosed list

. (S.Malaviya)


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Ref : EL/3.2.30/DC2 Dated : 3.6.1978

Modification Sheet No. RDSO/WAM4/69 1. Title of modification :

Provision of taper hole to accommodate the taper pin in the manual drive of tap changer type N-32 of M/s HBB make.


WAM4 and WCAM1 locomotives 3. Object of modification :

A few cases have been reported by Railways in which the taper pin marked (l) in enclosed Sketch SKEL 2888 had broken resulting in loco failure. Investigations have shown that the failure is due to hole not being reamed for proper taper of l in 50. It is proposed that the hole be properly reamed before driving in the taper pin.


RDSO SKEL 2888 5. Agency for implementation :

All electric loco sheds for locos in service. 6. (a) Material required :

Split taper pin 8 x 50 to IS: 6688-1972. (b) Material rendered surplus :

Nil 7. Work to be carried out :

Check the taper pin (l) for proper fitment. In case the hold is parallel, take out the taper pin and ream the hole with a l in 50 taper reamer. Assemble the manual drive by fitting the taper pin by hammering it in and splitting the end slightly.

8. Reference : CLW letter No. EL/DD/314/GR dated 19-3-77 9. Distribution : As per list attached.

DA : One RDSO sketch (Ramesh Chandra) SKEL 2888 and one list. for Director General (Elec.)

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Ref : EL/3.2.30/DC2 Dated : 5.2.1980


PROVISION OF DUCTING FOR SAFETY VALVES FOR TAP CHANGER TYPE NO. 32 HBB MAKE


Railways have reported a few cases of splashing of oil inside the locomotive due to blowing of tap changer safety valves. When there is flashing of main contacts of tap changer, the safety valves blow. The blown out oil splashes all around. In one case fire has been reported due to splashing of oil. It is proposed to provide a ducting for the oil blown out of safety valves so that the oil is drained out of locomotive without affecting other equipments.

2. Work to be carried out :

Fabricate the ducting (item 2 of SKEL 3215) for both safety valves and the oil tank (item 1) as shown in SKEL 2315. Fix the ductings on the top with the aid of fixing clamps. Fix two inner clamps (item 6) with the help of existing nuts on the base of GR bushing. Fix the other two clamps by means of cheese head screws (items 7) as shown in drawing, after drilling and tapping two holes of 8 mm dia at the corners of GR body to a depth of 6 mm only. Fix the oil tank at four places as indicated in the drawing with the help of existing nuts. Connect drain pipe at the bottom of oil tank. Take the drain pipe through the floor for drainage of oil outside the locomotive.


WAM4 locos, Applicable in principle to other classes of locomotives also provided with N-32 tap changers with suitable modification to oil tank (item 1) dimensions to suit the available space in the locomotive.

4. Material required :

As per drawing RDSO SKEL 3215.

5. Material rendered surplus :

Nil

6. Reference :

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HBB sheet No. TC-64


RDSO SKEL 3215

8. Agency for implementation :

i) CLW for locos under production

ii) Railways for existing locomotive.

9. Distribution :

As per list attached.

Encl: 1 Drg. No. SKEL 3215

(Ramesh Chandra) for Director General/Elec.

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Ref : EL/3.2.30 Dated : 9,July 1981 MODIFICATION SHEET No. WAM4/114

CLAMPING ARRANGEMENT FOR PHGR 1. Object:

Railways have reported many cases of cracking of copper pipe lines used for oil flow between tap changer, oil pump and oil filter. These failures are due to low frequency vibrations of the oil filter pump assembly, which is bolted to the tap changer at one end only. It is proposed to arrest these vibrations and consequent failures by clamping the oil filter suitably.

2. Work to be carried out : 2.1 Manufacture 2 clamping pieces as per general arrangement shown in

RDSO SK EL 3401 from 3 mm thick MS plate. The dimensions of the clamping pieces should be checked on a prototype to be fabricated before getting the bulk supply.

2.2 Fix the clamping piece " by means of 3 bolts at locations 3, 4 & 5 (Hex part No. 1304 and spring washer part No. 1305) used for fixing of selector cover (1203) as shown in BBC Manual AM 91018E.

2.3 Wrap the filter with a rubber sheet of shore hardness 70-80, 70 mm wide, 3 mm thick.

2.4 Fix clamping piece " B " to the clamping piece " A " by means of 2 Nos.. M 10 x 40 bolt.

2.5 While fixing clamping piece " B " ensure that the clamping piece or the fixing bolts, do not damage the oil pipe line in the vicinity. Care has to be particularly taken while inserting the bolt on the tap changer side as there is a pipe line just behind this location.

2.6 To ensure full tightness of the filter, there should be a minimum gap of 5 mm on both faces between clamping pieces A and B.

3. Application : All locomotives fitted with No. 32 tap changer

4. Material required : See SK EL 3401

5. Reference : Prototype developed by Ghaziabad shed.

6. Agency for implementation : All electric locomotive sheds and POH shops.

7. Distribution : As per list.

Encls. SK EL 3401 Mailing list. (H.B. Singh)


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No : EL/3.2.30/JCG Dated : 28.7.1981 20.8.1981


Modification to Control Lever of SMGR of TAP CHANGER NO. 32 HBB MAKE


A few cases of sticking of tap changer were reported by Railways due to malfunctioning of control lever (part No. 45) of new HBB design where the two components of the lever are fixed with a nut and bolt and one spring cotter. Investigation has revealed lateral movement between those two parts due to only one spring cotter resulting in jamming of the guide pin, which in turn results in sticking of the tap changer. It is proposed to fit 2 additional spring cotters to avoid the relative movement between the 2 components of control lever.


- Dismantle the control lever assembly.

- Check the free movement of guide pin part No. 4521.

- Check the tightness of Nut locked with spring cotter Part No. 4503. If looseness is observed, change bolt, nut and spring cotter. Tighten the nut fully and provide 2 mm dia spring cotter after drilling a hole in the bolt.

- Keep the template as per SK EL 3590 on spring loaded pin bearing part No. 4522 so that the template matches its Profile. Mark and drill 3.9 +0.1/-0.0 dia holes as per the template marking and assemble the 2 additional spring cotters CS4x14 Part 4528.

- Fit back the control lever.

- Check for smooth operation.

3. Application :

Locos fitted with No. 32 tap changers having control lever of new HBB design.


2 spring cotters CS 4x14 obtainable from M/s Hindustan Brown Boveri, Post Box No. 140, Manoja, Vadodara 390 001.

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5. Material rendered surplus :

Nil

6. Reference :

Para 1.3.2 (page 4) of the minutes of the meeting held between RDSO and M/s HBB. Minutes circulated vide RDSO letter No. EL/3.2.30/JCG dt. 24.10.80.


RDSO SK EL 3590


CLW CRJ : for locos under production. Railway Maintenance Sheds) : for existing locos. Elec Loco Workshops)

9. Distribution :


(Ramesh Chandra) for Director General (Elec) Enc: SK EL 3590 & Mailing list

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No. EL/3.2.30/JCG Dated : 27.3.1982

Modification Sheet No. WAM4/124

Modification to Special Washer used in Transition Resistance Assembly of Tap Changer No. 32 HBB Make.

1. Object :

Railways have reported many cases of cutting of insulated tubes of the RGR support bars. Investigation has shown that this was caused due to the hitting of special M.S. washers on the insulation of the tube continuously in service as inner dia of the special washer projects beyond the inner surface of the resistor element (grid).


- Dismantle the RGR resistor assembly.

- Replace the existing special M.S. washers of inner dia 22.5 mm. with the Special M.S. Washer of inner dia 26 mm having semi circular surface of radius 0.5 to 0.7 mm as shown in SK EL 3456.

- Assemble the RGR resistor.

3. Application :

Locos fitted with No. 32 tap changer of HBB make.

4. Material required. :

Special M.S. washers of inner dia 26 + 0.5 mm obtainable from M/s HBB, P.B. No. 140 Maneja Vadodra 390 001.

5. Material surplus :

Existing special M.S. washers of inner dia 22.5 +0.5 mm.

6. Reference :

1. Para 2.2.1 (page 4) of the minutes of the meeting held between railways and M/s HBB in August 1981 and minutes circulated vide RDSO letter No. EL/3.2.30/JCG dated 3.10.81.

2. M/s HBB's Drawing No. TC-82

3. Modified special washer introduced by M/s HBB from Dec. 1981 onwards.


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RDSO SK EL 3456

8. Agency of implementation :

All elec. locomotive sheds and POH shops.

9. Distribution :


Encl : SK EL 3456 &

Mailing list.

(K. Viswakumar) for Director General/Elec.

28162



No. EL/3.2.30/CG Dated : 15.9.1982

MODIFICATION SHEET NO. WAM4/128

MODIFICATION TO FIXING ARRANGEMENT FOR BLOW OUT COIL OF CGR TO ENSURE LOCKING - TAP CHANGER NO. 32 TYPE

1. OBJECT

Railways have reported a few cases of loosening of Allen screws provided at locations 2316-17 and 2319-2317 for fixing the blow out coil of load switch (CGR) of tap changer type No. 32. Investigation has shown that HBB have provided only one number plain washer with allen screw. The original BBC practice was to provide 1 number spring washer with hexagonal bolt as shown in their Instruction Sheet No. AM 91018 E. This deviation from the original fixing arrangement caused the loosening of allen screws during service.

2. WORK TO BE CARRIED OUT

- Unscrew the allen screw provided at locations 2316-17 & 2319-2317

- Remove the allen screw (2316) and provide hexagonal screw (2316) with special locking washer, spring washer (2317) and necessary shim as shown in Fig. 1 of SK EL 3504.

- Provide the existing hexagonal socket head cap screw (2319) with spring washer (2317) and punched washer of dia 6.6/11 x 1.6 mm (Plain washer) as shown in Fig. 2 of SK EL 3504.

- Tighten fully the unscrewed hexagonal screws.

3. APPLICATION

All locomotives fitted with No. 32 tap changer.

4. MATERIAL REQUIRED - Hexagonal screw - 12 Nos.. - Special locking washer - 6 Nos.. - Spring washer - 24 Nos.. - Shim - As per requirement for adjustment. - Punched washer - 12 Nos.. Material to be obtained from HBB works/Baroda.

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5. MATERIAL SURPLUS

- Existing allen screws (12 Nos.) at location 2316

- Existing plain washer (12 Nos.) at location (2316-2317)

6. REFERENCE

(i) HBB Drawing No. TC-83

(ii) Modified fixing arrangement of blow out coil introduced from HBB tap changer No. 31281208.

7. AGENCY FOR IMPLEMENTATION

All electric locomotive sheds and POH shops.

8. DISTRIBUTION


Encl: 1. SK EL 3504 (K. Vishwakumar) 2. Mailing list. for Director General (Elect).

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No. EL/3.2.30/CG Dated : 16.3.1984


MODIFIED FLEXIBLE CONNECTION (1623) BETWEEN CGR AND GR OF TAP CHANGER TYPE NO. 32 OF HBB MAKE.

1. OBJECT

Railways have reported many cases of breakages of solid connections provided between switching element (CGR) and Double pole bushing (GR) due to locomotive vibrations. It is proposed to provide a flexible connection in place of solid connection.


Replace the solid connection by flexible connection (SK EL 3726)

3. APPLICATION

Locos fitted with No. 32 tap changer of HBB make.

4. MATERIAL REQUIRED

Flexible connections as per RDSO SK EL 3726 obtainable from M/s HBB, P.B.No. 140, Vadodara 390 001

5. MATERIAL SURPLUS

Existing solid connection - 2 Nos.

6. REFERENCE

(i) Item (page 8) of the minutes of the meeting held between Railways & M/s HBB in August 83 and minutes circulated vide RDSO letter No. EL/3.2.30/CG dated 24.9.83.

(ii) M/s HBB Drawing No. TC 96 (Mod A) & TC 97 (Mod B)

7. MODIFICATION DRAWING

RDSO SK EL 3726.

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8. AGENCY OF IMPLEMENTATION

All electric loco sheds and POH shops. HBB/CLW - during manufacture and on tap changers in stock.

9. DISTRIBUTION


K. Vishwakumar

for Director General (Elec) Encl : 1.SK EL 3726 2. Mailing list.

34162



No. EL/3.2.30/CG Dated : 24.6.1985


Introduction of loctite between the mating surface of cams and cam shaft and on grub screws and tapped holes of tap

changer No. 32 of HBB make. 1. OBJECT

Railways have reported a few cases of breakage of grub screws provided to hold the cams on cam shaft resulting in cam shifting from the roller contact surface leading to locomotive failure. Following changes were made by BBC from time to time on cam shaft assembly (51).

i) Shaft design modified and material of cams changed from resin bonded paper to steel from 1968 onward upto tap changer No. 31281207. The cams were fixed to shaft by grub screws and check nuts, and spacers were eliminated.

ii) Introduction of loctite on grub screws of cam shaft (without spacers) from tap changer No. 31080126.

iii) In addition to item (ii), check nut of grub screw removed from tap changer No. 31281207.

iv) In addition to item (iii) loctite introduced on square portion of mating surface of cam and cam shaft from tap changer No. 31183303.

2. WORK TO BE CARRIED OUT :

Cam shaft assembly (51) of tap changers supplied from 1968 (without spacers) is to be modified as per the following instructions.

- Unscrew the check nut (5115) if provided

- Unscrew the grub screw (5114)

- Displace the cams from position

- Degree the grub screw, tapped hole for grub screw on cams and cam shaft, mating surface of cam shaft (5101) and cam (5105) with Trichlorethylene with the help of a brush.

- Allow the Trichlorethylene to evaporate completely before applying loctite, to ensure that it sets.

- Provide lotite "Blue" Code No. 0241, uniformly on threaded portion of grub screws, tapped holes, square mating surfaces of cam shaft and cams.

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- Cams are to be slided to its location and moved to and fro many times so that loctite gets filled properly in mating surfaces and entrapped air is released.

- Adjust the cams to its proper location.

- Fix and tighten the grub screw already provided with loctite.

- Excess loctite to be wiped off.

- Cam shaft is to allow for setting of loctite for minimum 5 hours.

IMPORTANT PRECAUTIONS FOR USE OF LOCITE :

- Close the loctite bottles immediately after use.

- Store the loctite below 200 C.

- Never pour superfluous loctite back into the bottle.

NOTE :

i) HBB have already incorporated res-i-glass tape in between the cams of cam shaft assembly and loctite application grub screw and cams from tap changer No. 31183303.

ii) BBC will provide steel spacers alongwith shims in between the cams alongwith the provision of loctite on grub screws and between the mating surface of cam shaft and cams in future supply.

iii) Refer for application of loctite item 3.3 of page 30 of BBC Overhaul Instructions No. HAMT 30074E on Rly. tap changer No.32/3.

3. APPLICATION :

Locos fitted with No. 32 tap changers of HBB make.

4. MATERIAL REQUIRED :

- Loctite - Supplier address : AEICORP PVT LTD. Mercantile Building, 10 Lall Bazar Street, Calcutta 700 001

- Trichlorethylene

- Grub screws if found broken during opening

5. MATERIAL SURPLUS :

Check nut (if provided) 4 Nos..

6. REFERENCE :

Item 2.1.7.3 (page 4) of the Minutes of the meeting held between RDSO, Railways and HBB in July, 1984 circulated vide RDSO letter No. EL/3.2.30/CG dated 29.9.84.

7. MODIFICATION DRAWING :

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Nil

8. AGENCY OF IMPLEMENTATION :

- Railways for existing locomotive.

- CLW for locomotives under production.

- HBB/BBC as per note given under item 2. 9. DISTRIBUTION : As per list attached.

(S.S. Khurana)

for Director General/Elec. Encl./ Nil

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No. EL/3.2.30/CG Dated : 24.6.1985

MODIFICATION SHEET NO. RDSO/WAM4/146

Provision of grub screws for locking bush and gear housing assembly of Manual Drive for Tap Changer No.32 HBB make.

1. OBJECT :

Railways have reported a few cases of slipping of notch indicator on the shaft and hence depicting wrong notch. Investigations have shown that BBC had provided only loctite instead of providing loctite at the interface of bush and gear housing as well as the grub screws. BBC supplied 74 sets of Manual Drive from 1970 onwards without grub screws but with loctite to Indian Railways. It is decided to provide two grub screws as per the following instructions.

2. WORK TO BE CARRIED OUT :

- Dismantle the manual drive assembly.

- Check that the grub screws are provided, if not.

- Drill and tap two numbers of M4 threaded holes diametrically opposite to each other with their centre coinciding with the joining dia of the two components as indicated in the enclosed SK EL 3835 (Ensure partial tapping in bush and partial tapping in gear housing).

- Insert hex socket headed grub screw M4 x 10 and ensure that it does not project out of the housing.

- Assemble the Manual Drive after normal overhauling.

3. APPLICATION :

Manual Drives supplied by BBC from 1970 onwards where the grub screws were not provided for locking bush and gear housing assembly.

4. MATERIAL REQUIRED :

Hex. socket headed grub screws (M4 x 10) - 2 Nos..

5. MATERIAL RENDERED SURPLUS :

Nil

6. REFERENCE :

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i) HBB Instruction No. SWT 5087

ii) Page 3 of minutes of the meeting held between Railways and HBB in July 1984 circulated vide RDSO letter No. EL/3.2.30/CG dated 29.9.84.

7. MODIFICATION DRAWING :

RDSO Drawing SK EL 3835.


i) CLW for locos under production.

ii) Railways for existing locomotives.

9. DISTRIBUTION :


(S.S. Khurana) Encl/Drg. No. SK EL 3835 & for Director General/Elec. Mailing list.

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No. EL/3.2.30/J-6 Dated : 10.6.1986

DISTRIBUTION ( AS PER THE LIST ATTACHED)


SAFETY VALVE OPERATED SIGNALLING AND OIL DUCT SYSTEM OF TAP CHANGER TYPE NO. 32 HBB MAKE

1. OBJECT

In modification Sheet No. RDSO/WAM4/91 dt. 5.2.80, it was proposed to provide ducting over the safety valves of the tap changer to prevent splashing of the oil inside the loco in the event of safety valve operation. It is further proposed to provide a limit switch in ducting arrangement to operate lamp and buzzer in both the cabs to give signal of blowing the safety valve to the driver, so that the driver may not operate tap changer after blowing of the safety valve. Minor improvements in the above for easy fitment of ducting & limit switch arrangement modification have also been incorporated as per drawing No.s SK EL 3885 & 3886. Limit switch is operatable by splashed oil.


Modify the existing ducting arrangement/fabricate new as per drawing No. SK EL 3885 & 3886 . Take a limit switch type 2 NO + 2 NC, Code - PS SIIR-Z of M/s Cuttler Hammer alongwith the lever. Keep the length of lever 110 mm from the centre of the operating part of the switch by cutting extra length. Cut upto slot level, the Coller of base of lever and remove sharp edges and burs as shown in enclosed drawings. Stainless steel cup of the outer dia 54 mm, height 37 mm thickness 0.3 to 0.5 mm is to be spot welded with switch lever. Provide the modified limit switch in the duct as shown. In normal condition the limit switch contact should remain open. Schematic wiring diagram of limit switch, lamp and buzzer is shown in SK EL 3886.

(ii) Open the selector cover part No. 1302.

(iii) Loosen the 4 Nos.. bolts (Pt 11) M10 x 25 and replace them with M 10 x 35/26 bolts Hex bolt alongwith fixing clamp (Pt. 4)

(iv) Replace the 2 bolts at the portion indicated at "B" with M 10 x 36/25 bolts after assembling holding strip (Pt. 2)

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(v) After keeping gasket (Pt. 3) in position place the oil duct pipe complete in the respective position. Ensure that the fixing clamps (Pt. 4) rest on flange of oil duct pipe complete. Keep the Hex. screw (Pt. 15) in position alongwith punched washer (Pt. 14) and Belleville spring washer (Pt. 16)

(vi) Ensure the valve disc (1309) moves freely inside the oil ducting by pushing the disc upwards by hand from inside the selector before tightening the bolts (Pt. ) of fixing clamp (Pt. 14) . If necessary, use punched washers (Pt. 14) as a packing while tightening the hex. (Pt. 10) of hex. screw (Pt. 15) to ensure proper alignment.

(vii) After tightening again ensure the free movement of guide disc inside the ducting when operated by hand. The force required to operate the valve disc 10+2 Kg.

(viii) Refit the selector cover, assemble the special stud (Pt. 18) and mount the oil storage backet (Pt. 1) with limit switch (Pt. 12).

(ix) Connect drain pipe at the bottom of the oil storage bucket as shown in the drawings.

(x) Ensure that the oil cup of limit switch is not touching the oil guide of oil storage bucket and the limit switch is in the 'normally open' condition.

(xi) Provide indication lamp and buzzer in each cab and connect them with existing loco battery of 110 VDC through limit switch as per drawing.

(xii) The collection of oil in oil cup due to splashing will cause the limit switch to close and the connected bulb and buzzer will be operated.

NOTE : (a) Free movement of guide disc is to be checked during every AOH.

(b) In IOH in addition to (a) change gasket (Pt. 3) and spring and belleville washers.

3. Application to class locomotives

WAM4 locos applicable in principle to other classes of locomotives also provided with NO 32 tap changers with suitable modification to oil bucket dimensions to suit the available space in the locomotive.

4. Material required

As per RDSO drawing No. SK EL 3885 & 3886.

5. Material rendered surplus

Nil

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6. References

(i) Modification Sheet No. RDSO/WAM4/91, dt. 5.2.80

(ii) Sr. DEE (TRS)/BRC letter No. EL/TRS/90/10/6/8 dt. 3.12.82 and enclosed Drg. No. WR/BRCY/EL/3 TDD-042

(iii) M/s HBB Sheet No. TC-100 (Mod.B) & TC 64 (Mod. C)

(iv) Item 10 (page 7) of the minutes of the meeting held between Railway & M/s HBB in Jan., 1986 circulated vide RDSO letter No. EL/3.2.30/J-6 dated 14.2.86.

7. Modification drawing

RDSO SK EL 3885 & 3886

8. Agency of implementation

(i) M/s HBB from tap changer No. IB 30186411

(ii) CLW for locos under production.

(iii) Railways for existing locomotives

9. DISTRIBUTION As per the list attached.

Encl : SK EL No. 3885 & 3886 (S.S. Khurana) for Director General/Elect.

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No. EL/3.2.30/J-6 Dated : 29.5.1986

MODIFICATION SHEET NO. RDSO/WAM4/152 STAGGERING OF RGR GRIDS OF TAP CHANGER NO. 32 HBB MAKE

1. OBJECT Railways have reported a few cases of melting/overheating of indigenous

grids. Investigations have revealed that these failures are mainly due to touching of the grids in vibration with each other during loco run. It is, therefore, proposed to stagger the grids to increase the end spacing between the elements and facilitate better cooling. 2. WORK TO BE CARRIED OUT

- Dismantle the existing RGR grids, - Assemble the RGR elements by staggering them alternately from both

sides instead of one side of insulated tubes as per enclosed drawing. - Washer arrangement between the grids are the same as in the existing

assembly. - Provide necessary punched washers on both ends of RGR grid

assembly as shown in SK EL 3892. - Measure the resistance value of modified resistor assembly . It should

be within 1.6+10% Ohm. 3. APPLICATION TO CLASS OF LOCOMOTIVES

All electric locomotive fitted with indigenous RGR on Tap Changer type No.32. 4. MATERIAL REQUIRED

Nil 5. MATERIAL RENDERED SURPLUS

Nil 6. REFERENCE

Item 9 (Page 6) of the minutes of the meeting held between Railways and M/s HBB in Jan. 1986 circulated vide RDSO letter No. EL/3.2.30/J-6 dated 14.2.1986. 7. Modification drawing No. SK EL 3892 8. AGENCY OF IMPLEMENTATION

- Railways for existing locomotives. - CLW for locos under production. - M/s HBB on new supply of tap changer.

9. DISTRIBUTION : As per the list attached.

(S.S. Khurana) Encl.: SK EL : 3892. for Director General/Elect

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No. EL/3.2.30 Dated : 3.11.1989


Modification in insulating ring (1218, 1219) fixing arrangement.

1. OBJECT

Railways have reported a few case of flashing over inside the selector housing assembly of tap changers. Investigations have shown that one of the reason for the flashing was intermediate contact terminals were touching the insulating ring. In case of copper deposition the chances of creepage between taps are more. In order to increase the path it is decided to provide an additional machined washers in between insulating ring (1218, 1219) and fixing contact terminal (1208, 1209).


- Dismantle the contact plate assembly.

- Replace the existing special bolt (1221) of 22 mm length with 24 mm length.

- Provide No.1 mm additional machined washer zinc plated φ6.4 xφ14x1 in between insulating ring and the stud at the screwing points.

- Reassemble the contact plate.

3. APPLICATION TO CLASS OF LOCOMOTIVES

All classes of locos provided with No. 32 tap changers.


Special bolt (1221 ) of length 24 mm - 11 Nos.. machined washer zinc plated φ6.4 x φ14x1 - 11 Nos..

5. MATERIAL REQUIRED SURPLUS

Existing special bolt (1221) - 11 Nos..

6. REFERENCE

HBB Sketch No. TC - 118


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RDSO Drg. SK EL 3962


(1) All electric loco sheds and POH shops

(2) Incorporated by HBB from tap changer Sr. No. IB 41088024 onwards.

9. DISTRIBUTION


Encl : Drg. No. SK EL 3962 (S. S. Khurana)

Mailing list. for Director General/Elect.

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No. EL/3.2.30 Dated : 20.5.1991


Replacement of cast iron transition resistances (RGR) by stainless steel transition resistances in tap changer Type No. 32 of M/s HBB make.

1. OBJECT

1.1 Railways have reported a large number of cases of overheating / melting /burning of cast iron (CI) resistances (RGR). Investigations have revealed that these failures are primarily due to shorting of the grids as a result of vibrations encountered in service as well as deformation due to overheating. RDSO, vide Modification Sheet No. RDSO/WAM-4/152 have already implemented staggering of the grids to overcome the above. Though this modification has arrested the problem to a certain extent, it has not been possible to completely eliminate the same.

1.2 Service trials have been conducted on locomotives homed at Ghaziabad, Tatanagar and Kanpur Electric Loco Sheds using stainless steel (SS) RGR and no adverse reports have been received regarding their performance. Tests to evaluate the thermal capabilities of the stainless steel RGR vis-a-vis cast iron RGR under identical loading conditions were also carried out jointly by Ghaziabad Electric Loco Shed, RDSO and the Manufacturers. These have also been satisfactory.

1.3 M/s ABB/Switzerland and M/s GANZ/Hungary have already switched over to the use of stainless steel RGR grids in their tap changers.

1.4 It has therefore been decided to use stainless steel RGR in place of cast iron RGR.

1.5 The use of stainless steel RGR has definite advantages over the use of cast iron RGR as under :-

(a) High melting point as compared to cast iron grids;

(b) Improved mechanical strength to withstand vibrations and shock in service and also accidental mishandling;

(c) High alumina ceramic insulators and bushes used in stainless steel RGR in place of problematic mecanite tubes;

(d) Casting defects eliminated as stainless steel grids formed from sheets;

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(e) In case of tap changer sticking between notches, the stainless steel RGR grids open circuit, but do not melt and fall;

(f) Stainless RGR is light in weight.


Replace the existing CI RGR with stainless steel RGR.


All electric locomotives fitted with No. 32 tap changers.


4.1 Brief technical specification of the stainless steel RGR.

4.1.1 The grids used in the stainless steel RGR should be punched from prime quality cold rolled stainless steel sheets Grade AISI 304.

4.1.2 Chemical composition : Ni : 8 to 12 %

Cr. : 17 to 20 %

C : 0.08% Max.

Mn : 2.0% Max.

S : 0.03% Max.

P : 0.045% Max.

4.1.3 Electrical parameters . - Resistance : 1.61 + 10%

- Current rating : Continuous 77A. Temperature rise should be within 300 0C. Short time 165 A RMS. Three consecutive cycles each cycle of duration 12 sec. ON. 30 sec. OFF. Temperature rise should be within 140 0C.

- High Voltage withstand : 3 KV, 50 Hz. for 1 minute.

- between element and mounting rod

- between mounting rod and mounting

bracket.

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4.2 Construction

(1) The grids shall be punched from cold rolled SS sheet Grade AISI 304 at least 1.2 mm thick and maximum 230 mm. wide.

(2) The minimum intergrid spacing shall be 12 mm.

(3) The intergrid connection of each section shall be through spot welded SS links. The spot welding shall be done by a precision spot welding machine pneumatically operated and having a timer and electronic control.

(4) The total assembly of grids shall consist of 6 to 8 sections (with welded links). These sections shall be bolted to each other by using spring washer/check nut and the current shall flow through copper spacers.

(5) The intergrid connections shall be through two parallel paths.

(6) All hardwares used shall be of high tensile steel.

(7) The grid shall be sturdy and suitable stiffeners shall be provided.

(8) The grids shall be mounted on four ceramic insulating rods.

(9) The mounting rods and the grids shall be insulated by High Alumina/Steotite Interlocking Bushes.

(10) The secondary insulation between the mounting rod and the bracket shall be through round glazed porcelain insulators and Hylam Tube.

(11) The end terminals shall be of copper suitably connected with the end grids and supported on the mounting rods.

(12) Interchangeability shall be possible with existing CI grid resistor assembly without any modification.

(13) Overall general arrangement and broad details of SS grid RGR shall be as per RDSO SK EL 4031.

4.3 Manufacturer : M/s Lachhman Electronics, 11-B, Jaipur Estate, Nizamuddin East, New Delhi - 110 013. 5. MATERIAL RENDERED SURPLUS

Existing CI RGR.

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6. Reference :

(i) Item 3 ( Page 3 ) of the Minutes of the meeting held between Railways and M/s HBB in July, 1989 and circulated vide. RDSO letter No. EL/3.2.30 dated 28.8.1989.

(ii) Item 4 ( page 1 ) of the Minutes of the meeting held between M/s ABB Engineers and RDSO in March, 1990.

7. Modification Drawing Number :

RDSO SK EL 4031


- Electric Loco Sheds and POH shops for existing AC locomotives.

- CLW for AC locos under production.

- M/s ABB on new supply of tap changer.

9. Distribution :

As per mailing list attached.

(Arun Srivastava) for Director General/Elec.

Encl : Modification Drawing SK EL 4031

55162

No. EL/3.2.30 Dated : 03.4.1995

MODIFICATION SHEET NO. RDSO/WAM-4/187

PROVISION OF CANOPY ON SAFETY VALVES OF TAP CHANGER TYPE NO. 32 OF M/S ABB

1. OBJECT

Railways have reported maintenance problems on tap changers provided with ducting arrangement. In order to overcome the same it has been decided to provide canopy (cover) on safety valves of GR with Tray and drain pipe (for draining out the discharged oil) in place of the ducting. M/s ABB have already introduced this canopy arrangement on their build tap changers from S.No. IB40 492 392.


2.1 Procure two Nos.. of canopy as per RDSO Drg. No. SK EL 4339.

2.2 Remove the two holding bolts from one side of the base of the GR bushing.

2.3 Place the canopy on the safety valve to match its clamps holes with the holes of GR bushing from where the bolts have been removed.

2.4 Refix the removed bolts over the canopy clamps and tighten them.

2.5 Repeat 2.2 to 2.4 for fixing the canopy on the other side of the bushing.

2.6 Provide metalic pipe of dia 50 mm and length 500 mm in the centre of the existing tray ( as per RDSO modification No. WAM-4/24) on its back side below tap changer.

2.7 Where tray below GR has not been provided due to space limitations, provide metalic pipe of the above size below GR for drainage of discharged oil.


All ac and ac/dc locos fitted with No. 32 tap changers of ABB make.

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4. MATERIAL REQUIRED 4.1 Canopy as per Drg. RDSO SK EL 4339 4.2 Metallic pipe 50 mm dia. 500 mm length.

5. REFERENCE (i) ABB sketch No. TC - 201A. (ii) RDSO letter No. 3.2.30 dated 7.11.89. (iii) Para 2 of the page 2 of the minutes of the Coordination Meeting held

on 8.1.92. (iv) Para 2.1.2 of page 7 of Minutes of the Coordination Meeting held on

5/6th Aug. 93.


SK EL - 4339


All ac electric loco sheds and POH shops.

Encl : ( R.N. Lal ) Copy to :- for Director General (Elect.)

The Chief Electrical Engineers :

1. Central Railway, Bombay VT - 400 001

2. Western Railway, Churchgate, Bombay - 400 020

3. Southern Railway, Park Town, Madras - 600 003

4. Northern Railway, Baroda House, New Delhi - 110 001

5. Eastern Railway, Fairlie Place, Calcutta - 700 001

6. South Eastern Railway, Garden Reach, Calcutta - 43

7. South Central Railway, Secunderabad (A.P.)

8. Chittaranjan Locomotive Works, Chittaranjan, Dist. Burdwan (West Bengal)

9. Secretary (Electric Traction), Railway Board, New Delhi.

( R. N. Lal )

Encl : One for Director General (Elect.)

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No. EL/3.2.30 Dated : 4.6.1996

May 96

MODIFICATION SHEET NO. RDSO/WAM-4/192

PERMANENT CONNECTION OF 16TH TAPIN PLACE OF SPRING LOADED CONNECTION

1. OBJECT

Railways were facing difficulties in removing the roll pin from the gear box housing for changing the potential contact assembly in case of open circuit at 16th tap due to jamming of its compression spring. Investigation has shown that the above problem is only on tap changers manufactured upto March 1994 due to non projection of roll pin from the gear box housing.

It has been decided to use permanent connection between the 16th tap and gear box housing with copper flexible wire covered by an insulating sleeve on tap changers manufactured upto March 1994.

In tap changers manufactured after Mach 1994, M/s ABB used projected roll pin for facilitating changing of the potential contact.


The permanent connection is to be fitted between the 16th tap and gear box housing cover as per the following procedure (refer SK EL - 4373) :

- Remove the old contact stud and replace it with the new contact stud having threads for fixing the connection.

- Connect one end of the connection having the lug suitable for M5 screw (lug of Dowells 7114) with the contact stud using the M5 screw. Use one number each plain washer and spring washer to prevent loosening due to vibrations.

- Remove one M8 hex. screw (S-1457) of gear box housing cover (M8 screw which is nearest to the 16th tap).

- Fix the other end of the flexible connection having lug suitable for M8 screw (lug of Dowells 7020) with the same M8 screw. Lock the screw by a locking sheet (S-1452)

- Check the electrical continuity between the 16th tap and gear box housing.

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3. APPLICABLE

Locomotives fitted with tap changers (ABB make) manufactured upto March 1994


- Contact stud (inner) AG 416333 P3 1 No.

- Flexible connection SWT 435555 R1 1 No.

- Spring washer B5 Mt 430197 P608 1 No.

- Punched washer dia 5.5/10x1 Mt 430827 P2010 1 No.

- Hex. screw M5x10 Mt 430106 P2406 1 No.

5. MATERIAL SURPLUS

Contact stud (inner) - 1 No.

6. REFERENCE

M/s. ABB Drawing No.TC - 155


RDSO SK EL 4373


All electric Loco Sheds and POH shops

9. DISTRIBUTION


Encl. SK EL - 4373 (Arun Srivastava) Mailing list. for Director General (Elect.)

61162

Government of India

(Ministry of Railways) Research, Designs & Standards Organisation

Manak Nagar, Lucknow – 226 011 No. EL/3.2.30 Dated 25.10.1999

Modification Sheet No. ELRS/MS/0269

MODIFICATION IN THE AIR SUPPLY LINE TO ENSURE EFFECTIVE OPERATION OF THE OIL PUMP (PHGR) FITTED WITH THE OIL PUMP

DEVICE (OPD) IN THE ADTRANZ MAKE TAP CHANGER NO 32 1.0 OBJECT

1.1 It has been reported that the oil pump (PHGR) even when fitted with the oil pump device (OPD) in the Adtranz make tap changer type No. 32 has not been working. The reasons for not working of the PHGR have been identified as under :- • Air leakage from ‘T’ connection • Air leakage from Solenoid Valve • Choking of air pipe line

1.2 In order to insure effective operation of the oil pump in the tap changer,

it has been decided to (a) remove the ‘T’ connection from the air pipe line between EVPHGR

and inlet to PHGR. (b) follow specific pre-commissioning maintenance instructions for

EVPHGR, air pipe line, PHGR and oil pump device. 1.3 The modified air pipe line arrangement to be adopted is shown in

RDSO Drg. No. SKEL –4539

1.4 Follow specific pre-commissioning instructions for EVPHGR, air pipe line, PHGR and oil pump device as laid down in this modification sheet.

2.0 WORK TO BE CARRIED OUT (a) Removal of ‘T’ Joint

2.1 Remove ‘T’ joint in the air pipe line between EVPHGR and inlet to PHGR.

2.2 Instead provide a straight through joint at the location where ‘T’ joint

exists (Ref. Drg. No. SKEL-4539).

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(b) Pre-commissioning Maintenance 2.2 Overhaul EVPHGR and ensure its proper operation. Any dummy

washer, if provided on the inlet of EVPHGR/PHGR, should be removed.

2.3 Check the healthiness of the air pipe line of PHGR. Replace the pipe line if found cracked/choked. Replace all copper washers with new annealed copper washers.

2.4 Overhaul PHGR before fitment of OPD. Replace all ‘O’ rings, gaskets and micro filter element with new once.

2.5 Dismantling and assembling of the oil pump device must be carried out with the help of special tools to avoid bending of the pistion of OPD/oil pump device.

2.6 Ensure that the working air pressure is set at 3.5 kg/cm sq. at the pressure reducer in the ZSM panel.

3.0 APPLICATION

All 25 KV AC electric locomotives fitted with Adtranz make tap changer No.32.

4.0 MATERIAL REQUIRED

Straight through joint for replacement of the ‘T’ joint as per RDSO Drg. No. SKEL –4539.

5.0 MATERIAL RENDERED SURPLUS

One ‘T’ joint

6.0 AGENCY FOR IMPLEMENTATION CLW for future built locomotives All AC electric loco sheds/shops

7.0 DISTRIBUTION

As per enclosed list (Arun Srivastava)

Encl.: RDSO Drg. No. SKEL-4539 for Director General(Elect.)

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No. EL/3.2.30/DC-2 Dated : 25.5.1978

SPECIAL MAINTENANCE INSTRUCTIONSNO. RDSO/ELRS/SMI/17

1. Title :

Breakage of manual drive taper pin of tap changer type N-32 HBB make.

2. Application to class of locomotive :

All locos fitted with N-32 tap changers.

3. Object of special maintenance instructions :

A few cases have been reported by Railways in which the manual drive taper pin had broken while the driver tried to operate the tap changer manually. Investigations have revealed that such cases ocurred due to the driver trying to turn the manual drive handle without cutting off the air supply to SMGR. Under these conditions abnormal forces have to be applied to the manual handle drive.

4. Instructions :

4.1 The tap changer has an inbuilt feature that the manual drive handle can only be taken out after cutting off the air supply. However, in some cases due to the theft of handles, this arrangement has probably been bypassed and the handles kept in the personal custody of drivers. This practice is to be discouraged.

4.2 In case, removal of handle is inevitable, the drivers should be instructed to first cut off air supply and only then to operate the handle.


All electric locomotive sheds.

6. Distribution :


Encl. One list

(Ramesh Chandra)


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No. EL/3.2.30/DC-2 Dated : May, 1978

SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI/18

1. Title :

Malfunctioning of modified control lever (Part NO. 45) of the tap changer N-32 HBB make.

2. Application to class of locomotive :


3. Object of special maintenance instructions :

A few cases have been reported by Railways in which the modified control lever was provided only with bolt 3 and the spring dowell 2 was missing (refer RDSO Sketch No. SK EL 2812 attached). This resulted in relative movement of parts A & B resulting in failure of tap changer. It is proposed to check the provision of spring dowell and to provide it if found missing.

4. Instruction Drawing :

RDSO SK EL -2812

5. Instructions

The modified control levers are supplied by M/s HBB with tap changers IB 003225 onwards. On these tap changers, check whether spring dowell 2 is provided. In case it is found missing, drill a hole and fit the spring dowell which maybe obtained from M/s Hindustan Brown Boveri, Post Box No. 124, Maneja, Baroda - 391 710. Results of the survey should be advised to RDSO.

Reference : BBC maintenance manual AM 91001 E.


All electric locomotive sheds for locos in service. CLW for locos under production.

7. Distribution - As per list attached.

Encl. 1. One drawing RDSO SK EL 2812 (Ramesh Chandra) 2. One list.. for Director General (Elect)

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No. EL/3.2.30/DC-2 Dated : 25.5.1978

SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI-20

1. Title

Sluggish operation of SMGR of N-32 tap changer HBB make.

2. Application to class of locomotive


3. Object of special maintenance instructions

Railways have reported a few cases of sluggish operation of SMGR of N-32 tap changer. Investigations have revealed that it is due to the poor quality of 'U' section rings (Part No. 2303) which perish in a short time. It is proposed to introduce additional check on the tap changer for an indication of the condition of rings and replace these by good quality ones, if required.

4. Instructions

Check the quick progression and regression time of tap changer in trip examination and monthly schedules. The time should be recorded. If the time is more than 13 seconds, examine the condition of 'U' rings. Clean cylinder and connecting rod with piston and relubricate with BBC 909 : LM 2g (shell). Renew damaged U-section rings (part No. 2303). Use only imported 'U' section rings obtained through M/s Hindustan Brown Boveri, Post Box No. 124, Maneja, 391 710, Baroda, till such time suitable indigenous sources are located.

Reference : BBC maintenance manual AM 91001E for N-32 tap changer.


All electric locomotive sheds.

6. Distribution : As per list attached.

Encl : One list.

(Ramesh Chandra)


68162



No. EL/3.2.30/DC-2 Dated : 14.6.1978


1. Title

Breakage of support block of auxiliary switch (BBC type) at the fixing point in N 32 tap changers, HBB make, and Master controllers, CLW make.

2. Application to class of locomotives

All locos fitted with No 32 tap changers and CLW make master controllers.


Railways have reported a few cases of locomotive failures due to the breakage of the support block of auxiliary switch (BBC type). The cracks which appear before breaking are shown in red in the enclosed drawing SKEL 2886. To avoid failures on this account it is proposed to make a cyclic check on the switches and to replace those with cracks before a failure takes place.


RDSO SK EL 2886

4. Instructions

During every monthly schedule open the cover of tap changer/master controller and examine the switches for cracks at the location shown in enclosed sketch. The switches with cracks should be replaced by new ones. A report of the number of such cases with details, such as loco No., date of commissioning and made of switches should be sent to RDSO after two months, together with all defective switch bodies.


All electric loco sheds.

6. Distribution As per list attached.

Encl. One drawing RDSO/SK EL/2886 and one list (Ramesh Chandra)


70162



No. EL/3.2.30/DC-2 Dated : 14.6.1978


1. Title

Sticking of tap changer type N-32 HBB make in between notches.


All locos fitted with N 32 tap changers.


A few cases have been reported by Railways in which the tap changers got stuck between notches due to the mal-operation of control block. Investigations have revealed that it was due to the disturbances of armature and core setting of the control block resulting in higher pick up voltages. It is proposed to prevent such failures by periodical checking and adjustment of these settings.

4. Instruction drawing RDSO SK EL 2894.

5. Instructions

During every AOH, IOH, and POH, check and adjust the pick up voltage of control block both regression and progression units to 45V. The procedure for adjustment is described in the enclosed Instruction Sheet RDSO/SK EL/2894, extracted from BBC Maintenance Manual for N 32 tap changer AM 91001E. Make a few operations of the unit at 45V.


All electric loco sheds and shops.

7. Distribution


Encl. : One RDSO SK EL 2894 and one list.

(Ramesh Chandra)


72162



No. EL/3.2.30/E/C1 Dated : 9.6.1978 SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI/24 1. Title :

Looking of contact screws of moving contact carrier assembly - ZSMGR switch (N 32 tap changer)

2. Application :

WAM 4 locomotives

(Applicable in principle to all classes of locos at similar locations)

3. Object : A number of cases of cracking/breaking of ZSMGR moving contact carrier

have been reported by Railways, on WAM 4 locomotives. Investigations have been shown that the contact fixing screws (item 1) some times become loose due to vibrations. If the knob (item 7) is pressed under such conditions, the screw heads (item 1) touch the fixed contact carrier plate (item 2) causing excessive stress on the moving contact carrier (item 5) and the fixed contact plate. This results in breakage of the moving contact carrier assembly around the section XX which is the weakest portion. 4. Reference Drawing :

RDSO SK EL 2736

5. Details of special instructions : Tighten the moving contact screws (item 1) and ensure that a minimum

visible clearance of 2 mm is available between the head of the screw and the fixed contact carrier plate (item 2) when the knob is fully pressed. (Ref. position 2)

Lock the screws in position with drops of araldite loctite. If the clearance is inadequate, the required clearance may be obtained by

adding washers at 'A'. 6. Material Required:

Araldite/loctite - Quantity sufficient.

7. Periodicity of implementation :

As early as possible.

8. Agency for implementation : POH workshops Maintenance sheds. Sd/-

S.S. Malaviya for Director General (Elec)

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No. EL/3.2.30/DC2 Dated : 27.3.1979

SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI/46 1. Title :

Sticking of control lever guide pin of tap changer type N 32 HBB make. 2. Application to class of locomotives :

All locos fitted with N 32 tap changers. 3. Object of special maintenance instructions :

A few cases have been reported by Railways in which the control lever guide pin (1) (Ref. SK EL 2812) had stuck up due to gear lubricating grease entering the guide pin bearing and restricting its free movement. Investigations have revealed that this happened due to use of excessive and thicker grade grease. Carry out proper lubrication of these components according to the instructions given below.

4. Instruction Drawing : RDSO SK EL 2812

5. Instructions : Examine the control lever guide pin, if traces of grease are observed on its surface, clean the guide pin and its bearing with petrol thoroughly, till entire grease is removed. Check for free movement of guide pin by hand. When dry, apply two drops of graphite oil LM 2g : BBC 909. Wipe the grease from the notches of the corresponding gear. Apply a thin layer of grease Shell Alvania EP2 or lithium EP2 or Beacon EP2 or Servogem 2 on the contact of the gear notches. Do not fill the notches will grease. Remove excess grease.

6. Periodicity of implementation : a) During AOH b) Earlier in case of plunger sticking up is observed.

7. Agency of implementation : Railways : Locos in service. CLW : For locos under manufacture.

8. Distribution : As per list enclosed.

Encl. 1. RDSO SK EL 2812 2. Distribution list.

(Ramesh Chandra)


76162



Ref. EL/3.2.30/DC2 Dated : 11.4.1979 SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI/47

1. Title

Malfunctioning of reducing valve of SMGR of tap changer type N32 HBB make.


All locos fitted with N32 tap changers.


A few cases have been reported by Railways in which the reducing valve of SMGR functioned erratically. Investigations have revealed that it is due to wrong fitment of the diaphragm of the reducing valve. The proper fitment of diaphragm is to be ensured in accordance with the instruction given below :

4. Instruction drawing

RDSO SK EL 2964.

5. Instruction

Whenever the reducing valve is opened for erratic operation or during overhaul, ensure that the diaphragm is in good condition. While re-assembly ensure that the diaphragm is fitted in the manner indicated in the enclosed sketch 2964. The projected surface on the periphery (1) (SK EL 2964 attached) should face downwards with main body of reducing valve in the normal mounting condition and should fit in the corresponding groove of the metal seat.

That the reducing valve after assembly and adjust the setting to 3.5 kg/cm2 for input air pressure of 8 kg/cm2.


Railways - for locos in service.

7. Distribution

As per list enclosed. Encl : 1. RDSO SK EL 2964.

2. Distribution list.

(Ramesh Chandra)

for Director General/Elec

78162



No. EL/3.2.30/DC2 Dated : 28.3.1979


1. Title

Adjustment of lead angle of control cylinder of tap changer type N32 HBB make.


All locos fitted with N 32 tap changers.


It has been reported by some sheds that they adjust the sector lever movement (lead angle of control cylinder) in case SMGR is found to have sluggish operation. Normally this adjustment is not to be disturbed. SMGR stuck up/sluggish operation is due to any of the following reasons :

(i) 'U" section ring perished (Ref. RDSO/ELRS/SMI/20)

(ii) Incorrect setting of control block (Ref. RDSO/ELRS/SMI/22)

(iii) Strainer in pneumatic circuit ineffective (Ref. RDSO/ELRS/SMI/10)

(iv) Control lever guide pin jammed (Ref. RDSO/ELRS/SMI/46)

In cases where lead angle of control cylinder has already been distunned, follow the procedure as given below to report at the same.

4. Instruction drawing

RDSO SK EL 3070

5. Instructions

The setting of the sector lever movement (lead angle of control cylinder) should not be disturbed even during the overhaul of tap changer. For dismantling the control cylinder for overhaul, remove hollow bolts 4425 and air lines 4427 and 4428. Unscrew nuts 4418 at screwed pin 4416. By doing this, attention can be given to piston, cylinder etc. ON NO ACCOUNT UNSCREW NUTS 4413 AND 4415, OTHERWISE PISTION STROKE HAS TO BE RESET AFTER REASSEMBLY.

79162

In case, if the piston stroke has already been disturbed, due to any reason, the following procedure should be adopted for readjustment.

Stop air supply and release the valve plungers. Give 'notching up' signal and with the signal still persisting, read the can shaft rotating with the help of can plate 6202. Adjust it to 750 with the help of setting screw 4406 in the front. Similarly with the 'notching down' signal adjust to 750 on the other side, with the help of setting screw 4406. on the back. After this adjustment is over, check once again for 750 lead in both directions. Secure setting screws (4406) by fixing pins (4407) on both sides.


Railways - on locos in service

7. Reference

i) BBC Instruction Manual AM 91001E para 7.3.5, page 61

ii) HBB SWT 5013.

8. Distribution

As per list enclosed Encl : 1. RDSO SK EL 3070 2. Distribution list

(RAMESH CHANDRA)

for Director General (Elec).

81162



No. EL/3.2.30/DC-2 Dated : 26.3.1979


1. Title

Lubricants to be used for tap changers type N32 HBB make.


All locos fitted with N32 tap changers.


A few cases have been reported by Railways in which the equipment failed due to improper lubricant being used. The proper lubricants for the various components of tap changer are given below.

4. Instruction Drawing Nil

5. Instructions

Use strictly the following lubricants :-

i) For lubrication of air motor Shell Alvania EP2 or piston buckets and control Lithium EP2 or Beacon EP2 or cylinder Servogem2. ii) For lubrication of all gears As above

iii) For lubrication of control Graphite oil EM2g - BBC 909 lever guide pin

iv) For lubrication of cam points As above including auxiliary switch roller axles


Railways - on Locos in service

7. Distribution

As per list enclosed. Encl : Distribution list

(Ramesh Chandra)

for Director General/Elect.

82162



No. EL/3.2.30/DC2 Dated : 30.3.1979 SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI/50

1. Title

Testing of contact pressure of CGRI, II and III of tap changer type N32 HBB make.


All Locos fitted with N32 tap changers.


A few cases have been reported by Railways in which flashing of main contacts of tap changers had ocurred. Investigations have revealed that in most cases this happened due to worn out contact pieces/inadequate contact pressure of CGR contacts. The wear limits of the contacts pieces and the procedure of measuring the contact pressure are given below.

4. Instruction Drawing

RDSO SK EL 3075

5. Instructions

i) Wear limit of contact pieces --

Measure the dimension 'a' (Refer SK EL 3075 enclosed) with a vernier callipers. The values of 'a' for new and worn out contact pieces are given below :

New contact pieces - 46 mm Warn out contact pieces - 36 mm Do not permit contact pieces, worn out beyond 36 mm in service.

Replace such contact pieces by new ones in pairs, i.e. replace both top and bottom contact pieces together. Fit new contact pieces by allen screws (2335), in the contact 'closed' position. Replace washers also at the time of changing the contact pieces.

ii) Testing of contact pressure

The contact pressure P1 (refer SK EL 3075) for healthy unit is as follows --

Old design : 13.4 kgs + 15% New design : 7.8 kgs + 15%

To measure the contact pressure, insert a hexagonal bar with a good fit the into the hexagonal socket of the securing screw (2335) . Attach a spring balance of suitable

83162

renage in the manner shown in SK EL 3075 enclosed. Pull the hook of the spring balance till the contact pieces just part and record the value P2, for the cam position shown . Ensure that the pull P2 is extended at 900 to the bar. The contact pressure P1 will be -

P1 = (L1+L2)/L1 x P2 where L1 = 160 mm

for simplicity, choose a bar such that L2 is 160 mm. The P1 = 2 P2, and the contact pressure can be obtained by directly multiplying the reading of spring balance by 2.

In case the pressure is found less than these limits, replace the contact springs by new ones obtainable from M/s Hindustan Brown Boveri, P.O. No. 124, Maneja, Badodra (Gujrat) - 391 710.

Note : The new design can be identified from old design by looking at the contact system of CGR. In the new design flexible copper connections are provided between the movable arm (part No. 2306) of the contact system to the fixed arm (part No. 2302). In the old design, the flexible copper connections do not exist.


a) During AOH

b) Earlier in case flashing of contacts is observed.


Railways - on Locos in service

8. Reference :

HBB SWT 5007

9. Distribution :

As per list enclosed. Encl : 1. RDSO SK EL 3075 2. Distribution List

(Ramesh Chandra)


85162



No. EL/3.2.30/DC2 Dated : 5.2.1980


TIGHTENING OF ELECTRICAL CONNECTIONS BETWEEN GR, CGR, RGR OF TAP CHANGER TYPE N32 HBB MAKE.

1. Object

1.1 A few cases of flashing of main contacts of tap changer have been reported by Railways. Investigation has shown that this was caused by the loosening in service or breakage of the electrical connections between CG-CGR-RGR either due to vibration or to inadequate fitting/tightening initially.

1.2 It is necessary initially to tighten all the electrical connections and mounting screws fully, to use correct locking devices and there after to check periodically that the connections are remaining tight.

1.3 Vibration causes not only loosening but also fatigue cracks and breakage of connections. It is impossible, in practice, to detect such cracks in time to prevent failures. Therefore, it is very important to minimise vibration. This can be done by implementation of Modification Sheet No. RDSO/WAM4/52 dated 29.8.77

2. Instructions

2.1 Tighten fully the following electrical connection. Ensure the presence and effectiveness of spring washer also.

i) Terminals (all the four bolts) on GR bushing connected to CGR I & III (item I of SK EL 3227)

ii) Terminals on CGR I & III connected to GR bushing (item 2).

iii) Terminals on CGR II & III connected to RGR (item 3).

iv) Terminals on RGR connected to CGR II & III (item 4)

v) Terminal on CGR connected to transformer (item 5)

Remove the arc chutes of CGR i, II & III. Tighten fully the following allen screws. Ensure the presence and effectiveness of spring washer also.

i) All the six allen screws for fixing the main contacts of CGR I, II & III (item 7)

ii) All the six allen screws for mounting the CGR I, II & III (item 6)

86162

2.2 Implement Modification Sheet No. RDSO/WAM4/52 of 29.8.77 on priority.


RDSO SK EL 3227


All locos fitted with N32 tap changer of HBB make


Railways on existing locomotives.

6. Periodicity of implementation

6.1 One cycle to be completed on all locos.

6.2 Subsequently during the next IC inspection.

6.3 If no loosening is noticed during 6.2, then during every AOH.

7. Distribution


Encl: 1 Drg SK EL 3227

(Ramesh Chandra)

for Director General/Elec.

88162



Ref. EL/3.2.30/DC2 Dated : 25.7.1980 SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI/63

FLASHING OF TAP CHANGER TYPE N-32 HBB MAKE 1. Object

Railways have reported a few cases of flashing of the main oil immersed contacts of the tap changer type N32. These contacts normally operate on on-load and the most common cause of flashing is a break in the circuit of the load switches CGR 1-3. Investigations have shown that such failures are due to any of the following reasons -- i) Loose connections due to heavy vibration on CGR-RGR assembly. ii) Loose connections/open circuit between GR-CGR-RGR. iii) Inadequate contact pressure of CGR main contacts. iv) Insufficient oil in GR chamber. It is necessary periodically to check the tap changers for the above abnormalities and take corrective action as given below.

2. Instructions i) Carry out modification No. RDSO/WAM4/52 alongwith SK EL 2650

to reduce failures due to vibration. ii) Carry out instructions according to Special Maintenance Instructions

No. RDSO/ELRS/SMI/62 alongwith SK EL 3227 to ensure proper electrical connections between GR-CGR-RGR.

iii) Ensure proper contact pressure of CGR main contacts according to the Special Maintenance Instructions No. RDSO/ELRS/SMI/50 alongwith SK EL 3075.

iv) Check oil level of the GR chamber through the oil level indicator. Replenish if necessary.

3. Instruction Drawing Nil 4. Application to class of locomotives

All locos fitted with N-32 tap changers. 5. Agency of implementation

Railway sheds for existing locomotives fitted with N-32 tap changers. 6. Periodicity of implementation :

For item (ii) - IC For item (iii) - AOH For item (iv) - Monthly

Government of India

89162

Ministry of Railways Research, Designs & Standards Organisation

Manak Nagar, Lucknow - 226 011 No. EL/3.2.30/JCG Dated : 12.6.1981 SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI/80

Lubricants to be used for Tap changer Type No. 32 -- M/s HBB make

1. Object : 1.1 Investigations have shown that a few cases of malfunctioning of tap changer reported by Railways were due to use of improper lubricants. 1.2 It is proposed to standardise the lubricants based on the recommendation of Tap Changer Manufacturer for the various locations of tap changer. 1.3 Use and correct lubricants is essential for ensuring reliability. 2. Instructions :

Use the lubricants at the various locations of the tap changer is indicated below : Sl. No.

Location/part to be lubricated

Method of application

Lubricant Source of

Supply i) Contact level pivots

of switching elements cgr 1, 2 & 3 (Pt. 2303/2528)

With a grease gun through grease nipples

Bharat MP2 Grease

BPC

ii) Bearing bore of spring bolt in spring guide assembly (Pt. 2538, 2537)

-- Oil special2 (earlier named as BBC oil 909)

HBB

iii) Cylinder of air motor and piston (Pt. 1201, 2305)

Grease with a brush from below with piston in the upper position

Bharat MP2 grease

BPC

iv) Periphery of notching disc on crank shaft (Pt. 2201, 2101)

With greased brush

-do- -do-

v) Spur and bevel gears -do- -do- -do- vi) Cylinder and piston

(Pt. 4401, 4403) Dismantle and lubricate with greased brush

-do- -do-

Sl. Location/part to be Method of Lubricant Source

90162

No. lubricated application of Supply

vii) Bushing of connecting rod at the locations indicated by red arrows in the equipment (Pt. 2309)

Without dismantling connecting rods

Oil special 2 HBB

viii) Guide sectors and intermediate wheel (Pt. 6103)

Light oil guide parts

-do- -do-

ix) Bearing groove of control disc (Pt. 5401)

-do- -do- -do-

x) Aux. cam switch (Pt. 5514)

Apply one drop of oil on activating roller and contact lever shaft

Bharat Hydrol 27

BPC

xi) Guide pin of control lever assembly (Pt. 4521)

-do-

-do-

-do-

xii) Bearing bolt (Pt. 5301)

Through lubricating holes of link (5303)

Oil special 2

HBB

xiii) Periphery of cam plate (Pt. 5105)

With greased brush

Bharat MP Grease 2

BPC

xiv) Bearing area of push rod where pin is seated (Pt. 5309, 5306)

Lightly oil

Oil Special 2 HBB

xv) Selector switch housing

-

Transformer oil

IOC

* In case of non-availability of Bharat MP Grease 2, the equivalents are -- (1) Servogem 2(loc) & (2) Lithon 2 ( HPC)

--------------------------------------------------------------------------------------------

3. Instruction Drawing : Nil

91162

4. Application :

All electric locomotives fitted with No 32 tap changer of M/s HBB


All Electric Loco sheds and POH workshops


S. Nos.. (i) to (v) and (vii) to (xiv) during AOH; (vi) will be during IC for indigenous U section rings.

S.No. (xv) : First time after 10,000 km after commissioning and subsequently during every AOH.

7. Distribution :

As per the attached list.

Encl. List (H.B. Singh)


Distribution List (2 copies):-

1. The Secretary (Electric Traction), Railway Board, Rail Bhawan, New Delhi-110001.

Chief Electrical Engineers --

2. Central Railway, Bombay VT- 400 001 (Maharashtra)

3 Eastern Railway, Fairlie Place, Calcutta - 700 001 (W.Bengal)

4. Northern Railway, Baroda House, New Delhi - 110 001

5. Southern Railway, Park Town, Madras - 600 003 (Tamil Nadu)

6. S.C. Railway, Rail Nilayam, Secunderabad - 500 025 (A.P.)

7. S.E. Railway, Garden Reach, Calcutta - 700 043 (W.Bengal)

8. Western Railway, Churchgate, Bombay - 400 020 (Maharashtra)

9. C.L.W., Chittaranjan, Dist. Burdwan - 713 331 (W. Bengal)

Deputy Chief Electrical Engineers ---

92162

10. Eastern Railway, Kanchrapara Shops, Kancharapara, 743 145 (W.Bengal)

11. Central Railway, Elect. Loco POH shops, Bhusaval - 425 210 (Maharashtra)

12. Dy. CEE (Inspection), C.L.W., Chittaranjan, Dist. Burdwan, West Bengal - 713 331

13. Dy. C.E.E. (Dev), C.L.W., Chittaranjan, Dist. Burdwan - 713 331 (W.Bengal)

14. Dy. C.E.E. (TRS), S.E.Rly. Tatanagar - 831 002 (Bihar)

15. Dy.C.E.E. (Works), S.E. Rly. Tatanagar - 831 002 (Bihar)

Sr. Divl. Elec. Engineers (TRS) ---

16. Electric Locoshed, Eastern Rly. Moghalsarai - 232 101 (U.P.)

17. Electric Locoshed, Eastern Rly. , Asansol 713 201 (W.Bengal)

18. Elec. Locoshed, N. Rly. , Kanpur 208 001 (U.P.)

19. Elec. Locoshed, S.E.Rly. Tatangar 831 002 (Bihar)

20. Elec. Locoshed, S.E.Rly., Bhilai 490 001 (M.P.)

Sr. Divl. Electrical Engineer (TRS), Electric Loco Sheds ---

21. Central Railway, Kalyan, Bombay 421 301 (Maharashtra)

22. Central Railway, Bhusaval 425 201 (Maharashtra)

23. Northern Railway, Ghaziabad 201 001 (U.P.)

24. Western Railway, Vadodra 390 002 (Gujrat)

25. S.E. Railway, Waltair 530 001

26. S.C.Railway, Vijayawada 520 001

27. Sr. Divl. Elec. Engineer, Traction Moto Shop, Fazalganj, Kanpur 208 001 (U.P.)

28. JDIE/CLW, Chittaranjan, West Bengal 713 331.

93162



REf. EL/3.2.30/DSE 7-7-1981

SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI/82 ROLLER CONTACT FORCE IN TAP CHANGER NO. 32

1. Object :

1.1 The roller contact force in tap changer type N 32 has to be within the limits 12.4 kg + 1.9 kg at each end of the roller. In any electrical contact the normal force between contacts is vital. It is more so in a system which operates in insulating oil.

1.2 Investigations of tap changer failures has shown that in some roller assemblies the four springs, which provide the roller contact force, are weak. This is being taken up with the manufacturer, M/s Hindustan Brown Boveri, Baroda.

1.3 In the meanwhile, Sheds and Shops take action as follows.

2. Instructions :

2.1 Dismantle the roller contact assembly.

2.2 Apply a load of 6.2 kg on the spring, as shown in enclosed sketch No. SK EL 3400.

2.3 If the spring height under this load of 6.2 kg is less than 15.3 mm replace the spring. New springs should be obtained from M/s Hindustan Brown Boveri.

3. Periodicity :

3.1 On all tap changers Phase III indigenisation as early as possible.

3.2 On all tap changers undergoing overhaul.


5. Application of class of locomotive :

All locomotives provided with NO32 tap changer

6. Agency for implementation : All Electric Loco Sheds and Repair Shops of the Railways.

7. Distribution : As per list attached. Encl. SK EL 3400 Distribution list Sd/-(A. A. Hattangadi) for Director General (Elect)

95162



No. EL/3.2.30/JCG Dated : 29.3.1982

SPECIAL MAINTENANCE INSTRUCITONS N0. RDSO/ELRS/SMI/88

Oil leakage through 3-way cock of tap changer No. 32 HBB make 1. Object :

Railways have reported many cases of oil leakages through existing 3-way cocks (part No. 1312). M/s HBB then provided Ball type 3-way valve on few tap changers. Railways faced difficulty in draining out the oil as the time taken was very high due to smaller dia hole of the 3-way valve. Now M/s HBB are providing ball type 3-way valve of larger dia hole i.e. 8.5 mm. Railways are requested to report the performance.

2. Instructions :

Assembly procedure

2.1 Assemble valve seat 1 & valve seat 2 in Body 13 & Nipple 14.

2.2 Insert ball 18 inside the Body 13 of valve and position it with dia 8.5 rod as shown in sectional elevation view. This is to ensure that opening of Ball 18 matches with the opening of Ball-13.

2.3 Assemble the valve seat 7 & 8 Nipple 11 & 12. Place seating gaskets 6 & 5 in position. Screw in Nipple 11 & 12 till they just touch the Ball 18. Screw in or out Nipple 11 or 12 with their end touching the Ball-18, till the ball is centrally placed. In this condition the gap between Nipple 11 and Body -13 will be equal to gap between Nipple 12 and Body 13.

2.4 Place gasket 3 in position Screw in Nipple-14. After tightening slightly, place gasket 9 in position. Insert stem-19 with sealing gasket 10 and Nut 15 into the Body 13 to take its location in the Ball 18. (To put the gasket 10 Nut 15 is position Cap 17 to be removed and than to be fitted.) Then remove the positioning rod. Fully tighten the nipple -14.

2.5 Screw in Nipple 11 & 12 little by little alternatively till they are fully tightened against Body-13

2.6 Tighten Nut 15 fully to hold the stem 19 in position.

2.7 Place sealing gasket 4 in position and screw in Nipple 16 fully.

2.8 Rotate stem 19 by 90o to and fro 3-4 times. The valve is now ready for use.

2.9 Ascertain oil leakage proofness before using the valve.

96162

Reference : 1. Para 2.2.2(ii) of the minutes of the meeting held between RDSO, HBB & CLW in Feb. and minutes circulated vide RDSO letter No. EL/3.2.30/JCG dated 9/15-2-82.

2. HBB's instruction SWT/5088

3. Modified arrangement provided by M/s HBB from tap changer No. 30381170 onwards.

3. Periodicity 3.1 During AOH

3.2 Earlier, in case of leakage is observed through 3=way valve.


RDSO SK EL 3458

5. Application of class of locomotives

Locomotives fitted with No. 32 tap changer having Ball type 3 way valve.


All electric loco sheds and repair shops of Railways.

7. Distribution :


Encl : SK EL 3458 Mailing list.

(K. Vishakumar) for Director General/Elec.

98162



No. EL/3.2.30/CG Dated : 15.9.1982


TIGHTENING OF ELECTRICAL CONNECTIONS OF LOAD SWITCH CGR (Tap changer No. 32)

1. Object : Railways have reported a few cases of loosening of electrical connections provided on load switch resulting in the flashing of the oil immersed contacts of HBB tap changer No. 32. Investigation has shown that Railways/HBB/CLW are using different types of main washers and different practices of placing the workers on load switch frame. These cases of failures are due to any of the following reasons :

i) Loose connections due to different type of washer used.

ii) Loose connections due to different practices adopted in putting the washers.

iii) Loose connections due to heavy vibrations.

2. Instructions :

(i) Ensure the presence and effectiveness of

- 2 Nos. of belleville spring washers (Bronze) at locations 2153 and 2 Nos. belleville spring washers at locations 2155 on each of the top connections of load switch I, II & III as shown in Fig. 1 and Fig. 2.

- 1 No. belleville spring washer at locations 2155 on each of the bottom Connection of load switch I II and III as shown in Fig. 3,4 and 5.

- 1 No. belleville spring washer and 1 no punched washer is provided for each connection from CGR to selector as per Fig. 6 of SK EL 3453.

- All other washers at locations indicated in enclosed sketch.

- Ensure that all the bolts are properly tightened.

ii) Ensure that the correct practice of putting the belleville spring washer is adopted.

iii) Vibrations can be minimised by implementation of modification sheet No. RDSO/WAM4/52 dated 29.8.1977.

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3. Reference :

i) Para 8.6.1 of minutes of meeting held between Railways and HBB in August, 1981 and circulated vide this office letter of even number dated 3.10.1981.

ii) HBB's Drawing No. TC83.


RDSO SK EL 3453

5. Application :

All electric locomotives fitted with No. 32 tap changers of M/s HBB


All electric loco sheds, POH workshops and CLW. HBB have already implemented this practice from tap changer No. 30981200 onwards.


CLW - Assembly stage

Sheds - POH/IOH

Workshops - POH

8. Distribution :


(K. Vishwakumar) Encl: 1. Drawing SK EL 3453 for Director General (Elec.) 2. Mailing list.

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101162

No. EL/3.2.30/JCG Dated : 29.10.82

SPECIAL MAINTENANCE INSTRUCITONS NO. RDSO/ELRS/SMI/101

Method for confirming that the pin is nitrided and procedure for replacement of journal pin (Pt. no 4518) tap changer No. 32 type of

HBB make.

1. Object :

Railways have reported a few cases of breakage of journal pin (pt. No. 4518) on stage III tap changers. Investigation has shown that this was due to the un-nitrided pins used on some of the stage III tap changers by mistake at HBB works during assembly.

2. Instructions :

2.1 Method to confirm that the existing pins are nitrided :-

The scratch pen (already distributed by HBB to Rlys) to be rubbed against the ground surface of all existing pins (part No. 4518) as shown in SK EL 3523. In the case of assembled journal pins the rubbing can be done beyond the circlip groove portion.

Result:- The pen should not make any scratch mark on the ground surface.

2.2 If it makes a scratch mark, the Bearing complete (Pt. No. 4518) with journal pin to be replaced as follows --

- Remove the Fly Wheel.

- Take out the lever complete 4501

- Remove the broken journal pin alongwith its block (4518)

- Assemble the new bearing block with its journal pin (4518) in position with the help of roll pins and bolts.

- Slide the lever complete on to the journal pin to seat in position. At this point the following conditions are to be fulfilled.

- The teeth of toothed segment (4502) meshes smoothly with teeth of planet ring with pinion (5209) without any load and also without any excessive play.

- If it is observed that the toothed segment in planet ring with pinion meshes with interference or having excessive play, the following procedure is to be adopted to overcome this problem.

(a) Remove the two fixing roll pins on the toothed segment.

(b) Remove the screw (4503) after dismantling nut locked with pin (4504).

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(c) Use new screw (4503) and hold the toothed segment in position after slightly tightening the nut. Adjust the toothed segment such that its teeth smoothly match with pinion. Under this condition tighten the nut firmly. Locate and secure the toothed segment firmly in position after drilling two holes of φ4 similar to the one existed in the opposite direction, and by assembling the two roll pins. Then the nut 4504 to be locked with φ 2 through hole in nut and screw.

- Appropriate No. of shims are to be provided on the journal pin to maintain 0.4 to 0.7mm gap between guide pin 4521 and intermediate wheel 6103 and the gap between circlip 4514 and lever is bridged with additional shims.

- Check the minimum lead angle on either side of segment of intermediate wheel 6103 is within 63 + 50

- Put the fly wheel and maintain the minimum gap 0.7 mm between toothed segment and fly wheel back face through out its notching up and notching down operation.

- Check and ensure that the fly wheel is fitted back as per the condition given above.

- Adjust the lead angle to 75 + 40 - Finally check the operation of the air motor.

Reference : 1. Item 2.1.3 of the minutes of the meeting held between Rlys. and HBB in June-July 1982 and minutes circulated vide RDSO letter No. EL/3.2.30/CG dated 29.7.82.

2. HBB's instruction TC-92 and SWT-5089

3. BBC's instruction AM91001E.

3. Periodicity :

- During periodical maintenance - A cyclic check to be given on all tap changer in service.

- Earlier in case of breakage of pin


5. Application of class of locomotives :

Locomotives fitted with No. 32 tap changer


All electric loco sheds and repair shops of Railways. 7. Distribution : As per list attached.

Encl: SK EL 3423. (K. Vishwakumar) for Director General/Elect.

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No. EL/3.2.30/CG Dated : 8.4.1983 SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI/105 LUBRICATION TO THE GROOVE OF PISTON SKIRT (2304) OF TAP

CHANGER TYPE N0. 32 HBB MAKE 1. OBJECT

Railways have reported a few cases of cylinder walls of servomotors becoming dry resulting in malfunctioning of tap changers. Investigation has shown that in every 'to' and 'fro' stroke of the piston assembly, grease gets scraped and is collected at the two extremities of the cylinder thereby resulting in the dryness of the cylinder walls of the servo motor (Pt. No. 12). It is therefore decided to lubricate the piston skirt (Pt. No. 2304) also with Bharat MP2 grease.

2. Instructions

Apply Bharat MP2 grease in the groove of the piston skirt (pt. No. 2304) also during the lubrication to the servomotor. Total quantity of grease to be applied is 77.5 cc (40 gms) for all the four cylinders put together.

Reference : i) CLW letter No. ELDD/3252(A)/GK dated 1.11.81. ii) Para 6 of Record Note of discussions held between HBB, CLW

and RDSO at Lucknow in February 1982 circulated vide this office letter of even No. dated 15.2.82.

iii) HBB letter No. PWSAS/S 43/5/TAP/DAJ dt. 16.3.83. 3. Periodicity

- During AOH/IOH/POH - During assembly at HBB works.


RDSO SK EL 3510 5. Application of class of locomotives

Locomotives fitted with No. 32 tap changers. 6. Agency of implementation

- All electric loco sheds and repair shops of railways. - HBB during assembly.

7. Distribution As per list attached.

Encl : SK EL 3510 Mailing list. (K. Vishwakumar)


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No. EL/3.2.30/CG Dated : 10.6.1983


Cleaning of the selector after 10,000 km run of tap changer No. 32 HBB make

1. Object

Railways have reported a few cases of flashing of contacts of tap changer selector assembly. In some cases, railways also reported unusual/excessive copper deposits in the tap changer selector. Investigations have shown that such failures are due to excessive copper deposits in addition to the reason indicated in RDSO/ELRS/SMI/63 and 82 dt. 25.7.80 and 7.7.81 respectively. The copper deposits during the first 10,000 km run, are required to be checked to overcome flashover failures, as per procedure given below.

2. Instructions

Procedure for cleaning the selector of tap changer after first 10,000 km run by flushing of the oil, without opening (dismantling) of the selector assembly.

- Before draining the existing oil, the contact arm (Part 15) to be run from 0-32 and 32-0 notch atleast 25 times. Immediately after this open the 3-way cock for the drainage. While draining the oil, run the contact arm from 0-32 and 32-0 notch.

- Fill the fresh/treated insulating transformer oil through the selector over opening (Pt. 1314) upto the normal oil level. Run the oil pump atleast for one hour. Then notching up and down of contact arm atleast 25 times may be carried out. Immediately after this, open the cock (Pt. 1312) to drain the oil. Notch up and down of contact arm 15 times during draining operation.

- Fill with fresh/treated insulating (transformer oil) oil in selector.

Note :- Cleaning is essential as the oil in the selector side gets contaminated mainly with small metal particles, especially at the beginning of the tap changer working till such time the contact rollers get set.

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Reference

i) Para 2.1.2 (b) (Page 4) of the minutes of the meeting held between railways and M/S HBB held in march 1982 and minutes circulated vide RDSO letter no. EL/3.2.30/CG dt. 8/21-4-1982

ii) Deputy Railway Adviser/Paris letter no. PAR/RLY/565 dt. 2.11.82.

iii) HBB's letter No. PWSAS/S43/5/TAP/DAJ DT. 16.3.1983.

3. Periodicity of implementation

During 1st IA schedule (after first 10,000 km run).


Nil

5. Application

i) Locomotives fitted with new No. 32 tap changers.

ii) Locomotives fitted with tap changers in which so far no overhauling/cleaning of selector assembly carried out.



7. Distribution


Encl : Mailing list. (K. Vishwakumar)


Government of India

108162


Manak Nagar, Lucknow - 226 011

No. EL/3.2.30/CG Dated : 16.3.1984


LIST OF VARIOUS TORQUE VALUES AND ASSEMBLY TOOLS/ADAPTERS USED AT VARIOUS LOCATIONS IN TAP CHANGER NO. 32 TYPE AND AIR

BLAST CIRCUIT BREAKERS (DJ) DBTF 30 i 250 TYPE OF HBB MAKE

1. Object :

Railways have reported a few cases of malfunctioning of tap changer and DJ. Investigation has shown that in number of cases , the failures are mainly due to any of the following reasons --

i) Improper tightness of nuts, bolts and screws; and

ii) Misalignment.

2. Instructions :

In addition to the special maintenance instructions SMI no 62 and 90 dated 5.2.80 and 15.9.82 respectively issued by RDSO, ensure that the following parts are tightened with the torque values specified as under -

Tap Changer

Selector Part No Torque value range in mkg.

(i) Hexagonal bolts on selector housing with mounting frame.

1203 3.5

(ii) Terminal nut 1207 1.4 to 1.5

(iii) Special hexagonal bolt for fixing insulating ring inner and outer

1221 0.5 to 0.6

(iv) Special nut and conical nut 1214 & 1217

2.5 + 0.5

(v) Hex. socket head bolts of bevel gear 1409 1.5

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Load Switch (CGR)

vi) M6 socket head screw/Hex. bolt 2318 1.2 + 0.1

M8 socket head screw/hex. bolt 2318 2 + 0.1

Air Blast Circuit Breaker (DJ)

i) Hex. nut for resistor assembly 7172 4.5

ii) Nuts on receiver for tightening press ring 2021 & 1.2 to 1.5 2023

Note - Torque wrenches of suitable torque range may be procured from any standard manufacturer/supplier. However details of Britool (made in England) torque wrenches of the following types are given as for your reference and guidance

Type Range

A) EVT 1200 A 3-14 kg m.

B) AVT 300A 0.5 - 3.4 kg m.

Supplier's address : Britool Products marketed James Neill (Sheffield) Ltd. England.

Indian Agent : M/s Tool Centre Industrial House, 51-53 Nagdevi Crosslane, Bombay 400 003.

Reference : Page 5 item 2.1.7 of Record Note of discussions held between HBB, CLW and Railways at Baroda in Aug. 83 circulated vide this office letter of even No. dated 24.9.83.

Assembly Tools :

Different types of assembly tools adapters used in tap changer assembly are shown in sketch No. SK EL 3704 & 3705. These can be procured with the help of the above sketches.

3. Periodicity : Sheds - AOH/IOH earlier in case found loose or reassembly done.

Workshops - POH


RDSO SK EL 3704 & 3705

5. Application of class of locos/EMUs :

Locos fitted with No. 32 tap changers of HBB make

Locos/EMU fitted with circular type DBTF 30 i 250

110162



All EMU Car sheds.

7. Distribution :


(K. Vishwakumar)


111162

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No. EL/3.2.30/CG Dated : 4.4.1984

SPECIAL MAINTENANCE INSTRUCTION NO. RDSO/ELRS/SMI/117

BREAKGE OF NEEDLE BEARING ROLLER (PART 2311) OF TAP CHANGER TYPE NO 32 OF HBB MAKE.

1. Object

Railways have reported a few cases of breakage of needle bearing roller of tap changer. Investigation has shown that in a number of cases, the failures are mainly due to the grease of the needle bearing being removed/washed away during cleaning of contact lever (2306) with petrol in the regular Maintenance schedule resulting breakage of the needle bearing, thus being dry/starved of the grease.

2. INSTRUCTIONS

- Needle bearing (2311) is generally with high temperature grease. It does not require replacement for 10-12 years.

- Replace during second POH as per BBC overhaul in instructions HAMT 300 74 E the contact lever assembly 2306 (i.e. alongwith needle bearing 2311).

- In any case if the contact lever (2306) is cleaned with petrol resulting in the removal of the grease of the needle bearing during maintenance, Re-grease the bearing as under:

- Remove the bearing as per Pt 7.3.1, page 30 of BBC Manual AM 910018 E.

- Clean the bearing with petrol and remove the old grease.

- Fill the Benonite grease (grease used for high temperature application) covering 50 to 60% of empty space of bearing.

- Refit the bearing in the contact lever assembly (2306).

Note: In case of non-availability of Benonite grease, the equivalents are : (a) NORVA 275 (ESSO); (b) DARINA-2 (SHELL) (c) ENERGREASE HTB2 (BP) and (d) SERVOFEX EP2 (IOC)

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3. Reference

i) Item 5 (Page 9) of the minutes of the meeting held between Railway and M/s HBB in August 83 and minutes circulated Vide RDSO letter No EL/3.2.30/CG dt 24-9-83.

ii) HBB`s letter No PWSAS/S43/5/Tap/KTR dated 11-10-83.,

4. Instruction drawing :

Nil


All locomotives fitted with No 32 tap changer of HBB make. 6. Agency of implementation Sheds/shops on existing locomotives. 7. Periodicity of implementation Wherever grease of needle bearing removed washed away during maintenance of contact lever (2306). During 2nd POH, replace contact lever assembly (2306) alongwith bearing (2311). 8. Distribution : As per list attached.

(K. Viswakumar) for Director General (Elec) Encl. Nil

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No. EL/3.2.30/CG Dated : 5.5.1984


TIGHTENING OF CONNECTING TERMINAL (1206) WITH NUT (1207) ON CONTACT PINS (1208 & 1209) OF TAP CHANGER NO. 32 OF HBB MAKE

1. Object

Railways have reported a few cases of overheating at the joints of terminals. Investigations has shown that this was due to the defective nuts used during terminal assembly of stage III tap changer at HBB works, with the result the terminal assembly got loose and overheated in service.

2. Instruction

Following are the general guide lines for terminal assembly --

- Tighten the Nut (1207) to terminal on contact pins (1208 & 1209)_ with a torque of 1.4 kg.m.

- Maintain a minimum gap of 2.5 mm between terminal face and nut face i.e. Gap B = 2.5 mm (min)

- Similarly tighten the nut on the transformer pins with a torque of 1.4 kg. m.

- Maintain a minimum gap of 2.5mm between terminal face and nut face i.e. Gap A = 2.5 mm (min)

Note : i) Reduced gap A & B can be permitted especially if the torque 1.4 kg.m. is maintained for successive tightening. If there is no gap, the nut is to be replaced by a new nut, to be obtained from M/s HBB

ii) Connectors are now being checked using a dummy plug and full tightening of nut is ensured by M/s HBB from tap changer No. 31180130 onwards.

3. Reference

Item 2.1.7.1 (page 7) of minutes of the meeting held between Railways and HBB in March 1982 and minutes circulate divide this office letter of even number dated 3/21.4.82

HBB's sketch No. TC 91

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4. Periodicity

- A special cyclic check to be made on all stage III tap changers before serial No. 31180130 in service.

- During AOH/IOH/POH on all No. 32 tap changers

- Earlier in case of any abnormality.


RDSO SK EL 3743

6. Application of class of locomotives

All electric locomotives fitted with No. 32 tap changer of HBB make


CLW - during assembly/mounting.


8. Distribution

As per attached list.

(K. Vishwakumar)

for Director General (Elec) Encl. : SK EL 3743

and Mailing list

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No. EL/3.2.30/CG Dated : 29.7.1985


REPLACEMENT PROCEDURE FOR BEVEL GEAR 1924/1925

OF NO. 32 TAP CHANGER OF HBB MAKE 1. OBJECT :

Railways have reported a few cases of breakage of teeth of Bevel gear 1924/1925. In such cases defective Bevel gear is to be replaced by new Bevel gear as per the following instructions.

2. INSTRUCTION :

Replacement of Bevel Gear 1925 :

1. Remove air motor by loosening bolts 1914.

2. Remove the circlip in front of gear 1925.

3. Remove only gear 1925 from its assembly. The gear holder which is secured firmly to the main shaft 1401 with roll pins will remain in position with the six pins and rubber bushes.

4. Push in new Bevel Gear 1925 on to the holder taking care to see that the red dot on the gear is positioned just above the top most pin of gear holder. After completely pushing the gear to its final position ensure that there is no gap between mating surface of gear/holder by lightly tapping the gear with Nylon Hammer; put the circlip into position.

5. Fit the air motor on to the support 1911 with the help of bolt 1913 spring washer 1914 and nut 1915. Ensure that the gear 1924 meshes correctly with gear 1925 and without play. The two red dots of gear 1923 should coincide with one red dot of gear 1924.

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Replacement of Bevel Gear 1924 :

After dismantling air motor, remove the circlip and spacer in front of gear 1924, pull out the bevel gear 1924 from the crankshaft using a puller. Push in a new bevel gear making use of M10 threaded hole of crankshaft and a spacer. Put back the spacer and circlip in their respective position. Assemble the air motor on to the tap changer as indicated under pt. 5.

The dismantling and assembly is to be done in tap zero position and it is required to lock the load switch shaft to prevent movement of main shaft during working.

3. REFERENCE :

HBB Instructions No. SWT 5101

4. INSTRUCTION DRAWING :

Nil

5. APPLICATION :

Electric locomotives fitted with No. 32 tap changer of M/s HBB


All electric loco sheds and POH workshops.

7. PERIODICITY OF IMPLEMENTATION :

Whenever Bevel Gear 1924 and 1925 required replacement.

8. DISTRIBUTION :


(S.S. Khurana)

for Director General/Elec.

Government of India

120162


Manak Nagar, Lucknow - 226 011

No. EL/3.2.30/J-6 Dated : 16.10.1987

SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI/134 REPLACEMENT PROCEDURE OF AIRMOTOR SUPPORT

1. OBJECT

Railways have reported a few cases of breakage/cracking of SMGR support plate. Investigation has shown that these are mainly due to interchanging the SMGR alongwith support plate from one unit to the other, which is not recommended.

2. INSTRUCTION

After the fitment of the support place on a tap changer, it is locked for a particular tap changer. Interchangeability with other tap changer is not permissible with the same locating holes. It require proper alignment and relocation of roll pin (1912). Support plate should only be removed and replaced in case of breakage of support plate. In such condition, the following procedure may be adopted for fitment.

- The old support plate with air motor to be removed from the loco.

- The new support plate of modified design tube fixed on the mounting frame loosely with the help of 3 hex. bolts (1909)

- Dismantle air motor

- Take only bearing plate with crank shaft assembly with bevel gear (1924) from dismantled air motor.

- Fit this assembly on the support plate fitted on the mounting frame such that the gear (1924) correctly meshed with gear 1925 on the main shaft.

- If required, the support plate is to be taken up or down to ensure correct fitment of bevel gear (1924) or (1925)

- Apply thin coat of blue on few teeth of gear 1925 and main shaft with gear 1925 to be rotated (either by hand drive or separate handle) to take the blue impression on bevel gear 1924 on crankshaft. There should be uniform impression of blue on teeth of bevel gear 1924 on both flanks and the blue impression should be more than 50 of flank area. If it is not achieved, the fixing bolts of support plate are loosened and support should be taken up or down till the both bevel gear teeth mesh properly. The fixing screws to be tightened and once again the blue impression is seen.

This process is to be repeated till blue impression on bevel gear 1294 is correctly achieved as indicated above.

- Tighten the support plate in correct position with fixing screws.

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- Drill another hole 8↵ in the mounting frame and insert roll pins 8x28 & 5x28

- Now take out the bearing plate alongwith crank shaft.

- Assemble the air motor on the stand and fit the assembled motor on the support plate already mounted on the frame.

NOTE : (1) The stand can be procured/manufactured as per the enclosed drawing No. SK EL 3920

(2) It should be noted that the design of the support plate is now modified so that the same size bolts can be provided. In case the support plate is of old design i.e. raised rib at the middle portion of the support plate, the central bolt may be changed from M 10x35 to M 10x40. Also introduce plain washer of dia 28x10.5x3.2 below the belleville washer (1910) to ensure proper sitting of the bolt and as well as tightening of the same. This has been introduced from S.No. 1B80783290 onwards by HBB. Sheds/workshops will implement the above on the existing SMGR.

3. REFERENCE

Item 13 of minutes of the meeting held between Railways & HBB in Jan. 1986 and circulated vide this office letter of even No. dated 14.2.86

4. PERIODICITY

During replacement/reassembly of air motor support

5. INSTRUCTION DRAWING

RDSO SK EL 3920

6. APPLICATION

On locomotive fitted with No. 32 tap changer


- Electric loco shade and repair shops of railways.

- M/s HBB during assembly.

(S.S. Khurana)

for Director General(Elect)

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No. EL/3.2.30/J-6 Dated : 21.10.1987 DISTRIBUTION AS PER THE LIST ATTACHED


Dismantling instructions and fixture details for the removal of pinion (Pt. No. 6101) of crank shaft on (SMGR).

1. OBJECT

Railways have reported a problem in replacing the pinion (Pt. No. 6101) from the crank shaft in case of worn out Pinion.

2. INSTRUCTION

The following procedure is to be adopted for the removal of pinion (6101). The required fixture can be made/procured as per enclosed HBB drawing No. SWT 5114 sheet 2.

- Remove the flywheel (Pt. No. 2112) from the crank shaft;

- Hold the pinion (Pt. No. 6101) in the clamping plate (P1) using hex. screw M6x35 as shown in the drawing;

- Screw the stud P4 on the clamping plate;

- Fix the spacer (3) and support plate (2) on to the crankshaft using hex. screw M10x40;

- Screw on the hex. nut M10 on the stud P4 as shown by alternatively screwing the nuts on the two studs. Then the clamping plate alongwith the pinion pt.No. 6101 will come out.

3. REFERENCE

HBB Instructions No. SWT 5114 in two sheets.

4. PERIODICITY

Whenever required.


HBB Drawing No. SWT 5114 sheet 2.

124162

6. APPLICATION

Locomotives fitted with No. 32 tap changer.


Electric loco sheds and repair shops of railways.

Encl : Two (S.S. Khurana)

for Director General/Elect.

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No. EL/3.2.30 Dated : 27.8.1992


Maintenance Schedule for Tap Changer Type No. 32

1. Object :

Schedule of maintenance issued by RDSO (El/LOCO/MS/OOIA) Sept, 1977 does not give details of elaborate maintenance and checks to be done on tap changer. In view of problems on tap changers, study was made by RDSO and elaborate. maintenance schedule covering in detail the checks and maintenance during inspection and overhauls has been prepared. The maintenance schedule is being issued as an SMI so that document can be preserved alongwith SMI's and modification sheet issued for tap changers and can be followed by Railways as a standard schedule.

2. Instructions :

The work to be carried out during each inspection and overhaul is given in the maintenance schedule enclosed.


Nil. (BBC manuals for maintenance may be referred for which references are given in the Schedule enclosed).

4. Application :

All electric locomotives fitted with No. 32 tap changers of M/s ABB




As per maintenance schedule enclosed.

7. Distribution :

All CEE`S of Indian Railways.

(Mahendra Singh)

DA/Maintenance Schedule for Director General (Elec)

127162

MAINTENANCE SCHEDULE INSPECTION CHART FOR TAP CHANGER

Parts to be inspected Inspection details IA IB IC AOH IOH

Tap changer 1) Check the condition of RGR for overhauling/continuity

X

X X X X

2) Check connection from CGRS to RGR and CGRS to A34

X X X X X

3) Check selector oil level, if less than top up

X X X - -

4) Check the condition of silica gel and treat if requires.

X X X X X

5) Check the condition of RPGR & back plate for crack marks.

X X X X X

6) Check connection from double pole bushing to CGR 1 & 3

X X X X X

7) Cleaning of tap changer condenser bushing are chute, insulation

- X X X X

8) Checking of mounting bolts for tighten and ensure that bolts are high tensile type

- X X X X

PHGR 9) Check for any oil leakage/air leakage

- X X X X

i) Working of oil pump (PHGR) No air bubble in the oil flow indicator permitted

X X X X X

ii) Overhaul PHGR, replace rubber component in a

- - - X X

iii) Clean the element, replace if necessary

- - X X X

Tap changer 10) Check the oil leakage from tap changer

- - X X X

11) Check drain pipe dummy if missing provide new one

- - X X X

12) Lubricate all parts as per RDSO SMI 49

- - X X X

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Parts to be inspected Inspection details IA IB IC ID

AOH IOH

Air Motor 13) i) Dismantle the sub assemblies of air motor

- - - X X

ii) Replace the wornout components

- - - X X

iii) Replace the rubber components

- - - X X

iv) Lubricate assembly the as per RDSO SMI 49

- - - X X

v) For the general guidelines for dismantling /ASSY replacement of components follow tap changer Manual. 91001E 91018E HAMT 30076E & Maintenance Manual

- - - X X

vi) Control block for stroke 1.6 to 2mm as per manual AM 91001B page 24

- - - X X

vii) Setting of lead angle as per RDSO SMI 48

- - - X X

viii) Check gap 0.4 to 0.7mm between valve push rod and valve push rod bolt

- - - X X

viii) Check gap 0.4 to 0.7mm between valve push rod and valve push rod bolt

- - - X X

ix) Check gap 0.4 to 0.7mm between lever and inter wheel.

- - - X X

x) Check/eliminate looseness of fly wheel/ wabbling of fly wheel

- - - X X

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xi) Maintain min. 0.7 gap between selector lever and fly wheel

- - - X X

xii) Ensure tightness of bolts/fixing screws/locking of parts and assembly

- - - X X

xiii) Check leak proofness of Air Motor assembly and air motor.

X X X X X

Selector i) Drain the selector oil and fill the fresh oil of 48KV BDV

- - X X X

ii) Open the selector cover and do the maintenance as per MI HAMT 30076B

- - - X X

iii) Tighten the contact and insulating rings with torque of 2-5m.kg. and 0.5 mkg respectively.

- - - X X

iv) Check the making and breaking angles on contacts.

- - - - X

v) While fitting the oil ducting ensure the operation of safety valve

- - - X X

vi) Fill heat treated silica gel in the breather.

- - X X X

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vii) Change the 'O' ring of safety valve

- - - - X

viii) Replace roll pins - - - - X Load Switch/RGR/Control Panel/Manual Drive

i) Carryout the maintenance as per MI HAMT 30076Es

- - - X X

ii) Check load switch making and breaking angles

- - - - X

iii) Check continuity of 1 lakh ohm resister

- - - X X

iv) Check RGR for element breakage, cutting of mica tube gap between elements, and replace the defective components

- - - X X

v) Open the Run Indicator Manual Drive, Lubricate Gear assembly with Bharat MP2 grease and replace wornout components.

- - - X X

vi) Replace the taper pin/roll pins of coupling shaft of manual drive

- - - - X

vii) Open pressure regulator, clean, set the pressure setting 6.5 kg/cm2 and lock

- - X X X

131162


GR Contacts 1) Check the condition of arc chute of CGR 1, 2 & 3

X X X X X

2) Measurement of contacts (new contact gap) 46-48mm condemning limit 38mm.

X X X X X

3) Tightness of contacts fixing screw

X X X X X

4) Condition of contacts and arc chute

X X X X X

5) Tightness of CGR assembly, fixing screws (Check on assembly

X X X X X

6) Condition of CGRs buck plate lever and cams

X X X X X

7) Conditions for connection of shunts from CGR 1 & 3 to double pole bushing

- X X X X

8) Cleaning of assembly with petrol and duster e.g. Condenser bushing, vertical insultating support and arc chutes.

- X X X X

9) Check working of CGR's by manual operating the GR

- - X X X

10) Tightness of connection (M1-2) (between GR- CGR- RGR of tap changer)

- - X X X

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11) Check the flow of air through 3 way of control panel

- - - X X

12) Ensure the proper functioning of foot pedal switch/pacco switch

- - - X X

Note :- 1. Do overhauling (POH) as per overhaul (instructions HAH) ? 2. All the points indicates in IOH and also to be taken care off. 3. In selector open the contact plate contact stands and replace the

rubber component (‘O’ ring gaskets). 4. Replace all gaskets/locking/belleville washer/roll pin.

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No. EL/3.2.30 Dated : 25-9-1992.


FLASHING INSIDE THE SELECTOR OF TAP CHANGER No. 32

1. OBJECT

Railways have reported cases of flashing inside selector assembly. The probable reasons and remedial measures to minimise these flashovers are listed in the following enclosed instructions for compliance.

2. INSTRUCTIONS

i. Flashing inside selector, probable reasons and remedial measures Annexure - 1)

ii. Cause effect diagram (Annexure - 2)

iii. Guidelines for correction of making and breaking angles of contact segments and load switch contact of tap changer (Annexure - 3)

iv. Check sheet for the flashing inside selector (GR) of tap changer No. 32 (Annexure - 4)

v. Modification in insulating ring (1218, 1219) fixing arrangement (Already issued by RDSO WAM4/157 on 3.11.1989)

3. REFERENCE

Instructions already circulated to Railways by M/s ABB during co-ordination meeting held on 8.1.1992 at Baroda.


Nil

5. APPLICATION TO CLASS OF LOCOMOTIVE

All locomotives fitted with No. 32 tap changer of M/s ABB make


Sheds/Shops

7. PERIODICITY OF IMPLEMENTATION

As per the instructions enclosed.

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8. DISTRIBUTION

All Chief Electrical Engineers

(Arun Srivastava)

Krite Maha Nideshak/Vidyut. Encl./As above

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ANNEXURE (I)

FLASHING INSIDE SELECTION, PROBABLE REASONS AND REMEDIAL MEASURES.

1 Deterioration of transformer oil due to moisture absorption & copper deposition.

2 Tracking of insulating ring/contact plate due to copper deposition

3 Incorrect making and breaking angle of contacts and load switch.

4 Looseness of contact segments

5 Looseness of insulating ring

6 Discontinuity of contact of central gearing with 16th notch

7 Discontinuity of 1 lakh ohm resister across load switch

8 Lesser contact pressure between roller and taps

9 Wrong assembly

10 Failure of connection of condenser bushing

11 Failure of RGR

12 Sticking of SMGR

(II) The probable cause of moisture absorption of transformer oil are --

1. Through Air breather

2. Suction of air through oil pump pipe connection joints

3. Safety valve and condenser bushing sealing becoming ineffective

(III) The copper deposition inside selector could be due to

1. Non functioning of oil pump

2. Periodic cleaning/replacing of filter element of PHGR not being done

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(IV) To prevent flash over inside selector the following guidelines are suggested --

1. During trip inspection / IA /IB 10,000 Km run condition of silica gel in the breather to be observed. If it has turned to pink it should be changed.

2. The 'o' ring of safety valve condenser bushing to be changed every IOH

3. Proper functioning of oil pump is to be ensured. During every AOH all the 'o' rings and cup seals (32 , 3235) are to be changed, only BharatMP2 grease is to be used for lubricating slide valve housing 3269 and cylinder 3243.

It is some times observed that the piston complete 3270 gets stuck up and the pump stops functioning. This is mainly due to higher frictional force exerted due to swelling of cup seal, leakage at the joints and poor finish of housing itself. These points are to be taken care and as a final check the free movement of piston complete to be checked with a load 800 gm. It should move freely from one end to other at this load

4. When oil pump is running, oil flow in the oil flow indicator is to be observed. If there is no clear oil and air bubbles are seen air is being sucked into the selector. To prevent the same all pipe joints are to be made leak proof. Oil pump 'O' rings are to be changed every AOH.

5. Replace filter in AOH

6. The making and breaking angles of contact and load switch are to be checked during every AOH. The wear and tear of components , the play in the assemblies affect these angles. (Refer Annexure - 3_)

7. The contact segments are to be tightened with 2.5 kg meter torque. While tightening care should be taken to see that the segments are not tilted. This can be done with the help of shims. Further the tightness of segments to be checked by hand. (Refer RDSO/SMI/113 dated 16.3.1984)

8. The special hex. bolts of insulating ring are to be tightened with 0.5 kg metre torque

9. In the case of insulating ring having under gone a years service, during AOH they can be heated at 70 to 80 C for 4 to 6 hours to drive away the moisture . Soon after the heating they should be kept in the filtered oil or Elmo-luft 1A of Dr. Beck's varnish may be applied which is an air during varnish.

10. Continuity of potential contact with 16th notch to be ensure during every AOH.

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11. After 10,000 km. run, after commissioning of loco the transformer oil in GR to changed with fresh filtered oil. The oil strength should be min. 48 kv/mm

12. It is recommended to incorporate the 1 x mm spacer between stud and insulating ring at their fixing points to increase the creak distance. The modification to be done as per sketch TG-118. The special bolt 1221 also to be changed to accommodate the spacer ( 6.4 x 14 x 1) (Refer RDSO Modification Sheet No. WAM4/157 dated. 3.11. 1989)

13. The moisture content and acidity test of transformer oil of GR to be done during every IC inspection and if required oil is to be changed.

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GUIDE LINES FOR CORRECTION OF MAKING AND BREAKING

ANGLES OF CONTACT SEGMENTS AND LOAD SWITCH CONTACT OF TAP CHANGER NO. 32

The making and breaking angles of contact segments and load switch cams are maintained within + 30 during manufacturing.

The various factors which determine the accuracy of these angles are :

1. Play between level gear pairs 1924/1925, 1408/1480.3, 1481.7/1449, 2103/1490.1,2109/2209

2. Play between coupling pin 1435 and coupling shaft 1480.5/1481.5

3. Play between lantern gear roller 1470.2 and drive wheel 1457.

4. Play between actuating plug 1470.4 and stepping wheel slot 1501.

5. Correct positioning of contact plate 1201

6. Correct positioning of contact segment 1215/1216

7. Proper Assembly of contact arm complete 15

8. Component accuracy of insulating rings 1218/1219, contact segment 1215/1216,contact roller 1515 stepping wheel 1501, drive wheel 1457, lantern gear 1470, contact plate 1201, roller housing 1513 and other associated components.

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In service the wear and tear of the following components affect these angles

a.) Insulating ring 1218/1219

b.) Contact roller 1515

c.) Contact segment 1215/1216

d.) Lantern gear roller 1470.2

e.) Lantern gear pin 1470.4

f.) Wear on teeth profile of stepping wheel 1501

g.) Drive wheel profile wear 1457

h.) Coupling pin 1435

i.) Bevel gear

j.) Cam Disc. complete 2220.1/2220.2/2220.3

k.) Looseness of coupling pin 2102.3

l.) Wear of contact 259

A variation of + 4.50 is permitted to take care of the wear and tear of above components. In case the angles are going beyond the above limits attention is to be paid to the above points/components and change the components, if required, to bring the angle within limits. The permissible play between the affecting components are given below for necessary checking.

1. Max. permissible play 0.2mm between Bevel gear pairs 1924/1925, 1408/1480.3, 1481.7/1449, 2103/1490.1, 2109/2209.

2. Max. permissible play 0.2 mm between coupling pin 1435 and coupling shaft 1480.5/1481.5

3. Max. permissible play 1mm between lantern gear roller 1470.2 and drive wheel 1457.

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4. Max. permissible play of 0.3 mm between actuating plug 1470.4 and stepping wheel slot 1501

5. Max. permissible tilting of 0.25 mm of contact segment 1215/1216 from the normal position

6. Max. 0.5 mm groove may be permitted on contact segment 1215/1216

The following dimensions can be taken as guide line for changing the components.

a. Contact roller Ø 17mm (1515)

b. Lantern gear roller Ø 15.5mm (1470.2)

c. Lantern gear pin Ø 9.8mm (1470.4)

d. Coupling pin dim. 9.8mm (1435)

e. Cam disc. complete Ø 109mm (2220.1), (2220.2) (2220.3)

f. Contact wear max. 5mm (2529)

The maximum contact arm (part No. 15) play permissible in full notch condition is 10 mm and in half notch condition is 4 mm.

It should be noted that the above limits are given for guidance purpose only. If the limits of many of the components are on the extreme side the angles may still go out due to the combined effect. In that case some components may have to be replaced to minimise the play.

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If the contact segment angles are going beyond the limits. Following procedure may be adopted.

1) Check the Titling of Contact Segment. Maximum permissible Tilting 0.25mm. Reposition Segment within the permissible value and check angle.

2) Reposition Insulating ring utilising the play in its fixing bolts and measure the angle.

3) Check wear on the Insulating Ring milled edges. If the edges are tapered off due to wear change the Insulating Ring and measure angle.

4) Measure the Contact Arm play in full notch and half notch position. If they are beyond 10mm and 4mm respectively then measure play of mating components as detailed above and change/adjust the play of components to bring the contact arm play within limits.

5) If Contact Arm play is within the limits and still Angles are going out it is an indication that the initial contact arm position itself is shifted. In that case gear plate assembly 1477 alongwith gear box assembly 1453 is to be repositioned utilising the play in the fixing bolts. Alternatively the play is to be minimised by changing new components which are detailed above.

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If load switch cam angles are going beyond limits adopt the following procedure.

1. Check and minimise Bevel gear play 2103/1490.1, 2109/2209, 1924/1925

2. Measure Contact wear. If it is very near to the limiting pt. change the Contacts.

3. Measure wear on cam disc complete 2220 and replace if necessary

4. Check looseness of coupling pin 2102.3. If looseness is found change the coupling shaft 2102

5. Check the looseness of cam disc complete 2202.1 in the hex. shaft 2220.4. If looseness is found avoid play using suitable shims between shaft and cam disc complete.

(K.K. Rao)

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CHECK SHEET FOR THE FLASHING INSIDE SELECTOR (GR) OF TAP CHANGER NO 32

GENERAL :

1. Sr. No. of selector (GR)

2. Loco Sr. No./Type

3. Commissioning date

4. Whether it is a line failure . if not when detected.

5. When last AOH done

6. When oil was changed (of GR)

7. When last BD value of GR oil checked. What was the value?

8. Whether oil pump was working

9. What is the colour of silica gel. in Breather of failed Tap changer

10. Whether Q44 Relay has operated

11. When contact angle measurement last done

12. Whether there is any failures in the associated equipments.

If yes, what is the failure

13. Whether 1 lakh ohm resistor is ok

14. Whether there is any associated failures of Air Motor/Load Switch.

If yes, give details

15. Whether safety valve has operated

16. Whether oil changed afte first 10,000 km.

If yes, when changed.

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Hindustan Brown Boveri Ltd. Vadodara. After opening the selector record the following : 1. Whether there is copper Heavy Medium deposition. Whether it is heavy medium or light. Light 2. Whether there is continuity of Yes No.

potential contact at 16th notch

3. Whether there is flash mark in the Yes No. central gearing.

If yes which part 4. Whether there is flash mark at the selector Yes No. housing/cover. 5. Are the contact flashed. Yes No.

If yes which are the contacts

5.1 Does the flashing is at the leaving and making Yes No. portion of contact.

If No. explain with sketch

6. Does Insulating Rings affected. Yes No.

If yes give details.

7. Has the roller flashed. Yes No If yes give details.

8. If there is flash mark on contact rings. Yes No.

If yes give details.

9. Is there flash mark on connection of Yes No. condenser bushing.

10. Condition of contact plate.. Good Carbonised Broken If carbonised/broken give details with sketch.

Make of contact plate Imported HBB Local

11. Explains condition of contact Arm

12. Any other abnormal condition inside selector which might have caused failure

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No. EL/3.2.30 Dated - -1992 Government of India Ministry of Railways


SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI-145 CRANK SHAFT FRACTURE OF NO.32 TAP CHANGER

1. OBJECT Railways have reported cases of Crank Shaft fracture of tap changer ABB make. The probable reasons and remedial measures to overcome above failures are listed in the following enclosed instructions for compliance. 2. INSTRUCTIONS i. Instructions for assembling crank shaft with the help of fixture (Annexure-1) ii. Maintenance of Crank Shaft in AOH, IOH and POH (Annexure-2) iii. Cause effect diagram (Annexure-3) iv. Check sheet for Crank shaft breakage (Annexure-4) 3. REFERENCE i. M/SABB Instruction No. SWT 5126, SWT 5129 and SWT 5131 ii. Co-ordination Meeting held on 8.1.1992 at ABB, Baroda. 4. INSTRUCTION DRAWING

Enclosed with instructions 5. APPLICATION TO CLASS OF LOCOMOTIVE

All locomotives fitted with No.32 tap changer of M/S ABB make. 6. AGENCY OF IMPLEMENTATION

Sheds/Shops. 7. PERIODICITY OF IMPLEMENTATION As per the instructions enclosed. 8. DISTRIBUTION All Chief Electrical Engineers.

(Arun Srivastava) Encl As above Krite Maha Nideshak/Vidyut.

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No. EL/3.2.30 Dated : 20.10.1992 SPECIAL MAINTENANCE INSTRUCTIONS NO. RDSO/ELRS/SMI/146

Breakage of Journal pin of SMGR Tap Changer No. 32 - ABB Make 1. OBJECT :

Railways have reported cases of breakage of journal pin of SMGR. The probable reasons and remedial measures to overcome these failures are listed in the following enclosed instructions for compliance.

2. INSTRUCTION : a. Cause effect diagram (Ref. Annexure-1) b. Journal pin modification (Ref. Annexure-2) c. Check sheet for failure of journal pin (Ref. Annexure-3)

3. REFERENCE

Co-ordination meeting held on 8.1.1992 at ABB, Baroda

4. INSTRUCTIONS DRAWING :

HBB Drawing NO.SWT 435429 (Enclosed as Annexure 2)

5. APPLICATION TO CLASS OF LOCOMOTIVE :

All locomotives fitted with no 32 tap changer of M/s ABB make


Sheds/shops

7. PERIODICITY OF IMPLEMENTATION :

As per the instructions enclosed.

8. DISTRIBUTION :

All Chief Electrical Engineers.

(Arun Srivastava)

Encl :As above for Director General (Elec)

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GOVERNMENT OF INDIA - Central Railway · 17-19 8. WAM4/11 4 Clamping arrangement for PHGR 9.7.81...

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Transcript of GOVERNMENT OF INDIA - Central Railway · 17-19 8. WAM4/11 4 Clamping arrangement for PHGR 9.7.81...