DC Drilling Motor Maintenance Manual

7/31/2019 DC Drilling Motor Maintenance Manual

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Joliet Equipment Corporation

Engineered Drilling Motors

Maintenance &Spare Parts Manual

Models: JEC75YZB, JEC75YZE, JEC75ZB,JEC75ZE, JEC75ZB-F, JEC75ZE-F


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General Product Information

Parts List/Diagram 6-7

Models 8

Differences Between Models 9

General Specications 10-12

General Operation Information 13

GeneralFeatures 13

ATEXCerticationSafetyConsiderations 13

SafeElectricalParametersShuntWound 14

SafeElectricalParametersSeriesWound 14

Warnings 14-15

ClosedCoolingSystems 15

SpecialHandlingRequirements 15

Grounding 15-16 Lubrication 16

SpecialTools 16

Inspections 17

MonthlyInspections 17-19

InspectionpriortoOperation 20

InspectionsforClosedCoolingSystems 20

Semi-AnnualInspections 20

Motor Overhaul 21

TestingtheMotorbeforeDisassembly 21

DisassemblingtheMotor 21

RemovingtheHub 21-22

RemovingtheArmatureFromtheFrame 22-23

TestingafterOverhaul 23

TestingSeriesModels 23

TestingShuntModels 24

Cleaning 25

SteamCleaning 25

VaporDegreasing 25

CleaningAnti-FrictionBearings/ShaftTapers/BearingFits 25

Contents

Contents:Part1

Rev. 07152010


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Working with the Motor Parts

The Brush and Brushholder

ReplacingtheBrushes 26

RemovingtheBrushes 26

InstallingtheBrushes 26

ReplacingtheBrushholders 26

InstallingtheBrushholders 27

AdjustingtheBrushholderClearance 27

InspectingandTestingtheBrushholders 27

ReplacingtheBrushholderSleeves 27

ReassemblingBrushholders 28

The Armature 28

InspectingandTestingtheArmature 28

ReplacingtheArmatureCreepageBand 28 AssemblingtheArmatureintotheFrame

(ModelsYZE,YZK,ZE-F,ZK-F,ZE,ZK) 28-30

AssemblingtheArmatureintotheFrame

(ModelsYZB,YZH,ZB-F,ZH-F,ZB,ZH) 30-31

RemovingtheArmatureLockingArrangement 31

LockingtheArmatureforShipment 31

TestingtheArmatureafterRepair 31

ArmatureVarnishTreatment 32

BalancingtheArmature 32

Inspections 32

InspectingtheInsulation 32

InspectingtheCommutator 32

InspectingtheArmatureShaftBearingFits 32

InspectingtheCreepageBand 32

Resurfacing the Commutator 33

Grinding 33

Turning 33

Undercutting 33

Raking 34 Polishing 34

The Motor Frame 35

Inspecting and Testing the Motor Frame 35

ReplacingtheMotorFrameFieldCoil 35

RemovingtheCoil 35

InstallingtheCoil 36

Contents


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The Motor Frame (continued)

Brazing the Coil Terminals 36

UsingtheMachineBrazingMethod 36

UsingtheGasTorchBrazingMethod 36

FloodDippingtheCoiledFrame 37

Testing the Coiled Frame 37

TestingafterRepair(withoutArmature) 37

TestingafterRepair 37

The Connection Boxes 38

ChangingthePositionoftheConnectionBox 38-39

InsulatingtheTerminalConnections 39

AssemblingtheConnectionBox 39- 40

DifferencesforShuntMotors 40

The Commutator 41 ResurfaceBasedonCondition 41

SafetyRequirements41

PreparingtheCommutatorforResurfacing 41

PreparingforResurfacingforSeriesMotors 41

PreparingforResurfacingforShuntMotors 42

SandingtheCommutator 42

HandStoningtheCommutator 42-43

FixtureGrinding 43

InstallingtheGrinder 43

GrindingtheCommutator 43-44

AirCuringtheCommutator 45

The Bearings 46

InspectingtheBearings 46

ReassemblingtheBearings 46

ReassemblingtheArmatureBearings 46

ReassemblingtheDrive-EndBearing46-47

ReassemblingtheCommutator-EndBearing(ShuntWoundMachines) 47

ReassemblingtheCommutator-EndBearing(SeriesWoundMachines) 47

The Hubs 48 HubFitting 48

MountingtheHub 48- 49

The Bolts50

LubricatingtheBolts50

StandardBoltTorqueValues 51

Index 52-54

Contents


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JOLIETEquipmentCorporationcontinuouslyinvests

inglobalmanufacturingalliancestobringthebestin

electricmotorsandrelatedtechnologytoAmerica.

OneofNorthAmericasleadingsuppliersoflarge,

heavy-dutyelectricmotors,JOLIETEquipment

Corporationhasbeenbuildingandrebuildingelectric

motorsformorethan75yearswithbettervalueand

unequaledqualityandsupport.JOLIETEquipment

Corporationmeanspowerinsteelmills,papermills,

petrochemicaloperationsandhigh-performance,

deep-drillingoffshoreequipmentsettingheavy-duty

operatingstandardsfromtheAmericastothePacic

Rimandcustomersitesaroundtheworld.

Formorethantwogenerations,JOLIETEquipment

Corporationhasbeensettingqualitystandardsand

specicationsforelectricmotors.Carefullychosen

alliancesandqualitycontrolmeasuresinsurethat

JOLIETEquipmentCorporationcustomerswillreceive

theabsolutebestinelectricmotorperformanceand

value.

General Product Information

Joliet Equipment Corporation Bringing You the Best in Electric Motors

Reconditioned DC Drilling Motors

JEC75ZB JEC75ZEJEC75YZF(Top Drive)

JEC75ZB-F JEC75ZE-F

Type: (Series/Shunt) Series Shunt Series/Shunt Series Shunt

HP: (Continuous) 1000 1000 1085/1130 1085 1130

HP: (Intermittent) 1250 1250 1320/1365 1320 1365

Voltage: (VAC) 750 750 750 750 750

Full Load Current: (Continuous) 1050 1050 1150/1185 1150 1185

Full Load Current: (Intermittent) 1400/1435 1400 1435

Full Load RPM: 965 1040 965/1040 965 1040

Horizontal / Vertical: Horizontal Horizontal Vertical Horizontal Horizontal

Torque: (@ Base RPM): (Continuous) 5200 5050 5900/5705 5900 5705

Torque: (@ Base RPM): (Intermittent) 6800 6300 7530/6745 7530 6745

Available Certication: ABS ABS ABSATEX ABS ABS

Approx. Weight: (lbs.) 6900 6900 7150 7150 7150

Add1aftermodelnumberforMarineDutyAdd3aftermodelnumberforLandDuty

New DC Drilling Motors

JEC75YZB JEC75YZEJEC75ZF

(Top Drive)

Type: (Series/Shunt) Series Shunt Series/Shunt

HP: (Continuous) 1085 1130 1085/1130

HP: (Intermittent) 1320 1365 1320/1365

Voltage: (VAC) 750 750 750

Full Load Current: (Continuous) 1150 1185 1150/1185

Full Load Current: (Intermittent) 1400 1435 1400/1435

Full Load RPM: 965 1040 965/1040

Horizontal / Vertical: Horizontal Horizontal Vertical

Torque: (@ Base RPM): (Continuous) 5900 5705 5900/5705

Torque: (@ Base RPM): (Intermittent) 7530 6745 7530/6745

Available Certication: ABSATEX ABSATEX ABSATEX

Approx. Weight: (lbs.) 7150 7150 7150

Add1aftermodelnumberforMarineDutyAdd3aftermodelnumberforLandDuty


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DESCRIPTION PART NUMBER

1 Outer Seal 10-53 D0011

2 Drive-End Outer Bearing Cap 10-53-D0012

3 Drive-End Bearing Cap Bolts 10-53-D0013

4 Bearing Cap Lock Washers 10-53-D0014

5 Drive-End Outer Gasket 10-53-D0015

6 Drive-End Bearing 10-53-D0016

7 Hi-Torque Endbell 10-53-D0017

8 Bolts & Washers 10-53-D0018

9 Drive-End Bearing Spacer/Slinger 10-53-D0019

10 Drive-End Inner Bearing Cap 10-53-D0020

11 Inner Seal 10-53-D0021

12 Cable S2 10-53-L0022

13 Cable S1 10-53-L0023

14 Cable A2 10-53-L0024

15 Cable A1 10-53-L0025

16 Frame/Lead Grommet 10-53-L0026

17 Blower Seal Tite 10-53-L0027

18 Seal Tite 10-53-L0028

19 Seal Tite 10-53-L0029

20 Armature with Shaft 10-53-A0030

21 Exhaust Cover B 10-53-F0031

22 Exhaust Cover C 10-53-F0032

23 Exhaust Cover A 10-53-F0033

24 Exhaust Cover D 10-53-F0034

25 Inner-pole Bolt 10-53-F0025

26 Inner-pole Pole Piece 10-53-F0036

27 Inner-pole Coil 10-53-W0037

28 Inner-pole Shims 10-53-F0038

29 Inner-pole Shims 10-53-F0039

30 Commutator Covers - Upper 10-53-F0040

31 Field Coil Bolt 10-53-F0041

32 Field Coil Bolt Washer 10-53-F0042

33 Field Coil Open 10-53-W0043

34 Field Coil Crossed 10-53-W0044

35 Field Coil Spring Plate 10-53-F0045

36 Field Coil Pole Piece 10-53-F0046

37 Frame 10-53-F0047

38 Blower Mount Bolt 10-53-B0048

39 Blower Mount Washer 10-53-B0049

40 Blower Assembly 10-53-B0050

41 Commutator-End Bearing Cap Bolts 10-53-C0051

DESCRIPTION PART NUMBER

42 Commutator-End Outer Bearing Cap 10-53-C0052

43 Commutator-End Bolts & Washers 10-53-C0053

44 Gaskets 10-53-C0054

45 Commutator-End Endbell 10-53-C0055

46 Commutator-End Bearing Lock NutSet Screw

10-53-C0056

47 Commutator-End Bearing Lock Nut 10-53-C0057

48 Commutator-End Bearing / Outer Ring 10-53-C0058

49 Commutator-End Bearing 10-53-C0059

50 Commutator-End Inner Bearing Cap 10-53-C0060

51 Brush Holder Assembly 10-53-C0061

52 Carbon Brush 10-53-C0062

53 Washer 10-53-F0063

54 Bolt 10-53-F0064

55 Bottom Bolt-on Cover 10-53-F0065

56 Bottom Spring Cover 10-53-F0066

57 Copper Bus Connection 10-53-T0067

58 Terminal Box Covers 10-53-T0068

59 Bolt 10-53-T0069

60 Washer 10-53-T0070

61 Bolt 10-53-T0071

62 Washer 10-53-T0072

63 Washer 10-53-T0073

64 Glastic Stand Off 10-53-T0074

65 Bolt 10-53-T0075

66 Connection Plate 10-53-T0076

67 Gland 10-53-T0077

68 Terminal Box 10-53-T0078

69 Crouse-Hinds Lockout Switch 10-53-T0079

70 Pressure Switch (XP) 10-53-T0080

71 Space Heater (120/240 VAC) 10-53-T0081

72 Terminal Board w/Indicator 10-53-T0082

73 Oileld Hub 10-53-S0083

74 Hi-Torque Endbell 10-53-D0084

75 Exhaust Cover Gasket 10-53-F0085

76 Nomex Gasket 10-53-F0086

77 Nomex Gasket 10-53-F0087

78 Blower Gasket 10-53-B0088

79 Blower Filter 10-53-B0089

PartsList/Diagram

Parts List/Diagram


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Model Series Wound (H) Shunt Wound (K)

C75ZB(E)

Reconditioned 1000HP DC Drilling

Continuous rating for mud pump and

rotary table applications of 1000 HP

Intermittent rating for drawworks

applications of 1250 HP

Continuous rating is at 750 VDC,

1050 Amperes, 965 RPM





Continuous rating is at 750 VDC, 57

Amps, 1050 Amperes, 1040 RPM

C75ZB(E)-FReconditioned DC Hi-Torque Drilling Motor





Continuous rating is at 750 VDC,1150 Amperes, 965 RPM





Continuous rating is at 750 VDC,60 Amps, 1185 Amperes, 1040 RPM

Models

C75YZB(E)New DC Hi-Torque DC Drilling Motor





Continuous rating is at 750 VDC, 1150Amperes, 965 RPM





Continuous rating is at 750 VDC,60 Amps, 1185 Amperes, 1040 RPM


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Differences Between Models

ThefollowingtableliststhedifferencesbetweenthevariousmodelsofJOLIETEquipmentCorporationmotors.

Model Differences

C75ZB / H

Reconditioned 1000HP DC Drilling

C75ZB Horizontal Series; left-hand terminal box

C75ZH Horizontal Series; right-hand terminal box

C75ZE / KReconditioned 1000HP DC Drilling

C75ZE Horizontal Shunt; left-hand terminal box

C75ZK Horizontal Shunt; right-hand terminal box

C75ZB-F / HReconditioned DC Hi-Torque Drilling Motor

C75ZB-F Horizontal Series; left-hand terminal box

C75ZH-F Horizontal Series; right-hand terminal box

C75ZE / K-FReconditioned DC Hi-Torque Drilling Motor

C75ZE-F Horizontal Shunt; left-hand terminal box

C75ZK-F Horizontal Shunt; right-hand terminal box

C75YZB / HNew DC Hi-Torque DC Drilling Motor

C75YZB Horizontal Series; left-hand terminal boxC75YZH Horizontal Series; right-hand terminal box

C75YZE / K

New DC Hi-Torque DC Drilling Motor

C75YZE Horizontal Shunt; left-hand terminal box

C75YZK Horizontal Shunt; right-hand terminal box


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General Specications

Locationofmainconnectionboxes(lookingatcommutator-end)

Connectionboxonleftside,modeldesignationswithsufxletterB and E.

Connectionboxonrightside,modeldesignationswithsufxletterH and K.

Motor Part / Motor Characteristic Specication Data

Max. Permissible Speed Motors 2300 RPM

Max. Permissible Vibration (Commutator End) 0.002 in.

Resistance at 25C (ohms) Min. Max.

Armatures

Models: C75ZE(K), C75ZE(K)-F, C75YZE(K) 0.00749 0.00800

Models: C75ZB(H), C75ZB(H)-F, C75YZB(H) 0.00749 0.00800

Exciting Fields

Models: C75ZE(K), C75ZE(K)-F, C75YZ(K) (With Cables) 1.13 1.22Models: C75ZB(H), C75ZB(H)-F, C75YZB(H) (With Cables) 0.00513 0.00549

Commutating Fields

Models: C75ZE(K), C75ZE(K)-F, C75YZE(K) (With Cables) 0.00431 0.00492

Models: C75ZB(H), C75ZB(H)-F, C75YZB(H) (With Cables) 0.00431 0.00492

Carbon Brushes

Type T900

Size 3/4 x 2-1/4 x 2 in.

Minimum Brush Length (length at which brush becomes

inoperative measure brush on the longest side)

1-3/32 in.

Spring Pressure on Brush, Preset 10-12 lb.Brushholder

Clearance to Commutator 1/16-3/32 in.

Clamp Bolt Torque 225-250 lbs-ft

Commutator

Side Mica Thickness 0.060 in.

Slot Depth 0.047 in.

Undercutting Saw

Width 0.063 in.

Diameter 1.000 in.

Commutator DiameterNew 16.625 in.

Worn (minimum permissible) 15.375 in.

Riser Width (minimum permissible) 0.625 in.


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Motor Part / Motor Characteristic Specication Data

Lubrication Armature Bearings

Grease Capacities

Drive-end 32.5 oz.

Commutator-end

Models YZE/K, YZB/H, ZE/K-F, ZB/H-F, ZE/K, ZB/H 12.25 oz.

Model YZF, ZF-F, ZC, ZF 31.8 oz.

Lubricant Shell Cyprina RA

Weights (approximate)

Complete 6720 lb.

Armature Only 2100 lb.

High-Potential Test 60 Hz, a-c, to ground for one minute (All Windings) (Volts)

New or Rewound Armature 3500 V

Reconditioned 2000 V

Minimum Megohmmeter Reading (ohms) 2 megohms


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General Operation Information

p

JOLIETdrillingmotorsareusedtopoweroffshore

andland-baseddrillrigsusedbytheoilandgas

industry.Forthespecicratingsforeachmotor,see

Models.

General Features

Inprovidingthebestelectricmotorsandrelated

technology,JOLIETdrillingmotorsinclude:

Alargearmatureslotcongurationprovidinga

heavycoppercrosssectiontoincreasethemotors

capabilityforcarryinghighcurrentloads.

Aspiralgroovecommutatorwhichhelpscoolthe

commutator(high-torquemodels).

Highcurrentexcitingandcommutatingpoleeld

coils.

Improvedinternalairowforincreasedcooling.

Anopenpinion-endframeheadforincreased

cooling(high-torquemodels).

Theabilitytooperatethedrillingmotorineither

rotationaldirection.

Theabilitytomountthepressurizedcontrolbox

oneithersideofthemotor.Formoreinformation,

seeChanging the Position of the Connection Box.

ATEX Certication SafetyConsiderations

Thefollowinglistprovidesthespecialconditionsyou

shouldfollowforsafeuseofanyJOLIETdrillingmotor:

1. Youmustfollowthesepressurizationand

purgingrequirements:

a. Aminimumairowof3000ft.3/min.

(85m3/min.).

b. Aminimumpurgetimeof5minutesplus10

secondsforeveryadditional35.3ft.3(1m3)

ofducting.

c. Aminimumlowpressuresettingof2in.of

WG(5mbar).

2. Itisyourresponsibilitytoensurethatany

certiedancillariesusedinconjunctionwiththe

motormeettheconditionsfortheiruse.

3. Youhaveconnectedthewindingresistance

temperaturedetectors(RTDs)eitherintointrinsi-

callysafecircuits,oryouhavetheminterlocked

withthepurgingsystemsothattheycannotbe

energizeduntilthemotorhascompletedapurge

cycle.

4. TheSpecialConditionsforsafeuseorthe ScheduleofLimitationsasappropriatefor

Certicates.

5. Whenyouactivatetheauxiliaryswitch,thatis

youhavepinnedthemotors,ACvoltagemay

stillbepresentonthedeviceterminalboards.

Thespaceheater(240VAC)andblowerunit

(460or575VAC)maystillbeonunlessyou

havepreviouslyswitchedthemoff.Thereisa

dangerofasevereelectricalshockifyoudo

notswitchoffthespaceheaterandblowerunit

whenyouactivatetheauxiliaryswitch.


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Safe Electrical Parameters Shunt Wound

Thefollowingtableliststhesafeelectricalparameters

forshuntwoundJOLIETdrillingmotors.

Category Rating

Shaft horsepower 1130

Armature Volts DC 750

Armature Amps DC RMS 1185

Shunt eld Amps 60

Full Load RPM 1040

Maximum RPM 2300

Maximum ambient temperature 40C

Internal free volume (cu. ft.) 6.6

Minimum purge / cooling ow

rate

3000 CPM

Minimum purge time 5 min (plus 10 seconds for

each cubic meter of duct)

Minimum overpressure at

enclosure

2.00 in. WG

Minimum differential pressure

through frame

6.00 in. WG

Incoming cable maximum

operating temperature

125C

Safe Electrical Parameters Series Wound

Thefollowingtableliststhesafeelectricalparameters

forserieswoundJOLIETdrillingmotors.

Category Rating

Shaft horsepower 1085

Armature Volts DC 750

Armature Amps DC RMS 1150

Full Load RPM 965

Maximum RPM 2300

Maximum ambient temperature 40C

Internal free volume (cu. ft .) 6.6

Minimum purge / cooling ow

rate

3000 CPM

Minimum purge time 5 min (plus 10 seconds for

each cubic meter of duct)

Minimum overpressure at

enclosure

2.00 in. WG

Minimum differential pressure

through frame

6.00 in. WG

Incoming cable maximum

operating temperature

125C

Warnings

Toensureyoursafety,followthefollowingwarnings

whenworkingonJOLIETdrillingmotors:

1. Poorlygroundedequipmentcanbeashock

hazard.Youmustgroundtheequipmentbefore

use.Thereisapotentialforseriousorfatalinjury

fromelectricalshockifyoudonotproperly

groundelectricalequipment.

2. Usingcompressedairforcleaningpurposescanraisedebrisandyingparticles.Compressedair

mayalsocontainmoisture;donotuseon

energizedmotor.Wearsafetyglassesandother

personalprotectiveequipmentwhenusing

compressedairforcleaningpurposes.Flying

debrisandparticlesmayalsopresentahazard

topersonnelintheimmediatearea.Improper

protectioncanresultinseriousinjury.


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3. Removingorreplacingbrusheswhilethe

equipmentisenergizedorrotatingcanbe

ashockhazard.Donotremoveorreplace

brusheswhiletheequipmentisenergizedor

rotating.Electricshockcancauseseriousor

fatalinjury.

4. Testingcanbeashockhazard.Electricshock

cancauseseriousorfatalinjury.Takeproper

precautionsduringtesting.

5. Resurfacingoperationscanraisedustand

yingparticles.Wearsafetyglassesanda

respiratorforprotectionfromdustandying

particlesduringresurfacingoperations.Improper


6. Highpotentialtestingcanbeashockhazard. Electricshockcancauseseriousorfatalinjury.

Takeproperprecautionsduringhighpotential

testing.

7. Brazingrequiresextremelyhightemperatures.

Wearsafetyglassesandleatherglovesatall

timesduringbrazingoperations.Improper


8. UsingMEKasacleaningsolutioncanbea

healthhazard.Donotinhalethefumes.Use

MEKonlyinawell-ventilatedarea.Take

adequateprecautionstoprotectyoureyes,

skinandhands.Improperprecautionscan

resultininjur y.

Youwillseethesewarningsthroughouttheservice

catalogasareminderoftheseconditions.

Closed Cooling Systems

YoucanmountJOLIETdrillingmotorsinatotally

closedcoolingsystemwithanairtowaterheatex-changer.Ifyouusethisalternatecoolingsystem,ithas

thefollowingrequirements:

Acleanableairlter

Aseawaterheatexchangerthatrequires50

GPMof22Corcoolerwater

A15horsepowercentrifugalblower

A240VAC(440,460or575)volt,60cycle

3-phaseexlosion-proofmotorwithassociated

ductingandaccessories

Ifspeciedandttedwithproperaccessories,the

motorsareCertiedforHazardousAreas.Whenutilizingdifferentaccessories,thesemotorsarealso

availableCertiedforHazardousAreaswithouta

totallyclosedcoolingsystem.

Special Handling Requirements

Youmustusespecialliftingdeviceswhenhandling

JOLIETdrillingmotorswiththeircoolingsystems

attachedtoavoiddamagingthecoolingandpurge

systems.Youmustnotlifttheentiremotorassembly

withtheliftingeyesontheheatexchangerorblower

assembly.Thiscandamagethecoolingandpurgesystem.

Grounding

s WARNING sPoorly grounded equipment can be a shock hazard.

You must ground the equipment before use. There is apotential for serious or fatal injury from electrical shock

if you do not properly ground electrical equipment.

Youmustprovidegroundingforthefollowingequip-

menttoprotectyourpersonnelfrompotentiallyhazard-

ousconditions:

Themotorframestoprotectyourpersonnelfrom

electricshockshouldtherebeaninsulation

failureinthemachine.


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Theconductorsbetweenthemachineframe

andtheadjacentsupportingstructureonwhich

apersonmaybestandingwhiletouchingthe

machine.

Note: This type of ground connection is referred to in elec-

trical standards as equipment grounding or enclosure

grounding which is not to be confused with system or cir-

cuit grounding. Drilling drive systems typically do not have

intentional circuit ground connections, except through high

impedance detectors.

Thedrillingunitsonwhichtheconstructionofthe

unitand/ortheinstallationofthemachinesdonot

inherentlyinsurepositivegroundingofthe

equipment.

Thisisrequiredinportable(modular)platformrigs

andlandrigswhichdonotalreadyhavegroundcables

toallmachinerystructures.Offshorerigswithequip-

mentfastenedtothedecksbyboltingorwelding

shouldnotrequireadditionalgrounding.(Forfurther

informationsee:ABSRulesforBuildingandClassing

SteelVessels,Section35.9.6,andIEEEStandard

45-1977,RecommendedPracticeforElectrical

InstallationsonShipboard,Section21.4.)

Thefollowingprocedureprovidesthestepstofollow

foreffectivelygroundingthemotor.

Note: We provide a 0.375 in. grounding stud on one of the

mounting feet you can use to connect the ground cable to

the drilling motor. Refer to the appropriate Outline drawing

for the stud location.

1. Preparea4/0sizeorlargercoppercableground

conductorlongenoughtorunfromthemotor

frametoeitheranexistinggroundconductor

systemorasuitableequipmentgroundpointas

denedbytheNationalElectricalCodeArticle250orotherapplicableregulation.(Forfurther

information,see:NationalElectricalCode,1978

Edition,Table250-95.)

2. Checkthatthesystemgrounddetectoris

connectedtothecommongroundpointforthe

rigandmaketheconnectionifnecessary.

3. Obtaintwocableterminalstot:

Thegroundcableonthedrillingmotorend

largeenoughforthe0.375diametergrounding

stud.

Theoppositeendofthecableandits

groundingconnection.

4. Installbothcableterminalstothecable.

5. Removepaint,rustandoilfromthesurfacesto

whichthecablesaretobeattached.

6. Connectbothcableterminalssecurely.

7. Usingadigitalohmmeter,checkthattheconnec-

tionsaresolid,lowresistanceconnectionsfrom

thecableconductortothegroundpointandto themotorframe.

Themeterreadingshouldbe0.2ohmsorless.

Lubrication

YoudonotneedtolubricateanyJOLIETdrillingmotor

designedforhorizontaloperationbetweenoverhaul

periods.Formoreinformation,seeOverhaul.

Special Tools

Thefollowingtableliststheitemsyourequireto

maintain,repairandoverhaulJOLIETdrillingmotors:

Tool Part

Megohmmeter 1,000 volts Fluke or equivalent

Voltmeter Multimeter

Resurfacing Stones

Medium Grade 8828492P11

Finish Grade 8828492P8

Brush-Seater Stone (White) 106X98

Hub Assembly Gauge 41D790941G1Hub Puller (less pump) 41B535703G1

Pump (for above) 8843947G1


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Caution: All models of JOLIET drilling motors require cooling. The cooling air should be free of combustible

gases which could be ignited by a spark. If you must run your equipment in these conditions, make sure you

provide an adequate supply of non-contaminated cooling air. If necessary, use a drill motor with provisions

for ducting suitable cooling air and containing other protective equipment such as spark arrestors.

Monthly Inspections

Thefollowingtableliststhetasksyoushouldperformaspartofyourmonthlyinspection.

Part Standard Operation Monthly Service

Exterior The exterior should be clean and damage-free.

Inspect the exterior of the machine, including cables, fordamage and replace as required.

Clean the exterior using clean, dry compressed air.

Covers, Seals, Latches The covers, seals and latches should beintact and operate properly.

Remove the inspection covers and ensure covers tproperly and cover latches work properly.

Clean the interior using clean, dry compressed air andblow the dirt and carbon dust from the machine.

Check exterior covers to ensure seals are intact;replace missing or damaged covers or seals asrequired.

Brushholders andBrushholder Sleeves

Brushholders and brushholder sleevesshould be damage free and be installedsecurely.

Inspect the brushholders for damage. If you mustreplace brushholder(s), see Brushholders, Workingwith the motor parts for more information.

Use a clean, lintless cloth and wipe dirt and grease from

the Teon brushholder sleeves; if necessary, use acleaner such as MEK (methyl ethyl ketone) to clean thesleeves. Be sure to follow standard safety precautionsfor handling a volatile solvent.

Inspect sleeves for cracks and thin spots caused byashovers. Replace any damaged brushholder or onehaving a damaged sleeve.

Inspect the brushholder cables and make sure allterminal bolts and all brushholder clamp bolts are tight.

Inspections

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Brush Spring The brush spring should move freely and

brush spring pressure should be within

accepted pressure value limits.

Check for free movement of the spring assembly by

lifting the brush pressure ngers to the toggled-up

position.

Inspect brush springs for obvious failure or damage.

Check brush-spring pressure by comparing spring

pressure with a spring known to be good. For brush

spring-pressure value, see General Specications.

Brushes Brushes should be long enough to last until

the next inspection, be free of excessive

wear and be positioned correctly.

Check brushes for wear:

Lift the brush spring, remove the brush and measure

the brush length on the longest side from the top of

the carbon.

Ensure brushes have enough length to last until the

next monthly inspection. For more information on

brush length, see General Specications.

Check brushes for surface integrity:

Inspect all brushes to ensure the brushes are not

chipped or broken.

Inspect brush shunts to ensure they are not frayed or

broken.

Note: Brushes that are chipped, burned or rough-faced may

indicate that the commutator needs resurfacing.

Check brushes for positioning and connections:

Move the brushes up and down in their carbonways

to ensure brushes slide freely.

Check the brush shunts to be sure they are not

twisted or out of position.

Make sure all brush-shunt terminal connections and

all brushholder cable connections are tight.

Recommendation: We recommend you replace a brush that

shows any damage of any kind. We also recommend that if one

brush is showing wear, that you change all brushes at the same

time. For more information on installing brushes, see Brushes,

Working with the motor parts.

Inspections


19/56

19


Commutator The commutator should be clean, smooth,

glossy and free of high mica, high bars, at

spots or rough surfaces.

Inspect the commutator for possible ashover damage.

Verify that the commutator is perfectly round; if there

are indications that the commutator is out-of-round

(such as variations in the width of the ridge betweenbrush paths), check the concentricity of the commutator

with a dial indicator.

For more information on the condemning limits for

concentricity, see General Specications. If the commuta-

tor requires grinding, see Commutator, Working with the

motor parts and Resurfacing.

Creepage Band The creepage band should be clean and

installed tightly on the commutator cap.

Clean the creepage band (located on the commutator

cap) with a clean cloth dipped in an approved solvent.

Inspect the band for possible ashover damage.

Ensure the creepage band is installed tightly on thecommutator cap.

Flash Ring The ash ring should be clean and varnish-

free.

Examine the ash ring for possible ashover damage.

Wipe the ash ring clean with a clean cloth dipped in an

approved solvent.

Insulation The insulation should have a normal

resistance level and not show cracking.

Measure the insulation resistance with a megohmmeter;

if the reading is low, inspect the insulation to determine

if the cause is insulation failure or excessive moisture.

Correct the cause of the low readings before returning

the motor to service.

Inspect all accessible parts of the eld coil insulation for

cracking and evidence of overheating.

Power Cables The power cables should appear in good

condition.

Inspect the power cables for signs of excessive heating,

poor insulation or mechanical damage.

Ensure all power cable terminals are secured tightly.

Mounting Bolts All mounting bolts should be tight. Check all mounting bolts to ensure that they are

maintaining the correct bolt load.

Air Filters If applied, air lters should be free of

containments.

Inspect the air lter in the cooling system assembly.

Clean or change the lter as needed at each inspection.

p


20/56

20

Inspection prior to Operation

Youshouldperformthefollowinginspectionsbefore

bringinganewJOLIETdrillingmotoron-line:

Removerodentguardsand/orducttapeoverthe airexitportsatthepinion-endofthemotor.

Removeandreversetheshipping/exhaustcover

priortooperation.

Verifythatallnecessaryequipmentblowersand

ductworkareinplaceandingoodcondition.

Removetheprotectionmaterialappliedtothe

commutatortopreventdamagewhilethemotor

wasintransit.

Removetheyellowarmaturelockingboltinstalled topreventmovementduringshipping,replaceit

withthesuppliedbolts,andre-torquetheboltto

100-120lbs-ft(seeFigure1below).

CAUTION: You must provide adequate cooling for

your JOLIET drilling motor. Without adequate cool-

ing, you could cause the equipment to overheat

which in turn could shorten equipment life and

negatively affect warranty coverage.

Inspections for Closed CoolingSystems

Thefollowingtableliststhetasksyoushouldperform

wheninspectingclosedcoolingsystems.

Time Period Activities

Every 7 days Check the three zinc anodes in the heat

exchanger; you should replace them as soon as

they start weeping water.

Every 30 days Check for air or water leaks; tighten all connec-

tions which may have become loose during

operation.

Every 90 days Inspect the carbon dust lter element. Ifrequired, clean the element with compressed

air, water or steam. Let the dust lter element

dry completely before you reinstall. Do not

clean using chemical solvents.

Semi-Annual Inspections

1. Performtheinspectionoperationslistedunder

MonthlyInspections.

2. Checktheclearancebetweenthebrushholders

andthecommutatorsurface.Forinformationon

brushholderclearancedimensions,seeGeneral

Specications.

3. Ifthedimensionsdonotmeettheminimum

requirements,adjustthebrushholderclearance.

Formoreinformation,seeBrushholders and

Brushes,Working with the motor parts,Adjusting

the Brush-holder Clearance.

Inspections

Yellow Armature Locking BoltsFigure1


21/56

21

Recommendation: We recommend that you perform a

basic motor overhaul at least every two years, or 18,000

operating hours of normal operation. Exactly when you

perform an overhaul can vary, depending on the condi-

tion of the machine and your overall operation.

Thissectioncoversprocedurestodisassemble,

clean,inspect,repair,reassembleandtestthe

machine.

Testing the Motor before Disassembly

Thefollowingtableliststhetestsyoushouldperform

beforedisassemblingthemotor.

Test Description

Megohmmeter Test Determine the condition of the

insulation by:

1. Lifting the brushes.

2. Performing a megohmmeter

test on the armature windings

and eld coils.

If you receive a reading of less

than 2 megohms you should

check the quality of the insulation,

whether the insulation has

excessive dirt accumulation or

moisture.Bar-To-Bar Resistance Test Test for open or short-circuited

armature coils by:

1. Passing a regulated d-c current

through the armature coils.

2. Reading the voltage drop

between the commutator bars

with a millivoltmeter.

If you receive a reading that varies

more than 5% from the average

value, there is a defective or

short-circuited coil.

Disassembling the Motor

Removing the Hub

Useasuitablepullerwhenremovingahub.

Recommendation: We recommend a puller similar to Part

41B535703G1. This simple, efcient hydraulic puller uses

the oat method. A complete unit consists of a pump kit, a

backing plate, an adapter, a felt ring and a bolt.

Caution: Do not heat the hub before pulling it or use steel

wedges between the hub and bearing cap.

1. Removetheset-screwplugfromthetappedholeintheendoftheshaft.

2. Withthefeltringinplace,screwthebacking

platetotheendoftheshaftbyhand.Makethe

screwastightaspossible.Toprovidesufcient

clearanceforthehubtopopoff,backoffthe

backingplatetolineuptheslotwiththetapped

holeintheendoftheshaft.

3. Screwthepressure-ttingadapterintothehole

intheshaftuntilitseatsatthebottom.

4. Attachthepump.Screwtheconnectorononeendofthepressuretubeintotheadapter,and

theotherendintothepump.

5. Closethehandreliefvalveandworkthepump

handletoforceoilintothegrooveinthearma-

tureshaftunderthehub.Whenyouhavebuiltup

sufcientpressure,thehubwillpopofftheshaft

andbestoppedbythefeltwasherandbacking

plate.

Note: The capacity of the pump is 40,000 psi. It holds suf-

cient oil to remove eight to ten hubs. To ensure you have

sufcient oil, you should check the level at each use. When

required, remove the lling plug and rell with SAE-10

lubricating oil.

Motor Overhaul


22/56

22

6. Openthereliefvalveandperformthefollowing

steps:

a.Disconnectthepumpfromtheadapter.

b.Removetheadapterandbackingplate fromtheshaft.

c.Liftoffthehub.

7. Whenthehubisoff,reinserttheplugtoprevent

cloggingthehole.

CAUTION: When either lifting the armature in

the vertical position or turning the armature to

a horizontal position, you should take special

precautions to avoid damage to the armature end-

windings, bearings or bearing ts, and the com-

mutator.

Removing the Armature From the Frame

Ifequippedwithcoolingsystemcomponents,remove

thembeforeproceeding.(Refertotherespective

suppliersinstructionsasnecessary.)

Beforeturningthemachinefromhorizontaltovertical

(orvice-versa),attachthearmaturelockingarrange-

menttopreventthearmaturefrommovingaxially.

Removethearmaturelockingarrangementbefore

operatingthemachine.

s WARNING sWhen using compressed air for cleaning purposes,ying debris and particles may present a hazard topersonnel in the immediate area. Personnel shouldbe provided with, and trained in the use of, personal

protective equipment as specied by applicable federalor state safety regulations.

1. Cleantheoutsideoftheframe,usingcom-

pressedair,asteam-jennyorcleaningsolvents,

toremoveaccumulateddirt.

2. Removethecouplinghubfromtheshaft,ifnot

alreadyremoved.

3. Removethecommutatorcovers.Disconnectand

removeallbrushes,andwrapheavypaper

aroundthecommutatorforprotectionduring

handling.

4. Removeboltsandwashers(41)whichholdthe

innerandouterbearingcapstothecommutator-

endframehead.Takeoffouterbearingcap(42)

andgasket(44).

5. Turnthemachineonendonastand,commuta-tor-enddown,andlevelitsothatthearmature

canbeliftedverticallyoutoftheframewithout

damagingthebearings,commutatoror

brushholders.

6. Screwthreeguidepinsintothecommutator-

endinnerbearingcap(46)tohelpguidethe

armatureoutoftheframe.Screwaliftingbail

ontothedriver-endoftheshaft.

7. Removedrive-endframeheadboltsandwash-

ers(8)andinsertjackscrewsinthethreadedholesprovidedintheframehead(7).

8. Lineupthehoistcablewiththecenterlineofthe

armaturebeforeengagingthehookinthelifting

bailontheendoftheshaft.Engagethehook

andliftslightly.Withsufcientstrainonthehoist

cabletotaketheweightofthearmatureoffthe

framehead,jackthedrive-endframeheadloose,

andliftthecompletearmatureassemblyoutof

theframe.DONOTDAMAGETHE

CUMMUTATOR.

CAUTION: Special precautions should be taken to

avoid damage to the armature end-windings, bear-

ings or bearing ts, and the commutator when lift-

ing the armature in the vertical position or turning

the armature to a horizontal position.

9. Placethearmaturehorizontallyinanarmature

saddleforbearingdisassembly.

10. Removethetwosetscrewsfromthesecuring

nutatthecommutator-endoftheshaft.

11. Removethenutfromtheendoftheshaftusinga

spannerwrench.

12. Installpullertoolandpulltheinnerraceofroller

bearing(50)fromthecommutator-endofthe

shaft.Sleeve(49)willcomewiththebearing.

13. Removeinnerbearingcap(46).


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23

14. Usingpullertool,pulltheoutersleeve(1)from

thedrive-endoftheshaft.Thesleevehas

tappedholesforapplyingthepuller.Heatmay

beapplied.

15. Removeboltsandwashers(3,4),andthen

removeouterbearingcap(2)andgasket(5).

16. Slideframehead(7)offtheshafttogetherwith

theouterraceandrollersofbearing(6).The

innerracewillremainontheshaft.

17. Pulltheinnerbearingraceofftheshaftwith

puller.

18. Removeslinger(9)andinnerbearingcap(10)

withpullerbyinsertingthefourpullerbolts

intothetappedholesininnerbearingcap(10).

19. Ifnecessary,removeinnersleeve(20)withpuller.

20. Presstheouterbearingraceandrollersfrom

theframeheadwithanarborpress.

Note: Before pressing the drive-end outer bearing race out of

the framehead, observe and record the number on the face of

the race. Mark the framehead in relation to the number. Rotate

90 degrees upon reassembly. After removal, mark the date

(with an electric pencil) under this number to indicate that this

position has been used. Reassemble the bearing with anothernumber opposite the mark. Etch the numbers 1, 2, 3 and 4

(spaced 90 degrees apart) on the face of race with an electric

pencil. Locate number 1 opposite the mark on the framehead

and mark it with the date.

21. Ifnecessarytoremovethecommutator-end

framehead(45),turntheframecommutator-

endupandremoveboltsandlockwashers

(43).Useboltsintheframeheadjack-out

holestobreakthetandremove.

Testing after Overhaul

Testing Series Models

Refertovendorpublicationsfortestingthecooling

systemsonmodelYZB(H).Afterthemotorhasbeen

reconditionedandreassembled,performthefollowing

teststoensureitoperatesasexpected.

InthistestyouwillconnectthemotortoaDCarc-

weldinggeneratorandrunthemachineseries-con-

nectedwithoutloadat900rpminordertomeasure

bearingtemperatures.

1. Useaputty,suchasDuxsealfromJohnsManvilleCompany,toholdthethermometerson

thedrive-endandcommutator-endouterbearing

caps.Forbestresults,thethermometersshould

contactthebearingcaps.

2. Seatthebrushesandrunfortenminutesat900

rpm.Theframetemperatureshouldnotrise

greaterthan25C.

3. Withthemachinerunninguptospeed,measure

thevibration.Thevibrationshouldnotexceed

0.1in/seconthecommutator-end.Ifthevibration exceedsthisvalue,rebalancethearmature.

4. Checkthecommutatorforroughnessandmake

surethebrushesareridingproperly.

5. Checkfornoisybearingsusingalisteningrod.

6. Stopthemachineandmountanindicatoronthe

frame.Whileturningthearmaturebyhand,

measurecommutatorrunout.Therunoutshould

notbegreaterthan0.001in.

7. Measuretheeldimpedance.With60HzACand24amperesthrougheacheld,measurethe

voltagedropacrosstotalexcitingandcommutat-

ingelds.Forvoltagelimits,seeGeneral

Specications.

s WARNING sTesting can be a shock hazard. Electric shock can

cause serious or fatal injury. Take proper precautionsduring testing.

8. Performahigh-potentialtesttothewindings oftheassembledmachine.Fordetailsonthe

highpotentialtest,seeGeneral Specications.

s WARNING sHigh potential testing can be a shock hazard. Electricshock can cause serious or fatal injury. Take proper

precautions during high potential testing.


24/56

24

Testing Shunt Models

Refertovendorpublicationsfortestingthecooling

systemsonmodelYZE(K).Afterthemotorhasbeen

reconditionedandreassembled,performthefollowingteststoensureitoperatesasexpected.

Afterthemotorhasbeenreconditionedandreassem-

bled,performthefollowingteststoassureitwill

operatesatisfactorily.

Youconductthistestwiththemotorventilatedat2800

CFMatthecommutatorchamberwitha10HPblower.

1. ConnectthemotortoaDCweldinggenerator.

Refertoconnectiondiagram(Figure3)for

connections.

2. Runthemachinebyseparatelyexcitingtheshunt

eldfroma125VDCsource.Fromanother

sourceofpower,applyvoltagetothearmature

circuituntilyouhavereachedthedesiredspeed.

3. Holdseparateeldexcitationat57.5amperes.

Varythearmaturevoltagetoobtaintherequired

RPM.Atapproximately700terminalvolts(no

load),thespeedwillbe900RPM.

4. Ifthemotorisnotventilated,performthe

followingtest:

a. Holdtheseparateeldexcitationat10to

15amperes.Varythearmaturevoltageto

obtaintherequiredRPM.Atapproximately

338terminalvolts(noload),thespeedwill

be900RPM.

b. Runthemotorforveminutesat450RPM.

c. Increasethespeedto900RPMandrunfor

twohours.Thebearingtemperaturesshould

notexceed70C(158F).Rununtilthe

bearingtemperatureremainsconstantfor30

minutes.

d. Increasethespeedto1300RPMandholdit

whileperformingSteps2,3and4.Thenshut

downthemotor.Donotexceed1300RPM.

e. Measurethevibrationwhenrunningthe

motoruptospeed.Thevibrationshouldnot

exceed0.1in/secIfthevibrationexceeds

thisvalue,rebalancethearmature.

f. Checkthecommutatorforroughnessand

makesurethebrushesareridingproperly.

g. Checkfornoisybearingsusingalistening

rod.

h. Stopthemotorandmountanindicatoron

theframe.Turnthearmaturebyhandand

measurecommutatorrunout.Therunout

shouldnotbegreaterthan0.001in.

s WARNING sTesting can be a shock hazard. Electric shock can

cause serious or fatal injury. Take proper precautionsduring testing.

i. Measuretheinsulationresistanceofthewindingswithamegohmmeter.Iftheresis-

tancemeasuresmorethanonemegohm,

applyanAChighpotentialtesttogroundfor

oneminute.Fordetailsonthehighpotential

test,seeGeneral Specications.

s WARNING s

High potential testing can be a shock hazard. Electricshock can cause serious or fatal injury. Take proper



25/56

25

Cleaning

Toensureproperoperation,werecommendthe

followingmethodsforcleaningtheyourdrillingmotor.

Steam Cleaning

Youcanusethismethodforcleaningbothinsulatedandmetalparts.

1. Usesteamincombinationwithacommercial

non-causticcleaner.

CAUTION: Never use caustic soda solution on the

armature or coiled frame.

2. Suspendthepartinapositionwhereitcanbein

thedirectowofsteamfromthehosefromall

directions.

3. Rinseallresiduefromthepartsusingamixture

ofcleansteamandwater.

4. Bakeinsulatedpartsforatleast8hoursat

150C(302F)toremoveallmoisture.

Vapor Degreasing

Youcanusethismethodjustformetalparts.

1. Bringthecleaningsolutiontoaboil,andallow

thevaporlineinthetanktorisetothecondensercoilsatthetopofthetank.

2. Keepthevaporizedcleaningsolutionatabout

120C(248F).

3. Lowertheparttobecleanedintothevapor-

ladenatmosphere,sothevaporwillcondenseon

thepart.

4. Tospeedtheremovalofheavydirtaccumula-

tions,sprayhotsolutiondirectlyfromthetank

ontothepartbeingcleaned.Thetemperatureof

thesolutionmustbekeptbelowitsboilingpoint.

5. Removethecleanedpartfromthedegreaser.

6. Drainandcoolthepart.

Cleaning Anti-Friction Bearings/ShaftTapers/Bearing Fits

Youcanuseacleaningsolutionthatleavesanoillm

toprotectnishedsurfacesfromrust.Kerosene,petroleumspiritsorotherpetroleum-basedcleaners

providelimitedprotectionforthesesurfaces.

g


26/56

26

The Brushes and Brushholders

Replacing the Brushes

Youshouldcheckthebrushspringpressurebefore

replacingbrushes.Thebrushspringpressureis

pre-setandnon-adjustableforthebrushholdersused

onthesemachines.Ifyouhaveabrushholderthatis

eitherdamagedorhasalowspringpressure,you

shouldreplaceitbeforeinstallingnewbrushes.You

measurespringpressurewitha20-lb.springscale

pullingradiallyonthebrushpressurengeroverthe

centerofeachbrush.Forinformationonlimits,see

General Specications.

Recommendation: When replacing brushes, we recom-

mend you use only the brush grades listed in the GeneralSpecications. If you mix brush grades in the same motor or

change brushes to another grade you can seriously affect

commutation, surface lm, commutator and brush life.

Removing the Brushes

Usethefollowingproceduretoremovebrushes.

1. Removethecommutatorinspectioncovers.

2. Disconnectthebrushshuntfromtheterminal

screwlocatedonthebrushholderbody.

3. Liftthepressurengerawayfromthebrushto

thetoggled-upposition.

4. Removethebrush.

5. Usedry,compressedairtoblowthecarbon

dustfromthecarbonway.

s WARNING s

Using compressed air for cleaning purposes can raisedebris and ying particles. Wear safety glasses and otherpersonal protective equipment when using compressedair for cleaning purposes. Flying debris and particles

may also present a hazard to personnel in the immediatearea. Improper protection can result in serious injury.

Installing the Brushes

Usethefollowingproceduretoinstallbrushes.

1. Insertanewbrush;ensurethatthebrush

slidesfreelyinthecarbonway.

2. Carefullylowerthespring-loadedbrush

pressurengeronthebrush.

Caution: Do not allow the nger to snap down on

the brush as this can chip and damage the brush.

3. Attachthebrush-shuntterminalstothe

brushholderbodyunderthescrewsprovided.

Arrangethebrushshuntstrandssothatthey

clearthepressurengers.

4. Cleantheterminalsandtightentheterminal

screw(s).

Caution: Make sure brush shunts are not posi-

tioned under the pressure ngers.

5. Checkandtightenallbrushholdercable

connections.

6. Seatthenewbrusheswithawhiteseater

stone.

7. Installthecommutatorcoversonthemotorand

checkforpropertandlatchoperation.

Replacing the Brushholders

Usethefollowingproceduretoremovethe

brushholder.

1. Removebrushesfromthebrushholders.

2. Coverthecommutatorwithheavypaper.Youwill

leavethepaperonthecommutatortoprotectit

untilyouhaveinstalledthenewbrushholder.

3. Disconnectthecablefromthebrushholder(s)

youareplanningtoremove.

4. Removethebolt,washerandbrushholderclamp.

5. Liftthebrushholderoutoftheframe.

Working with the Motor Parts


27/56

27

Installing the Brushholders

Usethefollowingproceduretoinstallthebrushholder.

1. Positionthebrushholderintheframewiththe

brushholderstudsrestingintheclampsurfacesofthebrushholdersupport.

2. Installtheboltandwasher.Tightentheboltbut

donottorquetheboltuntilyouhavedetermined

thebrushholder-to-commutatorclearance.For

moreinformation,see Adjusting the Brushholder

Clearance.

3. Afteryouhavesetthebrushholderclearance,

connectthebrushholdercableandremovethe

protectivepaperfromthecommutatorsurface.

4. Checkthebrushestoinsurethattheyexceed

theminimumbrushlengthdimensionandare

freeofanydamage.Youcanreusethemif

theyarelongenoughandarenotdamaged.

Ifnot,youshouldreplacethemwithnew

brushes.

Adjusting the Brushholder Clearance

Usethefollowingproceduretoadjustthebrushholder

clearance.

1. Removethebrushes.

Caution: Do not allow the brushholder to touch,

bump or rest on the commutator.

2. Inserta1/16in.berspacerbetweenthebottom

ofthebrushholderandthecommutator.Youmay

havetoloosenthebrushholderifthegapisless

than1/16in.

Caution: Do not use a metal spacer.

3. Loosenthebrushholderclampboltsandmove

thebrushholderssotheytouchtheberspacer.

4. Tightentheclampboltsto225-250lbs-ft.torque.

Removethespacerandrecheckthebrushholder

clearancegaptoensureitis1/16in.

5. Connectthecableleadstothebrushholder

terminalsandtightentheterminalbolts.

Inspecting and Testing the Brushholders

Performthefollowingstepswheninspectingand

testingbrushholders.

1. Checkthebrushholderforashoverdamage,

cracksandburnedorpittedareas.

2. Checkthebrushspringstoensuretheymove

freelyanddonotbind.

3. Insertanewbrushinthecarbonwayandmove

itupanddowninthecarbonwaytobesureit

movesfreely.

Replacedamagedbrushholdersiftheyaredamaged

orshowsignsofexcessivewear.Formoreinformation,

seeReplacing Brushholders.

Replacing the Brushholder Sleeves

Usethisproceduretoreplacebrushholdersleeves.

1. RemovethedamagedTeonsleevefromthe

brushholderstudbyheatingthebrushholderin

anovento150C(302F)thenpeelingor

cuttingthesleevefromthestud.

s WARNING s

Wear safety glasses and leather gloves at all times whenworking with equipment heated to extreme temperatures.

Improper protection can result in serious injury.

2. Thoroughlycleanthesurfaceofthestudto

removeanybuild-upofcarbonordirt.

3. HeatanewTeonsleeveina150C(302F)

ovenfor15minutes.

4. Immediatelyassemblethehotsleeveonthe

stud.


28/56

28

Reassembling the Brushholders

Usethisproceduretoreassemblethebrushholder.

1. Usingaboltandwasher,attachthebrushholder

clamptotheframemount.

2. Positionthestudsofthebrushholderinthe

clamp,andmovethebrushholderradially

outwardasfaraspossible.

3. Tighten,butdonottorque,thebrushholder

clampbolt.Formoreinformationontheproper

lubricationofassemblyhardware,see

Lubricating Bolts.

4. Installallbrushholders.Formoreinformation,

see Installing the Brushholders.

5. Connectthebrushholdercables.

The Armature

Inspecting and Testing the Armature

Toavoiddamagetothecore,banding,endturns,

shafttsandcommutator,handlethearmaturecareful-

lyduringinspectionandtesting.Forfurtherprotection:

Supportthearmatureinasaddletoprotectthe

commutatorandthecoilends.

Coverthecommutatorwithheavypaperuntil

youcompletedallworkonthearmature.

Usethisproceduretoinspectandtestthearmature:

1. Bringthearmaturetoroomtemperature,25C

(77F).

2. Performadielectrictestofthearmatureinsula-

tionusinga500or1000VDCmegohmmeter.

Youwantareadingofonemegohmorhigher.

Ifyougetavaluelowerthanonemegohm

performthefollowingactionstoincreasethe

resistancevalueoftheinsulation:

a. Performadditionalcleaningandbaking

operations.

b. Replacethecreepageband.

c. Rewindthearmature.

3. Measureandrecordthearmatureresistance.

Forresistancevalues,see General

Specications.

4. Iftherearenogroundedarmaturecoils,

performabar-to-barcomparisontesttocheckforopenorshort-circuitedarmaturecoils.

a. PassaregulatedDCcurrentthroughthe

armaturecoils.

b. Readthevoltagedropbetweenthe

commutatorsegmentswithamillivoltmeter.If

thereadingvariesmorethan5%,youhave

adefectiveorshort-circuitedcoil.

5. Ifthearmaturefailsthebar-to-bartest,you

mustrewindthearmature.

Replacing the Armature Creepage Band

Werecommendyouusethehotbondprocesswhen

replacingthearmaturecreepageband.Thisprovides

superioradhesionpropertieswhenattachingthe

Teoncreepagebandontheouterendofthecom-

mutator.Youreceiveacopyofthisprocessineach

TeonBandKit(PartNo.76518).Youcanorderthekit

[email protected].

Assembling the Armature into the Frame(Models YZE, YZK, ZE-F, ZK-F, ZE, ZK)

Usethisproceduretoassemblethearmatureintothe

frameformodelsYZE,YZK,ZE-F,ZK-F,ZE,ZK:

Note: For information on the proper lubrication of assembly

hardware, see Lubricating Bolts.

1. Assemblethebrushholders(51)intotheframe.

a. Positionthebrushholderwellbackfromthe

commutatortokeepthemclearfromthe

commutator.

b. Fastenandinsulatetheconnectionsand

installoutgoingcables.

2. Assemblethecommutator-endframehead(45)

totheframe.

a. Tightenboltsandwashers(43)uniformly.


29/56

29

b. Torqueboltsto45050lbs-ft.

3. Usingaheavydutystand,blockandlevelthe

frameinaverticalposition,commutator-end

down.

4. Assemblealiftingbailontothedrive-endofthe

shaft.

5. Wrapheavypaperaroundthecommutatorto

provideextraprotection.

6. Installthebearingpilotonthethreadsofthe

commutator-endoftheshaft.

7. Withthebearingpilotandthecommutator-end

bearinginnerraceassembledontotheshaft,

lowerthearmaturepartwayintotheframe.Use

thebearingpilottoaligntheshaftwiththecenterofthebearing.Lowerthearmatureinto

theframeuntilthedrive-endframeheadstarts

intotheframet.

8. Insertthedrive-endframeheadboltsand

washers.

a. Removeanyburrsordirtbetweenthets

oftheframeheadandthemagnetframe.

b. Drawdowntheboltsandwashersuniformly

topressthearmatureintoplace.Makesure

todrawthemdownevenlytoavoidcocking thebearingassemblyanddamagingthe

races.

CAUTION: Uneven tightening of bolts could dam-

age bearings or related tted surfaces.

9. Torqueframe-headbolts(43)to45050lbs-ft.

10. Removethebearingpilot.

11. Removethecommutator-endbearingcap(42).

12. Usingafeelergauge,checktheradialclearance

betweentherollersandtheinnerraceonthe

commutator-endbearing.Theassembled

clearancemustmeasurebetween0.001and

0.003in.

13. Placethemachineinahorizontalposition.

14. Checkthecommutator-endbearingrunout.

a. Withthetipagainsttheouterraceofthe

bearing,clampanindicatortothe

commutator-endoftheshaft.

b. Toeliminateend-playanddetermineifthe

outerraceistrue,pushthearmature

towardthecommutator-end.Iftheouterraceisoutmorethan0.003in.,besure

thatthedrive-endframeheadboltsare

pulleduptightandthatthereareno

burrsordirtbetweenthetsoftheframe

headandthemagnetframe.

c. Assemblethethrustringontotheendof

theshaft.Positionittightlyagainstthe

bearinginnerrace.

d. Usingan18-in.spannerwrench,assemble

theretainingnutontotheendoftheshaft.

e. Firmlytaptheendofthewrenchwitha

10-lb.bronzehammeruntilthenutstops

turning.Ifyouhaveatorquewrench

available,torquethenutto500lbs-ft.

f. Locktheretainingnut(48)byassembling

andtighteningtwosetscrews(47)witha

torquewrenchsetto38to42lbs.-ft.Ifa

suitabletorquewrenchisnotavailable,

tightenthesetscrewswithastandard

Allenwrenchbyrmlytappingthe

wrenchwitharawhidemalletuntilthe

screwsstopturning.Theimpression

madebythesesetscrewsintheshaft

lockstheretainingnutinplace.

g. Lockthesetscrewsbyprick-punching

thethreadsintwoplaces.

h. Pack2.8oz.ofgreaseintotheouter

circumferenceofthebearingcap(42).

i. Placethegasket(44)intopositiononthe

outerbearingcap(42);assemblethecaptotheframehead(45)withboltsand

lockwashers;andtightenboltsto110to

120lbs-ft.

15. Checkthedrive-endbearingrunout.

a. Removethedrive-endouterbearingcap

(2)andcheckthealignmentoftheouter

bearingracebyclampinganindicatorto

theshaft.


30/56

30

b. Iftheouterracerunsoutmorethan0.004

in.,besuretherearenoburrsordirt

betweentheregistertsoftheframe

headandthemagnetframeandthatthe

frameheadboltsarepulleduptight.

16. Usingafeelerguage,checktheradialclearance

betweenthedrive-endbearingrollersandthe

innerrace.Theassembledclearanceofthe

drive-endbearingmustbebetween0.0012and

0.004in.

a. Withthebearing(6)andcap(10)properly

lledwithgrease,andthegaskets(5)in

place,assembletheouterbearingcap(2)

andtightenthebolts(3)to110to120lbs-ft.

b. Heattheoutersleeve(1)to110C(230F)

andshrinkitontotheshaftuntilitistight againsttheinnerraceofthebearing.

17. Usingadialindicator,checkthearmature

end-play;end-playshouldmeasure

between0.006and0.010in.

Assembling the Armature into the Frame

(Models YZB, YZH, ZB-F, ZH-F, ZB, ZH)

Usethisproceduretoassemblethearmatureintothe

frameformodelsYZB,YZH,ZB-F,ZH-F,ZB,ZH:

Note: For information on the proper lubrication of assembly

hardware, see Lubricating Bolts.

1. Assemblethebrushholders(51)intotheframe.

a. Positionthebrushholderwellbackfromthe

commutatortokeepthemclearfromthe

commutator.

b. Fastenandinsulatetheconnectionsand

installoutgoingcables.

2. Assemblethecommutator-endframehead (45)totheframe.

a. Tightenboltsandwashers(43)uniformly.

b. Torqueboltsto46727lbs-ft.

3. Usingaheavydutystand,blockandlevelthe

frameinaverticalposition,commutator-end

down.

4. Assemblealiftingbailontothedrive-endofthe

shaft.

5. Wrapheavypaperaroundthecommutatorto

provideextraprotection.

6. Withthecommutator-endbearingandbearing

housingassembledontotheshaft,lowerthe

armatureintotheframeuntilthebearinghousingenterstheframehead.Continuetolowerthe

armatureintotheframeuntilthedrive-endframe

headstartsintotheframet.

7. Insertboththedrive-endandcommutator-end

frameheadboltsandwashers.

a. Removeanyburrsordirtbetweenthets

oftheframeheadandthemagnetframe.

b. Drawdowntheboltsandwashersuniformly

topressthearmatureintoplace.Makesure

todrawthemdownevenlytoavoidcocking thebearingassemblyanddamagingthe

races.

CAUTION: Uneven tightening of bolts could dam-

age bearings or related tted surfaces.

8. Placethemachineinahorizontalposition,

tightenallframeheadbolts(41)andtorquebolts

to46727lbs-ft.

9. Pack5.25oz.ofgreaseintotheoutercircumfer-

enceofbearingcap(42).

a. Placethegasket(44)inpositiononthe

bearingcap.

b. Assemblethecaptotheframehead(45)

withboltsandlockwashers(41,43).

c. Torquebolts(41)to110to120lbs-ft.

10. Checkthedrive-endbearingrunout.

a. Removethedrive-endouterbearingcap

(2)andcheckthealignmentoftheouter

bearingrace.

b. Clampanindicatortothedrive-endofthe

shaftwiththetipagainsttheouterraceof

thebearing.

c. Pushthearmaturetowardthedrive-endto

eliminateend-playandrotatethearmature

toseeiftheouterraceistrue.Iftheouter

racerunsoutmorethan0.004in.,besure

therearenoburrsordir tbet weenthe

registertsoftheframeheadandthe


31/56

31

magnetframeandthattheframehead

boltsarepulleduptight.

11. Withafeelerguage,checktheradialclearance

betweenthedrive-endbearingrollersandthe

innerrace.Theassembledclearanceofthe drive-endbearingmustbebetween0.0012and

0.004in.

a. Withthebearing(6)andcap(10)properly

lledwithgrease,andthegaskets(5)in

place,assembletheouterbearingcap(2)

andtightenbolts(3)to110to120lbs-ft.

b. Heattheoutersleeve(1)to110C(230F)

andshrinkitontotheshaftuntilitistight

againsttheinnerraceofthebearing.

12. Usingadialindicator,checkthearmature end-play;end-playshouldmeasurebetween

0.006and0.010in.

Removing the Armature LockingArrangement

Usethisproceduretoremovethearmaturelocking

arrangement:

1. Removethetwoshippingboltsfromthebearing

cap.Theseboltshaveyellowheadsandare

longerthantheotherbolts(seeFigure1).

2. Installthetworegularbolts.Theregularboltsareinabagattachedtooneoftheshippingbolts.

3. Torquetheregularboltsto115lbs-ft.

Note: Put the shipping bolts back in the bag and save them

in case you need to lock the armature at a later date.

Locking the Armature for Shipment

Locatethebagwhereyouhavetheshippingboltsand

usethisproceduretolockthearmatureforshipping:

1. Removetwodiametricallyoppositeboltsinthe

commutator-endbearingcap.

2. Installtheshippingbolts(thelongerboltswith

theheadspaintedyellow,asshowninFigure1)

withjamnutsapplied.

3. Torquetheboltsto30lbs-ft.andtightenthe

jamnuts.

Caution: Do not rotate the armature when the

locking bolts are in place. This can damage the

bearings and the commutator.

4. Placethetworegularboltsinthebagandattach

thebagtooneoftheshippingbolts.

Testing the Armature After Repair

Onceyouhavecompletedallworkonthearmature,

usethisproceduretotestthearmaturebeforebringing

itbackintoservice:

1. Applyahighpotentialtestvoltagebetweenthecommutator(withallsegmentsshorted)andthe

shaftbasedonthefollowingcriteria:

Usedarmature-2000volts,60Hzforone

minute

Rewoundarmature-3500volts,60Hzforone

minute

s WARNING s

High potential testing can be a shock hazard. Electric

shock can cause serious or fatal injury. Take properprecautions during high potential testing.

Note: Measure leakage current to ground during test 3-85.0

milliamps.

2. Conductaresistancemeasurement.Forthe

armatureresistancevalue,seeGeneral

Specications.

Yellow Armature Locking BoltsFigure1


32/56

32

Armature Varnish Treatment

Afteryouhaveeithercleanedandrepairedorre-

woundthearmature,itmustbevacuumpressure

impregnated(VPI).

Balancing the Armature

Dynamicallybalancethearmaturewithin10grams

(0.35oz.)onthedrive-endand12grams(0.42oz.)on

thecommutator-endbyaddingweightsonthecommu-

tatorcapandthearmaturehead.

Inspections

Inspecting the Insulation

Inspecttheinsulationofarmaturecoilsforcracks,physicaldamage,burnsanddeterioration.Replaceor

repairtheinsulationasrequired.

Glass Band,Commutator-endInspecttheglass

bandsforsplittingorfraying;ensurethereareno

looseconnections.

Wire Band,Drive-endInspectthewirebandfor

physicaldamage,loosetieclipsorbrokenwire.

Creepage Band Inspectthesurfaceofthe

Teoncreepagebandforpossibleashover

damage.Tapthebandlightlyandcheckfor movement.Youmustreplacethebandifitisloose

orhasdeepburns.Formoreinformation,see

Replacing the Armature Creepage Band.

Inspecting the Commutator

Checkthecommutatorforthefollowingconditions:

Overallappearancetoensurethe

commutatorisfreeoftreading,pitting,

grooving,burns,atspots,highbarsand

copperdrag.

Concentricitytoensurethatthecommutator

isnotout-of-round.Forconcentricitylimits,

see General Specications.

Propersizetoensurethediameterofthe

commutatoriswithintheallowablesize

range.Fortheminimumpermissible

commutatordiameterdimension,see

General Specications.

Properalignmenttoensuretherearenohighbars

(thecommutatorisnotloose).

Whenrequired,resurfacethecommutator.Formoreinformation,seeResurfacing the Commutator.

Note: If after resurfacing, the brush surface diameter will

be less than the minimum permissible diameter, you must

replace the commutator.

Inspecting the Armature Shaft Bearing Fits

Comparethearmatureshaftbearingtdimensionsto

ensuretheyarewithinthefollowingtolerances:

+ 0.0000

- 0.0008

5.9077 BEARING

FIT PE

+ 0.0000

- 0.0008

5.1203 DIA. BRG.

FIT OPE

(Double Shaft)

+ 0.0000

- 0.0007

3.9389 DIAM.

(BRG. FIT) OPE

Ifthedimensionsarenotwithinthetolerancesyou

mustrepairorreplacethearmatureshaft.

Inspecting the Creepage Band

Inspectthecreepagebandforthefollowingconditions:

Nogapsshouldbevisibleatthejointorbetween

theedgeoftheTeonbandandthecopperbars.

Thebandsurfaceshouldbesmooth,freeof

varnishandbondedtotheunderlaymaterial.

NobubblesshouldappearundertheTeon.

Thebandshouldhavenobuckling.

Thesurfaceshouldbefreeofdamageandnot havescratchesorcuts.

Replacethecreepagebandwhenrequired.


33/56

33

Resurfacing the Commutator

Beforeturningorgrindingthecommutator,youmust

ensurethereissufcientstocksothecommutatorwill

notbeturnedorgroundbelowtheminimumpermissi-

blediameter.SeeGeneral Specicationsforthe

minimumpermissiblecommutatordiameterdimension.

Formoreinformation,seePreparing the Commutator

for Resurfacing.

Note: If after resurfacing, the brush surface diameter will

be less than the minimum permissible diameter, you must

replace the commutator.

s WARNING s

Resurfacing operations can raise dust and ying parti-cles. Wear safety glasses and a respirator for protectionfrom dust and ying particles during resurfacing opera-

tions. Improper protection can result in serious injury.

Grinding

Usethefollowingproceduretogrindthecommutator:

1. Truetheshaftcenterswithrespecttothebearing

tsbyscraping.

2. Placethearmatureeitherinalatheequipped

withagrindingattachmentorinagrinding

machine.Checktheconcentricityofthebearing

ts.TheTIRshouldnotexceed0.001in.

3. Coverthearmaturewindingstokeepitclear

fromdebris.

4. Grindthecommutatorandcheckthecommuta-

torrunoutwithadialindicator.Themaximum

commutatorrunoutis0.001in.

5. Performtherequiredundercutting,rakingandpolishing.

Turning

Ifthesurfaceofthecommutatorisbadlyworn,burned

orscarred,itrequiresturning.Usethefollowing

proceduretoturnthecommutatorinalathe:

1. Truetheshaftcenterswithrespecttothebearing

tsbyscraping.

2. Placethearmatureinalatheandcheckthe

concentricityofthebearingts.TheTIRshould

notexceed0.001in.

3. Coverthearmaturewindingstokeepitclear

fromdebris.

4. Setthecuttingtoolforturningcopper,andset

lathespeedtogivethecommutatorasurface

speedof300feetperminute.

5. Makeclean,smoothcutstoremovejustenough

coppertorenewthecommutatorsurface.Donot

allowthecuttingtooltochatter.Forthedimen-

sionsofthedustgroove,see General

Specications.

6. Afteryouhavecompletedtheturning,checkthe

commutatorrunoutwithadialindicator.The

maximumcommutatorrunoutis0.001in.

7. Performtherequiredundercutting,rakingand

polishing.

Undercutting

Youcanuseahacksawbladetoundercutthecom-

mutator.Werecommendyoukeepthebladesharp;as

thebladedullsitcanproducesmallcracksinthemica

wheredirtormoisturecanbuildupandbreakdownthe

insulationbetweenthecommutatorsegments.With

practice,youcanuseahand-heldpowerundercutter.

Whenusingapowerundercutter,followthetool

manufacturersinstructionsanduseslotguidesanddepthgaugestoensureaccurate,uniformcuts.We

recommendyoutakeafewpracticepassesovera

scrapcommutatortogetabetterunderstandingon

howthetoolreacts.Youmustkeepthepowerunder-

cutterfromjumpingoutoftheslotandacrossthe

commutatorsurface;thehigh-speedoperationofthe

bladewillquicklygougethecommutator.

Afteryouhaveresurfacedthecommutator,usethis

proceduretoundercutthecommutator:

g


34/56

34

1. Undercutthemicabetweenthebarstoadepth

of0.047in.Youshouldperformtheundercutting

withasharp-edgedtoolhavingacuttingwidthof

0.063in.

2. Blowloosematerialoffthecommutatorwithdry,compressedair.

s WARNING s

Using compressed air for cleaning purposes can raisedebris and ying particles. Wear safety glasses and otherpersonal protective equipment when using compressed

air for cleaning purposes. Flying debris and particles mayalso present a hazard to personnel in the immediate area.


Raking

Resurfacingtypicallyleavesparticlesandsliversof

coppereitherhangingonthebaredgesorlodgedin

theundercutslots.Theseparticlescanbridgetheside

micaandcauseaashover.Toensuresafeoperation,

youmustremoveparticlesbeforeyoucanplacethe

motorbackinservice.

Usethisproceduretorakethecommutator:

1. Usingastiff-bristlenylonbrush,brushoutany

loosedirtorcoppersliversattachedtothe

trailingedgeofthebars.Youcanalsouseanew

paintbrushorstencilbrushwiththebristlescut

shorttoaddstiffness.

2. Ifstoningandundercuttingpulledalargeamount

ofcopperfromtheedgesofthebars,useeither

arakingtoolorapieceofberboardapproxi-

mately0.045in.thicktoremovethecopperns

andraggededges.Whenusingarakingtool,use

thetooltorakethebaredgeswiththepoint

insertedintheslotsothatsidesofthetoolrake

thetrailingedgeofthebar.Ifthetoolisground

withatsidesandusedwithmoderatepressure,itwillremoveraggedcoppernsandbreakthe

sharpedgesofthebars.

3. Aftertheslotshavebeenraked,usenesandpa-

pertosandthecommutatortoremoveadditional

smallpiecesofcopperattheedgesoftheslots.

4. Thoroughlycleanthearmaturecoreand

commutatorwithdry,compressedairtoremove

copperanddust.

s WARNING sUsing compressed air for cleaning purposes can raise

debris and ying particles. Wear safety glasses and otherpersonal protective equipment when using compressed



Polishing

Ifthecommutatorisdiscoloredorsmudged,usethis

proceduretopolishthecommutator:

1. Usingcanvas,crocuscloth,ne(4/0)sandpaper

or400ATriemitepaper,polishthecommutator.If

youareusingabrasivepaper,youshouldmount

itonawoodenblockcurvedtotthesurfaceof

thecommutator.

CAUTION: Never use an emery cloth on a com-

mutator. The abrasive particles on emery cloth

scratch the commutator surface and lodge in the

grooves between commutator segments. This can

create conditions that can eventual lead to ash-

over which could seriously damage the machine.

2. Blowloosematerialoffthecommutatorwith

dry,compressedair.

s WARNING s




3. Checkthecommutatorconcentricitywithadial

indicator.Fortherun-outlimits,seeGeneral

Specications.

4. Coverthecommutatorwithheavypaperorfeltto

protectitfromdamageuntilyouarereadyto

bringitbackintoservice.


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35

The Motor Frame

Inspecting and Testing theMotor Frame

Usethefollowingproceduretoinspectandtestthe

motorframe:

1. Inspectthefollowingelementsofthemotorframe:

a. Checktheconnectionstrapinsulationand

theinsulationonthecoilsfordamage,signs

ofburning,cracksordiscoloration.

b. Checktheleadcablesfordamage,

overheatingandsignsofdeterioration.

2. Replaceanymotorframepartsthatfailthe

inspection.Formoreinformation,see

Replacing the Motor Frame Field Coil.

3. Performthefollowingtests:

a. Conducta1,000voltmegohmmetertest

onthecoilsandlookforareadingof20

megohmsormore.

b. Measureandrecordcommutatingand

exciting-coilresistance.RefertoTable1to

determinethecorrectconnectiondiagramfor

themachinebeingrepaired.

c. High-potentialtesttheeldcoilstogroundby applyingahigh-potentialtestof3,400VDC,

60Hzforoneminute.

s WARNING s



4. Replaceanymotorframepartsthatfailtesting.

Formoreinformation,seeReplacing the Motor

Frame Field Coil.

Replacing the Motor FrameField Coil

Youperformthefollowingstepswhenyoureplacethe

motorframeeldcoil:

RemovingtheCoil

InstallingtheCoil

ContactJOLIETEquipmentCorporationtodetermine

thecorrectcoiledframeassemblydrawingforthe

machinebeingrepaired.

Removing the Coil

1. Removeterminalinsulationanddisconnectthe

coilleads.Useeitheragastorchorbrazingtongstoseparatethebrazedconnections.When

youareusingbrazingtongs,uselowvoltageand

highACcurrenttoheatthecoilconnections.

s WARNING s

Brazing requires extremely high temperatures. Wearsafety glasses and leather gloves at all times duringbrazing operations. Improper protection can result in

serious injury.

2. Packabsorbentbotharoundtheinsulationnearthecoilconnectionandovertheadjacentcoils.

Note: If you are using a gas torch, protect the coil insulation

from the heat using a non-ammable heat absorbent, such

as interwoven glass cloth.

3. Ensureallexposedinsulationiscoveredwitha

thicklayerofabsorbent,thenheatandseparate

thecoilconnections.

4. Softenthevarnishinordertoremovethepole

boltsbyheatingthecoiledframeinanovenat

150C(302F)forfourhours.

5. Removethepoleboltsandthecoil-poleassem-

blyfromthemagnetframe.

6. Markanyshimsforreassemblywiththecorre-

spondingpolewhenthecoil(s)isinstalledinthe

frame.

p

g

g


36/56

36

Installing the Coil

Youmustinstallanyexcitingcoilsandbrazetheir

connectionsbeforeyoucaninstallcommutatingcoils.

Formoreinformation,seeBrazing the Coil Terminals.

Usethefollowingproceduretoinstallnewcoil-pole

assemblies:

1. Cleanboththepolecontactsurfaceonthe

frameandthepolepiecemountingsurface.

2. Installthenewpoleandcoilintheframewith

NomexInsulatorandanyshimsthatwereonthe

damagedcoil.Replaceoldwashersunderthe

boltheadswithnewwashers.

3. Lubricatetheboltheads,threadsandwashers

anddrawthepoleboltsmoderatelytight.

4. Brazethecoilconnections.Formoreinforma-

tion,seeBrazing the Coil Terminals.

Brazing the Coil Terminals

Youmustbrazeallcoilconnectionswithsilversolder,

JECAG101.Usetwopiecesofsolder(0.010x1in.x1

in.)betweentheterminalsurfaces.Youcanbrazethe

coilterminalsusingeitherthemachinebrazingmethod

orthegastorchmethod.

Using the Machine Brazing Method

Usethefollowingproceduretobrazethecoiltermi-

nalsusingmachinebrazing:

1. Setthebrazingcurrentto10,800amperesat

1.6volts.

2. Insertsilver-solderbrazingstripsbetween

connections.

3. Clampthebrazingtongsontheconnectionand

brazethejoint.Ifnecessary,addadditionalsoldertollthejointandformalevelsurface.

4. Brazeallexciting-coilconnections.When

complete,youcaninstallthecommutating

coils.

Using the Gas Torch Brazing Method

Usethefollowingproceduretobrazethecoiltermi-

nalsusingthegastorchbrazingmethod:

1. Packthecoilinsulationwithnon-ammableheatabsorbentmaterialsuchasinterwovenglass

cloth.

2. InsertthebrazingstripsanduseaC-clampor

vise-gripplierstoclamptheconnectionsurfaces

tightlytogether.

3. Useatorchtipwitha0.1in.oriceandadjust

thetorchtoobtainaslightlyreducedame.

4. Meltthebrazingstrips;astheymelt,addmore

soldertollthejointandformalevelsurface.

5. Removetheheatabsorbentpackingfromthe

insulation.Usedry,compressedairandblow

outtheinsideoftheframe.

s WARNING s




6. Torquethepolebolts.Formoreinformation,see

Standard Torque Values.

7. Checkthepolarityoftheeldpoles;energizethe

eldcircuitwithabatteryandcheckthepole

polaritywithacompass.

8. Insulatetheconnectionswithsiliconeputtyand

wraptheconnectionswithMylarlm.

9. Usingglasstape,wraptheconnectionsothat

theglasstapeextends1/2inchbeyondthebareareaoftheconnection.

10. Installandconnectanycablesthatyou

previouslyremoved.

11. Flooddipthecoiledframe.Youcanood-dipthe

coiledframeonlyafteryouhaveinsulatedthe

connectionsandinstalledanycablesyouhad

previouslyremoved.Formoreinformation,see

Flood Dipping the Coiled Frame.

Braz

ingtheCoilTer

minals


37/56

37

Flood Dipping the Coiled Frame

Youinsulatethecoiledframebyooddippingonly

afteryouhaverepairedorreplacedtheeldcoilsand

havecompletedallelectricaltests.

Youusevarnishforooddipping.Forbestcoverage,

agitatethevarnishfor15minutesbeforedippingthe

frame.

Usethefollowingproceduretoooddipthecoiled

frame:

1. Checkthatyouhavemadeallcoilconnections;

thattheconnectionsareproperlyinsulated,and

thatallcablesandtiesforcablesandconnection

strapsareinplace.

2. Tiecableendsabovethevarnishlevel.

3. Coatallmachine-tsurfaceswitheitherblack

varnishorstrippingcompoundandplugbolt

holeswithdummybolts.

4. Heatthecoiledframeto40-80C(104-176F)

anddiptheframedrive-enddown(withallcoil

connectionscovered)foratleast15seconds.

5. Drainandremovetheframefromthevarnish

andallowtheframetodrainforatleast5min-

utesinaverticalposition,drive-enddown.

6. Pre-heattheovento150C(302F)andbake

theframebasedonthevarnishmanufacturers

specications.

7. Cleanthevarnishfromallmachinedsurfaces

andunplugthetappedholes.

Testing the Coiled Frame

Testing after Repair (without Armature)Usethefollowingproceduretotestthecoiledframe

(withoutarmature)afterrepair:

1. Pass24.0amperes(60Hzcurrent)throughthe

exciting(series)eldandreadthevoltagedrop.

Itshouldbewithinthefollowingrange:

MinimumVolts13.1

MaximumVolts15.6

2. Pass24.0amperes(60Hzcurrent)throughthe

commutating(CP)eldandreadthevoltage

drop.

Fornon-magneticretainersitshouldbeinthe

followingrange:

MinimumVolts7.3

MaximumVolts8.5

Formagneticretainersitshouldbeinthefollow-

ingrange:

MinimumVolts10.7

MaximumVolts12.4

Testing After RepairUsethefollowingproceduretotestthecoiledframe

afterrepair:

1. Applyahighpotentialtestvoltageaccordingto

thefollowingcriteria:

Usedcoils2000volts,60Hzforone

minute

Newcoils3500volts,60Hzforone

minute

Duringthistest,measureleakagecurrenttoground;themaximumallowableleakageis5.0

milliamps.

s WARNING s



2. Conductaresistancemeasurement.Forthe

resistanceoftheexcitingandcommutating

elds,seeGeneral Specications.


38/56

38

The Connection Boxes

Changing the Position of the

Connection Box

Youcanchangetheconnectionboxonamachine

fromonesidetotheother.

Usethefollowingproceduretochangeaconnection

boxforseriesmotorsfromtherightsideofthemachine

totheleftside.Therearedifferencesinworkingwith

theF1andF2cableswhenchangingthepositionof

theconnectionboxesonshuntmotors.Formore

information,seeDifferences for Shunt Motors.

Note: To change the connection box from the left side of the

machine to the right side, reverse the specic side-orientedsteps.

1. Disconnectallaccessoriesfromtheconnection

box.

2. Removetheconnectionboxcovers.

3. DisconnecttheF1,F2,A1andA2leadsfromthe

connectionbox.

4. Loosenthestrainreliefconnectorsatthebottom

oftheboxandremoveallcablesandconduitfromthebottomofthebox.

5. Disconnecttheblowerandheaterleadsfromthe

terminalboard,theblowerandheaterconduit

andttingsfromtheconnectionbox,andremove

theleads.

6. Disconnectthepressurizingassemblyandtting

fromtheconnectionbox.

7. Disconnectthepressuresensingtubefromthe

rearoftheconnectionbox.

8. Removethemountingboltsandlifttheconnec-

tionboxoffoftherightsideofthemotor.

9. Removethepressuresensingtubeandtting,

theheaterconduitandtting,andthepressuriz-

ingconduitandttingfromtheright

sideofthecommutatorchamber.

10. Removethepipeplugsfromtheleftsideofthe

commutatorchamberandinstallthepipeplugs

inmatchingholesontherightside.

11. Removetheheaterleadsandheaterfromthe

commutatorchamber.

12. ChangetheF1andF2leadsfromtherightside

totheleftsideusingthefollowingsteps:

a. Removethelowersplashguardsfrom

thedrive-endofthemotor.

b. RemovetheinsulationfromtheF1and

F2connectionsinsideofthemagnet

framethroughtheairoutletholes.

c. Removetheboltsfromtheconnections

andremovetheF1andF2externalleads

fromtheelbowinthemagnetframe.

d. Removetheelbow.

e. Insulatethebareterminalsleftinthe

magnetframeand,ifnecessary,tie

downtheleads.Formoreinformation,

seeInsulating the Terminal Connections.

f. Removethepipeplugfromtheleftside

offrameandinstallintheholevacated

bytheelbowandtheF1andF2leads.

g. RemovetheinsulationfromtheF

terminalsinsideofthemagnetframeon

theleftsidethroughtheairoutlethole.

h. InstalltheelbowandtheF1andF2leads

intheholeontheleftsideofthemagnet

frame.

i. ConnecttheF1andF2leadstothecorrect

Documents

DC Drilling Motor Maintenance Manual