S6260-BJ-GTP-010 0910-LP-108-0244 VOLUME 1 REVISION 1 [SGML VERSION: SEE CHANGE RECORD] TECHNICAL MANUAL ELECTRICAL MACHINERY REPAIR; VOLUME 1, ELECTRIC MOTOR, SHOP PROCEDURES MANUAL DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED. THIS MANUAL SUPERSEDES S6260-BJ-GTP-010, DATED 15 NOVEMBER 2005, AND ALL CHANGES THERETO. PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND. 9 JUL 2009 TITLE-1 / (TITLE-2 Blank)@@FIpgtype@@TITLE@@!FIpgtype@@ @@FIpgtype@@TITLE@@!FIpgtype@@ TITLE-2 @@FIpgtype@@BLANK@@!FIpgtype@@ S6260-BJ-GTP-010 RECORD OF CHANGES CHANGE NO. DATE TITLE OR BRIEF DESCRIPTION ENTERED BY NOTE THIS TECHNICAL MANUAL (TM) HAS BEEN DEVELOPED FROM AN INTELLIGENT ELECTRONIC SOURCE KNOWN AS STANDARD GENERALIZED MARKUP LANGUAGE (SGML). THERE IS NO LOEP. ALL CHANGES, IF APPLICABLE, ARE INCLUDED. THE PAGINATION IN THIS TM WILL NOT MATCH THE PAGINATION OF THE ORIGINAL PAPER TM; HOWEVER, THE TECHNICAL CON- TENT IS EXACTLY THE SAME. RECORD OF CHANGES-1 / (RECORD OF CHANGES-2 Blank) RECORD OF CHANGES-2 @@FIpgtype@@BLANK@@!FIpgtype@@ S6260-BJ-GTP-010 FOREWORD This Electric Motor Repair Shop Procedures Manual is for use by IMA personnel engaged in electric motor repair. For maximum effectiveness, this manual should be used as a supplement to any ongoing on-the-job training in the IMA electrical repair shop. Both mechanical and electrical test equipment and tools are discussed with detailed ″how-to-use″ informa- tion. This manual provides specific step-by-step inspection and test procedures with related safety precautions. Troubleshooting procedures with symptom recognition and listings of probable faults are explained. ″How-to-do- it″ step-by-step disassembly, checkout, repair, replacement and reassembly procedures are all illustrated with ″hands-on″ diagrams for easy understanding. To ensure reliable equipment operation and equipment long life, installation procedures are provided with quality control provisions. Navy equipment technical manuals and NAVSEA technical manuals provide the necessary instructions about what must be done for the maintenance and repair of equipment. This Shop Procedures Manual supple- ments the information in the preceding Navy references and other publications and provides the necessary details on how the repair work is to be done to ensure equipment reliability. This Electric Motor Repair Shop Procedures Manual has been developed with a primarily functional for- mat instead of a topical format. This is designed to facilitate equipment repairs. A repair technician finds useful information in the necessary sequence and can perform a single task, or a related series of tasks, by referring to only one section of the manual. Necessary descriptive information has been retained, but is presented as part of the relevant functional procedures. This functional format improves the effectiveness of the manual and is espe- cially suited to the improvement of technician performance. Ships, training activities, supply points, depots, Naval Shipyards and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of NAVSEA technical manuals. All errors, omissions, discrepancies and suggestions for improvement to NAVSEA technical manuals shall be forwarded to: COMMANDER, CODE 310 TMDER, BLDG 1388 NAVSURFWARCENDIV NSDSA 4363 MISSILE WAY PORT HUENEME CA 93043-4307 on NAVSEA/SPAWAR Technical Manual Deficiency/Evaluation Report (TMDER), NAVSEA form 4160/1. All feedback comments shall be thoroughly investigated and originators will be advised of action resulting therefrom. One copy of NAVSEA form 4160/1 is at the end of each separately bound technical manual 8-1/2 x 11 inches or larger. Copies of NAVSEA form 4160/1 may be requisitioned from the Naval Systems Data Support Activity Code 310 at the above address. Users are encouraged to transmit deficiency submittals via the Naval Systems Data Support Activity web site located at: https://nsdsa2.phdnswc.navy.mil/tmder/tmder-generate.asp?lvl=1 Individual electronic TMs do not contain NAVSEA form 4160/1 but are linked to an electronic version on the resident CD-ROM. Therefore, we encourage the user to transmit deficiency submittals via the Naval Systems Data Support Activity web site located above. FOREWORD-1 / (FOREWORD-2 Blank) FOREWORD-2 @@FIpgtype@@BLANK@@!FIpgtype@@ S6260-BJ-GTP-010 TABLE OF CONTENTS Chapter/Paragraph Page 1 INTRODUCTION SECTION .............................. 1-1 1-1 SCOPE. ........................................... 1-1 SECTION I QUALITY ASSURANCE ................................ 1-1 1-2 INTRODUCTION TO QA. ................................ 1-1 1-4 DEFINITION OF TERMS. ................................ 1-2 1-5.1 Quality Control (QC). ............................... 1-2 1-5.2 Quality Assurance (QA). ............................. 1-2 1-5.3 Objective Quality. ................................. 1-2 1-5.4 Controlled Material. ................................ 1-2 1-5.5 Formal Work Procedures (FWP). ........................ 1-2 1-5.6 Material Identification and Control (MIC) Number. .............. 1-2 1-5.7 Certified Level I Material. ............................ 1-2 1-6 WORK PACKAGES. ................................... 1-3 1-8 CRITICAL QUALITY CONTROL POINTS. ...................... 1-3 1-9 SHIPS MAINTENANCE ACTION FORM (OPNAV Form 4790/2K). ........ 1-4 1-10 MAINTENANCE PLANNING AND ESTIMATING FORM (OPNAV Form 4790/2P). ......................................... 1-4 1-11 CONTROLLED WORK PACKAGES (CWPs). ..................... 1-4 1-12 LEVELS OF ASSURANCE. ............................... 1-4 1-13.1 Level A. ...................................... 1-5 1-13.2 Level B. ...................................... 1-5 1-13.3 Level C. ...................................... 1-5 1-14 MATERIAL REQUIREMENTS. ............................. 1-9 1-16 DEPARTURES FROM SPECIFICATIONS. ....................... 1-10 1-17.2 Reporting Departures from Specifications. ................... 1-10 1-17.3 Types of Departures from Specification. ..................... 1-10 1-17.4 Permanent and Temporary Approval of Departure from Specification. .... 1-11 1-18 RESPONSIBILITIES OF SHOP QUALITY CONTROL INSPECTOR (QCI). .... 1-11 1-20 RESPONSIBILITIES OF REPAIR PERSONNEL. ................... 1-12 SECTION II INTRODUCTION TO TAG-OUT ........................... 1-13 1-22 INTRODUCTION TO TAG-OUT. ............................ 1-13 i S6260-BJ-GTP-010 TABLE OF CONTENTS - Continued Chapter/Paragraph Page 1-24 TAG-OUT RESPONSIBILITIES. ............................. 1-13 1-25 TAG-OUT PLANNING. .................................. 1-14 1-26 TAGS AND RECORDS. ................................. 1-14 1-27.1 CAUTION Tag. .................................. 1-14 1-27.2 DANGER Tag. .................................. 1-14 1-27.3 DANGER/CAUTION Tag-out Record Sheet. .................. 1-14 1-27.4 Tag-out Log. .................................... 1-14 1-27.5 Preparation of Tags and Record Sheets. ..................... 1-14 1-28 TAG-OUT OF ELECTRIC MOTORS. .......................... 1-15 SECTION III ELECTRIC MOTOR REPAIR ............................. 1-20 1-30 INTRODUCTION TO ELECTRIC MOTORS. ..................... 1-20 1-32 MOTOR RATINGS. .................................... 1-20 1-33 VOLTAGE AND FREQUENCY VARIATIONS. .................... 1-20 1-34 DESCRIPTION OF AC MOTORS. ............................ 1-20 1-35 FUNCTIONS OF THE ELECTRICAL REPAIR SHOP. ................ 1-21 2 TEST EQUIPMENT AND MEASURING INSTRUMENTS ............ 2-1 2-1 SCOPE. ........................................... 2-1 2-2 PURPOSES OF TYPICAL ELECTRICAL TEST EQUIPMENT. ........... 2-1 2-3.1 Measurement of Insulation Resistance. ..................... 2-1 2-3.2 Measurement of Winding Resistances. ..................... 2-2 2-3.3 Phase Comparison of Windings. ......................... 2-2 2-3.4 Measurement of Phase Current. ......................... 2-2 2-3.5 DC High-Potential Test. ............................. 2-2 2-3.6 Polarization Index Test. .............................. 2-2 2-3.7 AC High-Potential Test. ............................. 2-2 2-3.8 Core Test. ..................................... 2-2 2-4 GENERAL RADIO MEGOHM BRIDGE. TYPE 1644A. ............... 2-2 2-6 CONTROLS AND CONNECTORS. ........................... 2-4 2-7 OPERATION. ....................................... 2-4 2-8 GENERAL RADIO MEGOHMMETER, TYPE 1863. ................. 2-7 2-10 RANGE. .......................................... 2-8 ii S6260-BJ-GTP-010 TABLE OF CONTENTS - Continued Chapter/Paragraph Page 2-11 CONTROLS AND CONNECTORS. ........................... 2-9 2-12 PREPARATION. ...................................... 2-9 2-13 MEASUREMENT SETUP. ................................ 2-10 2-14 MEASUREMENT PROCEDURE. ............................ 2-13 2-15 VALHALLA DIGITAL OHMMETER. .......................... 2-14 2-17 CONTROLS AND CONNECTORS. ........................... 2-14 2-18 OPERATION. ....................................... 2-15 2-19 BAKER ST112E SURGE/DC HIGH-POTENTIAL TESTER. ............. 2-18 2-21 CONTROLS AND CONNECTORS. ........................... 2-19 2-22 OPERATION. ....................................... 2-19 2-23 OPERATION. ....................................... 2-24 2-24 EXTERNAL GROWLER. ................................. 2-26 2-25 TYPICAL CLAMP-ON AMMETER. .......................... 2-28 2-27 CONTROLS AND CONNECTORS. ........................... 2-28 2-28 OPERATION. ....................................... 2-29 2-29 TYPICAL DIGITAL AC/DC CLAMP-ON MULTIMETER. .............. 2-31 2-31 CONTROLS AND CONNECTORS.