FOUO C04.0 2.1 S6260-BJ-GTP-010 Elec Machinery Repair, Electric motor manual.pdf

TECHNICAL MANUAL

FOR

[SGML VERSION; SEE RECORD OF

REVISIONS ]

SHOP PROCEDURES MANUAL

ELECTRICAL MACHINERY

REPAIR

ELECTRIC MOTOR REPAIR

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS

UNLIMITED.

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS

RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC 2751, ET

SEQ.) OR THE EXPORT ADMINISTRATION ACT OF 1979, AS AMENDED, TITLE 50,

U.S.C., APP 2401 ET SEQ. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO

SEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH PROVISIONS

OF DOD DIRECTIVE 5230.25(D).

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLO-

SURE OF CONTENTS OR RECONSTRUCTION OF THIS DOCUMENT.

SUPERSEDURE NOTICE: THIS PUBLICATION IS EFFECTIVE UPON RECEIPT AND

SUPERSEDES NAVSEA 0900-LP-060-2010 DATED 4 MAY 2000 AND ALL CHANGES

THERETO.

S6260-BJ-GTP-010

0910-LP-104-6967 VOLUME 1

TITLE-1 / (TITLE-2 Blank)@@FIpgtype@@TITLE@@!FIpgtype@@ @@FIpgtype@@TITLE@@!FIpgtype@@

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND.

15 NOV 2005

TITLE-2

@@FIpgtype@@BLANK@@!FIpgtype@@

RECORD OF REVISIONS

REVISION NO. DATE TITLE AND/OR BRIEF DESCRIPTION/PREPARING ACTIVITY

0 15 NOV 2005 CHANGED TMIN FROM 0900-LP-060-2010 AND INCORPORATED

TMDER N00024-05-JA03. CHANGE AUTHORIZED BY NSWCCD-SSES

CODES 9442 AND 9344. MADE CHANGES TO THE USE OF

EXTENDED LIFE DOUBLE SEAL BALL BEARINGS AND USE OF

SOLVENTLESS VARNISHES BY REPAIR ACTIVITIES.

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 CONTENT IS EXACTLY THE SAME.

ANY CHANGES RECEIVED AFTER RECEIPT OF THIS TM WILL ONLY FIT IN THIS PAGINATED VERSION.

S6260-BJ-GTP-010

RECORD OF REVISIONS-1 / (RECORD OF REVISIONS-2 Blank)

RECORD OF REVISIONS-2

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:

http://nsdsa.phdnswc.navy.mil/tmder/tmder.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

TABLE OF CONTENTS

Chapter/Paragraph Page

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SECTION I. QUALITY ASSURANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 INTRODUCTION TO QA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-4 DEFINITION OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-6 WORK PACKAGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-12 LEVELS OF ASSURANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-14 MATERIAL REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-16 DEPARTURES FROM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-18 RESPONSIBILITIES OF SHOP QUALITY CONTROL INSPECTOR (QCI). . . . . 1-11

1-20 RESPONSIBILITIES OF REPAIR PERSONNEL. . . . . . . . . . . . . . . . . . . . 1-13

SECTION II. INTRODUCTION TO TAG-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1-22 INTRODUCTION TO TAG-OUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1-24 TAG-OUT RESPONSIBILITIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1-26 TAGS AND RECORDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

1-35 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. . . . . . . . . . . . 2-2

2-4 GENERAL RADIO MEGOHM BRIDGE. TYPE 1644A. . . . . . . . . . . . . . . . 2-3

2-8 GENERAL RADIO MEGOHMMETER, TYPE 1863. . . . . . . . . . . . . . . . . . 2-8

i

TABLE OF CONTENTS - Continued

2-11 CONTROLS AND CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-15 VALHALLA DIGITAL OHMMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2-19 BAKER ST112E SURGE/DC HIGH-POTENTIAL TESTER. . . . . . . . . . . . . . 2-19

2-24 EXTERNAL GROWLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

2-25 TYPICAL CLAMP-ON AMMETER. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

2-33 STROBOTAC, TYPE 1531-AB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

2-37 POLARIZATION INDEX TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

2-38 LEXSECO CORE TESTER 1081D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

2-39 AC DIELECTRIC TEST SET, HIPOTRONICS, INC., MODEL 710-1. . . . . . . . . 2-43

2-45 AC AND DC DIELECTRIC TEST SET, HIPOTRONICS, INC., MODEL 115-A. . . 2-48

2-53 TYPICAL DIAL INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

2-58 TYPICAL BORE GAGE AND RING MASTER. . . . . . . . . . . . . . . . . . . . . 2-59

2-62 TYPICAL SNAP GAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

3 IN-PLACE ELECTRICAL AND MECHANICAL TROUBLESHOOTING . . . 3-1

3-1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2 IN-PLACE TEST AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-4 VISUAL INSPECTION PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-5 ELECTRICAL TEST PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-6 MECHANICAL INSPECTION PROCEDURES. . . . . . . . . . . . . . . . . . . . . 3-5

3-9 BEARING RUNOUT TEST PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . 3-9

3-10 OPERATIONAL TEST PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

4 RIGGING AND TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 PREPARATION FOR MOVING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ii

4-7 RIGGING FUNDAMENTALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-15 TRANSPORTING THE MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-18 TRANSPORTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4-19 MOTOR ROTOR TRANSPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

5 IN-SHOP ELECTRIC MOTOR INSPECTION AND DISASSEMBLY . . . . . . 5-1

5-1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2 ELECTRIC SHOP RECORDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-7 INITIAL MECHANICAL INSPECTION PROCEDURES. . . . . . . . . . . . . . . . 5-2

5-11 DISASSEMBLY PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5-18 ELECTRICAL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

6 MOTOR BEARINGS AND BEARING PROBLEMS . . . . . . . . . . . . . . . . 6-1

6-1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 TYPES OF MOTOR BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-4 BALL BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-6 BEARING IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-7 BEARING DESIGN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-9 CARE OF UNMOUNTED BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-10 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-11 CARE OF MOUNTED BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-17 BEARING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6-21 DISASSEMBLY AND BEARING REMOVAL. . . . . . . . . . . . . . . . . . . . . . 6-28

6-25 BEARING INSTALLATION AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 6-39

6-30 SPECIAL PROCEDURES FOR DUPLEX BEARINGS. . . . . . . . . . . . . . . . . 6-46

6-33 GREASE PACK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53 iii

6-37 POSTREPAIR INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54

6-39 MOTOR BEARING CONVERSION: EXTENDED-LIFE DOUBLE SEAL BALL

BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57

7 PREPARATION FOR MOTOR RECONDITIONING . . . . . . . . . . . . . . . 7-1

7-1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2 CLEANING THE MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-10 DRYING THE MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-16 TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-18 CLEANING ELECTRICAL EQUIPMENT AFTER SEAWATER DAMAGE. . . . . 7-9

7-20 CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

8 BURNOUT AND STRIPPING PROCEDURES . . . . . . . . . . . . . . . . . . . 8-1

8-1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-2 WINDING IDENTIFICATION AND DATA COLLECTION. . . . . . . . . . . . . . 8-1

8-12 OVEN BURNOUT AND STRIPPING. . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8-16 STRIPPING A STATOR BY WARMING AND PULLING. . . . . . . . . . . . . . . 8-10

8-22 STATOR CLEANUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8-30 STATOR SEALING OR VARNISHING. . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

9 MOTOR REWIND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9-1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9-2 MOTOR REWIND EQUIPMENT AND MACHINE SETUP. . . . . . . . . . . . . . 9-1

9-8 WINDING SAMPLE COILS AND WINDING GROUPS. . . . . . . . . . . . . . . . 9-4

9-15 INSULATION PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

9-21 WINDING THE STATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15

9-26 MAKING AND TESTING CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . 9-23

9-34 POSTWINDING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29 iv

9-38 REWINDING MOTORS WITH A SEALED INSULATION SYSTEM (SIS). . . . . 9-30

10 VARNISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10-1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10-2 CHARACTERISTICS OF VARNISH. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10-3 TERMINOLOGY USED WITH VARNISH. . . . . . . . . . . . . . . . . . . . . . . . 10-2

10-4 VARNISH SELECTION CRITERIA. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

10-5 FUNCTIONAL CONSIDERATIONS OF VARNISH. . . . . . . . . . . . . . . . . . . 10-4

10-8 CONSTRUCTION OF A VARNISH TANK. . . . . . . . . . . . . . . . . . . . . . . 10-6

10-13 VARNISH TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

10-20 THINNING AND STORING VARNISH. . . . . . . . . . . . . . . . . . . . . . . . . 10-11

10-23 VARNISHING RECONDITIONED WINDINGS . . . . . . . . . . . . . . . . . . . . 10-12

10-27 VARNISHING NEW WINDINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13

11 ELECTRICAL TEST, REASSEMBLY, AND FINAL INSPECTION . . . . . . . 11-1

11-1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11-2 STATOR PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11-4 TESTING THE WINDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11-6 CHECKING SHAFT BEARING JOURNALS AND BEARING HOUSINGS. . . . . 11-2

11-8 VISUAL INSPECTION OF END BELLS. . . . . . . . . . . . . . . . . . . . . . . . . 11-2

11-10 MOTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

11-12 FINAL ELECTRICAL TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7

12 TRANSPORTATION, INSTALLATION, AND TESTING . . . . . . . . . . . . . 12-1

12-1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12-2 TRANSPORTING MOTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12-4 MOUNTING MOTOR TO FOUNDATION. . . . . . . . . . . . . . . . . . . . . . . . 12-1 v

12-6 TESTING MOTOR ROTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

12-9 TESTING THE CONNECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3

12-11 TAG-IN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

12-13 MOTOR TEST PREPARATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

12-15 MOTOR STARTING AND TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

A SUPPORT DOCUMENTATION AND SOURCES . . . . . . . . . . . . . . . . . . A-1

B SPECIFIC REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

C MOTOR WINDING CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

D IDENTIFICATION OF WINDINGS . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

E PROCEDURE FOR DETERMINATION OF ELECTRIC MOTOR

CONNECTIONS IN ENCAPSULATED MOTORS . . . . . . . . . . . . . . . . E-1

F DESCRIPTIONS AND FEDERAL STOCK NUMBERS OF ELECTRICAL

INSULATING MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

G ELECTRIC MOTOR REWIND QUICK REFERENCE . . . . . . . . . . . . . . G-1

vi

LIST OF TABLES

Table Title Page

2-1. General Radio Megohm Bridge, Type 1644A, Controls and Connectors . . . . . . . 2-4

2-2. General Radio Megohmmeter, Type 1863, Front Panel Controls and Connectors . . . 2-11

2-3. General Radio Megohmmeter, Type 1863, Rear Panel Controls and Connectors . . . 2-12

2-4. Valhalla Digital Ohmmeter Controls and Connections . . . . . . . . . . . . . . . . . 2-16

2-5. Baker ST112E Surge/Hipot Tester Controls and Connectors . . . . . . . . . . . . . . 2-22

2-6. Typical Growler Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

2-7. Clamp-on Ammeter Controls and Connectors . . . . . . . . . . . . . . . . . . . . . . 2-30

2-8. AC/DC Digital Clamp-On Multimeter Controls and Connectors . . . . . . . . . . . . 2-34

2-9. AC/DC Digital Clamp-On Multimeter LCD Display . . . . . . . . . . . . . . . . . . 2-36

2-10. Strobotac Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

2-11. AC Dielectric Test Set Controls and Connectors . . . . . . . . . . . . . . . . . . . . 2-45

2-12. AC and DC Dielectric Test Set Controls and Connectors . . . . . . . . . . . . . . . . 2-50

2-13. Typical Bore Gage Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

2-14. Bearing Housing Diameter Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

2-15. Shaft Measurement Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

2-16. Bearing Shaft Diameter Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

3-1. Electric Motor Failure Symptoms and In-Place Corrective Action . . . . . . . . . . . 3-1

3-2. Insulation Resistance for Generators and Motors . . . . . . . . . . . . . . . . . . . . 3-5

3-3. Recommended Maximum Axial Runout for Bearing, Shaft, and Housing Assemblies Using Quiet Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

6-1. Common Bearing Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2. Ball Bearing Interchangeability Data for Grade 00 Bearings (Bore Code 09) . . . . . 6-4

6-3. Shaft Diameter Limits for Grade 00 and Quiet Bearings . . . . . . . . . . . . . . . . 6-10

6-4. Housing Bore Limits for Grade 00 and Quiet Bearings . . . . . . . . . . . . . . . . . 6-11

6-5. Repair Methods for Undersized Bearing Shaft Seats . . . . . . . . . . . . . . . . . . 6-13

6-6. Torque Values for Bearing Locknuts (Dry Threads) . . . . . . . . . . . . . . . . . . . 6-45

6-7. Recommended Prevailing Torque Values, Locknut Reuse . . . . . . . . . . . . . . . . 6-46 vii

LIST OF TABLES - Continued

6-8. Recommended Torque (in Foot-Pounds) for Bolts, Nuts, and Studs on End Caps and End Bells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

6-9. Recommended Maximum Axial Runout for Bearing, Shaft, and Housing Assemblies Using Quiet Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54

6-10. ELDS Bearings NSNs and Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . 6-58

7-1. Vapor Pressure of Water at Different Temperatures . . . . . . . . . . . . . . . . . . . 7-7

7-2. Insulation Resistance for Generators and Motors . . . . . . . . . . . . . . . . . . . . 7-9

8-1. Motor Speed Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8-2. Lead Wire Table for Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

8-3. Wire Table Standard Annealed Solid Copper Wire (American Wire Gage - B&S) . . 8-8

10-1. Varnishing Procedure: Solvent-Containing Varnish . . . . . . . . . . . . . . . . . . . 10-14

10-2. Varnishing Procedure: Solventless Varnish . . . . . . . . . . . . . . . . . . . . . . . . 10-15

11-1. Recommended Torque (in Foot-Pounds) for Bolts, Nuts, and Studs on End Caps and End Bells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7

F-1. Identification of Types of Magnet Wire . . . . . . . . . . . . . . . . . . . . . . . . . F-1

F-2. Round Film Insulated Magnetic Wire (J-W-1177) 1, 2 . . . . . . . . . . . . . . . . . F-2

F-3. Slot and Phase Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3

F-4. MIL-I-24204, Polyamide Paper, Federal Supply Class 5970 (For Equipment Rated 600 Volts and Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4

F-5. Insulation Sleeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4

F-6. Insulation Sleeving, MIL-I-3190C, Acrylic Glass (Temperature Index 155) Federal Supply Class 5790, U/I Ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4

F-7. Insulation Sleeving, MIL-I-3190C, Silicone Rubber Glass (Temperature Index 200) Federal Supply Class 5790, U/I Ft. . . . . . . . . . . . . . . . . . . . . . . . . . . F-5

F-8. MIL-I-3190C, Polyamide Glass (Temperature Index 220) Federal Supply Class 5970, U/I Ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5

F-9. MIL-P-997, Glass Silicone Type GSG (Temperature Index 200) . . . . . . . . . . . . F-6

F-10. Identification of Types of Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6

F-11. MIL-T-43435A, Polyamide Tape - Heat Resistant, Flat Braids, Navy Supply Class 5970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6

F-12. MIL-Y-1140, Tape, Textile, Glass, Untreated, ECC-B, Federal Supply Class 8315 . . F-7 viii

LIST OF TABLES - Continued

F-13. MIL-T-15126, Tape, Adhesive, Glass Backing Federal Supply Class 5970 (Temperature Index 155) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7

F-14. MIL-T-19166, Tape, Adhesive, Glass Backing Federal Supply Class 5970 (Temperature Index 200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7

F-15. Lead Wire, MIL-W-16878 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7

F-16. Formed Polyamide Paper (U Shape) Federal Supply Class 5970, U/I Ft. . . . . . . . F-8

F-17. Miscellaneous Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . F-9

F-18. MIL-I-24092, Varnish, Clear, Baking, Solvent-Containing Types 1 . . . . . . . . . . F-9

F-19. MIL-I-24092, Varnish, Clear, Air-Drying, Solvent-Containing Type 1 . . . . . . . . . F-9

F-20. MIL-I-24092, Varnish, Clear, Air-Drying Type . . . . . . . . . . . . . . . . . . . . . F-9

F-21. Red Insulating Varnish, Air Dry 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10

F-22. Solventless Baking Varnish for Dipping for Use on Submarine Equipment . . . . . . F-10

F-23. Solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10

F-24. Flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10

G-1. Insulation Resistance for Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

G-2. Oven Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2

G-3. Motor Speed Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3 ix

LIST OF ILLUSTRATIONS

Figure Title Page

1-1. Material In-Process Control Tag (QA Form 2) . . . . . . . . . . . . . . . . . . . . . . 1-4

1-2. Maintenance Planning and Estimating Form (OPNAV Form 4790/2P) . . . . . . . . 1-6

1-3. Controlled Work Package (QA Form 9) Cover Sheet Maintenance Certification Record/Re-Entry Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-4. Test and Inspection Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-5. Controlled Work Package (QA Form 49) . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1-6. Departure from Specification Request (QA Form 12) . . . . . . . . . . . . . . . . . . 1-12

1-7. CAUTION Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1-8. DANGER Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-9. DANGER/CAUTION Tag-out Record Sheet (Page 1 of 2) . . . . . . . . . . . . . . . 1-17

1-9. DANGER/CAUTION Tag-out Record Sheet (Page 2 of 2) . . . . . . . . . . . . . . . 1-18

1-10. Handle Locking Devices for Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . 1-19

1-11. Cross Section and Schematic of a Typical Polyphase Induction Motor . . . . . . . . 1-22

2-1. Megohm Bridge, Type 1644A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-2. Grounding Link Connection, Megohm Bridge, Type 1644A . . . . . . . . . . . . . . 2-7

2-3. Megohmmeter, Type 1863 (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-4. Megohmmeter, Type 1863 (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-5. Grounding Link Connection, Megohmmeter, Type 1863 . . . . . . . . . . . . . . . . 2-13

2-6. Valhalla Model 4100 ATC Digital Ohmmeter . . . . . . . . . . . . . . . . . . . . . . 2-15

2-7. Motor Data Sheet (Electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2-8. Waveform for Two Good Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-9. Waveform for a Defective Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2-10. Baker ST112E Surge/Hipot Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2-11. Waveshapes of Typical Winding Faults . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2-12. Waveform for an Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2-13. DC High-Potential Test Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2-14. External Growler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 x

LIST OF ILLUSTRATIONS - Continued

2-15. Clamp-on Ammeter, Model SPR-300 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

2-16. AC/DC Digital Clamp-On Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

2-17. Strobotac Type 1531-AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

2-18. Insulation Resistance-Temperature Nomograph . . . . . . . . . . . . . . . . . . . . . 2-41

2-19. AC Dielectric Test Set Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . 2-44

2-20. AC and DC Dielectric Test Set Front Panel Controls . . . . . . . . . . . . . . . . . . 2-50

2-21. Dial Indicator (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

2-22. Shaft Runout Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

2-23. Motor Data Sheet (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

2-24. Measuring Bearing Inner Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

2-25. Typical Bore Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

2-26. Typical Snap Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

3-1. Motor Data Sheet (Electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2. Typical Motor Data Sheet (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-3. Checking Motor Shaft Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-4. Measuring Bearing Inner Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

4-1. Use of Wire Rope Clamp Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4-2. Wire Rope Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-3. Mousing Wire Rope Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-4. Types of Chain Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4-5. Single-Drum Hand Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-6. Two-Legged Bridle Sling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-7. Two-Legged Bridle Sling Lifting Motor with Safety Hook . . . . . . . . . . . . . . . 4-12

4-8. Yard and Stay Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-9. Shaft Protection Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-10. Typical Rotor Sling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 xi

5-1. Motor Data Sheet (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-2. Checking Motor Shaft Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3. Matchmarking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-4. End Bell Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-5. Installing Packing to Support Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-6. Shaft Runout Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-7. Removing Bearing Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-8. Typical Locknut Wrench and Table of Dimensions . . . . . . . . . . . . . . . . . . . 5-14

5-9. Motor Data Sheet (Electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

6-1. Mounting Methods for Vertically Mounted Ball Bearings . . . . . . . . . . . . . . . 6-7

6-2. Mounting Methods for Horizontally Mounted Ball Bearings . . . . . . . . . . . . . . 6-9

6-3. Typical Locknut Wrench and Table of Dimensions . . . . . . . . . . . . . . . . . . . 6-27

6-4. Application of Mounting and Dismounting Forces to Tightly Fitted Bearing Rings . 6-30

6-5. Arbor Press Method of Removing Bearings . . . . . . . . . . . . . . . . . . . . . . . 6-31

6-6. Bearing Puller Removal Using Split Puller Attachment and Shaft Protector . . . . . 6-32

6-7. Split Spacer Allows Use of Cover to Remove Inner Ring . . . . . . . . . . . . . . . 6-34

6-8. Using a High-Speed Grinder to Cut Outer Ring . . . . . . . . . . . . . . . . . . . . . 6-36

6-9. Cutting Inner Ring with High-Speed Grinder . . . . . . . . . . . . . . . . . . . . . . 6-37

6-10. Using Chisel to Remove Inner Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

6-11. Motor Data Sheet (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

6-12. Measuring Shaft Shoulder Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

6-13. Pressing Bearings on Shaft with an Arbor Press . . . . . . . . . . . . . . . . . . . . . 6-42

6-14. Effect of Dirt in Mounting Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

6-15. Conventional Locknut and Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

6-16. Self-Locking Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

6-17. Hammer Mounting (Use in Emergencies Only) . . . . . . . . . . . . . . . . . . . . . 6-49 xii

6-18. Duplex Bearing Arrangements Showing Relation of the Outer Ring Faces . . . . . . 6-50

6-19. Bearing Ring Radial Runout Alignment of Precision Bearing Pairs . . . . . . . . . . 6-51

6-20. Mounting of Duplex Bearing (DB Mount Shown) . . . . . . . . . . . . . . . . . . . 6-52

6-21. Measurement Location for Determining Bearing Axial Runout and Shaft Radial Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

6-22. Measurement Location for Determining Face and Rim Runouts . . . . . . . . . . . . 6-56

8-1. Motor Repair Identification Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8-2. Portions of Distributed and Basket Windings . . . . . . . . . . . . . . . . . . . . . . 8-6

8-3. Removing Slot Wedges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

8-4. Cutting Off End Turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

8-5. Coil Puller Setup for Electrical Heating . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

9-1. Motor Repair Identification Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9-2. Winding Head and Wire Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9-3. Tying of Coils on Winding Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

9-4. Tape Applied to Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

9-5. Cuffing of Slot Cell Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

9-6. Method of Fitting Slot Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

9-7. Slot Cell Width Precut with Feeder Paper . . . . . . . . . . . . . . . . . . . . . . . . 9-12

9-8. Lengths of Slot Insulator Pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

9-9. Folding Slot Insulation Cuffs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

9-10. Fitting the Pieces of a Slot Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

9-11. Slot Insulation Fitting for Feeder Paper . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

9-12. Completed Stator with Tools Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

9-13. Partially Completed Stator in Stator Holder . . . . . . . . . . . . . . . . . . . . . . . 9-17

9-14. Placing of Coil Sides from Slot Edges . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19

9-15. Protection of Coil Sides from Slot Edges . . . . . . . . . . . . . . . . . . . . . . . . 9-20

9-16. Temporary Wedge Holding Down Coil Sides . . . . . . . . . . . . . . . . . . . . . . 9-21 xiii

9-17. Cutting of Slot Cell Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22

9-18. Closing Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23

9-19. Placement of Phase Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24

9-20. Trimming of Phase Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25

9-21. Heat Sinks in Place and Placement of Sleeving . . . . . . . . . . . . . . . . . . . . . 9-27

9-22. Lacing of End Turns and Coil Connections . . . . . . . . . . . . . . . . . . . . . . . 9-28

9-23. External Connection Prior to Soldering . . . . . . . . . . . . . . . . . . . . . . . . . 9-29

10-1. Varnish Viscosity Chart, No. 2 Zahn Cup and No. 1 Demmler Cup . . . . . . . . . . 10-10

11-1. Motor Data Sheet (Electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

11-2. Motor Data Sheet (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

D-1. Single- and Two-Layer Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

D-2. Semi-Closed and Open Stator and Rotor Slots . . . . . . . . . . . . . . . . . . . . . . D-4

D-3. Chain and Distributed Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5

D-4. Full-Pitch and Fractional Pitch Windings . . . . . . . . . . . . . . . . . . . . . . . . D-6

D-5. Three-Phase, Four-Pole Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7

D-6. Three-Phase Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8

D-7. Wye Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9

D-8. Delta Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10

D-9. Four-Pole, Three-Phase, Series Wye Connection Diagram . . . . . . . . . . . . . . . D-11

D-10. Four-Pole, Three-Phase, Two-Parallel Wye Connection Diagram . . . . . . . . . . . D-12

D-11. Four-Pole, Three-Phase, Series Delta Connection Diagram . . . . . . . . . . . . . . . D-13

D-12. Four-Pole, Three-Phase, Two-Parallel Delta Connection Diagram . . . . . . . . . . . D-14 xiv

SAFETY SUMMARY

This publication describes physical and chemical processes which may require the use of chemicals, sol-vents, paints, or other commercially available material. The user of this publication should obtain the material safety data sheets (Occupational Safety and Health Act (OSHA) Form 20 or equivalent) from the manufacturers or suppliers of materials to be used. The user must become completely familiar with the manufacturer/supplier information and adhere to the procedures, recommendations, warnings, and cautions of the manufacturer/supplier for the safe use, handling, storage, and disposal of these materials. The following are general safety precautions and instructions that people must understand and apply during many phases of operation and maintenance to ensure personal safety and health and the protection of DOD property. Portions of this may be repeated elsewhere in this publication for emphasis.

DANGER, WARNING, AND CAUTION STATEMENTS. DANGER, WARNING, and CAUTION statements have been strategically placed throughout this text prior to operating or maintenance procedures, prac-tices, or conditions considered essential to the protection of personnel (DANGER and WARNING) or equipment and property (CAUTION). A DANGER, WARNING, or CAUTION statement will apply each time the related step is repeated. Prior to starting any task, the DANGER, WARNING, or CAUTION statements included in the text for that task will be reviewed and understood.

ELECTRIC SHOCK. People working around energized electric circuits and equipment must always observe safety precautions. Injury may result from electric shock. Short circuits can be caused by accidentally placing or dropping a metal tool, flashlight case, or other conducting article across an energized line. These short circuits can cause an arc or fire on even relatively low voltage circuits and may result in extensive damage to equipment and serious injury to personnel. For additional information, refer to NAVSEA S9086-KC-STM-

010/CH 300.

CAUSE OF ELECTRIC SHOCK. Current rather than voltage is the measure of shock intensity. The passage of even a very small current through a vital part of the human body can cause death. The ability of a circuit to produce a fatal current is dependent upon the resistance of the body, contact conditions, the path through the body, etc. Fatalities have occurred from circuits with voltages as low 30 volts. For additional information, refer to NAVSEA S9086-KC-STM-010/CH 300.

RESCUE FROM ELECTRIC SHOCK. The rescue of electric shock victims depends on their prompt removal from the source of shock and the administration of first aid. Personnel trained in safe removal of a vic-tim from a source of electric shock and cardiopulmonary resuscitation (CPR) procedures should perform this emergency procedure. For additional information, refer to NAVSEA S9086-KC-STM-010/CH 300.

INDIVIDUAL RESPONSIBILITY. Individuals have a responsibility, not only to themselves but also to their shipmates, to always be alert to detect and report unsafe work practices and unsafe conditions. Each indi-vidual must

1. Observe all posted operating instructions and safety precautions.

2. Report any condition, equipment, or material that is believed to be unsafe.

3. Caution others to observe safety precautions.

4. Report to the supervisor any injury obtained in the course of their work.

5. Exercise caution in the event of an emergency, where deranged equipment or abnormal operating con-ditions could produce additional, unseen hazards.

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SAFETY SUMMARY - Continued

SHIPBOARD ELECTRICAL SYSTEMS.

EQUIPMENT GROUNDING AND SYSTEM GROUNDING. The word grounding is frequently used in ac electrical power systems for referring to both equipment grounding and system grounding.

Equipment grounding is an important safety measure. Equipment grounding intentionally connects the non-current-carrying conductive parts of electrical equipment to ground through a low-resistance path. If an ener-gized electrical conductor contacts the enclosure due to a fault or mechanical damage, the equipment ground pro-vides the lowest impedance path of electrical current to ground, shunting the current away from a possible human contact. Electrical power systems can be classified by the nature of the connection between the neutral of the power system and ground. The system is said to be ungrounded when the electrical system neutral or phase con-ductors are not intentionally connected to ground expect through potential measuring devices or other very high-impedance devices. Navy ships use an ungrounded system. Electric utility service for house wiring ashore uses a grounded neutral system so that a fault will produce a high current and quickly trip the circuit breaker or blow the fuse. For additional information, refer to NAVSEA S9086-KC-STM-010/CH 300.

GENERAL ELECTRICAL SAFETY PRECAUTIONS FOR EQUIPMENT MAINTENANCE.

EQUIPMENT MAINTENANCE. Safety from electrical hazards during any form of maintenance work can best be ensured by completely deenergizing equipment. Follow the tag-out instructions for working on deen-ergized equipment in Chapter 1 of this manual and NAVSEA S9086-KC-STM-010/CH 300. When it is neces-sary to work on energized equipment, the requirements of NAVSEA S9086-KC-STM-010/CH 300, para-graph 300-2.5, shall be carefully adhered to.

Equipment maintenance covers both preventive and corrective maintenance of electrical equipment and includes any or all of the following work:

Testing

Calibrating

Taking measurements

Troubleshooting

Repairing

Assembling

Disassembling

Making adjustments

GENERAL SAFETY PRECAUTIONS.

1. Do not touch a conductor, until it is tested, to be sure it is deenergized.

2. Obey all warning signs; read equipment warning labels before use.

3. Do not energize any equipment that is tagged out. Properly clear the tag first.

4. Use authorized equipment to perform maintenance work.

5. Close all fuse boxes, junction boxes, switch boxes, and wiring accessories.

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6. Never operate a switch with the other hand on a metal surface.

7. Never use outlets that appear to be burnt.

8. When using a metal-cased tool, ensure it is equipped with a three conductor cord, and three-pronged plug. Verify that the ground prong extends beyond the power blade of the plug.

9. Wear rubber gloves when using metal-cased portable electrical equipment, or when using electric handheld portable tools in hazardous conditions, such as wet decks and bilge areas. Leather gloves shall be worn over rubber gloves when the work being done could damage the rubber gloves.

10. Do not use equipment with worn or damaged cords, or crushed or damaged plugs.

11. Check the portable electrical equipment has been inspected and has a current inspection label affixed.

12. Only use electric equipment in explosive atmospheres if the equipment is approved for such use (explosion proof).

13. Do not allow cords to run over sharp objects, chemicals, or hot surfaces.

14. Do not join more than two 25-foot extension cords together. Single-length extension cords up to 100-foot are permissible.

15. Use a voltmeter or voltage tester to ensure that equipment or circuits are deenergized.

For additional information, refer to NAVSEA S9086-KC-STM-010/CH 300.

WORK ON DEENERGIZED EQUIPMENT.

EQUIPMENT TAG-OUT PROCEDURES. Safety from electrical hazards can best be ensured by com-pletely deenergizing equipment on which work is to be done. Always deenergize electrical equipment by open-ing the power supply circuit breaker or switch, or removing the appropriate fuse, and use the equipment tag-out procedure before continuing with work. For requirements concerning work on energized circuits or equip-ment, see NAVSEA S9086-KC-STM-010/CH 300, paragraph 300-2.5.

SAFETY-RELATED ITEMS. Refer to NAVSEA S9086-KC-STM-010/CH 300, table 300-2-1, for a list of safety-related items used for electrical and electronic maintenance and repair.

CHECKING FOR ENERGIZED CIRCUITS. Be sure electrical equipment is deenergized before work-ing on it. To verify a circuit is deenergized, first connect the leads of a voltmeter or voltage tester across the power source terminals of a known energized circuit to ensure the device is working properly. Next, connect the leads of the device across the power source terminals of the equipment under test and from each terminal to ground to verify it is deenergized. Recheck the voltmeter or voltage tester on the known energized circuit to ensure that the device is still working properly. For additional information, refer to NAVSEA S9086-KC-STM-

010/CH 300.

DISCHARGING DEENERGIZED CIRCUITS. The electrical charge retained by secured electrical equipment may be great enough to cause a severe shock. This danger must be considered before touching the terminals to an apparently deenergized equipment. Discharge the equipment to ground by momentarily connect-ing the terminal to ground using a short probe (see NAVSEA S9086-KC-STM-010/CH 300, table 300-2-1).

Capacitors and picture tubes can develop a charge after a period of time and may need to be shorted several times before being fully discharged. For additional information, refer to NAVSEA S9086-KC-STM-010/CH 300.

WORKING ON ENERGIZED EQUIPMENT.

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APPROVAL PROCEDURES. Electrical equipment is a source of great danger if not properly approached. The Commanding Officer is responsible for electrical safety. Energized electrical equipment shall not be disassembled nor undergo any maintenance without approval of such action by the Commanding Officer or, in his absence, the Command Duty Officer. The only exceptions to this policy are in those cases in which approval instructions issued by higher authority (equipment technical manuals, PMS, or an established trouble-shooting procedure) permit opening or inspecting equipments in the course of performing maintenance, routine testing, taking measurements, or making adjustments that require equipment to be energized. When external test points are provided on an equipment panel, testing with an instrument using these test points shall not be con-sidered as working on an energized equipment. For additional information, refer to NAVSEA S9086-KC-STM-

010/CH 300.

ENERGIZED CIRCUIT WORKING PROCEDURES. When maintenance must be done on energized circuits or equipment, the following precautions shall be observed in addition to the general precautions of NAVSEA S9086-KC-STM-010/CH 300, paragraph 300-2.5. These precautions do not apply for circuits or equip-ment less than 30 volts:

1. Never work on energized electrical or electronic equipment by yourself have another person (safety observer) qualified in first aid for electrical shock present at all times. The safety observer should also know which circuits and switches deenergize the equipment and will be given instructions to operate the switch immediately if anything unforeseen happens.

2. Workers shall not wear wristwatches, rings, watch chains, metal articles, or loose clothing that might accidentally contact energized parts or throw some part of their bodies into contact with mechanical/ electrical active components. Clothing and shoes shall be as dry as possible.

3. Insulate the deck or standing surface from ground by covering with insulating material. Rubber mat or rubber blankets shall be used for this covering. If mats or blankets are not available, and the work must be accomplished before the specified material is available, other suitable insulating materials are dry wood, dry canvas, dry phenolic material, or even several layers of heavy, dry paper. Be sure insu-lating material is dry, has no holes in it, and that no conducting materials are embedded in it. Cover enough area so that workers have adequate space to move about.

4. Use only one hand to do the work, if practical.

5. If the work being done permits, rubber gloves shall be worn on both hands; if not, a rubber glove shall be worn on the one hand not used for handling tools.

6. A face shield or spectacles shall be worn during work on energized equipment, since a short circuit could produce a high fault current capable of producing flying molten particles and intense heat.

7. Cover metal on hand-held tools with an electrical insulating material. One acceptable method is to use two layers of rubber or vinyl plastic tape, half-lapped. Another method is to coat tools with Plastisol;

see instructions in NSTM , Chapter 631, ″Preservation of Ships in Service.″ In an emergency, if time does not permit applying the foregoing materials, the tool handles and tool shafts may be covered with cambric sleeving, synthetic resin flexing tubing, or with insulation tubing removed from scrap of cer-tain kinds of electrical cable.

8. Take the following extra precautions when the nature of the work is particularly hazardous, such as when working in the interior of a switchboard or other cubical where exposed energized bus bars are in the vicinity of the work or the work actually requires contact by tools to the energized components:

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a. Station personnel with communications, as necessary, so that the circuit or switchboard can be deenergized immediately in an emergency.

b. Provide insulation barriers between the work and any energized metal parts adjacent to the work area as practicable.

c. Erect barriers to keep unauthorized personnel out of the maintenance area. Erect barrier at a mini-mum distance of three feet from the energized electrical work site.