Dismantling and Assembly Guide

Dismantling and assembly guide
Flameproof motors,
Ex d/Ex de
M3JP/KP/JM/KM 280 - 450
Table of contents
1.
Validity .................................................................................................................................................. 3
2.
General .................................................................................................................................................. 3
3.
Maintenance and lubrication ................................................................................................................ 4
4.
Storing and mounting of bearings......................................................................................................... 4
5.
Occupational safety ............................................................................................................................... 4
6.
Required tools........................................................................................................................................ 4
7.
Dismounting and lifting of the motor .................................................................................................... 5
8.
Removal of difficult and jammed parts ................................................................................................ 5
9.
Cleaning and drying of parts................................................................................................................. 5
10.
Checking the usability of the parts........................................................................................................ 6
11.
Motor screws ......................................................................................................................................... 6
12.
Shaft seals, V-rings ................................................................................................................................ 6
13.
Waste handling ...................................................................................................................................... 7
14.
Flamepath and spigot dimensions ......................................................................................................... 8
General description ..................................................................................................................................... 8

M3KP/JP/JM/KM 280-315........................................................................................................................... 9
M3KP/JP/JM/KM 355.................................................................................................................................10
M3KP/JP/JM/KM 400.................................................................................................................................11
M3KP/JP/JM/KM 450.................................................................................................................................12
Terminal box M3JP/JM 280 - 315 ...............................................................................................................13
Terminal box M3JP/JM 355 - 400 ...............................................................................................................14
Terminal box M3JP/JM 355-400 .................................................................................................................15
Terminal box M3JP/JM 355-400 (made of welded steel) ..............................................................................16
Terminal box M3JP/JM 450 ........................................................................................................................17
15.
Motor dismantling and assembly .........................................................................................................18
15.1.
Terminal box dismantling and assembly.........................................................................................18
15.2.
D-end dismantling .........................................................................................................................21
15.3.
N-end dismantling .........................................................................................................................23
15.4.
Dismounting of the bearings ..........................................................................................................25
ABB Oy, Motors and Generators/ Dismantling and Assembly guide M3JP/KP/JM/KM 280 to 450 EN, 10-2015
15.5.
Cleaning and inspection of components .........................................................................................26
15.6.
Mounting of new bearings .............................................................................................................28
15.7.
D-end assembly ............................................................................................................................31
15.8.
N-end assembly ............................................................................................................................34
15.9.
Mounting of an additional plate .....................................................................................................39
16. ............................................................................................................................ Motor construction
1.
Validity
These instructions are valid for the following ABB electrical machines (for both
motors and generators in service):
M3JP/KP/JM/KM frame sizes 280 to 450
M3JP/JM-motors have an Ex d terminal box
M3KP/KM-motors have an Ex e terminal box
The photographs in the instruction picture set have been taken from the M3JP 280
SMA 4 Ex d motor. Other sizes of motors may look different than those in the
instruction photos.
2.
General
A qualified person is to perform the disassembly and assembly of the motors, using
appropriate tools and instructions in accordance with the working methods. Only
39
trained personnel fully acquainted with Ex-standards are allowed to carry out repairs
of Ex-motors.
All the repairs of Ex-motors are to be performed according to the standard IEC/EN
60079-19 while complying with the valid national occupational safety norms. Other
conditions to be met for repairing Ex-motors see in the Installation, Operation,
Maintenance and Safety Manual delivered with the motor.
3.
Maintenance and lubrication
More detailed information on matters related to the motor maintenance, lubrication

and lubricants can be found from the Installation, Operation, Maintenance and Safety
Manual delivered with the motor. Available also separately upon request. Grease for
lubricating bearing seats is e.g. ROCOLASP or Klber ALTEMP Q NB50 or
equivalent.
Non-hardening joint grease for spigots is e.g. DSAX-RK2 TK Penetral.
4.
Storing and mounting of bearings
The bearing manufacturers effective specifications and instructions must be

observed during the storing, handling and mounting of bearings.
Information of the bearing types and sizes are to be found in chapter 15.6. Other
information about bearings and their lubrication are in the Installation, Operation,
Maintenance and Safety Manual delivered with the motor.
5.
Occupational safety
During maintenance work, special attention must be paid to occupational safety

concerning the lifting and transfer of heavy objects, handling of hot objects as well as
greases and solvents. The current electrical safety regulations must be observed
when making electrical connections. For the lifting of heavy objects, ensure that the
available lifting accessories are suitable and have been inspected. For the heating of
bearings and other components, fire safety (using a gas burner) as well as the use of
suitable tools and heat-resistant gloves must be taken into consideration. Protective
gloves must be used when handling solvents for the removal of grease and oils from
parts. Contact with oil-based products and solvents may lead to allergy symptoms.
6.
Required tools
The dismantling and assembly of the motor is executed quickly and smoothly when
the proper tools are used. In addition to the basic tools, some special ones are also
required.
The required tools are:
-
rotor lifting accessory

hydraulic extractor
(for lifting the rotor to the correct position)

(for dismounting the bearings)
induction heater or electric heating plate (for heating the bearings)

gas burner
(for heating the end shields)
cable wire cutters
(for cutting connector cables)
copper hammer
(for dismounting the end shield)
guide pin (x2)
(for aligning the bearing cover)
pneumatic nut driver
(for the end shield/cover screws)
pry bar (x2)
(for dismounting the end shield)
7. Dismounting and lifting of the motor

Only an authorized and qualified specialist familiar with the safety requirements is
allowed to disconnect the motor. Eyebolts must always be used when lifting motors
unless stated otherwise in the lifting instructions.
Ensure that the motor eyebolts are in good condition before proceeding with the
lifting. Do not use damaged eyebolts.
The threaded eyebolts must be tightened before lifting. If necessary, the eyebolts
must be adjusted to the correct position by using suitable plate washers. Detailed
instructions of various lifting situations are in the Lifting instructions.
8.
Removal of difficult and jammed parts
Depending on the working environment, parts of especially old motors may have
become jammed into place. This may make the removal of parts very difficult. The
jammed parts normally include the end shields and covers as well as parts of the
terminal box. During the removal of the jammed parts, using excessive force and/or
damaging any part of the motor, particularly the machined surfaces, must be
avoided. Do not damage the end shield and shaft flamepaths in Ex d(e)-motors and
additionally the terminal box flamepaths in Ex d motors.
9.
Cleaning and drying of parts
Depending on the conditions, a lot of dirt and grease can accumulate inside and
outside of the motor. The accumulated dirt and grease can be very difficult to remove
from the stator and rotor surfaces, as well as from between the coils. This is a reason
to clean the stator and rotor by washing.
Cleaning with water is recommended for the general wash, which is executed by
using a high-pressure cleaner. If necessary, solvents may be used to clean extremely
dirty and greasy motors. During the cleaning of the stator coils, do not aim the
pressure jet directly into the coils.
After washing, dry the stator and the rotor in an oven. The oven temperature is to be
90 C for 12 to 16 hours, and after this 105 C for 6 to 8 hours.
10. Checking the usability of the parts

When changing the bearings, the condition of the parts must be inspected. The
inspection applies mainly to the condition of the end shields and terminal box, as well
as the shaft bearing fits. The machined surfaces of the end shields, covers and
terminal box must be intact. There must not be any significant corrosion nor wear on
the shaft bearing journals and in the end shield bearing housings.
Machined guide surfaces, spigots, are forming the flamepathes in Ex d(e)/de-motors,
and they have to be protected against any kind of even slightest damage. Defective
parts must be replaced.
Refer to IEC 60079-19 and ABB training documents about parts which can be
repaired and the allowed repair methods.
11. Motor screws

The motor screws must meet certain strength requirements. Damaged screws are to
be replaced with screws of the same grade. The grade is indicated on a sticker on
the frame. As a general requirement, these must be grade 8.8/10.9 screws or A4-80/
A4 BUMAX109 stainless screws. The use of weaker screws is forbidden.
Tightening torques for screw are given in the respective chapters below.
12. Shaft seals, V-rings

Motors in standard version for IP55 class have shaft seals as shown below. IP higher
than 55 are all with labyrinth seals. Change V-ring seals always after disassembling a
motor. A new V-ring has to be mounted with the correct dimension. Mounting
dimensions in table 1 below.
Table 1: seal types
Motor
size
D-end
2-poles
N-end
2-poles
4 -poles
280
Labyrinth Labyrinth seal
V-ring, d=80/ B=9+/-1
V-ring, d=80/ B=9+/-1
315
V-ring, d=80/ B=9+/-1
V-ring, d=80/ B=9+/-1
355
V-ring, d=80/ B=9+/-1
V-ring, d=80/ B=9+/-1
400
450
4 -poles

Labyrinth seal
V-ring, d=95/ B=9+/-1
Labyrinth seal
Labyrinth seal
d= nominal diameter in mm; B= axial dimension after assembly in mm
13. Waste handling

All waste generated from the replacement of bearings must be disposed of
appropriately. After cleaning, the old bearings may be considered as mixed steel and
cast iron scrap. Lubricants, greasy cloths and rubber seals are hazardous waste.
14. Flamepath and spigot dimensions

General description
The Ex d(e)-motor parts, which have machined flamepath surfaces (spigots), must be
handled carefully. Do not damage or rub these surfaces. The points of the flamepath
surfaces are presented in the figure below.
Terminal Box Cover (Ex d)
Terminal Box Intermediate

plate (Ex d)
Intermediate plate
Stator frame
Stator frame Endshield
Endshield
Innerbearing cover
Shaft
Innerbearing cover
The terminal box and its parts form a spigot only in M3JP/JM-motors (Ex d), not in
M3KP-motors.
M3KP/JP/JM/KM 280-315
Table 1. Gap and spigot dimensions [mm]

Position
I
II
III
IV
V
VI
VII
min. length
max. width
min. length
max. width
min. length
max. width
min. length
max. width
min. length
max. width
min. length
max. width
I / IIB
IIC
62
82
0,40
0,26
62
82
0,40
0,26
16
28,7-16
16
28,7-16
0,07
0,14
0,07
0,14
16
28,7-16
16
28,7-16
0,07
0,14
0,07
0,14
5
27 - 5
5
27 - 5
0,07
0,20
0,08
0,15
5
27 - 5
5
27 - 5
0,07
0,20
0,08
0,15
See spigot III of tables 4, terminal box intermediate plate.
Flat: 7
0
Flat: 7
0
M3KP/JP/JM/KM 355

Position
I
II
III
IV
V
VI
VII
min. length
max. width
min. length
max. width
min. length
max. width
min. length
max. width
min. length
max. width
min. length
max. width
I / IIB
62
0,39
62
0,39
20
40 - 20
0,15
0,19
20
40 - 20
0,15
0,19
6
28,5 - 6
0,07
0,20
6
28,5 - 6
0,07
0,20
See spigot III of tables 5-7,
plate.
IIC
62
0,25
62
0,25
20
40 - 20
0,15
0,19
20
40 - 20
0,18
0,20
6
28,5 - 6
0,04
0,15
6
28,5 - 6
0,04
0,15
terminal box intermediate
10
M3KP/JP/JM/KM 400

Position
I
II
III
IV
V
VI
VII
min. length
max. width
min. length
max. width
min. length
max. width
min. length
max. width
min. length
max. width
min. length
max. width
I / IIB
IIC
62
0,39
62
0,39
5
0,15
5
0,15
8
0,07
8
0,07
62
0,26
62
0,26
5
0,15
5
0,15
8
0,05
8
0,05
40 - 5
0,20
40 - 5
0,20
30 - 8
0,2
30 - 8
0,2
40 - 5
0,20
40 - 5
0,20
30 - 8
0,15
30 - 8
0,15
See spigot III of tables 5-7, terminal box intermediate plate.
11
M3KP/JP/JM/KM 450

Position
I
II
III
IV
V
VI
VII
min. length
max. width
min. length
max. width
min. length
max. width
min. length
max. width
min. length
max. width
min. length
max. width
I / IIB
60
0,38
60
0,38
5
42 - 5
Flat: 3
0,15
0,20
0
5
42 - 5
Flat: 3
0,15
0,20
0
35
0,12
35
0,12
See spigot III of tables 10, terminal
Remarks
Identical to II
Detail B
Flat part = VIII in detail A
Flat part = IX in detail C
Identical to VI
Detail B
box intermediate plate.
12
Terminal box M3JP/JM 280 - 315
Table 5. Spigot dimensions [mm]
Position
I
II
III
min. length
max. width
min. length
max. width
min. length
max. width
I, IIB and IIC

30
0,13
27
0,13
26,5
0,12
13
Terminal box M3JP/JM 355 - 400
Position
I
II
III
min. length
max. width
min. length
max. width
min. length
max. width
I, IIB and IIC

30
0,13
27
0,13
27
0,12
14
Terminal box M3JP/JM 355-400
Position
I
II
III
min. length
max. width
min. length
max. width
min. length
max. width
I, IIB and IIC

33
0,15
39
0,15
27
0,13
15
Terminal box M3JP/JM 355-400 (made of welded steel)
Position
I
II
III
min. length
max. width
min. length
max. width
min. length
max. width
I, IIB and IIC

33
0,15
36
0,15
27
0,13
16
Terminal box M3JP/JM 450
Position
I
II
III
min. length
max. width
min. length
max. width
min. length
max. width
I / IIB
33
0,15
39
0,15
30
0,2
17
15. Motor dismantling and assembly

15.1.
Terminal box dismantling and assembly
Picture 1.
Remove the terminal box cover screws.
Remove also protective covers for screws if
there are some.
Picture 2.
Remove the terminal box cover. The cover
can be rotated to a different position to
facilitate the removal. If necessary, remove it
with the help of the pry bar. Do not damage
the flamepath of the cover!
Picture 3.
When assembling terminal box, if
there are protective covers for
screws install them under the
screw. The opening of the covers
needs to be to the middle of the
terminal box.
18
Picture 4.
Disconnect the control equipment wires from
their terminals (or remove the terminal block
rail) and clips. Finally, make sure that all the
wires have been disconnected from the
terminals.
Remove the terminal box mounting screws.
Picture 5.
Fix eyebolts into the threaded holes for
the cover and lift the terminal box off.
Picture 6.
Remove the intermediate flange screws.
19
Picture 7.
Cut the winding terminal cables as well as
the control equipment wires. (This is done
only if the intermediate flange or stator
pack is changed.)
Picture 8.
Fix eyebolts into the threaded holes of the
intermediate flange and lift the flange off.
The terminal box assembly is done in the reverse order of the disassembly. The
new cables must be carefully connected correctly into place according to their
markings. For terminals in Ex de-motors the spring washers are functionning as
anti-twisting devices and must be remounted.
For remounting of KP-terminal box (Ex e):

Clearances between live parts and between live and grounded parts:
For Ex e-boxes:
12 mm
For Ex nA-boxes:
7 mm
20
15.2.
D-end dismantling
Picture 9.
Remove the key from the shaft.
Picture 10.
Remove the locking ring from the shaft,
if there is one. Pull the labyrinth seal off
from the base of the bearing cover with
the extractor.
Alternatively, remove the V-ring.
Picture 11.
Remove the bearing cover screws and
pull the bearing cover off the shaft.
Take the cover off without scraping the
surface or the shaft. Remove also
protective covers for screws if there are
some.
21
Picture 12.
Fix suitable lifting hooks into the top-most
mounting holes of the shield. Protect the
shaft from possible surface damage,
which can be made by the shield during
its removal. Fix screws into two adjacent
mounting holes. Remove the end shield
from the guide by turning push screws
against the frame. Remove the end shield
with the crane. Do not damage the
flamepath surfaces of the frame and end
shield. (The end shield can also be
removed by mounting the extractor onto
the end shield with the existing M16
threads. See top arrow.)
Picture 13.
Depending on the mounting position, some
motors may have the shield in such a position
that the use of push screws is not possible. In
that case, the shield must be removed from
the guide with the help of pry bars. Remove
the end shield from the guide with the help of
a pry bar and a copper hammer. Place the
pry bar head behind the fastening lug and tap
the pry bar head gently. Also hit the fastening
lug on the opposite side of the shield. Do not
damage the machined guide surfaces!
22
15.3.
N-end dismantling
Picture 14.
Remove the extended grease and
vibration measuring nipples passing
through the motor N-end fan cover.
Picture 15.
Remove the fan cover screws and take
the cover off. Make sure that the grease
valve handle does not bend. Fan covers
of JM motors have to be removed by
using a lifting accessory.
Picture 16.
Remove the locking ring located in front
of the fan.
23
Picture 17.
Pull the fan off the shaft. If necessary,
take an extractor and use the two square
holes in the fan for it.
Do not pry the fan off against the end
shield. After this, remove the key from
the shaft as well as the locking ring
behind the fan.
Picture 18.
If there is a labyrinth seal at the N-end of
the motor, it must be removed before the
bearing cover. First remove the locking
ring possibly located in front of the
labyrinth seal and pull off the labyrinth
seal with the extractor.
Or alternatively remove the V-ring.
Picture 19.
Remove the bearing cover screws and
pull the bearing cover off the shaft.
24
Picture 20.
Remove the end shield screws. Fix
suitable lifting hooks into the top-most
mounting holes of the shield. Protect the
shaft from possible surface damage which
can be made by the shield during its
removal. Fix screws into the two adjacent
mounting holes. Remove the end shield
from the guide by turning push screws
against the frame. Remove the end shield
with the crane. Do not damage the
flamepath surfaces of the frame and end
shield. (The end shield can also be
removed by mounting the extractor onto
the end shield with the existing M16 threads. See top arrow.)
15.4.
Dismounting of the bearings
NOTE! Begin the bearing change by removing the D-end bearing first. The
removal of the N-end bearing is executed in the same manner as the removal of
the D-end bearing.
Picture 21.
Push the inner bearing cover off the
bearing and pull the rotor slightly out from
the inside of the stator. Please note the
detached coil springs possibly located in
the bearing seats (not in all motor types).
Do not damage the shaft flamepath
surfaces by unnecessarily rotating or
moving the bearing cover. The rotor is
pulled outwards to prevent damaging the
winding ends, either when dismounting
the bearing with the extractor or by
heating.
Place the extractor jaws behind the bearing outer ring and pull the bearing off. If
there is a valve disc possibly in front of the bearing, it will come off simultaneously.
After this, pull the bearing cover off the shaft. For the removal of the N-end bearing,
the locking ring located in front of the valve disc must be removed first. In some
motors there is a wave spring between the bearing and the valve disc which must be
removed. (NOTE! Never re-mount a bearing back into the motor with the extractor
because the extractor will damage the bearing!)
25
Picture 22.
Pull the rotor horizontally out of the stator.
Be careful not to damage the winding and
avoid bumping the rotor against the stator
surfaces.
Use an appropriate tool to lift the rotor out
of the motor.
Picture 23.
If no tool is available, use a long steel
tube to lift the rotor off.
15.5.
Cleaning and inspection of components
Picture 24.
Wipe the grease off the inner bearing
covers and check all machined surfaces.
If the flamepath surfaces are damaged,
then the cover must be replaced with a
new one.
Wash the bearing covers and dry these
afterwards.
26
Picture 25.
Clean the machined surfaces and the
flamepath surfaces of the end shields. Do
not use a hard scraper on flamepath
surfaces. Visually inspect the surfaces.
If flamepath surfaces are damaged, then
the shield must be replaced with a new
one.
If bearing housing surfaces are damaged
or are out of tolerance, they can be
repaired.
Picture 26.
Clean and check the condition of the
rotor. If necessary, it can also be
washed. The washing and drying is
done as per section 8 of the cleaning
and drying instruction.
Picture 27.
Clean and check the condition of the
shaft end, bearing seat and flamepath
surfaces. (Undersized bearing journals
may be fill-covered and machined to the
correct dimension. This is not allowed
for the flamepath surfaces).
27
Picture 28.
Clean the machined guide
(spigots) for the end shields.
surfaces
Clean and check the condition of the inside

of the stator pack and the winding. If
necessary, wash the stator and dry as per
section 8 of the Cleaning and drying
instructions.
Measure the insulation resistance of the stator winding according to the method
stated in the Installation, Operation, Maintenance and Safety Manual.
15.6.
Mounting of new bearings
Security measures while mounting the bearings:

Examine the bearing parts and remove all burrs. Clean the shaft and shoulders and
check the condition of the bearing joint faces. Examine the seals (if any) and change
these if they are damaged. Always change the rubber seals.
Do not remove the new bearings from their packing until just before mounting.
Protect the bearings from impurities for as long as possible. Check the surfaces of
the bearing rings, especially of isolated bearings. Do not mount damaged bearings.
Leave the rust-preventive grease in the bearing except for the hole and the outer ring
surface. Wipe the surfaces with industrial turpentine and allow to dry.
Bearing types and sizes (if not otherwise indicated on the nameplate):
Motor
size
D-end
N-end
poles
280
315
355
400
450
2
4 - 12
2
4 - 12
6316/C3
6316/C3
6316/C3
6316/C3
6316/C3
6319/C3
6316/C3
6316/C3
6316M/C3
6322/C3
6316M/C3
6316/C3
6317M/C3
6324/C3
6317M/C3
6319/C3
6317M/C3
6326M/C3
6317M/C3
6322/C3
28
Begin by mounting the bearing on the D-end. To do this, the rotor must be first
put in to place. The mounting of the N-end bearing is executed in the same
manner following the D-end assembly. NOTE! Pay careful attention to the
cleanliness of the work environment and the tools during the assembly of the
motor and especially during the handling of the bearings.
Picture 29.
Push the rotor into the stator through the
D-end. Be careful not to damage the
winding ends and avoid bumping the rotor
against the stator inner surfaces.
Use an appropriate tool to lift the rotor into
the motor, or use a long tube as shown in
picture 22.
Picture 30.
Push the inner bearing cover onto the
shaft, being careful not to damage the
flamepath surfaces.
Install the coil spring to the inner bearing
cover if applicable.
Picture 31.
Heat the bearing to a temperature of
110C e.g. with an induction heater or an
oven. (Do not, however, heat the bearing
with an open flame or gas burner.)
29
Picture 32.
Fill the bearings with grease.
Picture 33.
Push the heated bearing onto the shaft
firmly against the shaft shoulder.
Picture 34.
Heat the valve disc to a temperature of 110
C, e.g. with an induction heater or an oven
the same way as done with the bearings.
30
Picture 35.
Push the heated valve disc onto the shaft
against the bearing. Mount the wave spring
into place in then N-end in front of the valve
disc, if applicable.
15.7.
D-end assembly
Picture 36.
Fill the end shield grease channel using a
grease gun.
More detailed lubrication instructions can

be found from the Installation, Operation,
Maintenance and safety Manual
delivered with the motor.
Picture 37.
Spread aluminum-based, non-hardening
sealing paste onto the machined guide
surfaces (spigots) of the frame.
31
Picture 38.
Heat the D-end shield with a gas burner
around the bearing housing to a
temperature of about 70 C. Do not heat
the outer part of the shield!
Picture 39.
Screw a guide pin through a hole for the
bearing cover into the threaded hole of
the inner bearing cover. Push the heated
end shield on top of the bearing and
against the guide surface of the frame
with the help of the crane. Do not damage
the spigot surfaces!
Picture 40.
If there are protective covers for screws
install them under the screw. The
opening of the covers needs to be down
wards.
32
Picture 41.
Fix the end shield screws (M20 or M24
depending on the shaft height). Use
cross-tightening. (The screw type and
torque table can be found next page.)
Picture 42.
Push the outer bearing cover into place
against the shield. Remove the guide pin
and fix the bearing cover screws (M10).
Screw
Grade
Yield Strength
Tightening Torque (Nm)
M10
8.8 / A4-80
600 Nm/mm2
48
M12
10.9 / A4 BUMAX109
900 Nm/mm2
83
M20
8.8 / A4-80
600 Nm/mm2
395
M24
8.8 / A4-80
600 Nm/mm2
670
Picture 43.
Heat the labyrinth seal to a temperature of
110 C, e.g. with an induction heater or an
oven.
Then push the heated labyrinth seal onto
the shaft inside the bearing cover. Mount
the locking ring in front of the labyrinth
seal and the key into the shaft keyway.
Do not damage the felt seal located on
the base of the bearing cover.
33
15.8.
N-end assembly
Picture 44.
Mount the locking ring in front of the valve
disc and screw a guide pin into the
threaded hole of the inner bearing cover.
Picture 45.
Fill the end shield grease channel using a
grease gun.
More detailed lubrication instructions

can be found from the Installation,
Operation, Maintenance and Safety
Manual delivered with the motor.
Picture 46.
Grease the inner surfaces of the bearing
housing. Use KLBER ALTEMP Q NB 50
sliding paste or equivalent.
34
Picture 47.
sealing paste onto the machined spigot
surfaces of the frame.
Picture 48.
Screw a guide pin into the threaded hole
of the bearing cover. Push the end
shield on top of the bearing and against
the guide surface of the frame with the
help of the crane. Do not damage the
spigot surfaces! Fix the end shield
screws (M20 or M24 depending on the
shaft height). Use cross-tightening. (The
screw type and torque table can found
on the following page.)
Picture 49.
sealing paste onto the spigot surfaces of
the end shield and bearing cover. Push
the bearing cover into place against the
shield.
35
Picture 50.
Remove the guide pin and fix the bearing
cover screws (M10). Mount the V-ring
onto the shaft.
Screw
Grade
Yield Strength
Tightening Torque (Nm)
M10
8.8 / A4-80
600 Nm/mm2
48
M12
10.9 / A4 BUMAX109
900 Nm/mm2
83
M20
8.8 / A4-80
600 Nm/mm2
395
M24
8.8 / A4-80
600 Nm/mm2
670
Picture 51.
Some motors have a labyrinth seal also at
the N-end. Heat the labyrinth seal before
the installation to a temperature of 110
C, e.g. with an induction heater or an
oven.
Push the heated labyrinth seal onto the
shaft inside the bearing cover. Mount the
locking ring in front of the labyrinth seal.
Do not damage the felt gasket located on
the base of the bearing cover.
Picture 52.
Mount the locking ring onto the shaft
behind the fan. Mount the fan key into
place and push the fan against the locking
ring. Mount the other locking ring in front
of the fan.
Check that there is enough clearance
between fan and endshield.
36
Picture 53.
Mount the grease nipple and its extension.
Greasing of the bearings

Picture 54.
Grease the N-end bearing through the
end shield grease channel using a
grease gun. At the same time, rotate the
rotor slowly by hand so that the grease
will spread evenly.
(NOTE! The grease valve must be open
while greasing. Shut the grease valve
outlet after greasing.)
More detailed lubrication instructions can be found from the Installation,

Operation, Maintenance and Safety Manual delivered with the motor.
37
Picture 55.
Dismount the grease nipple again.
Mount the fan cover into place. Make
sure that the grease valve handle does
not be displaced. Tighten the fan cover
screws.
Check, that the fan rotates freely.
Fan covers of JM motors have to be
lifted by using a lifting accessory.
Picture 56.
Mount the extended grease and vibration
measuring nipples passing through the
motor N-end fan cover.
38
15.9.
Mounting of an additional plate
An additional plate, e.g. repairers work job plate, can be mounted on a safe place on
the motor frame or on the fan cover.
It is recommended to use a durable sticker or a plate fixed by rivets.
If the mounting place is on the frame, only cooling rips or dedicated places for
additional plates shall be used.
If holes have to be drilled, use a very short drill in order not to penetrate the frame
wall.
If the place is on the fan cover, make sure that the rivets do not diminish the safety
gap between the fan and the cover below the requirements, which is = (diameter of
fan)/ 100 (mm)
39
16.
Motor construction
40
11
Stator, complete
Stnder, komplett
Stator complet
Estator completo
Statore, completo
Stator, komplett
Staattori, tydellisen
28
Locking ring for D

D-setige Sicherungsring
Circlips CC
Anillo de seguridad lado acople
Anello di bloccaggio lato AS
D-ndans lsring
Terspidtinlaatta D
12
17
Endshield for D with screws

D-seitiges Lagerschild mit Schrauben
Flasque CC, avec vis
Escudo lado acople, con tornillos
Scudo cuscinetto lato AS, con viti
D-ndans lagerskld, med skruvar
Laakerikilpi D, ruuveineen
30
Pre-loading spring for bearings

Vorspannfeder fr lager
Ressort de pre-charge des paliers
Muelle de precarga de cojinetes
Molla di pre-carico cuscinetti
Frspnnings fjder fr lager
Laakeroinnin esikuormitusjousi
12
17
Flange shield with screws

Flanschlagerschild mit Schrauben
Flasque bride, avec vis
Escudo brida, con tornillos
Scudo flangiato, con viti
Flnslagerskld, med skruvar
Laippalaakerikilpi, ruuveineen
31
Pre-loading spring for bearings

Vorspannfeder fr lager
Ressort de pre-charge des paliers
Muelle de precarga de cojinetes
Molla di pre-carico cuscinetti
Frspnnings fjder fr lager
Laakeroinnin esikuormitusjousi
13
19
Endshield for N with screws

N-seitiges Lagerschild mit Schrauben
Flasque COC, avec vis
Escudo lado ventilador, con tornillos
Scudo cuscinetto lato NS, con viti
N-ndans lagerskld, med skruvar
Laakerikilpi N, ruuveineen
34
49
Inner bearing cover for D with screws

D-seitiger innerer Lagerdeckel mit Schrauben
Couvercle intrieur du roulement CC avec vis
Tapa interior del cojinete lado acople, con tornillos
Coperchio cuscinetto interno lato AS, con viti
D-ndans inre lagerlock, med skruvar
Laakeripohja D, ruuveineen
35
18
Bearing for D
D-seitiges Lager
Roulement CC
Cojinete lado acople
Cuscinetto lato AS
D-ndans lager
Kuulalaakeri D
Valve disc for D

D-seitige Ventilscheibe
Disque d'vacuation de graisse CC
Disco de evacuacin de grasa lado acople
Disco paragrasso lato AS
D-ndans ventilskiva
Imurengas D
24
Bearing for N
N-seitiges Lager
Roulement COC
Cojinete lado ventilador
Cuscinetto lato NS
N-ndans lager
Kuulalaakeri N
36
50
Inner bearing cover for N with screws

N-seitiger innerer Lagerdeckel mit Schrauben
Couvercle intrieur du roulement COC avec vis
Tapa interior del cojinete lado ventilador, con tornillos
Coperchio cuscinetto interno lato NS, con viti
N-ndans inre lagerlock, med skruvar
Laakeripohja N, ruuveineen
25
Ring
Ring
Bague
Anillo
Anello
Mellanring
Vlirengas
38, Outer bearing cover with screws, D-end

49 D-seitiger usserer Lagerdeckel mit Schrauben
Couvercle extrieur du roulement CC avec vis
Tapa exterior del cojinete lado acople, con tornillos
Coperchio cuscinetto esterno lato AS con viti
D-ndans yttre lagerlock med skruvar
D-pn laakerikansi ruuveineen
26
Valve disc for N

N-seitige Ventilscheibe
Disque d'vacuation de graisse COC
Disco de evacuacin de grasa lado ventilador
Disco paragrasso lato NS
N-ndans ventilskiva
Imurengas N
ABB Oy, Motors/ Dismantling and Assembly guide M3JP/KP/JM/KM 280 to 450 EN, 10-2015
41
40
Grease outlet valve for D-end

Schmierfettauslassventil fr D-Seite
Valve d'evacuation de graisse CC
Vlvula de evacuacin de grasa, lado acople
Valvola di scarico grasso Lato accoppiamento
Fettutloppsventil fr D-nda
Rasvanpoistoventtiili D-phn
41
Handle for grease outlet valve, D-end

Griff fr Schmierfettauslassventil fr D-Seite
Poigne de la valve d'evacuation de graisse CC
Maneta de vlvula de evacuacin de de grasa lado
acople
Asta apertura/chiusura valvola scarico grasso D-lato
Handtag fr fettutloppsventilen, D-nda
Rasvanpoistoventtiilin kahva, D-p
43
44
Grease outlet valve for N-end

Schmierfettauslassventil fr N-Seite
Valve d'evacuation de graisse COC
Vlvula de evacuacin de grasa, lado ventilador
Valvola di scarico grasso lato NS
Fettutloppsventil fr N-nda
Rasvanpoistoventtiili N-phn
Handle for grease outlet valve, N-end
Griff fr Schmierfettauslassventil fr N-Seite
Poigne de la valve d'evacuation de graisse COC
Maneta de vlvula de evacuacin de grasa lado
ventilador
Asta apertura/chiusura valvola scarico grasso N-lato
Handtag fr fettutlopps ventilen
Rasvanpoistoventtiilin kahva, N-p
45, Outer bearing cover with screws, N-end

50 N-seitiger usserer Lagerdeckel mit Schrauben
Couvercle extrieur du roulement COC avec vis
Tapa exterior del cojinete lado ventilador, con tornillos
Coperchio cuscinetto esterno lato NS con viti
N-ndans yttre lagerlock med skruvar
N-pn
laakerikansi
ruuveineen
47
51
53
V-ring for N
N-seitiger V-ring
Joint V-ring COC
V-ring escudo lado ventilador
Guarnizione a V lato NS
N-ndans V-ring
N-pn
V-rengas
Grease nipple for bearing, D- and N

Schmiernippel fr D- und N-seitiges Lager
Graisseur CC et COC
Tetinas de engrase para cojinetes lado acople y lado
ventilador
Ingrassatore per cuscinetto lato AS e lato NS
Smrjnippel fr D- och N-ndans lager
Voitelunippa D, N
54
Plug
Stpofen
Bouchon
Tapon
Tappo
Propp
Tulppa
55
Nipple extension
Nippelverlngerung
Extension du conduit de graisseur
Prolongacin de la tetina de engrase
Prolunga ingrassatore
Nippelfrlngning
Voitelunipan jatke
57, SPM-nipples, D and N

58 D- and N-seitiger SPM-Menippel
Prises pour capteurs SPM CC et COC
Tapn medidor de vibraciones SPM, lado acople y
lado ventilador
Attacco SPM lato albero e lato ventola
SPM-mtnipplar, D- och N-nda
SPM-nippa, D- ja N
61
Fan
Lfter
Ventilateur
Ventilador
Ventola
Flkt
Tuuletin
63
Key
Pafeder
Clavette
Chaveta
Chiavetta
Kil
Kiila
64
Locking ring
Sicherungsring
Circlips
Anillo de seguridad
Anello di bloccaggio
Lsring
Terspidtinlaatta
65
Locking ring
Sicherungsring
Circlips
Anillo de seguridad
Anello di bloccaggio
Lsring
Terspidtinlaatta
42
67
69
70
71
72
Fan cover with screws and clamps

Lfterhaube mit Befestigungselementen
Capot de ventilateur avec vis et pices de fixation
Protector ventilador con tornillos y abrazadera
Copriventola con viti ed attacchi
Flktkpa med skruvar och klmstycken
Tuulettimen suojus ruuveineen ja pitimineen
73
Key
Pafeder
Clavette
Chaveta
Chiavetta
Kil
Kiila
75
Rating plate
Leistungsschild
Plaque signaltique
Placa de caractersticas
Targhetta dati
Mrkskylt
Arvokilpi
80
Re-greasing plate
Schmierschild
Plaque de graissage
Placa de engrase
Targa di lubrificazione
Smrjskylt
Voiteluohjekilpi
478 Lead-through rubber

Gummidurchfhrung
Travers en coutchouc
Gomma de orificio
Goma pasa cables
Genomfringsgummi
Lpivientikumi
The spare parts list is available from ABB

Service.
43
Copyright 2015 ABB

All rights reserved
Specifications subject to change without notice.
3GZF500728-104 Rev E, only in
www.abb.com/motors&generators
Dismantling and assenbly guide EN, 10/2015
Contact us

Dismantling and Assembly Guide

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Dismantling and Assembly Guide

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Dismantling and assembly guide

Maintenance and lubrication ................................................................................................................ 4

Storing and mounting of bearings......................................................................................................... 4

Occupational safety ............................................................................................................................... 4

Dismounting and lifting of the motor .................................................................................................... 5

Removal of difficult and jammed parts ................................................................................................ 5

Cleaning and drying of parts................................................................................................................. 5

Checking the usability of the parts........................................................................................................ 6

Motor screws ......................................................................................................................................... 6

Shaft seals, V-rings ................................................................................................................................ 6

Waste handling ...................................................................................................................................... 7

Flamepath and spigot dimensions ......................................................................................................... 8

General description ..................................................................................................................................... 8

Motor dismantling and assembly .........................................................................................................18

Terminal box dismantling and assembly.........................................................................................18

D-end dismantling .........................................................................................................................21

N-end dismantling .........................................................................................................................23

Dismounting of the bearings ..........................................................................................................25

Cleaning and inspection of components .........................................................................................26

Mounting of new bearings .............................................................................................................28

D-end assembly ............................................................................................................................31

N-end assembly ............................................................................................................................34

Mounting of an additional plate .....................................................................................................39

16. ............................................................................................................................ Motor construction

Maintenance and lubrication

More detailed information on matters related to the motor maintenance, lubrication

Storing and mounting of bearings

The bearing manufacturers effective specifications and instructions must be

During maintenance work, special attention must be paid to occupational safety

rotor lifting accessory

(for lifting the rotor to the correct position)

induction heater or electric heating plate (for heating the bearings)

7. Dismounting and lifting of the motor

Removal of difficult and jammed parts

Cleaning and drying of parts

10. Checking the usability of the parts

11. Motor screws

12. Shaft seals, V-rings

Labyrinth Labyrinth seal

V-ring, d=80/ B=9+/-1

V-ring, d=80/ B=9+/-1

Labyrinth Labyrinth seal

V-ring, d=80/ B=9+/-1

V-ring, d=80/ B=9+/-1

Labyrinth Labyrinth seal

V-ring, d=80/ B=9+/-1

V-ring, d=80/ B=9+/-1

Labyrinth Labyrinth seal

13. Waste handling

14. Flamepath and spigot dimensions

Terminal Box Cover (Ex d)

Terminal Box Intermediate

Stator frame Endshield

Table 1. Gap and spigot dimensions [mm]

Table 2. Gap and spigot dimensions [mm]

Table 3. Gap and spigot dimensions [mm]

See spigot III of tables 5-7, terminal box intermediate plate.

Table 4. Gap and spigot dimensions [mm]

Terminal box M3JP/JM 280 - 315

Table 5. Spigot dimensions [mm]

I, IIB and IIC

Terminal box M3JP/JM 355 - 400

Table 6. Spigot dimensions [mm]

I, IIB and IIC