Service and Repair Electrical Motor TTLM

Logo Company Name: Form No.
የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

MINISTRY OF LABOR AND SKILLS
Form Title: Issue No:
Training module format 1
Military Armored Vehicle Electrical

and
Electronics Level- III
Based on November-2023, Curriculum Version-I
Module Title: Service and repair electrical motor

Module code: IND MVE3 M01 01123
Nominal duration: 64 Hours
Prepared by: Ministry of Labor and Skills
November, 2023
Addis Ababa, Ethiopia
Logo Company Name: Form No.:

Form Title: Issue No:
Training module format 1 Page I of 54
Table of Contents
table of contents .................................................................................................................... i
Acknowledgment ................................................................................................................. ii
Acronyms ............................................................................................................................ iii
Introduction to Module ........................................................................................................ iv
Unit One: Fundamintals of electrical motor ...........................................................................1
1.1 introductions of electrical motor ......................................................................................2
1.2 types of electrical motor ..................................................................................................3
1.3 constraction and working principl of electrical motor .......................................................9
1.4 OHS requirements ......................................................................................................... 18
Self-check 1.1 ..................................................................................................................... 21
Unit Two: servicing and repairing electrical motor .............................................................. 25
2.1 Testing electrical motor ................................................... Error! Bookmark not defined.
2.2 servicing electrical motor.............................................................................................. 35.
2.3 repairing electrical motor ............................................................................................... 36
Self-Check 2.1..................................................................................................................... 75
Operation Sheet 2.1 .......................................................................................................... 40. .
Operation Sheet 2.2 ............................................................................................................ 41.
Operation Sheet 2.3 ............................................................................................................ 44.
Operation Sheet 2.4 ........................................................................................................... 45 .
Self-check 2.1 ..................................................................................................................... 37
LAP Test 1 .......................................................................................................................... 48
References ........................................................................................................................... 49
Developer’s Profile ............................................................................................................. 50

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Training module format Page II of 54
Acknowledgment
Ministry of Labor and Skills wish to extend thanks and appreciate to the many
representatives of TVT instructors and respective industry experts who donated their time and
expertise to the development of this Teaching, Training and Learning Materials (TTLM).

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Training module format Page III of 54
Acronyms
AC Alternator current
DC Direct current
e.m.f Electromotive force
XL. inductive reactance
R Electrical Resistance
S.T.R. short time rated


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Training module format Page IV of 54
Introduction to Module
IN Military Armored Vehicle Electrical and Electronics field, Service and repair electrical
motor is very important for the overall understanding of electrical motor driving system in
Military Armored Vehicle. It helps to know basic electrical motor, methods of electrical motor
servicing and repairing.
Servicing and repairing electrical motor a unit without damaging the vehicle requires special
skill and advanced techniques. Hence, this module enable trainees to service and repair
electrical motor using specialist tools and equipment.
This module covers the units:
 Fundamentals of electrical motor
 Servicing and repairing of electric motor
Learning Objective of the Module
 Explain basic operation of electric motor
 Service and repair of electric motor
Module Instruction
For effective use this modules trainees are expected to follow the following module instruction:
1. Read the information written in each unit
2. Accomplish the self-checks at the end of each unit
3. Perform operation sheets which were provided at the end of units
4. Do the “LAP test” giver at the end of each unit
5. Read the identified reference book for Examples and exercise

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Training module format Page 1 of 54
1 Unit One: Fundamentals of electrical motor
This unit is developed to provide you the necessary information regarding the following content
coverage and topics:
 Introduction to electrical motor
 Types of electrical motor
 Construction and Working principle of electrical motors
 OHS Requirements
This unit will also assist you to attain the learning outcomes stated in the cover page. Specifically,
upon completion of this learning guide, you will be able to:
 Explain electrical motor
 Explain types of electrical motor
 Describe construction of electrical motor.
 Apply OHS requirements

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1.1 Introduction to electrical motor
Electrical motors are devices that convert electric energy into magnetic energy and finally into
mechanical energy Electromagnetism is the basis of electric motor operation by generating
magnetic forces necessary to produce either rotational or linear motion for rotating electric
motors, it is the interaction between the stator and rotor magnetic fields that creates motor
torque to drive external loads.
Today, electric motors come in a wide variety of types, sizes, operating characteristics and
configurations to suit different applications. They are used almost everywhere in the
world,.including industrial drives, household appliances, medical devices,. lectronic.products,.
robots, electric vehicles, machine tools, spacecrafts, and military equipment As one of the
fastest growing industrial sectors electric motor manufacturing represents.

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1.2 Types of electrical motor
To ensure that motors are applied properly, it is essential to understand the various types of
motors and their operating characteristics. Electric motors fall into two classes, based on the
power supply: Alternate current(AC) and direct current (DC). The most common types of
industrial motors are shown in Figure 1.1.
Figure 1-1 clasfication of motor
AC motors
AC electrical motors are essential components in various applications. Here are the main types:
1. Induction Motors 3. Single-Phase Motors
Squirrel Cage Induction Motor: Most Split-Phase Motor: Common in household
common type, robust and simple design. applications, uses two windings.
Wound Rotor Induction Motor: Allows for Capacitor Start Motor: Provides a higher
variable speed and higher starting torque. starting torque, used in pumps and fans.
2. Synchronous Motors Shaded Pole Motor: Simple design, low
Operate at a constant speed, synchronized starting torque, used in small appliances.
with the AC supply frequency. Used in
applications requiring precise speed.

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6. Three-Phase Motors
More efficient and powerful, commonly used in industrial applications.
Can be either induction or synchronous.
Universal Motors
Can operate on AC or DC, widely used in portable tools and appliances.
7. Stepper Motors
Used for precise control of position and speed, commonly found in printers and CNC
machines.
8. Servo Motors
Provide precise control of angular position, speed, and acceleration, typically used in robotics
and automation.
9. Reluctance Motors
Operate based on the principle of magnetic reluctance, used in specific applications where high
efficiency is needed.
Each type of motor has its advantages and is suited for different applications depending on
factors like torque, speed control, and efficiency

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Induction Motors
Induction motors include squirrel-cage and wound-rotor types. Induction motors rely on a
magnetic field to transfer electromagnetic energy to the rotor. The induced currents in the rotor
create a magnetic field that interacts with the stator field. The speed of the rotor’s magnetic
field is slightly less than that of the stator (this difference is the slip). As the load on the motor
increases, the slip also increases. The full-load speed is typically shown on the motor
nameplate. A typical induction motor is shown in Figure1-2.
Because squirrel-cage induction motors can

be designed and built to have a relatively
wide range of torque and slip
characteristics, the National Electrical
Manufacturer Association has developed a
set of classifications for these motors.
These classifications help engineers and
designers select the right motors for
applications that require certain starting
torques, operating torques, and slip rates.
Figure 1-2Induction moto
DC motors
DC motor refers to any class of rotary electrical motors that converts direct current electrical
energy into mechanical energy. The most common types of DC Motors are dependent on the
forces produced by magnetic fields. Simply stated, any electric motor that is operated using
direct current or DC is called a DC motor.
Classification of DC motors
DC motors are mainly classified into four types as listed below:
 Separately excited DC motor  Compound DC motor
 Shunt DC motor  The permanent magnet DC moto
 Series DC motor

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Separately excited DC motor: A field circuit is supplied from a separate constant voltage
power source.
of DC current as shown in the figure beside.
As the name suggests, in case of a
separately excited DC motor the supply is
given separately to the field and armature
windings. The main distinguishing fact in
these types of DC motor is that, the
armature current does not flow through the
field windings, as the field winding is
Figure 1-3 separately excited DC motor
energized from a separate external source
Shunt DC motor: A shunt motor is connected in the same way as a shunt generator
The field windings are connected in parallel

(shunt) with the armature windings. A field
circuit gets its power from the armature
terminals of the motor. Once you adjust the
speed of a dc shunt motor, the speed
Figure 1-4Shunt DC moto
remains relatively constant even under
changing load conditions.
Series motor: In the series-wound motor,

the field windings are connected in series
with the armature. Its starting torque is
greater than other types of dc motors.
Figure 1-5 Series motor


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A series DC motor is a DC motor whose Usually, either the bearings are damaged or
field windings consists of a relatively few the windings fly out of the slots in the
turns connected in series with armature armature. There is a danger to both
circuit. The speed of a series motor with no equipment and personnel. Some load must
load connected to it increases to the point ALWAYS be connected to a series motor
where the motor may become damaged. before you turn it on.
Compound motor: A compound motor field is connected in parallel with the series
has two field windings, One is a shunt field field and armature, it is called a "long
connected in parallel with the armature; the shunt" as shown in figure, otherwise, it is
other is a series field that is connected in called a "short shunt", as shown in figure.
series with the armature. When the shunt
The shunt field gives this type of motor
the constant speed advantage of a regular
shunt motor. The series field gives it the
advantage of being able to develop a large
torque when the motor is started under a
heavy load. It should not be a surprise that
Figure 1-6 Compound motor the compound motor has both shunt- and
series-motor characteristics
The permanent-magnet DC motor: A permanent magnet DC (PMDC) motor is a motor

whose poles are made out of permanent magnets.
Advantages: Since no field windings are needed, these

motors can be considerable smaller.
Since no external field circuit is needed,
there are no field circuit copper losses; Disadvantages:
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Since permanent magnets produces weaker

flux densities then externally supported
shunt fields, such motors have lower
induced torque.
There is always a risk of demagnetization

from extensive heating or from armature
reaction effects (via armature mmf). Figure 1-7 the permanent-magnet DC motor

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1.3 Construction and Working principle of electrical motors
Construction of an AC motor
An alternating current drives an AC motor. The stationary stator and the rotating rotor are
important parts of AC motors. In this section, let us study the different parts of an AC motor.
Figure 1-8AC Motor Diagram
Following are the different parts of an AC motor:
An induction motor is a type of electric motor that operates on the principle of electromagnetic
induction. Here’s a brief overview of its construction:
Construction of an AC Induction Motor
Stator: The stator is the stationary part of the motor that delivers a rotating magnetic field to
interact with the rotor.
Frame: The outer casing that supports the motor components.
Windings: Copper or aluminum coils placed in the slots of the stator core. When AC current
flows through these windings, it creates a rotating magnetic field.

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Core: Made of laminated silicon steel to reduce energy losses. The core provides a path for
the magnetic field.
Stator windings are stacked together, forming a hollow cylinder.
The slots of the stator core coils of insulated wires are insulated. Three symmetrically placed
windings (one for each phase) are fitted into slotted laminations, which are made from high-
grade alloy steel to reduce the effects of eddy currents. Generally the six ends of the three
windings are brought out into a terminal box. Figure 3 shows the stator Windings fitted into
the slotted laminations. The six colored leads from the winding ends are also visible. When the
assembled motor operates, the stator windings are connected to a power source. Each group of
coils, along with the steel core, becomes an electromagnet when the current is applied.
Rotor
A rotor is a central component of a motor type of rotor used in an AC motor is the

that is fixed to the shaft. The most common squirrel cage rotor.
A squirrel-cage rotor is cylindrical and is

made by stacking thin steel laminations.
Instead of inserting wire coils between the
slots, conductor bars are die-cast into the
evenly spaced slots around the cylinder.
Once the conductor bars are die-casted,
they are electrically and mechanically
Figure 1-9 squirrel-cage rotor
connected to the end rings.
Squirrel Cage: The most common type of rotor, consisting of conductive bars short-circuited
at both ends. It is placed inside the stator and rotates in response to the rotating magnetic field.
Wound Rotor: Contains three-phase windings connected to external resistances. It is less

common but allows for better control over speed and torque.

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End Bells or End Shields: These enclose the rotor and provide support for the bearings.
Bearings: Support the rotor and allow it to rotate smoothly within the stator.
Cooling System: Often includes ventilators or ducts to ensure the motor does not overheat
during operation.
Bearings: Bearings hold the motor shaft in place. The bearings minimize the shaft’s friction
connected to the casing, which increases the motor’s efficiency.
Enclosure: The enclosure protects the internal parts of the motor from water and other
environmental elements. The enclosure consists of a frame and two end brackets
Working principle of AC Motor
Figure 1-10 induction motor working
The working principle of an AC motor is described below:

 AC motors receive electric power from a source, typically an electrical outlet.
 The motor consists of two main parts: the stator and the rotor.
 When AC voltage is applied to the stator windings, a rotating magnetic field is
produced.
 The magnetic field induces a current in the rotor (in the case of a squirrel cage) or
excites the rotor windings (in a wound rotor).

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 This induced current creates its own magnetic field, which interacts with the stator's
magnetic field, causing the rotor to spin.
Construction of a DC Motor
Here is the schematic diagram of a DC Motor
Figure 1-11 schematic diagram of a DC Motor
A DC motor consists of six main parts, which are as follows

Yoke: The outer frame of a DC motor is a hollow cylinder made up of cast steel or rolled steel
is known as yoke. The yoke serves following two purposes
 It supports the field pole core and acts as a protecting cover to the machine.
 It provides a path for the magnetic flux produced by the field winding.
Magnetic Field System

The magnetic field system of a DC motor is the stationary part of the machine. It produces the
main magnetic flux in the motor. It consists of an even number of pole cores bolted to the yoke
and field winding wound around the pole core. The field system of DC motor has salient poles
i.e. the poles project inwards and each pole core has a pole shoe having a curved surface. The
pole shoe serves two purposes

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 It provides support to the field coils.

 It reduces the reluctance of magnetic circuit by increasing the cross-sectional area of it.
The pole cores are made of thin laminations of sheet steel which are insulated from each other
to reduce the eddy current loss. The field coils are connected in series with one another such
that when the current flows through the coils, alternate north and south poles are produced.
Armature Core
The armature core of DC motor is mounted

on the shaft and rotates between the field
poles. It has slots on its outer surface and
the armature conductors are put in these
slots. The armature core is a made up of soft
steel laminations which are insulated from
Figure 1-12armature core of DC motor
each other and tightly clamped together.
In small machines, the laminations are keyed directly to the shaft, whereas in large machines,
they are mounted on a spider. The laminated armature core is used to reduce the eddy current
loss.
Armature Winding
The insulated conductors are put into the slots of the armature core. The conductors are suitably
connected. This connected arrangement of conductors is known as armature winding. There
are two types of armature windings are used – wave winding and lap winding.

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Commutator
A commutator is a mechanical rectifier

which converts the direct current input to
the motor from the DC source into
alternating current in the armature winding.
The commutator is made of wedge-shaped
copper segments insulated from each other
and from the shaft by mica sheets. Each
Figure 1-13 commutator segment of commutator is connected to the
ends of the armature coils.
Brushes
armature windings. The brushes are made

of carbon and is supported by a metal box
called brush holder. The pressure exerted
by the brushes on the commutator is
adjusted and maintained at constant value
by means of springs. The current flows
Figure 1-14 brush with brush holder from the external DC source to the armature
The brushes are mounted on the winding through the carbon brushes and
commutator and are used to inject the commutator
current from the DC source into the

.
Fleming’s Left Hand Rule states that if
the index finger, middle finger, and thumb
of your left hand are extended mutually

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perpendicular to each other and if the index

finger represents the direction of Magnetic
Field, the middle finger indicates the
direction of the current, then the thumb
represents the direction in which force is
experienced by the Shaft of the DC motor.
Figure 1-15 Fleming’s lift hand rule
There are two main sources of magnetic fields:

1. magnetic fields due to electric currents in conducting materials
2. Fields arising from magnetic materials.
Lorentz force
 A current-carrying wire in a magnetic field experiences a force.
 The magnitude and direction of this force depend on four variables:
 The magnitude and direction of the current (I),
 The length of the wire (L),
 The strength and direction of the magnetic field (B),
 The angle between the field and the wire (Θ).
F = I L X B or in scalar terms: F = I L B SinΘ
When current is in amperes, length in meters, and magnetic field in teslas, the force is in
newton’s.
The direction of the force is perpendicular to both the current and the magnetic field, and is
predicted by the right-hand cross-product rule.
Working principle of dc motor


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 When the DC Motor, field coil is energized, a magnetic field is created in the air gap.
 The magnetic field that is created is in the direction of the radii of the armature.
 The magnetic field enters the armature from the side of the North Pole of the field coil and
exits from the South Pole side.
 The conductors located on the other pole get subjected to a force of the same intensity in
the opposite direction.
 These two forces create a torque that leads to the motor armature to rotate.
If the direction of current in the wire is reversed, the direction of rotation also reverses. When
magnetic field and electric field interact they produce a mechanical force that tends to rotate
the Armature.
All the armature conductors under N pole

carry current in one direction (say into the
plane of the paper), whereas all the
conductors under S pole carry current in the
opposite direction (say out of the plane of
the paper). As each conductor carrying a
current and is placed in a magnetic field,
hence a mechanical force acts on it.
Figure 1-16 DC Motor working principle
By applying Fleming’s left hand rule, it can be seen that the force on each conductor is tending
to move the armature in anticlockwise direction. The force on all the conductors add together
to exert a torque which make the armature rotating. When the conductor moves from one side
of a brush to the other, the current in the conductor is reversed and at the same time it comes
under the influence of next pole of opposite polarity. As a result of this, the direction of force
on the conductor remains the same. Therefore, the motor being rotating in the same direction.

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Generally DC motor consist field windings and armature windings. When current is applied
to the armature windings generate a magnetic field, which reacts against the outside field which
produces by the field winding. The interaction of the fields produces the movement of the
shaft/armature. Thus, electromagnetic energy becomes motion.
The magnetic field produced by the stator poles induces an EMF (voltage) in the rotor (or
armature) coils when the motor is rotated. This EMF opposes the flow of current in armature
winding and thus opposes applied voltage. Therefore this EMF is known as back EMF.

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1.4 OHS Requirement
 Protective cover is placed on TCV following safety procedures.

 Conducting Visual inspection by following service manual.
 Identified Technical specification, equipment and tools for diagnosing and prepared as
per manufacturer’s manual.
 Acquiring requiring information about the TCV including history in accordance with
organization procedures and guidelines.
 Appling questioning techniques to gather more information from customer and
determining nature of the customer inquiry.
 Selecting and preparing methods appropriate to the circumstances are in accordance
with standard operating procedures.
 Setting up scan tools/interface based on manufacturer’s manual.
Introduction
It is your responsibility to work safely to protect yourself from injuries and any other accidents.
You must exercise positive efforts to do this both for your own sake, and for the sake of your
family, your colleagues, and your company.
Accidents can be caused by human factors, physical factors, or a combination of both

Accidents due to human factors
Accidents that are caused by improper use of a machine or tool, by wearing inappropriate
clothes, carelessness of the technician, etc
Accidents due to physical factors
Those resulting from a malfunction of a machine or tool, lack of integrity of a safety device or
poor working environment. Therefore, you must make it a routine practice to correct hazardous
elements in your work place to prevent accidents.
Work wear

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Select work wear, which is strong and fits well for ease in work. Avoid work wear with
exposed belts, buckles and buttons, which can cause damage to TCV during work.
Have a clean work wear when at work, as oil and dirt on your clothing will spoil customers'
vehicle.
Work shoes
Choose proper footwear for working. It is dangerous to wear sandals or any other type of
footwear that slips easily. It is recommended to use with non-slip soles and hardened toe
caps.
Work gloves
When lifting heavy items or removing hot exhausts pipes or similar objects, it is advisable to
wear gloves, but it is not necessary to make a rule of wearing them for ordinary maintenance
work. In particular, during drilling and grinding and while working inside the engine
compartment when the engine is running, there is a danger of gloves being caught, so they
should not be worn in such cases.
Safe and tidy work-workshop rules
In the workshop:-
 Always keep the place where you work clean. When a job is finished, everything should
be replaced neatly in order.
 Keep your work area clean, and wastes should be disposed.
 The repair shop for engine, transmission and alignment units, etc., should be kept clean
at all times.
 Vehicles for repair must be properly parked. Do not park them in such a way that they
will block traffic in the shop.

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Self-check 1.1
Directions: Answer all the questions listed below.
Part I: say true or false
---------------1. Copper loss in an induction motor is due to eddy currents in the stator and rotor
core resistance of the stator and rotor windings
----------------3. If the centrifugal switch on a split phase motor goes permanently open circuit
the motor will not start.
-----------------4. The purpose of laminations in the core of an electrical motor to provide
electrical insulation
-----------------5. Back EMF determines the speed of a DC motor.
Part II: Choose the correct answer from the given alternatives.
1. What is the function of a commutator in an electrical motor?
a. To convert AC to DC
b. To provide electrical insulation
c. To reverse the direction of current
d. To regulate motor speed
2. Which type of motor uses brushes and a commutator?
a. DC motor
b. AC motor
c. Induction motor
d. Synchronous motor
3. Which type of motor does not require a separate power source for the rotor?
a. Synchronous motor
b. Induction motor
c. Brushless DC motor
d. Universal motor
4. What is the primary function of the stator in an electric motor?
a. To provide mechanical support

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b. To generate a rotating magnetic field

c. To convert electrical energy into mechanical energy
d. To regulate the motor’s speed
5. Which type of motor is commonly used in household appliances like refrigerators and air
conditioners?
a. Single-phase induction motor
b. Synchronous motor
c. Brushless DC motor
d. Universal motor
6. Which type of motor provides the highest starting torque?
a. DC series motor
b. DC shunt motor
c. AC induction motor
d. Brushless DC motor
7. Which motor is suitable for applications requiring variable speed control?
a. DC motor
b. AC motor
c. Stepper motor
d. Synchronous motor
8. What is the primary advantage of a brushless DC motor over a brushed DC motor?
a. Higher efficiency
b. Lower cost
c. Simplicity of construction
d. Greater torque output.
9. What is the role of a centrifugal switch in a single-phase induction motor?
a. To reverse the direction of rotation
b. To control the motor’s speed

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c. To provide electrical insulation

d. To disconnect the starting winding
10. Which type of motor is used in robotics and precision control applications?
a. Stepper motor
b. AC induction motor
c. Synchronous motor
d. Brushless DC motor
11. What is the primary advantage of a three-phase induction motor over a single phase
induction motor?
a. Higher efficiency
b. Lower cost
c. Smaller size
d. Simplicity of construction
12. Which motor type is suitable for high-speed applications?
a. Brushless DC motor
b. DC series motor
c. Induction motor
d. Universal motor
13. No-load speed of which of the following motor is highest?

A. Differentially compound motor C. Series Motor
B. Cumulative compound motor D. Shunt Motor
14. Which of the following rule is used to determine the direction of rotation of the DC motor?
A. Columba’s Law C. Fleming’s Right-hand Rule
B. Lenz’s Law D. Fleming’s Left-hand Rule
15. Which part of the DC motor can sustain maximum temperature rise?
A. Armature Winding C. Slip Ring
B. Field winding D. Commutator
16. The ratio of starting torque to full load torque is least in:

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A. Differential Compound Motor C. Series Motor

B. Shunt motor D. Cumulative compound motor
17. In which of the following applications DC series motor is used?

A. Centrifugal Pump C. Water pump drive
B. Motor Operation in DC and AC D. Starter for car
A. In the DC machine, the fractional pitch winding is used:

B. To reduce the Harmonic in D. Increase EMF
generated EMF E. To reduce the copper losses
C. Improve Cooling
Part III: write short answers
1. Explain how dc motor work?
2. Explain how AC motor work?
3. Explain a types of ac motor.
4. Explain a types of dc motor.
5. List a parts of dc motor and explain the functions of each parts
6. List a parts of single-phase induction motor and explain the functions of each parts
7. List a parts of three phase induction motor and explain the functions of each parts

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2 Unit Two: Servicing and repairing of electric motor
This unit is developed to provide you the necessary information regarding the following
content coverage and topics:
 Testing of electrical motors
 Servicing and repairing electric motors
This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Test AC-motor test
 Test DC-motor test
 Service of electric motors
 Rrepairer of Electrical motor

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2.1 Testing of electrical Motor
A. Visual Tests
 Check that motor frame is mechanically sound.
 Remove terminal cover plate and check for ingress of foreign material, moisture etc.
 Check for signs of overheating, arcing or burning.
 Check ventilation is clear.
B. Electrical Tests
 Identify windings using a continuity tester.
 Measure the resistance of the windings (3 identical readings).
 Measure the insulation resistance between each winding and between windings and
frame.
C. Mechanical Tests
 Check that the rotor is free to rotate and does so smoothly / quietly.
 Check that motor interior is free of dirt, dust, water and oil.
 Check for play in bearings.
D. Tests when Running
 Check run currents (If uneven check voltage at motor terminals).
 Check speed of motor at no load and full load.
 Check vibration levels and noise levels.
 Check for temperature hot spots.

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2.1.1 Testing ac motor
1. AC motor Stator Windings Resistance Test

This test is carried out on an isolated motor, to check the resistance of the stator windings. It
is necessary to make an accurate measurement, so allow reading ohmmeter or a high-resolution
digital multi meter should be used.
1. Isolate the motor electrically, and if necessary, mechanically.

2. Identify the way the motor terminal block is connected.
 Star connected.
 Delta connected.
 Star-Delta connected.
3. Identifythe3 stator windings- usually labeled U1-U2, V1-V2, and W1-W2.

4. Measure and record the resistance of each winding.
two, this indicates that a high resistance
fault is developing possibly due to a poor
quality solder joint. An infinite resistance
indicates an open circuit (or break) in the
winding.
If the resistance of one winding is lower

Figure 2-1 Winding resistance testing than the other two, this indicates that the
If there is any appreciable difference winding is becoming short-circuited. This
between one winding and the other two, is possibly due to an inter-turns short circuit
this indicates a fault condition. If one on that winding.
winding resistance is higher than the other

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It is usually the result of the winding overheating, which damages the insulation (varnish), or
because of mechanical damage. Both faults may necessitate having the motor rewound. The
following Figures to illustrate how to complete the winding resistance test.
1. Insulation Resistance Test
This is a test carried out to determine the quality of the insulation between:
 The windings and the motor frame

 Between the individual windings
Insulation Resistance Tests Between Windings and Frame
1. Isolate the motor electrically, and if necessary, mechanically.

2. Make a careful note of how the supply cables are connected so as to avoid errors when
re-connecting. Disconnect the supply cables from the motor terminal block to ensure
that there are no parallel paths via the control equipment, which would lead to false
low readings being obtained. Such disconnection of cables will also ensure that any
electronic equipment in the circuit will be isolated before the test commences, as it
may be damaged, by the Insulation Resistance Test, voltage.
3. Measure the insulation resistance 5. Measure the insulation resistance
between the U winding and frame. between the W winding and frame
Some motor manufactures (as shown step step3).
recommend a reading of not less
than 10 MΩ however a reading of
not less than 2 MΩ is generally
accepted. See Figure2- 19.
4. Measure the insulation resistance
between the V winding and frame
(as shown step step3). Figure 2-2 Winding resistance testing

Form Title:
1. Insulation Resistance Tests Between Windings

(Insulation Resistance Tests Between Windings must be infinity(OL) otherwise the motor
is multifunctional )
1. Insulation Resistance Test between

windings U and V.
2. Insulation resistance test between
windings U and W.
3. Insulation Resistance Test between
Windings V and W. as shown in
Figure 2-3Insulation resistance testing
figure
 Dc motor test
Field winding Resistance Test

An easy way to measure winding resistance is using an ohmmeter/ multimeter.
How to Use a Multimeter to Measure Motor Winding Resistance:
1. Turn off the power to your motor.
2. Access the motor's winding: you may need to remove a cover or disassemble the motor to
access the winding.
3. Identify the winding terminals: look for the motor's wiring diagram or markings on the
terminals to identify the winding's start and end points.
4. Turn on the ohmmeter/ multi-meter: if you’re using a multi-meter, select the ohmmeter
function. Choose the appropriate range for the expected resistance value of your motor's
winding. If you're not sure, start with the highest range and work your way down.
5. Connect the probes: connect the meter's probes to the winding terminals. Make sure that
the probes are making good contact and that there are no short circuits.

Form Title:
6. Pass a test current through the wire: the value of the test current should be selected
according to the nominal winding current. The test current should not exceed 10% of the
nominal winding current.
7. Read the resistance: Take note of the resistance value displayed on the meter. If the value
is within the manufacturer's recommended range, then your motor's winding is likely
functioning correctly. If the value is outside the range, then there may be a problem with
the winding or the motor.
8. Repeat the test: To ensure accuracy, it's a good idea to repeat the test a few times and take
an average of the readings.
ARMATURE TEST WITH GROWLER TESTER
It can be used to check for:-

I. Short circuit test
II. Open circuits to round test of the
armature winding.
 Always be sure that power switch is off
when connecting or disconnecting the
AC cord.
 Always be sure power switch is off
Figure 2-4 Growler armature tester
when placing or removing an armature
GENERAL INFORMATION: The from the jaws.
Armature Tester (growler) can be used to  Do not operate this tester without an
check the armatures of electric motors and armature in place. The transformer may
starter motors. burn out.

Form Title:
The test light and the two black probes are used to check the armature for shorts to ground and
other insulation problems. The test light may be checked by placing an armature in place in
the jaws, turning the power on, and shorting the two black probes together. The test light should
come on. The meter, two red probes, and the High/Low switch is a separate circuit used to
check the windings for defects. Shorting the probes will not cause the meter to operate. They
must be pressed against adjacent commutator segments. The meter is more sensitive when used
in the Low position.
SHORTS CIRCUIT TEST

1. Place armature in the jaws. vibrates, armature is shorted.
2. Turn power on. Replace armature
3. Turn the selector switch to
"SHORT" position.
4. With armature installed in growler
and power on, hold hacksaw blade
parallel with and touching armature
core segment as shown.
5. Rotate armature slowly one or more Figure 2-5 armature short circuit test using growler tester
revolutions. If hacksaw blade

OPEN CIRCUIT TEST
1. Place armature in jaws.
2. Turn power on.

Form Title:
Figure 2-6 armature open circuit test using corresponding commutator bar with
growler tester
one test prod and the adjacent bar with
the other prod. Watch the meter and if
3. Turn the selector switch to "VOLTS HI"
it reads LOW turn selector switch to
and rotate the armature slowly.
4. As each coil comes in position between VOLTS LOW.
the pole pieces, touch the

5. No readings on the meter indicates broken winding or open coil. If coils are OK, the meter
readings should remain the same for each coil as the commutator is rotated.
6. Assuming the first coil tested is OK, a lower meter reading, while testing the other coils,
would indicate an insufficient number of turns. A higher reading indicates there are too
many turns in the coil.
GROUND CIRCUIT TEST
1. Place armature in jaws.
2. Turn power on.
3. Place armature in growler turn the
selector switch to "GRND TEST" and
turn power on.
4. Touch one test probe to armature core,
other test probe to commutator as
shown. If test lamp glows, armature or
Figure 2-7 armature ground circuit test using
commutator is grounded. Replace growler teste
armature.
Note: Dirt and moisture between the commutator and on the insulator surface can cause
grounding and make the lamp dim. If grounding was indicated, carefully clean all dirt and then
recheck it. Replace the armature if it is grounded and unrepairable.

Form Title:
ARMATURE TEST WITH MULTIMETER TESTER
180 degree test
 Results
 Measuring values is not important but
should remain about the same value.
 Drop in resistance could indicates short
between winding wires
 Resistance spike could indicates
broken/Burt through the wires
Figure 2-8armature commutators 180 degree test
1. Bar to bar test

 Results
 Measuring values is not important but
should remain about the same value.
 Drop in resistance could indicates short
between winding wires
 Resistance spike could indicates
broken/Burt through the wires
Figure 2-9 armature commutator bar to bar test
2. Continuity test

Form Title:
Figure 2-10 continuity test between commutator  Using continuity setting should always
bars and armature cores
show 1 or OL (open loop) and not beep
 Result
sound.
 Commutator bars should never have
 If multi-meter shows OL or beep sound
electrical continuity to armature core.
there is short circuit between the
armature winding and core. We should
repair it

Form Title:
2.2 Serving and repairing electrical motor
Serving electrical motor

To effectively serve a electrical motor, you should consider several key aspects, including
maintenance, troubleshooting, and operating procedures. Here’s a structured guide to help you:
Regular Inspection: Check for signs of wear, loose connections, or damage to the motor
housing.
Cleaning: Keep the motor free from dust and debris. Use a soft brush or vacuum cleaner; avoid
using water or liquid cleaners.
Lubrication: Ensure that bearings and moving parts are properly lubricated according to the
manufacturer's recommendations.
Cooling: Ensure that the motor has adequate ventilation. Overheating can lead to premature
failure.
No Operation: Check power supply, fuse, and connections.
Unusual Noises: Inspect for mechanical issues, such as worn bearings or misalignment.
Overheating: Ensure the motor is not overloaded and that it is adequately ventilated.
Reduced Performance: Check for potential electrical issues, such as voltage drops, or
mechanical problems, such as friction.
Start-Up: Gradually apply power to avoid sudden surges. Use soft starters if necessary.
Load Management: Ensure the motor is not overloaded beyond its rated capacity.
Monitoring: Use sensors or gauges to monitor temperature, current, and speed.
Serving AC electrical motors involves several key aspects, including maintenance,
troubleshooting, and performance optimization. Here are some important points to consider:
Electrical Issues: Check for issues in the power supply, such as voltage fluctuations or phase
imbalance.
Mechanical Problems: Look for misalignment, bearing failure, or worn components.
Insulation Testing: Use a megohmmeter to check insulation resistance.

Form Title:
2.3 Repairing electrical motor
Repair: Includes incoming inspection and test, damage appraisal, cleaning, replacement
and/or repair of damaged part(s), assembly, post repair inspection and test, and refinishing.
Repairing an electrical motor involves several steps to ensure proper functionality and safety.
Here’s a structured approach:

Form Title:
Self-check 2.1
Directions: Answer all the questions listed below.
Part I: say true or false
-------------1. Misalignment, shaft imbalance and Bearing wear are some common causes of
motor failure.
-------------2. Servicing motor provide long working life for motor.
-------------3.becuase of brush loss its length abnormal is happen between commutator and
brush
------------4. Rated fuse/circuit breaker installing in motor control circuit it preventing a motor
form faults.
------------5. OVERLOAD RELAY TRIPS OR FUSES BLOW WHEN MOTOR STARTS
because of mechanical problem.
Part II: Choose the correct answer from the given alternatives.
1. While testing insulation resistance between windings in a motor, the pointer of megger
shall deflect to ______
a) Zero
b) One
c) Infinity
d) No deflection
2. Result/s which should be gathered while testing insulation resistance of Ac motor is/are:
a) Zero reading between U and V windings
b) Zero reading between U and W windings
c) Infinity reading between all windings and metallic body of motor
d) Zero reading between all windings and metallic body of motor
3. Phase sequence test on induction motor is mainly used
a) To determine the direction of motor
b) To apply rated supply voltage
c) To determine supply frequency
d) For limiting starting current

Form Title:
4. Which is common causes of motor failure?

a) Transient voltage
b) Voltage imbalance
c) Variable frequency drives
d) Operational overloads
e) all
5. Which is probable cause motor fails to start upon initial installation?
a) Motor is damaged and the armature is rubbing against the magnets.
b) Motor damaged and the fan guard is contacting the cooling fan.
c) No output power from controller
d) Motor is miswired.
e) all
6. Which is probable cause of motor runs but loses power?
a) Load had increased
b) Brushes may not be seated properly or worn beyond their useful length.
c) Motor may have an open connection.
d) Motor controller not properly set
e) Load had increased
f) all
Part III: write short answers
1. Explain what happen if short circuit is occurred in motor?
2. Explain what happen if open circuit is occurred in motor?
3. Explain the cause of abnormal vibrations in three phase induction motor.
4. Which parts of the motor servicing? Explain why?
5. When measuring motor winding resistance, explain why a measurement of very
high or very low might both indicate motor failure.
6. Explain probable cause, effect and remedy of the following faults.
A. The motor not start
 Single phase induction motor
 Three phase induction motor

Form Title:
 Dc motor
B. Abnormal vibration in three phase induction motor
C. Protection breaker or fuse trip or blow
D. Unequal resistance between three phase induction motor stator winding
E. Brush abnormal spark between commutators.

Form Title:
Operation Sheet 2.1

Operation Title: Testing AC motor
Purpose: To assess an AC motor functionality.
Conditions for the Operations:
Safe working area
Properly operated tools and equipment
Appropriate work attire
Equipped vehicle with a functioning heater system
Equipment, Tools, and Materials:
 Open circuit tester
 Multi-meter
 AC induction motor
Quality Criteria: Ensure all activities are performed as per the procedure.
Precautions:
 Wear appropriate clothing, safety glasses, and gloves.
 Ensure a hazard-free working area.
 Read and follow equipment manuals.
Steps in Performing the Task:
1. Visual Inspection
 Flashlight: To illuminate hard-to-see areas.
 Magnifying Glass: For closer inspection of small components.
2. Insulation Resistance Test
 Megohmmeter: For measuring insulation resistance.
3. Continuity Test
 Multimeter: To check for continuity in windings.
4. Resistance Measurement
 Digital Multimeter: For measuring winding resistances.
5. No-Load Test
 Power Supply: To provide the correct voltage and frequency.
 Clamp Meter: To measure current during operation.
 Tachometer: To measure the speed of the motor.
6. Locked Rotor Test

Form Title:
 Power Supply: Similar to the no-load test.

 Clamp Meter: To measure high starting current.
 Voltage Meter: To monitor supply voltage.
7. Vibration Analysis
 Vibration Meter: To measure vibration levels.
 Accelerometer: For more detailed vibration analysis.
8. Temperature Measurement
 Infrared Thermometer: To measure surface temperature.
 Thermocouples: For continuous temperature monitoring.
9. Shaft Alignment Check
 Alignment Tools: Such as laser alignment tools or dial indicators.
10. Bearing Inspection
 Bearing Puller: For removing bearings if needed.
 Sound Level Meter: To detect unusual noises.
 Caliper or Micrometer: For measuring bearing dimensions.
Report your findings and recommend repair or replacement if necessary.

Completion: Provide a detailed report on the Heater Control Valve's condition and
any recommended action
Operation Sheet 2.2
Operation Title: Testing a DC Motor
Purpose: To assess the DC Motor functionality.

Safe working area
Properly operated tools and equipment
Appropriate work attire
Equipped vehicle with a functioning heater system
 Open circuit tester

Form Title:
 Multi-meter
 Dc motor
Precautions:
1. Preparation:
 Disconnect the Motor: Ensure the motor is not connected to any power source.
 Access the Terminals: Remove any covers to access the motor terminals.
2. Testing Resistance of Windings:
 Set the Multimeter: Turn the multimeter dial to the resistance (Ω) setting.
 Measure Resistance:
 Place one probe on one terminal of the motor winding and the other probe on the
second terminal.
 Record the resistance reading.
 Check against Specifications:
 Compare the measured resistance to the manufacturer’s specifications.
Significant deviations may indicate winding issues.
3. Checking for Shorts between Windings:
 Test Each Winding:
 Measure the resistance between each winding terminal and the motor frame
(ground).
 A reading of zero or very low resistance suggests a short circuit to ground.
 Cross-Check Windings:
 Measure the resistance between the two winding terminals. A significant
difference in resistance between the windings can indicate a fault.
4. Testing for Open Circuits:
 If you get a reading of infinity (OL on digital meters) between the winding
terminals, it indicates an open circuit in the winding.

Form Title:
5. Checking Voltage (if applicable):

 Set to Voltage Measurement: If you want to check the voltage while the motor
is running, set the multimeter to the appropriate DC voltage range.
 Power the Motor: Connect the motor to the power supply.
 Measure Voltage: Carefully place the probes on the motor terminals and check
for the expected operating voltage.
Completion: Provide a detailed report on the Heater Control Valve's condition
and any recommended action

Form Title:
Operation Sheet 2.3

Operation Title: Repairing electrical motor
Purpose: To assess the electrical motor functionality.
 Safe working area
 Properly operated tools and equipment
 Appropriate work attire
 Equipped vehicle with a functioning heater system
 Screwdrivers  Wire Cutters
 Wrenches  Wire Strippers
 Pliers  Soldering Tools
 Multi-meter  Flashlight or Work Light
 Clamp Meter  Toolbox or Organizer
 Insulation Tester  Electrical motor
Precautions:
1. Preliminary Inspection
 Visual Check
 Listen for Noise
2. Testing Electrical Components
 Check Power Supply
 Inspect Brushes and Commutator

Form Title:
 Test Field Windings

3. Mechanical Inspection
 Bearings and Shafts
 Mountings (Ensure that the machine is securely mounted and aligned.)
4. Control System Check
 Inspect Controllers
 Wiring and Connections
5. Perform Repairs
 Replace Damaged Parts
 Rewire if necessary: Repair or replace damaged wiring and connectors.
6. Reassembly
 Reassemble Components
 Double-Check Connections: Confirm that all electrical connections are secure.
7. Testing and Calibration
 Power up the System: Gradually restore power while monitoring for issues.
 Run Tests: Conduct tests to ensure the machine operates correctly under load.
 Calibrate Settings: Adjust any control settings as needed for optimal performance.
8. Documentation
 Record Repairs: Keep a log of all repairs and parts replaced for future reference.
 Update Maintenance Records: Document the service for tracking performance over
time.
9. Final Inspection
 Conduct a Safety Check: Ensure all safety mechanisms are functioning.
 Monitor Performance: Observe the machine during initial operation for any anomalies.
Report your findings and recommend repair or replacement if necessary. Completion:
Provide a detailed report on the Heater Control Valve's condition and any recommended
action
Page 46 of 54

Form Title:
Operation Sheet 2.4

Operation Title: Servicing electrical motor
Purpose: To assess the electrical motor long working life functionality.
 Safe working area
 Properly operated tools and equipment
 Appropriate work attire
 Equipped vehicle with a functioning heater system
 Screwdrivers  Wire Cutters
 Wrenches  Wire Strippers
 Pliers  Soldering Tools
 Multi-meter  Flashlight or Work Light
 Clamp Meter  Toolbox or Organizer
 Insulation Tester  Electrical motor
Precautions:
1. Cleanliness and lubrication of moving parts of machine
2. Checking of all moving parts for unnatural vibrations and sounds
3. Checking of all moving and electrical parts for abnormal heat
4. Checking for lubricant levels
5. Checking of all switches and motors under Live and off conditions
6. Cleaning and reconditioning of dirty/carbonized switch contacts
7. Checking of motor winding and insulation condition

Form Title:
8. Checking of current reading

Completion: Provide a detailed report on the Heater Control Valve's condition and any
recommended action

Form Title:
Lap Test.2.1
 LAP Test-1
Practical Demonstration
Name: __________________________ Date: ____________
Time started: ____________________ Time finished: _______________
Instruction: Given necessary templates, tools and materials you are required to perform the
following tasks within 7 hours.
Task 1: Test electrical motor
Task 2. service and repair AC motor
Task 4. service and repair DC motor

Form Title:
References
1. http://www.google.com
2. http://www.pdma.com/pdfs/Articles/DC_Motor_Analysis.pdf
3. http://www.ohioelectricmotors.com/2015/07/a-generalguide-to-dc-motor-
maintenance
4. Testing commissioning Operation and maintenance of electrical equipment
S.Rao, Khanna Publishers
‘

Form Title:
Developer’s Profile
N Name Qualifi Field of Study Organizati Mobil E-mail
o cation on/ e
(Level) Institution numb
er
1 Le.col.Dejene MSc Industrial MGMB PTC 09129 tadegelove@g

Addis Engineering 62382 mail.com
2 Maj.Adane Kefale BSc Electrical MGMB PTC 09203 adaneyifter2@

Engineering 44448 gmail.com
3 Lt. Feleke Moja Level V Tank electric MGMB PTC 09790 -

32259
4 Lt.Derso Mengaw Level V Tank electric MGMB PTC 09219 dersomengaw8

38885 [email protected]
5 Sisay Tufa MSc Industrial MGMB PTC 09120 knbntf@gmail.

Engineering and 65407 com
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Logo Company Name: Form No.

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

Military Armored Vehicle Electrical

Module Title: Service and repair electrical motor

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

e.m.f Electromotive force

XL. inductive reactance

S.T.R. short time rated

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

1 Unit One: Fundamentals of electrical motor

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

1.1 Introduction to electrical motor

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

1.2 Types of electrical motor

Figure 1-1 clasfication of motor

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

Because squirrel-cage induction motors can

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

The field windings are connected in parallel

Series motor: In the series-wound motor,

Figure 1-5 Series motor

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

The permanent-magnet DC motor: A permanent magnet DC (PMDC) motor is a motor

Advantages: Since no field windings are needed, these

Since permanent magnets produces weaker

There is always a risk of demagnetization

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

1.3 Construction and Working principle of electrical motors

Figure 1-8AC Motor Diagram

Following are the different parts of an AC motor:

Construction of an AC Induction Motor

Frame: The outer casing that supports the motor components.

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

Stator windings are stacked together, forming a hollow cylinder.

A rotor is a central component of a motor type of rotor used in an AC motor is the

A squirrel-cage rotor is cylindrical and is

Wound Rotor: Contains three-phase windings connected to external resistances. It is less

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

Figure 1-10 induction motor working

The working principle of an AC motor is described below:

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

Figure 1-11 schematic diagram of a DC Motor

A DC motor consists of six main parts, which are as follows

Magnetic Field System

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

 It provides support to the field coils.

The armature core of DC motor is mounted

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

A commutator is a mechanical rectifier

armature windings. The brushes are made

commutator and are used to inject the commutator

current from the DC source into the

የሥራና ክህሎት ሚኒስቴር OF/MoLS/TVT/029

perpendicular to each other and if the index

Figure 1-15 Fleming’s lift hand rule

There are two main sources of magnetic fields: