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Replace a three phase motor

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Pre-Task Plan: Replace a Three-Phase Motor

Date: [DATE] Work Area: [WORK AREA] Task Supervisor: [SUPERVISOR NAME]

1. Task Description

Replacing a three-phase motor, including disconnecting the old motor, removing it, installing the new motor, and reconnecting it to the power supply.

2. Task Duration

Estimated Start: [START TIME] Estimated Completion: [END TIME]

3. Personnel Involved

  • Electrician
  • Maintenance Technician
  • Safety Officer

4. Task-Specific Hazards and Controls

HazardRiskControl Measures
Electrical shockSevere injury or deathEnsure power is disconnected and locked out before starting work. Use insulated tools and wear rubber gloves. Verify absence of voltage before touching any electrical components [1].
Moving heavy equipmentStrain or crush injuriesUse proper lifting techniques and equipment. Ensure team members are trained in manual handling and use of lifting devices [2].
Hot surfacesBurnsAllow motor to cool before handling. Use thermal gloves if necessary [3].

5. Required PPE for Today's Task

  • Insulated gloves
  • Safety glasses
  • Hard hat
  • Steel-toed boots

6. Tools and Equipment Needed

  • Multimeter
  • Insulated hand tools
  • Lifting equipment (e.g., hoist or crane)

7. Pre-Start Checklist

Area Preparation

  • [ ] Ensure work area is clear of obstructions.
  • [ ] Verify that all necessary permits are in place.
  • [ ] Confirm that all team members are briefed on the task and safety procedures.

Equipment Checks

  • [ ] Test multimeter for proper operation.
  • [ ] Inspect lifting equipment for any defects.
  • [ ] Ensure all tools are insulated and in good condition.

Communication

  • [ ] Establish clear communication signals for lifting operations.
  • [ ] Ensure all team members have radios or other communication devices.

8. Task Steps Overview

  1. Disconnect power and lock out the circuit.
  2. Verify absence of voltage using a multimeter.
  3. Remove the old motor using appropriate lifting equipment.
  4. Install the new motor and secure it in place.
  5. Reconnect the motor to the power supply and test for proper operation.

9. Emergency Response for This Task

  • Electrical shock → Call emergency services and administer first aid.
  • Injury from lifting → Provide first aid and seek medical attention if necessary.

10. Task-Specific Precautions

  • Ensure all team members are aware of the location of emergency shut-off switches.
  • Maintain a safe distance from the motor during testing.
  • Do not work alone; always have a team member present.

Pre-Task Briefing Confirmation

All workers understand the task, associated hazards, and required controls.

Team Lead Initials: [___] Date: [DATE] Time: [TIME]

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3 source record(s)

Sources used for this answer

[1] Kobelco SK235SR-2, SK235SRLC-2 Operation Manual

Page 299

Open source document

Source excerpt

## B. Procedures <!-- image --> Fig. 8-4 <!-- image --> - 1. Place chock blocks at front and rear of each track to prevent machine from moving when brakes are released. See Fig.8-1. - 2. Lower attachment to ground. See "8.4 LOWERING ATTACHMENT WHEN SUDDEN ENGINE FAILURE OCCURS" for proper procedures. See Fig.8-18. - 3. Turn key switch "OFF" and remove key. See Fig. 8-2. - 4. Remove check/fill plug from each travel motor using the 12 mm socket head wrench. See Fig. 8-3. - 5. Place a clean 6 liter (1.6 Gal) capacity drain pan under each travel motor drain plug and remove drain plug using the 12 mm socket head wrench. See Fig. 8-4. - 6. After all of the gear oil has drained, cover the drain pans to prevent contamination and move them to an area away from the machine. - 7. Remove the fifteen plate mounting bolts from the travel motor reduction unit cover plates. See Fig. 8-5. - 8. Remove the two bolts from the bossed areas and install the two M10-1.5 &amp;amp;times; 30 mm lifting eyes into each of these holes. See Fig. 8-6. - 9. Attach the overhead lifting device to the lifting eyes and remove most of the slack from the chain or cable. - 10. Using a rubber mallet, gently strike the edge of the cover plate to help release plate from housing. - 11. After cover plate has release from housing, carefully move cover away from machine with lifting device. Fig. 8-6 <!-- image --> <!-- image --> -Be careful not to damage lip of cover plate. Any damage to the lip could result in a gear oil leak. -When removing the following components it will be necessary to have a clean area free of dirt and grit to lay these components. ８

[2] Kobelco SK500XSLC-10, SK520XDLC-10 Operation Manual

Page 273

Open source document

Source excerpt

［ ## 4.16 1000 HOUR (12-MONTH) INSPECTION &amp; MAINTENANCE PROCEDURES Thoroughly read and understand "SAFETY PRECAUTIONS" of this manual before performing the inspection and maintenance. Perform this section together with "EVERYDAY CHECK-UP and 50, 100, 120, 250, and 500 HOUR INSPECTION &amp; MAINTENANCE PROCEDURES". ## 4.16.1 REPLACING RETURN FILTER ## PAYATTENTION TO HOT PARTS - · The oil in the hydraulic oil tank is under high pressure and high temperature. - Before removing the cover, stop the engine first, push breather cap (1) to release air from hydraulic tank. - · Immediately after engine operation, the oil is hot and it may cause burns. Wait until the oil temperature cools down before attempting to change the hydraulic oil. Hydraulic oil before filtration inside the filter contains dirt. When taking out the return filter, do not return the hydraulic oil remaining in the filter back to the tank. - · Order two return filter element kits (7) P/NoLC52V01004R100. - Replace the return filter after 50 hours of operation has been reached for the first time, and then every 1,000 hours. - For breaker specification, replace it every 250 hours. - · A warning is displayed on the gauge cluster not only when the remaining maintenance interval set from the gauge cluster becomes 0, but also when the return filter is clogged. (See "WARNING DISPLAY SCREEN" in Chapter 2) - Regardless of the setting time of maintenance, when the hydraulic oil filter replacement warning is displayed, replace the return filter. - 1. Move the machine to a level and firm place. - 2. Park the machine in the hydraulic oil level inspection position. - 3. Stop the engine and move the pilot control shut-off lever to the "LOCKED" position. <!-- image --> 4

[3] Rules for the Administration of the Oregon Safe Employment Act (Construction, Division 3, OSHA Oregon)

Page 473

Open source document

Source excerpt

## WIRING METHODS, COMPONENTS, &amp; EQUIPMENT FOR GENERAL USE - (F) An individual disconnecting means shall be provided for each motor, but a single disconnecting means may be used for a group of motors under any one of the following conditions: - (1) If a number of motors drive special parts of a single machine or piece of apparatus, such as a metal or woodworking machine, crane, or hoist; - (2) If a group of motors is under the protection of one set of branch-circuit protective devices; or - (3) If a group of motors is in a single room in sight from the location of the disconnecting means. - (iii) Motor overload, short-circuit, and ground-fault protection. Motors, motorcontrol apparatus, and motor branch-circuit conductors shall be protected against overheating due to motor overloads or failure to start, and against short-circuits or ground faults. These provisions do not require overload protection that will stop a motor where a shutdown is likely to introduce additional or increased hazards, as in the case of fire pumps, or where continued operation of a motor is necessary for a safe shutdown of equipment or process and motor overload sensing devices are connected to a supervised alarm. ## (iv) Protection of live parts - all voltages. - (A) Stationary motors having commutators, collectors, and brush rigging located inside of motor end brackets and not conductively connected to supply circuits operating at more than 150 volts to ground need not have such parts guarded. Exposed live parts of motors and controllers operating at 50 volts or more between terminals shall be guarded against accidental contact by any of the following: - (1) By installation in a room or enclosure that is accessible only to qualified persons; - (2) By installation on a balcony, gallery, or platform, so elevated and arranged as to exclude unqualified persons; or - (3) By elevation 8 feet (2.44 m) or more above the floor. - (B) Where live parts of motors or controllers operating at ov…

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