Disassembling and reassembling an AC induction motor involves several steps to ensure the process is carried out safely and effectively, adhering to the Code of Safe Working Practice. Here’s a detailed procedure to follow:

Disassembly Procedure:

Preparation and Safety Measures:
- Read the Manual: Before starting, refer to the motor's manual for specific instructions and safety precautions.
- Lockout/Tagout (LOTO): Ensure the power supply to the motor is disconnected and locked out. Use a tag to indicate that maintenance work is being carried out.
- Personal Protective Equipment (PPE): Wear appropriate PPE such as safety glasses, gloves, and safety boots.
- Work Area Preparation: Clear the work area of any unnecessary tools and ensure it is well-lit and clean to prevent accidents.
Marking and Documentation:
- Label Wires and Components: Label all wires and components to ensure correct reassembly. Take pictures or draw diagrams to aid in the reassembly process.
- Record Initial Conditions: Document the motor’s orientation and the position of components such as the terminal box, cooling fan, and bearing housings.
Remove the Motor from Service:
- Disconnect Electrical Connections: Carefully disconnect all electrical connections from the terminal box, ensuring no damage to wires.
- Remove Couplings and Mounting Bolts: Detach any couplings connected to the motor shaft and remove the mounting bolts securing the motor to its base.
Disassembly of External Parts:
- Remove the Cooling Fan and Fan Cover: Unscrew and remove the cooling fan cover, then carefully detach the cooling fan from the shaft.
- Remove the Terminal Box Cover: Open the terminal box and disconnect any remaining internal connections. Remove the terminal box cover and set it aside.
Disassemble the Motor:
- Remove the End Covers: Unscrew the bolts securing the end covers (also called end bells or bearing housings) and gently remove them. This exposes the bearings and the rotor.
- Extract the Rotor: Carefully slide the rotor out of the stator. Ensure not to damage the rotor or stator windings during this process.
- Remove Bearings (if required): If the bearings need replacement, use a puller to remove them from the shaft carefully.
Inspect and Clean Components:
- Inspect Components: Check the condition of the rotor, stator, bearings, and other components for signs of wear, damage, or corrosion.
- Clean Parts: Clean all parts using appropriate cleaning solvents. Avoid using water or abrasive materials that could damage the motor components.

Reassembly Procedure:

Prepare for Reassembly:
- Clean Work Area and Components: Ensure all components are clean and the work area is free of debris.
- Lubricate Bearings: If the bearings have been replaced or removed, apply appropriate lubrication to the new or cleaned bearings.
Reassemble the Motor:
- Install Bearings: Carefully install new or cleaned bearings onto the shaft.
- Insert the Rotor: Gently slide the rotor back into the stator, ensuring it is properly aligned.
- Reattach End Covers: Refit the end covers onto the motor, securing them with the appropriate bolts. Ensure that the bearings are seated correctly and that there is no binding when turning the rotor by hand.
Reassemble External Parts:
- Reattach the Cooling Fan and Fan Cover: Secure the cooling fan onto the shaft and reattach the fan cover.
- Reinstall the Terminal Box Cover: Reconnect the internal wiring in the terminal box as per the labels or diagrams made earlier. Secure the terminal box cover.
Reconnect the Motor to Service:
- Reattach Couplings and Mounting Bolts: Position the motor back onto its base, securing it with mounting bolts. Reattach any couplings to the motor shaft.
- Reconnect Electrical Connections: Connect the electrical wires to the terminal box as per the original configuration.
Testing and Final Checks:
- Check Alignment and Rotation: Verify the motor shaft alignment and ensure it rotates freely by hand.
- Remove Lockout/Tagout: Remove any lockout/tagout devices and restore power to the motor.
- Test Run the Motor: Perform a test run to check for smooth operation, unusual noises, or vibrations. Monitor the motor's current draw, temperature, and overall performance.
Final Inspection and Documentation:
- Conduct Final Inspection: Perform a thorough inspection to ensure all components are correctly assembled and the motor operates as expected.
- Update Maintenance Records: Document the disassembly and reassembly process, including any parts replaced and observations made.

Safety Considerations:

Ensure compliance with all safety protocols, including lockout/tagout and use of PPE.
Handle all components carefully to avoid damage to the motor and ensure personal safety.
Follow the manufacturer’s manual and the Code of Safe Working Practice for specific safety guidelines and procedures.

By following this detailed procedure, the AC induction motor can be safely disassembled and reassembled, ensuring continued reliable operation.