Novak Brushless Motor: Vulcan Motor (55-3640-1 Rev.3) - Manual

PRECAUTIONS PRECAUTIONS
NEVER FREE-REV THE MOTOR Free-running your brushless
motor in a no-load condition can result in rotor failure and ESC
transistor damage & will void the product’s warranty!
• WATER & ELECTRONICS DON’T MIX Never allow water, moisture, or other
foreign materials to get inside motor, or on PCBs.
• NOVAK MOTORS & ESCs FOR BEST RESULTS Use Novak sensor-based
motors with Novak Brushless ESCs for best performance & protection. Only
use motors with the proper number of turns to match ESC’s rating.
Use of this brushless motor with non-Novak ESCs and ESCs that
advance motor timing can result in excessive current draw & severe
motor damage that will NOT be covered by the product’s warranty!
• INSULATE EXPOSED WIRES Use heat shrink tubing to prevent shorts.
• NO SOLVENTS Do NOT expose the motor to any type of solvents.
• SET GEAR MESH PROPERLY Too tight of a gear mesh can result in
motor pinion shaft breakage--be sure to adjust mesh properly.
NEVER FREE-REV THE MOTOR Free-running your brushless
motor in a no-load condition can result in rotor failure and ESC
transistor damage & will void the product’s warranty!
• WATER & ELECTRONICS DON’T MIX Never allow water, moisture, or other
foreign materials to get inside motor, or on PCBs.
• NOVAK MOTORS & ESCs FOR BEST RESULTS Use Novak sensor-based
motors with Novak Brushless ESCs for best performance & protection. Only
use motors with the proper number of turns to match ESC’s rating.
Use of this brushless motor with non-Novak ESCs and ESCs that
advance motor timing can result in excessive current draw & severe
motor damage that will NOT be covered by the product’s warranty!
• INSULATE EXPOSED WIRES Use heat shrink tubing to prevent shorts.
• NO SOLVENTS Do NOT expose the motor to any type of solvents.
• SET GEAR MESH PROPERLY Too tight of a gear mesh can result in
motor pinion shaft breakage--be sure to adjust mesh properly.
MOTOR MAINTENANCE MOTOR MAINTENANCE
• CHECK ALL MOTOR SCREWS for loosening at regular intervals, just like
other hardware on your vehicle. Note: The 3 main socket head screws
that hold the motor together may require tightening after a few runs of
the motor. Also check the 3 flat head screws securing the bearing cap
on the back end of the motor.
• CHECK MOTOR BEARINGS periodically. The motor bearing shields will
keep the majority of dirt & debris out, but some will get in and cause wear.
Wipe off the bearings regularly and check if motor shaft spins freely. If
shaft does not spin freely, you may need bearing replacement (replacement
bearing accessory kits are available from Novak).If needed, apply a small drop
of light oil to the bearings periodically to help extend bearing life--(Too
much oil will attract dirt & will cause problems, so apply sparingly).
• CLEAN INSIDE MOTOR periodically by removing front end can,
removing the rotor, and blowing out the inside of the motor with
compressed air. Be sure not to lose any small shim washers that may be
on the ends of the rotor shaft & keep them in the correct location.
• CHECK ALL MOTOR SCREWS for loosening at regular intervals, just like
other hardware on your vehicle. Note: The 3 main socket head screws
that hold the motor together may require tightening after a few runs of
the motor. Also check the 3 flat head screws securing the bearing cap
on the back end of the motor.
• CHECK MOTOR BEARINGS periodically. The motor bearing shields will
keep the majority of dirt & debris out, but some will get in and cause wear.
Wipe off the bearings regularly and check if motor shaft spins freely. If
shaft does not spin freely, you may need bearing replacement (replacement
bearing accessory kits are available from Novak).If needed, apply a small drop
of light oil to the bearings periodically to help extend bearing life--(Too
much oil will attract dirt & will cause problems, so apply sparingly).
• CLEAN INSIDE MOTOR periodically by removing front end can,
removing the rotor, and blowing out the inside of the motor with
compressed air. Be sure not to lose any small shim washers that may be
on the ends of the rotor shaft & keep them in the correct location.
SERVICE PROCEDURES
Consider changing out motor parts yourself. All of the Vulcan’s main components are
available as service items--Refer to ‘Accessories’ section or check out our website. In
most cases, replacing motor parts is less expensive than sending in your motor for service.
After reviewing instructions, tech section and how-to video section of website, if you feel
your motor requires service (motor may appear to have failed when other problems exist), obtain
the most current product service options & pricing by one of the following methods:
WEBSITE: Print a copy of the product SERVICE FORM from the SERVICE section of the
Novak website. Fill out the needed information & return it with the Novak product.
PHONE/E-MAIL: Contact our customer service department by phone, fax, or e-mail,
and we will supply you with current service options.
WARRANTY SERVICE: You MUST CLAIM WARRANTY on product SERVICE FORM & include
a valid, itemized receipt with the purchase date on it, or an invoice from previous service
work. If warranty provisions have been voided, there will be a service fee.
ADDITIONAL NOTES:
• Dealers/distributors are not authorized to replace products thought to be defective.
• If a hobby dealer returns your product for service, submit a completed product SERVICE
FORM to dealer & make sure it’s included with items.
PRODUCT WARRANTY
Novak Brushless motors are guaranteed to be free from defects in materials or workmanship for a period of 120 days
from the original date of purchase (verified by dated, itemized sales receipt). Warranty does not cover incorrect instal-
lation, components worn by use, cross-connection of battery/motor power wires, overheating solder tabs, damage
resulting from thermal overload or operation above 175°F, use of excessive timing or overheating, splices or damage to
the sensor harness, damage from disassembling motor, tampering with internal electronics, allowing water, moisture,
or any other foreign material to enter motor or get onto the PC board, short-circuiting of motor by allowing exposed
wiring or solder tabs to cross-connect or ESC applying simultaneous power to more than one phase at a time from
switching to Brush Mode, free-revving motor, or any damage caused by a crash, flooding, or natural disaster. In no case
shall our liability exceed the product’s original cost. We reserve the right to modify warranty provisions without notice.
Because Novak R/C, Inc. has no control over the connection & use of motor or other related electronics, no liability may
be assumed nor will be accepted for damage resulting from the use of this product. Every motor is thoroughly tested and
cycled before leaving our facility and is, therefore, considered operational. This product is not a toy, and is not intended
for use by children under 14 years of age without the strict supervision of an adult. Use of this product in a uncontrolled
manner may result in physical damage or injuries. Take extra care when operating any remote control vehicle. By the act
of connecting/operating speed control, the user accepts all resulting liability.
e-mail: [email protected] • (949) 916-6044 • Monday-Thursday
©Novak R/C, Inc. California, U.S.A.
No part of these instructions may be reproduced without the written permission of Novak R/C, Inc.
All Rights Reserved. Novak motors are proudly designed in the U.S.A.
SERVICE PROCEDURES
Consider changing out motor parts yourself. All of the Vulcan’s main components are
available as service items--Refer to ‘Accessories’ section or check out our website. In
most cases, replacing motor parts is less expensive than sending in your motor for service.
After reviewing instructions, tech section and how-to video section of website, if you feel
your motor requires service (motor may appear to have failed when other problems exist), obtain
the most current product service options & pricing by one of the following methods:
WEBSITE: Print a copy of the product SERVICE FORM from the SERVICE section of the
Novak website. Fill out the needed information & return it with the Novak product.
PHONE/E-MAIL: Contact our customer service department by phone, fax, or e-mail,
and we will supply you with current service options.
WARRANTY SERVICE: You MUST CLAIM WARRANTY on product SERVICE FORM & include
a valid, itemized receipt with the purchase date on it, or an invoice from previous service
work. If warranty provisions have been voided, there will be a service fee.
ADDITIONAL NOTES:
• Dealers/distributors are not authorized to replace products thought to be defective.
• If a hobby dealer returns your product for service, submit a completed product SERVICE
FORM to dealer & make sure it’s included with items.
PRODUCT WARRANTY
Novak Brushless motors are guaranteed to be free from defects in materials or workmanship for a period of 120 days
from the original date of purchase (verified by dated, itemized sales receipt). Warranty does not cover incorrect instal-
lation, components worn by use, cross-connection of battery/motor power wires, overheating solder tabs, damage
resulting from thermal overload or operation above 175°F, use of excessive timing or overheating, splices or damage to
the sensor harness, damage from disassembling motor, tampering with internal electronics, allowing water, moisture,
or any other foreign material to enter motor or get onto the PC board, short-circuiting of motor by allowing exposed
wiring or solder tabs to cross-connect or ESC applying simultaneous power to more than one phase at a time from
switching to Brush Mode, free-revving motor, or any damage caused by a crash, flooding, or natural disaster. In no case
shall our liability exceed the product’s original cost. We reserve the right to modify warranty provisions without notice.
Because Novak R/C, Inc. has no control over the connection & use of motor or other related electronics, no liability may
be assumed nor will be accepted for damage resulting from the use of this product. Every motor is thoroughly tested and
cycled before leaving our facility and is, therefore, considered operational. This product is not a toy, and is not intended
for use by children under 14 years of age without the strict supervision of an adult. Use of this product in a uncontrolled
manner may result in physical damage or injuries. Take extra care when operating any remote control vehicle. By the act
of connecting/operating speed control, the user accepts all resulting liability.
e-mail: [email protected] • (949) 916-6044 • Monday-Thursday
©Novak R/C, Inc. California, U.S.A.
No part of these instructions may be reproduced without the written permission of Novak R/C, Inc.
All Rights Reserved. Novak motors are proudly designed in the U.S.A.
ACCESSORIES ACCESSORIES
VULCAN MOTOR INSTRUCTIONS
55-3640-1 Rev.3 4/2014
VULCAN MOTOR INSTRUCTIONS
55-3640-1 Rev.3 4/2014
black
orange
white
black
orange
white
plastic
tabs
plastic
tabs
red
blue
green
red
blue
green
metal
barbs
metal
barbs
raised
metal
barb
raised
metal
barb
metal socket on end of
Teflon sensor harness wires
metal socket on end of
Teflon sensor harness wires
Should any of the 26G Teflon wires pull out of the motor’s sensor
harness connector, re-insert them in the connector’s appropriate
slot as shown below. There is a small plastic tab that grabs a small
raised barb on the back of the metal socket crimped onto the Teflon
wire’s end. Check the plastic tab to make sure it has not deformed
excessively before inserting the socket into the plastic connector
housing with the barb toward the plastic tabs.
Note: Remove or loosen the bearing cap to remove or insert a sensor harness.
Should any of the 26G Teflon wires pull out of the motor’s sensor
harness connector, re-insert them in the connector’s appropriate
slot as shown below. There is a small plastic tab that grabs a small
raised barb on the back of the metal socket crimped onto the Teflon
wire’s end. Check the plastic tab to make sure it has not deformed
excessively before inserting the socket into the plastic connector
housing with the barb toward the plastic tabs.
Note: Remove or loosen the bearing cap to remove or insert a sensor harness.
SENSOR HARNESS WIRING SENSOR HARNESS WIRING
5332 Brushless Motor Connector Wire Set--14GA wire with 3.5mm bullet connectors.
5351 Brushless Shielded Sensor Harness--4”--Double-ended motor sensor harness.
5352 Brushless Shielded Sensor Harness--6”--Double-ended motor sensor harness.
5353 Brushless Shielded Sensor Harness--9”--Double-ended motor sensor harness.
5508 14GA Brushless Wire Set--2 pc each of 9” silicone blue, yellow, orange, black, & red.
5509 16GA Brushless Wire Set--2 pc each of 9” silicone blue, yellow, orange, black, & red.
5512 12GA Super-Flex Wire--Black, Red, & Blue--3 ft each color, silicone.
5514 14GA Super-Flex Wire--Black, Red, & Blue--3 ft each color, silicone.
5647 Black Cooling Fan--25x25x10mm--All purpose cooling fan with 2-pin JST connector.
5649 Black Cooling Fan--25x25x10mm--Cooling fan with 2mm Mini power plug installed.
5731 3.5mm Power Connectors/5 pair--Gold plated low-loss connectors for 12-14G wire.
5741 4mm Power Connectors/5 pair--Gold plated low-loss high-amp 12-14G connectors.
5831 Lead-Free 3% Silver Racing Solder/6gr--Low-resistance, high-conductivity solder.
5832 Lead-Free 3% Silver Racing Solder/15gr--Low-resistance, high-conductivity solder.
5836 Heavy Duty Lead-Free 3% Silver Racing Solder/25gr--Thicker 1.5mm solder.
5850 Heat Shrink Tubing/6pc--6” long heat shrink tubing in six sizes: 1/16” - 3/8”.
5851 Heat Shrink Tubing/24pc--6” long heat shrink tubing in six sizes: 1/16” - 3/8”.
S5903 Motor Insulator Pack--Replacement paper disk, fiberglass cover, & silicone grommet.
5909 Sintered 13mm Tuning Rotor--High-power 540 neodymium tuning rotor.
5927 Vulcan Vented Motor Can/Bearing--Black anodized/Factory-installed bearing.
S5928 Back End Bell/Vented--Replacement vented back end bell of motor. Black/Ribbed.
S5929 Bearing Cap/Back Bearing--Vulcan bearing cap with exposed, factory-installed bearing.
S5932 Motor Hardware Kit/540--Replacement motor screws & shim washers.
5941 Sintered 12.3mm Rotor--Replacement Vulcan/Ballistic 540 sintered neodymium rotor.
S5942 Timing/Sensor Assembly--Replacement 540/550 timing & sensor section of motor.
S5943 Bearing Cap/Back Bearing--Bearing cap with non-exposed, factory-installed bearing.
S5944 Back End Bell/Closed--Back end bell of motor without cooling vents. Black/Ribbed.
S5946 Bearing Cap/Ceramic Bearing--Bearing cap/Non-exposed, installed ceramic bearing.
5950 Crawler Sintered Tuning Rotor--14mm high-power sintered neodymium tuning rotor.
5941 Sintered 12.5mm Rotor--Sintered neodymium tuning rotor (std. in VulcanSpec 17.5T).
5960 Steel Ball Bearings/ABEC-3--Replacement front 3/16”I.D. flanged steel bearings.
5961 Steel Ball Bearings/ABEC-3--Replacement rear 1/8”I.D. flanged steel bearings.
S6630 Vulcan ULR Hand-Wound Stator/10.5T--Ultra-Low Resistance 10.5-turn stator.
S6633 Vulcan ULR Hand-Wound Stator/13.5T--Ultra-Low Resistance 13.5-turn stator.
S6637 Vulcan ULR Hand-Wound Stator/17.5T--Ultra-Low Resistance 17.5-turn stator.
S6638 Vulcan ULR Hand-Wound Stator/21.5T--Ultra-Low Resistance 21.5-turn stator.
S6640 Vulcan Spec Hand-Wound Stator/10.5T--Red Wire 10.5-turn stator.
S6643 Vulcan Spec Hand-Wound Stator/13.5T--Red Wire 13.5-turn stator.
S6647 Vulcan Spec Hand-Wound Stator/17.5T--Red Wire 17.5-turn stator.
S6648 Vulcan Spec Hand-Wound Stator/21.5T--Red Wire 21.5-turn stator.
S6655 Vulcan Mod Hand-Wound Stator/5.5T--Red Wire High-RPM 5.5-turn stator.
S6656 Vulcan Mod Hand-Wound Stator/6.5T--Red Wire High-RPM 6.5-turn stator.
S6657 Vulcan Mod Hand-Wound Stator/7.5T--Red Wire High-RPM 7.5-turn stator.
S6658 Vulcan Mod Hand-Wound Stator/8.5T--Red Wire High-RPM 8.5-turn stator.
5332 Brushless Motor Connector Wire Set--14GA wire with 3.5mm bullet connectors.
5351 Brushless Shielded Sensor Harness--4”--Double-ended motor sensor harness.
5352 Brushless Shielded Sensor Harness--6”--Double-ended motor sensor harness.
5353 Brushless Shielded Sensor Harness--9”--Double-ended motor sensor harness.
5508 14GA Brushless Wire Set--2 pc each of 9” silicone blue, yellow, orange, black, & red.
5509 16GA Brushless Wire Set--2 pc each of 9” silicone blue, yellow, orange, black, & red.
5512 12GA Super-Flex Wire--Black, Red, & Blue--3 ft each color, silicone.
5514 14GA Super-Flex Wire--Black, Red, & Blue--3 ft each color, silicone.
5647 Black Cooling Fan--25x25x10mm--All purpose cooling fan with 2-pin JST connector.
5649 Black Cooling Fan--25x25x10mm--Cooling fan with 2mm Mini power plug installed.
5731 3.5mm Power Connectors/5 pair--Gold plated low-loss connectors for 12-14G wire.
5741 4mm Power Connectors/5 pair--Gold plated low-loss high-amp 12-14G connectors.
5831 Lead-Free 3% Silver Racing Solder/6gr--Low-resistance, high-conductivity solder.
5832 Lead-Free 3% Silver Racing Solder/15gr--Low-resistance, high-conductivity solder.
5836 Heavy Duty Lead-Free 3% Silver Racing Solder/25gr--Thicker 1.5mm solder.
5850 Heat Shrink Tubing/6pc--6” long heat shrink tubing in six sizes: 1/16” - 3/8”.
5851 Heat Shrink Tubing/24pc--6” long heat shrink tubing in six sizes: 1/16” - 3/8”.
S5903 Motor Insulator Pack--Replacement paper disk, fiberglass cover, & silicone grommet.
5909 Sintered 13mm Tuning Rotor--High-power 540 neodymium tuning rotor.
5927 Vulcan Vented Motor Can/Bearing--Black anodized/Factory-installed bearing.
S5928 Back End Bell/Vented--Replacement vented back end bell of motor. Black/Ribbed.
S5929 Bearing Cap/Back Bearing--Vulcan bearing cap with exposed, factory-installed bearing.
S5932 Motor Hardware Kit/540--Replacement motor screws & shim washers.
5941 Sintered 12.3mm Rotor--Replacement Vulcan/Ballistic 540 sintered neodymium rotor.
S5942 Timing/Sensor Assembly--Replacement 540/550 timing & sensor section of motor.
S5943 Bearing Cap/Back Bearing--Bearing cap with non-exposed, factory-installed bearing.
S5944 Back End Bell/Closed--Back end bell of motor without cooling vents. Black/Ribbed.
S5946 Bearing Cap/Ceramic Bearing--Bearing cap/Non-exposed, installed ceramic bearing.
5950 Crawler Sintered Tuning Rotor--14mm high-power sintered neodymium tuning rotor.
5941 Sintered 12.5mm Rotor--Sintered neodymium tuning rotor (std. in VulcanSpec 17.5T).
5960 Steel Ball Bearings/ABEC-3--Replacement front 3/16”I.D. flanged steel bearings.
5961 Steel Ball Bearings/ABEC-3--Replacement rear 1/8”I.D. flanged steel bearings.
S6630 Vulcan ULR Hand-Wound Stator/10.5T--Ultra-Low Resistance 10.5-turn stator.
S6633 Vulcan ULR Hand-Wound Stator/13.5T--Ultra-Low Resistance 13.5-turn stator.
S6637 Vulcan ULR Hand-Wound Stator/17.5T--Ultra-Low Resistance 17.5-turn stator.
S6638 Vulcan ULR Hand-Wound Stator/21.5T--Ultra-Low Resistance 21.5-turn stator.
S6640 Vulcan Spec Hand-Wound Stator/10.5T--Red Wire 10.5-turn stator.
S6643 Vulcan Spec Hand-Wound Stator/13.5T--Red Wire 13.5-turn stator.
S6647 Vulcan Spec Hand-Wound Stator/17.5T--Red Wire 17.5-turn stator.
S6648 Vulcan Spec Hand-Wound Stator/21.5T--Red Wire 21.5-turn stator.
S6655 Vulcan Mod Hand-Wound Stator/5.5T--Red Wire High-RPM 5.5-turn stator.
S6656 Vulcan Mod Hand-Wound Stator/6.5T--Red Wire High-RPM 6.5-turn stator.
S6657 Vulcan Mod Hand-Wound Stator/7.5T--Red Wire High-RPM 7.5-turn stator.
S6658 Vulcan Mod Hand-Wound Stator/8.5T--Red Wire High-RPM 8.5-turn stator.