MOTOR MECHANISM

SECTION MM
CONTENTS
NOTE: SERVICE DATA AND SPECIFICATIONS . . MM-2
This section contains information and General Specifications . . . . . . . . . . . . . . . . MM-2
specifications for both General Overseas Market Tightening Torque . . . . . . . . . . . . . . . . . . . MM-2
(GOM) and North America. Therefore, ensure the TROUBLE DIAGNOSES AND
specifications or procedures you are looking at CORRECTIONS . . . . . . . . . . . . . . . . . . . . . . MM-3
are for the proper area. PRECAUTIONS AND PREPARATION . . . . MM-5
Precautions . . . . . . . . . . . . . . . . . . . . . . . . MM-5
Special Service Tool . . . . . . . . . . . . . . . . . . MM-5
TRACTION MOTOR . . . . . . . . . . . . . . . . . . MM-6
Component Parts . . . . . . . . . . . . . . . . . . . . MM-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . MM-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . MM-7
PUMP MOTOR . . . . . . . . . . . . . . . . . . . . . . MM-8
Component parts . . . . . . . . . . . . . . . . . . . . MM-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . MM-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . MM-9
MOTOR DISASSEMBLY AND
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . MM-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . MM-10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . MM-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . MM-12
 SERVICE DATA AND SPECIFICATIONS

General Specifications
Traction motor Pump motor
Applied model A1N1 series Applied model A1N1 series
Type Open-self AC motor GOM models North America model
Model TSA200-100-209
Type Open-self AC power
Rated voltage V 36 48
Model TSA200-140-207 TSA200-160-208
Rated output kW/h 5.2 7.1
Rated voltage V 48 48 36
Weight kg (lb) 35 (77)
Rated output 14.5 14.6 10.7
Maker SCHABMULLER (Germany) kW/S3-20%
Weight kg (lb) 48 (106) 52 (116)
Maker SCHABMULLER (Germany)

Tightening Torque
Traction motor Pump motor
TSA200-100-209 Unit TSA200-140-207 /
Unit
TSA200-160-208
Nm kg-m ft-lb
Nm kg-m ft-lb
Motor assembly
Motor assembly
Front bracket to rear 11 1.12 8.1
bracket fixing through Front bracket to rear bracket 15 1.53 11.1
bolt fixing through bolt
Terminal fixing nut 13 - 17 1.4 - 1.7 10 - 12 Terminal fixing nut 13 - 17 1.4 - 1.7 10 - 12
Motor installation
Motor installation Frame 38 - 52 3.9 - 5.3 29 - 38
Motor-to-drive Short 38 - 52 3.9 - 5.3 29 - 38 Mounting bracket side
unit fixing bolt bolt fixing bolt Motor 39 - 50 4.0 - 5.0 29 - 36
Long 38 - 52 3.9 - 5.3 29 - 36 side
bolt
Drive unit fixing M14 150 - 190 16 - 19 111 - 140
bolt bolt
M8 19 - 25 2.0 - 2.5 14 - 18
bolt

MM-2
 TROUBLE DIAGNOSES AND CORRECTIONS

! CAUTION

• The following tables list only typical examples. To perform an accurate diagnosis, carefully listen to
the user’s complaints and check the actual vehicle to fully understand under what conditions the
symptoms occur.
• The same symptoms as the following may occasionally be caused by the control system. Perform
the trouble diagnosis for not only mechanical cause but also control system cause. For the trouble
diagnosis of control system, refer to the CS section.

Condition Probable cause Corrective action

• Single-phase drive • Check by measuring the voltage of
controller output terminal or motor
cable terminal.
Speed suddenly drops
• Voltage drops • Check battery charge condition, and
charge.
• Overload • Stop overload drive.
• Voltage drops • Check battery charge condition, and
charge.
Motor overheats
• Overload • Stop overload drive
• Air flow orifice plugged with dust • Check and clean.
• Burnout bearing • Disassemble and replace with new
At motor unit, axis cannot
Motor stops ones.
be rotated manually.
Motor with
load (on the
• Malfunction of resistance balance • Disassemble and check. Repair or
vehicle)
Nasty smell from motor or insulation on each phase (with replace as necessary.
cable terminal disconnected)
• Open circuit or short circuit in • Disassemble and check. Repair or
motor cable replace as necessary.
Motor stops
• Controller malfunction • Check controller. (Refer to CS
section.)
• Single-phase drive • Check by measuring the voltage of
controller output terminal or motor
Noise/vibration while driving cable terminal.
• Looseness of each assembly part • Check and retighten.

Bearing overheats, noise from bearing (check • Bearing malfunction • Disassemble and replace with new
by proper tools) ones.
• Misconnection • Connect the cable terminals while
The rev direction is opposite adjusting to each phase (replace 2
out of 3).
• Gap between stator iron core and • Disassemble and check. Repair or
If it is Whining noise rotor iron core is unbalanced replace as necessary.
no-load
condition,
motor turns • Partially short circuit in stator coil • Disassemble and check. Repair or
Yoke overheats
replace as necessary.
Bearing noise • Bearing malfunction • Disassemble and replace with new
ones.

MM-3
 TROUBLE DIAGNOSES AND CORRECTIONS
Condition Probable cause
• Malfunction of battery, controller,
and wiring
No rotation sound • Open circuit in wiring
• Open circuit in stator coil
• Loose terminal connection
Even if it is no- • Single-phase drive
load condition,
motor does not
turn When turning by hand, motor turns • Open circuit in single-phase of
in any direction wiring between motor and controller
• Open circuit in single-phase of
stator coil
• Loose terminal connection
• Damaged bearing(s)
Whining noise is heard, but motor
does not turn • Prying of rotation axis by looseness
of bolts
MM-4
Corrective action
• Check controller. (Refer to CS section.)
• Check battery charge condition, and
charge.
• Check and repair, or replace.
• Disassemble and check. Replace as
necessary.
• Tighten completely.
• Check by measuring the voltage of
controller output terminal or motor
cable terminal.
• Check and repair.
• Disassemble and check. Replace as
necessary.
• Tighten completely.
• Disassemble and replace with new
ones.
• Disassemble and check. Properly
assemble and retighten bolts.
 PRECAUTIONS AND PREPARATION

Precautions
! CAUTION
• Be extremely careful when hoisting and moving heavy
objects. These can be extremely dangerous operations.
• When removing or installing motor assembly, be sure to
turn the key switch OFF and disconnect battery plug to
cut power supply in advance. This prevents motors from
unexpectedly rotating, avoiding danger.
• Always assemble parts in a clean work place to prevent
foreign matter from entering assembly.
• Before disassembling, be sure to clean off the parts.
• Do not use water or cleaning oil to clean any part. Use
compressed air or wipe with dry rag.
• Carefully handle removed motor so as not to drop or impact
the motor.

NOTE:
Be sure to use the special service tool when lifting and supporting
traction motor.

Special Service Tool

Purchase locally
Tool number Description
Tool name
Lifting and supporting traction motor

SST
Eyebolt

M8 x 1.25

MM-5
TRACTION MOTOR

Component Parts

Removal
1. Remove battery from vehicle. Refer to BC section.
2. Remove floor mat and floor panel. Refer to BF section.
3. Remove pedal bracket. Refer to BR section.
4. Disconnect cables connected to traction motor.
5. Remove traction motor and drive unit as a unit. Refer to DU
section. Then remove traction motor from drive unit.

MM-6
TRACTION MOTOR

Installation
To install, reverse the order of removal. Observe the following:
For inspection of revolution sensor and temperature sensor, refer to
CS section.
Traction motor-to-drive unit securing bolt:
Long bolt
: 39 - 50 Nm (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
Short bolt
: 39 - 52 Nm (4.0 - 5.3 kg-m, 29 - 38 ft-lb)

! CAUTION
• When installing motor to drive unit, be careful not to
damage oil seal of front bracket at shaft spline and drive
unit.

MM-7
PUMP MOTOR

Component Parts

! CAUTION

• Always relieve oil pressure remaining in hydraulic lines.

• When disconnecting pipes, be careful to avoid splashing
hydraulic fluid to other parts by covering with waste cloths
around the disconnected areas.
• When connecting pipes, be careful that foreign material
does not enter into pipes.
• Clamp suction hose so that the hydraulic fluid does not
leak.

Removal
1. Remove floor mat and floor board. Refer to BF section.
2. Remove brake pedal bracket. Refer to BR section
3. Remove piping from hydraulic pump.
4. Disconnect motor cables.
5. Lift up the motor with hydraulic pump.
6. Remove bracket hydraulic pump from motor.

MM-8
PUMP MOTOR

Installation
To install, reverse the order of removal. Observe the following:
Pump motor mounting bracket fixing bolt:
Frame side
:39 - 52 Nm (4.0 - 5.3 kg-m, 29 - 38 ft-lb)
Pump motor side
:39 - 50 Nm (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
Oil pump fixing bolt:
:24.5 - 31.3 Nm (2.5 - 3.1 kg-m, 18 - 23 ft-lb)

! CAUTION
• When installing the oil pump to the pump motor, apply the
molybdenum disulfide grease to the oil pump shaft spline.

Connector tightening torque (discharge side)

: 79 - 88 Nm (8.1 - 8.9 kg-m, 59 - 64 ft-lb)
Connector tightening torque (suction side)
: 92 - 108 Nm (9.4 - 11.0 kg-m, 68 - 79 ft-lb)

MM-9
 MOTOR DISASSEMBLY AND ASSEMBLY

Disassembly
Component parts

(1) Screw (2) Cover (3) Spur wheel (4) Screw

(5) Revolution sensor (6) Tolerance ring (7) Nut (8) Schnorr disc
(9) Nut (10) Disc (11) Terminal board (12) Terminal bolt
(13) Temperature sensor (14) Through bolt (15) Drive end shield (16) Non-drive end shield
(17) Rotor (18) Wave washer (19) Bearing (20) O-ring
(21) Cir-clip (22) Bearing (23) O-ring (24) Cir-clip
(25) Wave washer (26) Stator

MM-10
MOTOR DISASSEMBLY AND ASSEMBLY

Disassembly (cont’d)
1. Remove the cover.
2. Remove the revolution sensor and spur wheel.
(1)Revolution sensor
(2)Spur wheel
(3)Tolerance ring

3. Remove terminal board for motor cables.

4. Put the matching marks between drive end shield and stator and
between stator and non-drive end shield, and then remove the
through bolts.
5. Remove the drive end shield.
6. Remove rotor assembly.

! CAUTION
• Be careful not to damage oil seal of front bracket at shaft
spline.

7. Remove the non-drive end shield from stator.

8. Remove the cir-clip and disassemble the rotor assembly, if
necessary.

Assembly
Assemble in the reverse order of disassembly. Observe the
following:
Terminal fixing screw:
: 13 - 17 Nm (1.4 - 1.7 kgf-m, 10 - 12 ft-lb)
Front bracket to rear bracket fixing through bolt:
Traction motor
: 11 Nm (1.12 kgf-m, 8.1 ft-lb)
Pump motor
: 15 Nm (1.53 kgf-m, 11.1 ft-lb)

• Should it be necessary to remove the bearings in case of repair,

they should be replaced. In any case the sealing parts have to be
replaced.
• If a bearing which is to be replaced has only one sealing lip, this
should be greased with quality bearing grease.
• After approximately 10,000 operating hours the bearings have to
be replaced.

Inspection
For inspection of revolution sensor and temperature sensor, refer to
CS section.

MM-11
MEMO

MM-12