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    Yale g807 Erp 15 20 VT Erp 30 40vt Service Manual PDF Download

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    joao

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    © All Rights Reserved
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    of 1968
    Yalea Maintenance AC MOTOR REPAIR ERP15-20VT (ERP030-040VT) [G807]; ERP16- 20VF (ERP30-40VF) [A955]; ERC22-35VG (ERC045- 070VG) [A968]; ERC16-20VA (ERC030-040VA) [A969]; ERP22-35VL (ERP045-070VL) [A976]; ESCO30AC, ESCO35AC, ESCO40AC [B883] PART NO. 524327049 620 YRM 1385 SAFETY PRECAUTIONS MAINTENANCE AND REPAIR ‘When lifing parts or assemblies, make sure all sings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to ‘support the weight of the load. Do not it heavy parts by hand, use a lifting mechanism, Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric It trucks. Disconnect the battery ground cable on internal combustion it trucks. ‘Always use correct blocks to prevent the unit from rolling or faling. See HOW TO PUT THE LIFT ‘TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance soction keep the unit clean and the working area clean and ordty Use the correct tools forthe job. keep the tools clean and in good condition Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specications of the original equipment manufacturer. Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. ‘Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or ifthe unit needs repairs. Be sure to follow the WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleun Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure 10 follow the necessary salely precautions when handling these fuels and when ‘working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the ‘rea. Make sure the area is well ventilated, NOTE: The following symbols and words indicate safety information in this manual: & warnine Indicates a hazardous situation which, if not avoided, could result in death or serious injury. &, caution Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background. ‘AC Motor Repair Table of Contents, TABLE OF CONTENTS General, 1 Discharging the Capacitors for Lift Truck Models ESC030-040AC (8883) 5 Discharging the Capacitors (All Other Models) 6 ‘Traction Motor Repair. 7 For Lift Truck Models ERP15-20VT (ERPO30-040VT) (G807), ERP 16-20VF (EAP30-0VF) (ASS5), and ESC030-040AC (B883) 7 Remove. _ 2 Disassemble 8 Electrical Connector Repair or Replacement. 10 Clean 10 Inspect 10 Assemble 10 Install 1" For Litt Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERCO30-040VA) (A969) 14 Remove. Disassemble 14 Electrical Connector Repair or Replacement. 7 Clean. 7 Inspect . 7 Assemble. 18 Install. 18 For Lift Truck ERP2.2-3.5VL (ERPO45-070VL) (A976) 18 Remove. 18 Disassemble 18 Clean. 20 Inspect 20 ‘Assemble 21 Install. 21 Hydraulic Motor Repair... a For Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (8883). 21 Remove. 21 Disassemble 22 Electrical Connector Repair or Replacement. 23 Clean 24 Inspect... 24 Assemble . 2 Install 27 For Lift Truck ERC22-35VG (ERCO45-070VG) (A968) 28 Remove. 28 Disassemble 29 Electrical Connector Repair or Replacement. 30 Clean 31 Inspect 31 Assemble 82 Install 33 For Lift Truck Models ERP2.2-3.5VL (ERPO#S-O70VL) (A976) and ERC16-20VA (ERCO30-040VA) (A969) os Remove. Disassemble Electrical Connector Repair or Replacement. ©2011 Yale Materials Handling Corp. Table of Contents AC Motor Repair TABLE OF CONTENTS (Continued) Clean 38 Inspect. 39 Assemble. 39 Install 42 Torque Specifications . 44 Traction Motor for Lift Trucks ERP16-20VT (ERPO3O-O40VT) (G807) and ERP 16-20VF (EAP30-40VF) (A955) Tston to Li Tack EIG22 S6VG (EACDA8-O7OG)(ABSEjond ERCTG SOWA (ERCO30-040VA) (A968). Traction Motor for Lift Truck ESCO30-O40AC (6863)... Hydraulic Motor for Lift Trucks ERP15-20VT (ERPOS (ERP30-40VF) (A956)... Hydraulic Motor for Lift Truck ERC22-35VG (ERCO45-070VG) (A968)... Hydraulic Motor for Lift Truck ERP22-35VG (ERPO45-070VG) (A976) Hydraulic Motor for Lift Truck ERG16-20VA (ERCO30-040VA) (A969). Hydraulic Motor for Lift Truck ESC030-040AG (B883) This section is for the following models: ERP15-20VT (ERPO30-040VT) [G807}; ERP 16-20VF (ERP30-40VF) [A955]: ERC22-35VG (ERC045-070VG) [A968]; ERC16-20VA (ERCO30-040VA) (A969); ERP22-35VL (ERPO45-070VL) [A976] ESCO30AC, ESCO35AC, ESCO4OAC [B883] BEREE £E 620 YRM 1385 General General This section contains repair and maintenance proce- dures for the AC motors. Additional information con cerning the motors may be more closely related to other systems and included in those sections. Sections that contain information regarding the motors include: Electrical System 2200 YAM 1337 for it truck models: = ERP15-20VT (ERPO30-040VT) (2807) ‘+ ERP16-20VF (ERP30-40VF) (A955) Electrical System 2200 YRM 1369 for it truck models: + ERC22-35VG (ERC045.070VG) (A968) ‘+ ERP22-35VL (ERPO45-070VL) (A976) ‘+ ERC16-20VA (ERC030-040VA) (A969) Electrical System 2200 YRM 1414 for it truck models: + ESC030-040AC (B883) Periodic Maintenance 8000 YRM 1373 for lift truck models: + ERP16-20VF (ERP30-40VF) (A955) Periodic Maintenance 8000 YRM 1339 for lift truck models: + ERP15-20VT (ERPO30-040VT) (4807) Periodic Maintenance 8000 YRM 1364 for lit truck modets: + ERC22-05VG (ERCO45-070VG) (A968) Periodic Maintenance 8000 YRM 1372 for lift truck models: ‘+ ERP22-35VL (ERP045-070VL) (A976) Periodic Maintenance 8000 YRM 1418 for lift truck models: = ESC030-040AC (8883) Periodic Maintenance 8000 YRM 1442 for lift truck. models ‘+ ERC16-20VA (ERC030-040VA) (A969) @ warnine DO NOT make repairs or adjustments unless you are properly trained and have authorization to do so. Repairs and adjustments that are not correct can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, attach a DO NOT OPERATE. tag to the steering wheel and remove the key from the key switch. Throughout this section, forward will refer to travel in the direction of the forks and left and right will be deter- mined by sitting in the seat facing forward. See Figure 1 or Figure 2. Troubleshooting information about the trac- tion motors is available through on-board diagnostics and may be displayed on the dash display. Refer to one of the following sections for further explanation of dash display codes concerning the motors: User Interface, Service-Level Functions On-Board Dash Display 2200 YRM 1417 for it truck models: + ESC030-040AC (B883) User Interface, Service Technician 2200 YRM 1336 + ERP16-20VF (ERP30-40VF) (A955) + ERP15-20VT (ERP030-040VT) (4807) ERC22-35VG (ERCO45-070VG) (A968) ERP22-35VL (ERP045-070VL) (A976) ERC16-20VA (ERCO30-040VA) (A969) ® © A. LEFT SIDE c. FORWARD B. RIGHT SIDE TRAVEL Figure 1. Truck Orientation (Three-Wheel Models) ® © A. LEFT SIDE B. RIGHT SIDE Figure 2. Truck Orientation (Four-Whee! Models) c. FORWARD TRAVEL ‘The traction motors are mounted onto the transaxles for the following lift truck models: + ERP15.20VT (ERPO30-040V7) (G807) ‘+ ERP16-20VF (ERP90-40VF) (A955) + ERP22-35VL (ERPO4S-070VL) (A976) See Figure 3 for i truck models * ERP15-20VT (ERP030-040VT) (G807) + ERP16-20VF (ERP30-40VF) (A955) See Figure 5 for lit truck models + ERP22-35VL (ERPO45-070VL) (A976) Figure 3. Traction Motors for Lift Truck ERP15.20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) 620 YRM 1385 Legend for Figure 3 1. LEFT TRANSAXLE 2. TRACTION MOTOR 3. RIGHT TRANSAXLE For the following lift truck models, the hydraulic pump motor is mounted inside the counterweight: + ERP15-20VT (ERPO30-040VT) (6807) + ERP16-20VF (ERP30-40VF) (A955) + ERP22-35VL (ERPO45-070VL) (A976) See Figure 4 and Figure 5. The traction motor is mounted under the frame to the drive axle for the following lift truck models: + ERC22-35VG (ERCO45-070VG) (A968) + ERC16-20VA (ERC030-040VA) (A969) See Figure 6 for lit truck models + ERC22-35VG (ERCO45-070VG) (A968) See Figure 7 for lift truck models = ERC16-20VA (ERC030-040VA) (A969) 1. HYDRAULIC PUMP MOTOR 2) COUNTERWEIGHT Figure 4. Hydraulic Motor for Lift Trucks EAP15-20VT (ERP030-040VT) (B07) and ERP 16-20VF (ERP30-40VF) (A955) 620 YRM 1385 LEFT TRACTION MOTOR 4. LEFT TRANSMISSI 1 ION 2. RIGHT TRACTION MOTOR 5. HYDRAULIC PUMP AND MOTOR 3. RIGHT TRANSMISSION Figure 5. Traction Motor and Hydraulic Pump Motor for Lift Truck Models ERP22-35VL (ERPO45-070VL) (A976) ‘The hydraulic pump motor is mounted onto the frame The hydraulic pump motor is mounted onto the frame, beside the traction motor for the following lifttruck mod- opposite the traction motor on the following lift truck els: models ‘+ ERC22-35VG (ERC045-070VG) (A968) ‘+ ERC16-20VA (ERC030-040VA) (A969) See Figure 6. See Figure 7. General 620 VAM 185 5 aq ie te ¥ ANS Ae | 1. HYDRAULIC PUMP MOTOR 2. TRACTION MOTOR 3. FRAME Re ce Figure 6. Traction Motor and Hydraulic Pump Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968) ‘The traction motors are mounted onto the transaxles land the hydraulic pump motor is mounted vertically to the front wall behind the front cover for the following lift ‘ruck models: + ESC030-040AC (8883) 1. FRAME 2) TRACTION MOTOR 3. HYDRAULIC PUMP MOTOR Figure 7. Traction Motor and Hydraulic Pump Motor for Lift Truck ERC16-20VA (ERCOS0-040VA) (A969) 620 YRM 1385 DISCHARGING THE CAPACITORS FOR LIFT TRUCK MODELS ESC030-040AC (B883) @ warnina DO NOT make repairs or adjustments unless you have beon properly trained and authorized to do so. Improper repairs and adjustments can create dar gerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repai to your supervisor immediately. If repair is neces- sary, attach a DO NOT OPERATE tag on the steering wheel and disconnect the battery. Disconnect the battery and allow the capacitors to discharge before opening any compartment cov- ers or inspecting or repairing the electrical system. DO NOT place tools on top of the battery. If a tool causes a short circuit, the high current flow from the battery can cause personal injury or property damage. ‘Some checks and adjustments are performed with the battery connected. DO NOT connect the battery until the procedure instructs you to do so. Never ‘wear any metallic items on your fingers, arms, or neck. Metal items can accidentally make an electri- cal connection and cause injury. Before performing any tests or adjustments, block the lift truck to prevent unexpected movement. ‘The capacitor in the transistor controller(s) can hold an electrical charge after the battery is dis- connected. To prevent an electrical shock and personal injury, discharge the capacitor(s) before inspecting or repairing any component in the drive unit compartment. Make certain that the battery has been disconnected. DO NOT short across the motor controller terminals. with a screwdriver or jumper wire. 1. To avoid injury and prevent electrical shock, per- form the following steps (Step 2 through Step 7 below) to discharge the capacitors before trou- bleshooting, making adjustments or repairs, or ‘connecting or disconnecting a PC service tool: 2. Tum the key or keyless switch to the OFF position and DISCONNECT THE BATTERY by pushing for- ward on the battery disconnect lever. General 3. Block the lift truck so the drive wheels are off the floor to prevent lift truck from moving. 4. Remove the electrical compartment cover to ac- ‘cess the lift controller. NOTE: The lift and traction controllers are wired par- allel. Connecting the resistor across the lift controller will also discharge capacitors in the traction controllers if they are properly connected. 5. Discharge the capacitors in the controllers by con- necting a 200-ohm, 2-watt resistor across the lift controller's negative (B-) and positive (B+) termi- nals, Wait at least 20 seconds to be sure that the capacitors are fully discharged. See Figure 8, 6. If necessary to discharge the traction controllers, separately from the lift controller, connect a 200- ohm, 2-watt resistor across the controller's nega- tive (B--) and posttive (B+) terminals. Wait at least 20 seconds to be sure thal the capacitors are fully discharged. Repeat for the other traction controller as necessary. See Figure 9. B— TERMINAL By TERMINAL JUMPER LEADS 200-OHM, 2-WATT RESISTOR eee Figure 8. Lift Controller General 4. B+ TERMINAL 2) B_ TERMINAL 3. JUMPER LEADS 4, 200-OHM, 2-WATT RESISTOR, Figure 9. Traction Controller 7. Remove the resistor from the controller(s) and re- install the covers before returning the lift truck to service. DISCHARGING THE CAPACITORS (ALL OTHER MODELS) & warninc DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so. Improper repairs and adjustments can create dan- gerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is neces- sary, attach a DO NOT OPERATE tag on the steering ‘wheel and disconnect the battery. Disconnect the battery and discharge the capaci- tors before opening any compartment covers or in- specting or repairing the electrical system. DO NOT 620 YRM 1385 place tools on top of the battery. If a tool causes a short circuit, the high current flow from the battery ‘can cause personal injury or property damage. ‘Some checks and adjustments are performed with the battery connected. DO NOT connect the battery until the procedure instructs you to do so. Never wear any metallic items on your fingers, arms, or neck. Metal items can accidentally make an electri- cal connection and cause injury. Before performing any tests or adjustments, block the lift truck to prevent unexpected movement. ‘The capacitors in the transistor controller(s) can hold an electrical charge for about 10 seconds af- ter the battery is disconnected. To prevent an elec- trical shock and personal injury, discharge the ca- pacitor(s) before inspecting or repairing any com- ponent in the drive unit compartment. Make certain that the battery has been disconnected. DO NOT short across the motor controller terminals with a screwdriver or jumper wire. Make certain the Emergency-Stop Switch has not been activated. This will isolate the controller and prevent the capacitors from discharging properly. ‘The proper way to disconnect the battery is by sep- rating the battery connectors. 1. Ensure the capacitors are discharged by perform- ing Step 2 through Step 6 below. 2. Turn key or keyless switch to OFF position. 3. Disconnect the battery by separating the connec- tors. 4, Block drive wheels to prevent ltt truck from moving. 5. Make sure the Emergency-Stop Switch HAS NOT been activated. If the Emergency-Stop Switch is activated, rotate the switch to the right until it pops up. 6. Wait at least 10 seconds to be sure that the capac- itors are fully discharges. 620 YRM 1385 Traction Motor Repair Traction Motor Repair FOR LIFT TRUCK MODELS ERP15-20VT (ERPO30-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), AND ESC030-040AC. (6883) Remove NOTE: The procedures described in this section apply to both right and left traction motors. NOTE: Step 1 does not apply to ESC030-040AC (8883). lft tuck models. 1. Disconnect manual release cable from parking brake, 2. Disconnect parking brake wire harness from main wire hamess. See Figure 10. 3. Put lift truck on blocks so that the dive tires are suspended off the floor. See one of the following sections for procedures: Periodic Maintenance 8000 YRM 1339 for lift truck models: + ERP15-20VT (ERPO30-040VT) (6807) Periodic Maintenance 8000 YRM 1873 for lift truck models: ‘+ ERP16-20VF (ERP30-40VF) (A955) Periodic Maintenance 8000 YAM 1418 for lift truck models: ‘+ ESCO30-040AC (8883) 4. Turn the key or keyless switch to OFF position and disconnect the battery. TRANSAXLE PARKING BRAKE WIRE HARNESS SOCKET HEAD CAPSCREW LOCKWASHER, WASHER PARKING BRAKE ogsens 7. TRACTION MOTOR 8. SPLINED HUB 9. SNAP RING 10. WOODRUFF KEY 11. TRACTION MOTOR MOUNTING CAPSCREW Figure 10. Transaxle Assembly ‘Traction Motor Repair 5. Remove transaxlefraction motoriparking brake as- sembly from lift truck. See one of the following sec- tions for removal instructions: Transaxle 1300 YRM 1330 for lift truck models: + ERP15-20VT (ERP030-040V7) (G807) + ERP16-20VF (ERP30-40VF) (A955) ‘Transaxle 1300 YRM 1411 for lift truck models: + ESC030-040C (8883) 6. Move transaxle/traction motor/parking brake as- sembly to a bench or other suitable work surface. NOTE: Note placement and orientation of parking brake prior to removal to aid in installation. 7. Remove four socket head capscrews, lockwash- ers, washers and parking brake from traction motor shaft. See Figure 10. ‘8. Remove snap ring and splined hub from traction ‘motor shaft; recover woodruff key. See Figure 10. @ warnine ‘The traction motor weighs approximately 18.4 kg (40.6 Ib). Make sure lifting device has enough lifting ‘capacity to safely lift motor. NOTE: Use an approved lifting device to hold and lift traction motor during removal. 9, Remove four traction motor mounting capscrews, washers, and traction motor from transaxle. See Figure 10. 620 YRM 1385 Disassemble 1. Remove four socket-head capscrews and lock- washers from brake end head and transaxle end head. See Figure 11 NOTE: Carefully tap underside of brake end head with ‘a soft hammer to loosen brake end head from stator. 2. Remove brake end head from stator and slide brake ‘end head off rotor shaft. See Figure 11 8. Remove rotor from stator. See Figure 11. stator brake end down on workbench. Place: NOTE: Carefully tap underside of transaxle end head with a soft hammer to loosen transaxle end head from stator. 4, Remove transaxle end head from stator. See Fig- ure 11. ‘5. Remove snap ring from brake end head. See Fig- ure 11 6. Using bearing puller, carefully remove bearing from brake end head. See Figure 11. NOTE: Perform Step 7 and Step 8 if connection plate is damaged and must be replaced 7. Remove temp sensor wire harness from grommet. Soe Figure 11 8. Remove screws, nuts, washers, grommet, and con- nection plate from stator. See Figure 11. Legend for Figure 14 TRANSAXLE END HEAD ROTOR SOCKET-HEAD CAPSCREW AND LOCKWASHER, STATOR, TERMINALS, AND HARDWARE CONNECTION PLATE, SCREW, AND GROMMET es eps 6. BRAKE END HEAD 7. TEMP SENSOR CONNECTOR AND WIRING HARNESS 8. SNAP RING. 98. BEARING 620 YRM 1385 Traction Motor Repair Figure 11. Traction Motor ‘Traction Motor Repair Electrical Connector Repair or Replacement 1. If necessary, electric brake connector (see Fig- ture 10) may be repaired or replaced. See Deutsch Connectors section of Wire Harness Repair 2200 YRM 1128 manual for instructions. 2. If necessary, temp sensor connector (see Fig- ure 11) may be repaired or replaced. See AMP Superseal Connector Assemblies section of Wire Harness Repair 2200 YRM 1128 manual for in- structions. Clean B warning Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer's recommended safety procedures. 1. Clean components with a clean cloth moistened with solvent and allow to thoroughly dry. DO NOT apply liquid solvent directly to stator windings. Inspect 1. Inspect rotor and inside of stator for marks or grooves indicating contact between rotor and sta- tor. Replace if damaged. 2. Check that the bearings roll smoothly and are not loose from excessive wear. Replace as necessary. Replace the bearings regardless of condition if mo- tor has been subjected to thermal overload (see Step 3). In case of a catastrophic bearing failure, damage may result to other motor components and Possibly to transaxle. 3. Check stator windings for signs of thermal overload. Signs of thermal overload are dark-stained, brittle, ‘or bumt insulation. Thermal overload will shorten the life of the stator. 4. Check stator windings resistance as indicated be- low. To measure continuity between U, V, and W terminals of motor use a digital mutti-meter (OMM) set to Ohms. ‘a. Place one DMM probe on terminal U. 10 620 YRM 1385 b. Place the other DMM probe on terminal V. Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the ca- bles from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the motor windings in the stator have burned open and the motor must be repaired or replaced. ¢. Place one DMM probe on terminal V. 1d. Place the other DMM probe on terminal W. Meter must read less than 0.8 ohms. If the reading is more than 0.5 ohms, remove the ca- bles from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the ‘motor windings in the stator have burned open and the motor must be repaired or replaced. @. Place one DMM probe on terminal W. {Place the other DMM probe on terminal U Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the ca- bles from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the ‘motor windings in the stator have burned open and the motor must be repaired or replaced. NOTE: A likely cause of motor contamination may be from a damaged input bearing seal on the transaxle. 5. Check for signs of oil or other contaminants within the motor. If contaminants are present, locate ‘source and take corrective action. Assemble 1. Install transaxle end head onto stator. See Fig- ure 12. 2. Install rotor into stator with drive splines protruding through transaxle end head. See Figure 12. NOTE: Perform Step 3 through Step 5 if connection plate and hardware was removed 3. If removed, install connection plate, grommet, washers, and nuts onto stator. See Figure 13. 620 YRM 1385 TRANSAXLE END HEAD STATOR ROTOR DRIVE SPLINES Sep Figure 12. Transaxle End Head, Stator and Rotor NOTE: Terminal studs are located on top of connection plate. 4. Hold lower nut of terminal stud to prevent it from ‘turning and tighten upper nut to 12 Nem (106 Ib in). See Figure 14. 5. Inserttemp sensor wire harness into grommet. See Figure 13. & caution Use an arbor press and a proper size driver when installing bearings to avoid damage to bearings and/or end shields. Press only on the outer race of the bearing. 6. Carefully install bearing into brake end head. See Figure 13. 7. Install snap ring into brake end head. See Fig- ure 13. 8. Install brake ond head onto rotor shaft and stator. See Figure 13. 9. Install four lockwashers and socket-head cap- screws onto transaxle end head and brake end Traction Motor Repair head. See Figure 13. Tighten capscrews to 14 to 16 Nem (124 to 142 Ib in). Install & warnine ‘The traction motor weighs approximately 18.4 kg (40.6 Ib). Make sure lifting device has enough lifting capacity to safely lift motor. NOTE: Use an approved lifting device to lift and hold traction motor during install. Use caution when in- stalling motor to transaxle not to damage transaxle shaft seal. 1. Apply Dexron Ill transmission fluid to drive splines of traction motor and install traction motor onto transaxle, 2. Apply Loctite® 271 to four traction motor mounting capscrews. 3. Install four washers and traction motor mounting ‘capscrews into traction motor and transaxle. See Figure 15. Tighten capscrews to 48 Nem (35 Ibt ft. 4. Install splined hub and woodruff key (with counter- bore facing up) onto traction motor shaft. See Fig- ure 15. 5. Install snap ring onto traction motor shaft. See Fig- ure 15, NOTE: Close clearances require parking brake to be installed after traction motor is installed to transaxle. Parking brake mechanical release arm must be in ver- tical position when installed. 6. Install parking brake onto splined hub. See Fig- ure 15. 7. Install four washers, lockwashers, and socket-head ‘capscrews into parking brake and brake end head of traction motor. See Figure 15. ‘8. Connect parking brake wire hamess to main wiring harness. See Figure 15 NOTE: Step 9 does not apply to ESC030-040AC (8883) lift truck models. 9. Connect manual release cable to parking brake. " ‘Traction Motor Repair 620 YRM 1385 Figure 13. Traction Motor 620 YRM 1385 Traction Motor Repair Legend for Figure 13 1. TRANSAXLE END HEAD 2 ROTOR 3. SOCKETHEAD CAPSCREW AND LOCKWASHER 4. STATOR, TERMINALS, AND HARDWARE 5. CONNECTION PLATE, SCREW, AND GROMMET 10. Complete installation of transaxle into lit truck. See ‘one of the following manuals for instructions: ‘Transaxle 1300 YRM 1330 for lift truck models: + ERP15-20VT (ERPO30-040VT) (4807) + ERP16-20VF (ERP30-40VF) (A955) ‘Transaxle 1300 YRM 1411 for lift truck models: + ESC030-040AC (8883) 11. Lower the lift truck from the blocks. Refer to one of the following manuals for procedures: Periodic Maintenance 8000 YRM 1339 for lift truck models: + ERP15-20VT (ERPO30-040VT) (6807) Pe models: + ERP16-20VF (ERP30-40VF) (AS55) Maintenance 8000 YRM 1373 for lift ruck Periodic Maintenance 8000 YRM 1418 for lift truck models: + ESC030-0408C (8883) 12. Connect battery connector and turn key or keyless. switch to the ON position. Remove the blocks from the wheels. Test for proper operation. BRAKE END HEAD TEMP SENSOR CONNECTOR AND WIRING HARNESS SNAP RING. BEARING 1. TERMINAL STUD 2. LOWER NUT Figure 14. Terminal Studs and Nuts 3. UPPER NUT 13 ‘Traction Motor Repair 620 YRM 1385 TRANSAXLE PARKING BRAKE WIRE HARNESS SOCKETHEAD CAPSCREW LOCKWASHER, WASHER, peeps FOR LIFT TRUCK ERC22-35VG (ERC045-070VG) (A968) AND ERC16-20VA (ERC030-040VA) (A969) Remove 1. Remove traction motor from lift truck. See Frame 100 YRM 1342 for instructions. & caution ‘The traction motor can weigh as much as 136 kg (300 Ib). To prevent injury, use a lifting device capa- ble of lifting the assembly. 2. Place traction motor on level blocks on a flat surface with drive end pointing down. Remove floor jack. Disassemble 1. Remove capscrew Mé, lockwasher, and speed sen- sor from non-drive end head. See Figure 16. 1“ PARKING BRAKE TRACTION MOTOR, SPLINED HUB SNAP RING. 10. CAPSCREW Figure 15. Transaxle Assembly 2 a 4 5. Remove long socket-head capsorew, lockwasher, ‘sensor connector cover bracket, and sensor con- rector tab bracket from stator housing above sen- sor cable outlet. See Figure 16. Remove five capscrews, lockwashers, and washers from stator Z-nuts and non-drive end head. See Figure 16. Gently tap under non-drive end head and remove from stator housing. See Figure 16. Pull sensor cable outlet from stator housing (see Figure 16) and disconnect speed sensor and tem- perature sensor connectors. Using a bearing puller, remove and discard prox- imity sensor wheel from non-drive end head. See Figure 17. 620 YRM 1385 Traction Motor Repair > NON-DRIVE END SPEED SENSOR CAPSCREW M6 LOCKWASHER NON-DRIVE END HEAD LONG SOCKET-HEAD CAPSCREW SENSOR CONNECTOR COVER BRACKET SENSOR CONNECTOR TAB BRACKET STATOR HOUSING PNogsen= B. DRIVE END 9. SENSOR CABLE OUTLET 10. CAPSCREW 11. WASHER 12. STATOR Z-NUT 13. AMP SUPERSEAL TAB ASSEMBLY 44. TAB CONTACT 15. WIRE SEAL Figure 16. Traction Motor Non-Drive End Head NOTE: When replacing one bearing, itis strongly rec- ‘ommended to replace both bearings. NOTE: Note orientation of bearing components during disassembly to aid in assembly 7. Using bearing puller, remove bearing from non-drive end head. See Figure 17. 8. Remove bearing preload spring from non-drive end head. See Figure 17. 9. Remove three hex-head bolts, spring washers, ter- minal flags, terminal covers, terminal blocks, and special nuts from stator housing on non-drive end. See Figure 18. 10. Remove five capscrens, lockwashers, and washers from Z-nuts on stator housing and drive end head, See Figure 18. 1 a \ \ 1. PROXIMITY 3. BEARING SENSOR WHEEL 4. BEARING 2. NON-DRIVE END HEAD PRELOAD SPRING Figure 17. Traction Motor Non-Drive End Head Bearing 15 ‘Traction Motor Repair 11. Attach approved lifting device to stator housing and slowly lift straight up, removing it from rotor assem- bly and drive end head. See Figure 18, 12. Screw lifting eye into threaded hole in end of rotor assembly. Attach approved ifting device and lift ro- tor assembly straight up from drive end head. See Figure 19. NOTE: When replacing one bearing, it is strongly rec- ‘ommended to replace both bearings. 620 YRM 1385 NOTE: Note orientation of bearing components prior to disassembly to aid in assembly. 13. Using bearing puller, remove bearing from drive ‘end head. See Figure 19. 14. Remove and discard shaft seal from drive end head. See Figure 19. HEX-HEAD BOLT. SPRING WASHER TERMINAL FLAG. TERMINAL COVER TERMINAL BLOCK STATOR HOUSING CAPSCREW Negaeye 8 LOCKWASHER 9. WASHER 10. DRIVE END HEAD 11. ROTOR ASSEMBLY 12. STATOR Z-NUT 13, SPECIAL NUT Figure 18. Traction Motor Drive End Head 16 620 YRM 1385 4. SHAFT SEAL 2, ROTOR ASSEMBLY 3. DRIVE END HEAD 4. BEARING Figure 19. Traction Motor Rotor Assembly and Drive End Head Electrical Connector Repair or Replacement 1. If necessary, AMP Superseal tab assembly, tab contact, and wire seal (see Figure 16) may be re- paired or replaced. See AMP Superseal Connector ‘Assemblies section of Wire Harness Repair 2200 YRM 1128 manual for instructions. Clean @ warnine Cleaning solvents can be flammable and toxic and can cause skin Irritation. When using cleaning solvents, always follow the solvent manufacturer's recommended safety procedure 1. Clean components with a clean cloth moistened with solvent and allow to air dry. DO NOT apply liquid solvent directly to components. Inspect Inspect rotor assembly and inside of stator housing {for marks or grooves indicating contact between ro- tor and stator. Replace if damaged, 2. Check that the bearings roll smoothly and are not loose from excessive wear. Replace as necessary. Replace the bearings regardless of condition if mo- tor has been subjected to thermal overioad (see Step 3). In case of a catastrophic bearing failure, Traction Motor Repair damage may result to other motor components and Possibly to transaxle. Check stator windings for signs of thermal overload. Signs of thermal overload are dark-stained, brittle, or burnt insulation. Thermal overload will shorten the life of the stator. Check motor windings resistance as indicated be- low. To measure continuity between U, V, and W terminals of motor use a digital multi-meter (OMM) set to Ohms. ‘a. Place one DMM probe on terminal U. b. Place the other DMM probe on terminal V. Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the ca- bles from motor to inverter and measure again. If this reading is other than 0.5 chm or less, the ‘motor windings in the stator have burned open land the motor must be repaired or replaced. ©. Place one DMM probe on terminal V. d. Place the other DMM probe on terminal W. Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the ca- bles from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the motor windings in the stator have burned open and the motor must be repaired or replaced, e. Place one DMM probe on terminal W. f. Place the other DMM probe on terminal U. Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the ca- bles from motor to inverter and measure again. if this reading is other than 0.5 ohm or less, the ‘motor windings in the stator have burned open and the motor must be repaired or replaced. Check terminal flags for cracks or other damage. Replace if damaged. Check for signs of oil or other contaminants within motor. If necessary, locate source of contaminants and take corrective action, Inspect all other components and replace as nec- essary, 7 ‘Traction Motor Repair Assemble 1. Using a seal driver, install new shaft seal into drive end head. See Figure 19, & caution Use an arbor press and a proper size driver when Installing bearings to avoid damage to bearings and/or end shields. Press only on the outer race of the bearing. Always replace bearings in sets. 2. Install bearing into drive end head as noted during disassembly. See Figure 19. 3. Screw lifting eye into threaded hole in the end of rotor assembly. Attach approved lting device and lower rotor assembly onto drive end head. Ensure bearing is fully seated against drive end head. See Figure 19, 4. Remove lifting device and lifting eye from rotor as- sembly. NOTE: Make sure holes for stator Z-nuts are aligned with capscrew holes. 5. Using approved lifting device, lower stator housing ‘onto drive end head. See Figure 18. 6. Install five washers, lockwashers, and capscrews into drive end head and stator Z-nuts on stator housing. See Figure 18. Tighten capscrews to 25 to 30 Nem (18 to 22 Inf f) 7. Install three special nuts, terminal blocks, terminal covers, terminal flags, spring washers, and hex- head bolts onto stator housing, non-drive end. See Figure 18. ‘8 Install bearing preload spring into non-drive end head. See Figure 17. 9. Install bearing into non-drive end head as noted during disassembly. See Figure 17. 10. Install new proximity sensor wheel into non-drive end head. See Figure 17. 11. Place sensor cable outlet into position on stator housing (see Figure 16). Connect proximity sen- sor and temperature sensor connectors to sensor cable outlet. 18 620 YRM 1385 12. Install non-drive end head onto stator housing. See Figure 16. 13, Install five washers, lockwashers, and capscrews into non-drive end head and stator Z-nuts on stator housing. See Figure 16. Tighten capscrews to 25, to 30 Nem (18 to 22 Ibf ft) 14. Install sensor connector tab bracket, sensor con- ector cover bracket, lockwasher, and long socket- head capscrew onto stator housing over sensor ca~ ble outlet. See Figure 16. 15. Install speed sensor, lockwasher, and capscrew M6 ‘onto non-drive end head and stator housing. See Figure 16. Install 1. Install traction motor onto drive axle. See Frame 100 YRM 1342 for installation instructions. FOR LIFT TRUCK ERP2.2-3.5VL (ERPO45-070VL) (A976) Remove NOTE: The procedures described in this section apply to both right and left traction motors. 1. Remove transaxle assembly from lift truck. See Transaxle 1300 YRM 1370 for instructions. 2. Remove service and parking brake components from traction motor housings. See Transaxle 1300 YRM 1370 for instructions. 3. Remove the AC motor to be repaired from the out- put housing. See Transaxle 1300 YRM 1370 for instructions. Disassemble 1. Remove nine nuts and washers from terminals on connection plate. See Figure 20. 2. Remove two screws and connection plate from sta- tor housing. See Figure 20. 3. Remove and discard front shaft seal from brake end bell. See Figure 20. 620 YRM 1385 Traction Motor Repair TERMINAL, WASHER, CONNECTION PLATE SCREW FRONT SHAFT SEAL REAR SHAFT SEAL SNAP RING. exooaepo 9, BRAKE END BELL 10. O-RING 11. BEARING 42. ROTOR 43, STATOR 14. WAVE WASHER: 45. STATOR HOUSING 16. DOWEL PINS Figure 20. Traction Motor ‘Traction Motor Repair Remove and discard rear shaft seal from stator housing. See Figure 20. 5. Remove snap ring from rotor at brake end bell. See Figure 20. NOTE: Use threaded holes on the brake end bell to move the end bell away from the stator housing. 6. Remove six screws, dowel pins if present, and brake end bell from stator housing. Remove and discard O-ring. See Figure 20. 7. Remove snap ring from inside brake end bell. See Figure 20. ‘8 Carefully remove bearing from brake end bell. See Figure 20. NOTE: Bearing will remain with rotor during removal. 9. Remove rotor from stator housing. See Figure 20. 10. Carefully remove bearing from rotor. ure 20, See Fig 11. Carefully remove stator from stator housing. See Figure 20. Take care not to damage power loads. 12. Remove wave washer from stator housing. See Figure 20. Clean &@ warning Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer's recommended safety procedures. 1. Clean components with a clean cloth moistened with solvent and allow to thoroughly dry. DO NOT apply liquid solvent directly to stator windings. Inspect 1. Inspect rotor and inside of stator for marks of grooves indicating contact between rotor and sta- tor. Replace if damaged. 2. Check that the bearings roll smoothly and are not loose from excessive wear. Replace as necessary. Replace the bearings regardless of condition if mo- tor has been subjected to thermal overload (see 20 620 YRM 1385 Step 3). In case of a catastrophic bearing failure, ‘damage may result to other motor components and possibly to transaxle. 3. Check stator windings for signs of thermal overload. Signs of thermal overioad are dark-stained, britte, ‘or bumt insulation. Thermal overload will shorten the life of the stator. 4, Check motor windings resistance as indicated be- low. To measure continuity between U, V, and W terminals of motor use a digital multi-meter (DMM) sset to Ohms. ‘a. Place one DMM probe on terminal U. b. Place the other DMM probe on terminal V. Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the ca- bles from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the motor windings in the stator have burned open land the motor must be repaired or replaced. ¢. Place one DMM probe on terminal V. d. Place the other DMM probe on terminal W. Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the ca- bles from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the motor windings in the stator have burned open and the motor must be repaired or replaced. e. Place one DMM probe on terminal W. {Place the other DMM probe on terminal U. Meter must read less than 0.5 ohms. If the reading is more than 0.5 ohms, remove the ca- bles from motor to inverter and measure again. If this reading is other than 0.5 ohm or less, the motor windings in the stator have burned open and the motor must be repaired or replaced. NOTE: A likely cause of motor contamination may be from a damaged input bearing seal on the transaxle. ‘8. Check for signs of oll or other contaminants within the motor. If contaminants are present, locate ‘source and take corrective action. 620 YRM 1385 Assemble NOTE: The procedures described in this section apply to both right and left traction motors. 1. Install wave washer in stator housing. See Fig- ure 20. 2. Carefully instal stator into stator housing. See Fig- ure 20. Take care not to damage power leads. & caution Use an arbor press and a proper size driver when installing bearings to rotor to avoid damage to bear- ing. Press only on the INNER race of the bearing. Always replace bearings in sets. 3. Install bearing onto rotor. See Figure 20. 4. Install rotor into stator and stator housing. See Fig ure 20. & caution Use an arbor press and a proper size driver when in- stalling bearings to avoid damage to bearing. Press ‘only on the OUTER race of the bearing. Always re- place bearings in sets. 5. Install bearing into brake end bell, See Figure 20, 6. Install snap ring on inside brake end bell. See Fig- ure 20. 7. Install new O-ring on the brake end bell. Install the brake end bell dowel pins and six screws into Hydraulic Motor Repair stator housing. Tighten the six screws to 23 Nem (204 Ib in). See Figure 20. 8. Install snap ring on rotor at brake end bell. See Figure 20. 9. Install new rear shaft seal into stator housing. See Figure 20. 10. Install new front shaft seal into brake end bell. See Figure 20. 11. Using two screws, install connection plate on stator housing. Tighten screws to 3 Nem (27 Ibf in). See Figure 20. 12. Install nine nuts and washers on terminals on con- nection plate. Tighten bottom nuts to 8 Nem (71 Ibf in). See Fig- ure 20. NOTE: The procedures described in this section apply to both right and left traction motors. 1. Install repaired AC motor onto output housing. See Transaxle 1300 YRM 1370 for instructions. 2. Install parking brake and service brake components onto traction motor housings. See Transaxle 1300 YRM 1370 for instructions. 3. Install transaxle assembly onto lift truck. See Transaxle 1300 YRM 1370 for instructions, Hydraulic Motor Repair FOR LIFT TRUCKS ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), AND ESC030-040AC (8883) Remove 1. Flemove hydraulic pump and motor assembly from lift truck. See one of the following manuals for re- ‘moval instructions: Hydraulic System 1900 YRM 1333 for models: ‘+ ERP15-20VT (ERPO30-040VT) (6807) + ERP16-20VF (ERP3O-40VF) (A955) Hydraulic System 1900 YRM 1413 for models: + ESC030-040AC (8889) 2. Place hydraulic pump and motor assembly on a ‘clean work bench or other suitable surface. 3. Remove two capscrews and drive end bracket from hydraulic pump and motor assembly. See Figure 21, 4. Remove two capsorews and terminal end bracket {from hydraulic pump and motor assembly. See Fig- ure 21 a Hydraulic Motor Repair CAPSCREWS. DRIVE END BRACKET TERMINAL END BRACKET HYDRAULIC PUMP AND MOTOR ASSEMBLY pepe Figure 21. Hydraulic Pump and Motor Mounting '5. Remove two capscrews retaining hydraulic pump to hydraulic motor. See Figure 22 6 Remove hydraulic pump with drive coupling from hydraulic motor. Disassemble 1. Place hydraulic motor in a vise with terminal posts ‘on top and carefully clamp vise onto stator housing. 2. Remove hex nuts and disconnect power leads from terminal posts. See Figure 23. 3. Remove two capscrews, terminal posts, and ter- minal post bracket from stator housing. See Fig- ure 23, 4, Remove four tie rods holding non-drive end shield land drive end shield to stator housing. See Fig- ure 23, & caution Disposal of silicone sealant must meet local envi- ronmental regulations. NOTE: Note threading position and orientation of power leads and thermal sensor connactor wire through non- drive end shield during disassembly to aid in assembly. NOTE: Silicone seal for power leads and thermal sen- ‘sor connector wire must be broken prior to shield re- moval. 620 YRM 1385 5. Remove non-drive end shield from stator housing. See Figure 23. 6. Using bearing puller, remove non-

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