AC MOTOR REPAIR

N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470]; N30ZDRS,
N35-40ZRS [A265]

PART NO. 1590934 620 SRM 1186

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, 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 lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications 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 if the
unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety 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 area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
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 back-
ground. The CAUTION symbol and word are on yellow background.
AC Motor Repair Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Traction Motor Repair ....................................................................................................................................... 2
Disassemble ................................................................................................................................................... 2
Inspect ............................................................................................................................................................ 3
Assemble ........................................................................................................................................................ 3
Drive End Bearing, Replace.......................................................................................................................... 4
Hydraulic Motor Repair..................................................................................................................................... 5
Disassemble ................................................................................................................................................... 5
Inspect ............................................................................................................................................................ 7
Assemble ........................................................................................................................................................ 7
Troubleshooting.................................................................................................................................................. 8

This section is for the following models:

N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265]

©2009 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
620 SRM 1186 General

General
This section describes disassembly, assembly, inspec-
tion, and checks for malfunctions of AC motors.

AC traction motors and AC hydraulic pump motors

are similar in function. See Figure 1, Figure 2, and
Figure 3. Disassembly and repair of these motors is
similar.

Figure 2. AC Hydraulic Motor (N35ZDR,

N45ZR, N30ZDR, N35-40ZR)

Figure 1. AC Traction Motor

Figure 3. AC Hydraulic Motor (N30ZDRS,

N35-40ZRS)

1
Traction Motor Repair 620 SRM 1186

Traction Motor Repair

DISASSEMBLE Legend for Figure 4
1. END BELL
WARNING 2. SCREW
The bearings and seals on the traction motor 3. ENCODER WIRE
are serviceable parts. The AC traction motor 4. TEMPERATURE SENSOR WIRE
5. HOLDING BRACKET
weighs 109 kg (240 lb). To prevent injury, use
a lifting device of adequate capacity for lifting 4. Remove screws from the non drive rear end bell.
the assembly.
5. Place alignment marks on the end bell and motor
NOTE: When replacing the encoder bearing, also re- case. Marks will be used to correctly align the
place the bearing on the drive end of the motor. end bell on the motor case during assembly.
1. Remove traction motor from the lift truck. See 6. Lift end bell and rotor assembly from AC motor
Master Drive Unit 630 SRM 1022 for removal case. Place horizontally on a flat surface.
information.
7. Remove chain and lifting eye.
2. Screw lifting eye into the threaded hole in the
end of the rotor shaft and connect a chain to the 8. Remove screws from air guide.
lifting eye.
9. Remove end bell from rotor assembly. See Fig-
3. Remove temperature sensor wire and encoder ure 5.
wire from holding bracket. See Figure 4.

1. SCREW 3. END BELL SLOT

2. AIR GUIDE 4. ENCODER WIRE

Figure 5. Rotor Disassembly

10. Remove air guide, being careful not to damage

encoder bearing wire.

Figure 4. AC Motor Assembly

2
620 SRM 1186 Traction Motor Repair

Table 1. Traction Motor Windings

CAUTION
Never reuse a bearing that has been removed Winding to Line Resistance
from a rotor shaft. Voltage (Ohm)
NOTE: Before removing the encoder bearing, note its Min Max
orientation and install the new encoder bearing in 24 3.22 3.83
the same orientation.
36 3.22 3.83
11. Using a bearing puller, remove encoder bearing.
See Figure 6.
ASSEMBLE

CAUTION
To avoid damage to the encoder bearing elec-
tronics, use a bearing driver and arbor press.
Press only on the inner race of the bearing.

1. Install the bearing on the drive end of the rotor

shaft using a bearing driver and arbor press.

NOTE: The encoder bearing must be oriented as

noted during removal.

2. Using a bearing driver and arbor press, install

the encoder bearing as noted during removal.
1. ENCODER 2. BEARING PULLER Press only on the inner race of the bearing dur-
BEARING 3. ENCODER WIRE ing installation.

Figure 6. Bearing Removal 3. Place encoder wire through air guide and move
air guide back over encoder bearing. See Fig-
ure 7.
CAUTION
Never reuse a bearing that has been removed 4. Place end bell on rotor assembly.
from a rotor shaft.

12. Using a bearing puller, remove bearing from CAUTION

drive end of rotor shaft. To prevent damage to the encoder bearing, en-
sure encoder wire is inserted in end bell slot
INSPECT when air guide is attached to the end bell.

Inspect the rotor and the inside of the motor case for 5. Insert encoder wire in the end bell slot and attach
marks or grooves indicating contact between the ro- air guide to end bell.
tor and the motor case. Replace if damaged. Bear-
ings should fit snug where they seat on the shaft. If 6. Install eyebolt into end bell and rotor assembly
there is excessive wear, replace the bearing and/or and connect a chain to the lifting eye.
shaft. Check the bearings for smooth operation. If a
7. Lift the end bell and rotor assembly to a vertical
bearing does not roll smoothly, it must be replaced.
position.
Check that resistance between the windings and the
case is above 50,000 ohms. Resistance of the wind-
ings (line to line) should be within specification. See
Table 1.

3
Traction Motor Repair 620 SRM 1186

13. Install motor into the lift truck. See Master

Drive Unit 630 SRM 1022 for your lift truck
model for installation information.

DRIVE END BEARING, REPLACE

NOTE: Drive end bearing is to be replaced if worn or
damaged.

1. Follow Step 1 through Step 10 of Disassemble

procedure.

CAUTION
Never reuse a bearing that has been removed
from a motor.

2. Using a bearing puller, remove drive end bearing

from shaft. See Figure 8.

3. Using a bearing driver and arbor press, install

drive end bearing. Press only on the inner race
of the bearing during installation.
1. ENCODER WIRE
2. AIR GUIDE 4. Follow Step 3 through Step 12 of the Assemble
3. ENCODER BEARING procedure.

Figure 7. Alignment of Air Guide and End Bell

CAUTION
To prevent damage to the encoder wire, line up
end bell and rotor assembly slot with visible
mark to guide encoder wire into end bell and
rotor assembly case.

8. Using the alignment marks made during disas-

sembly, line up the end bell and rotor assembly
with the motor case.

9. Lower the end bell and rotor assembly back into

the case and place the encoder bearing and tem-
perature sensor wires into position.

10. Attach end bell and rotor assembly to AC motor

case.

11. Install temperature sensor wire and encoder 1. END BELL SLOT
wire onto holding bracket. 2. AIR GUIDE
3. DRIVE END BEARING
12. Remove chain and lifting eye. 4. ENCODER WIRE

NOTE: Wipe the motor shaft splines and the drive Figure 8. Alignment of End Shaft Bearing
unit input pinion clean. Apply a moderate coat
of Dow Corning® Molykote G-N paste to the shaft
splines and pinion splines with a small brush before
installing motor to the drive unit.

4
620 SRM 1186 Hydraulic Motor Repair

Hydraulic Motor Repair

DISASSEMBLE
1. Remove the pump and motor assembly from the
lift truck. See Hydraulic System 1900 SRM
1189 or Hydraulic System 1900 SRM 1307 for
instructions on removing the pump and motor
assembly.

2. Place the pump and motor assembly on a clean

work bench or other suitable surface.

3. Remove the two capscrews (3) retaining the

pump to the motor. See Figure 9 and Figure 10.
Remove the pump.

1. POWER CABLE TERMINAL NUT

2. DRIVE END HEAD
3. CAPSCREW
4. TERMINAL END HEAD
5. LIFT PUMP
6. MOTOR CASE
7. TIE BAR SCREW

Figure 10. Hydraulic Pump and Motor

(N30ZDRS, N35-40ZRS)
1. POWER CABLE TERMINAL NUT
2. SCREW 5. Loosen and remove the power cable terminal
3. CAPSCREW nuts. Remove the power leads from the terminal
4. TERMINAL END HEAD
5. DRIVE END HEAD block and remove the screws (2) retaining the
6. TIE BAR SCREW terminal block to the motor case. See Figure 9
7. MOTOR CASE and Figure 10. Remove the terminal block.
8. LIFT PUMP
6. Unscrew the four tie bar screws (6) holding the
Figure 9. Hydraulic Pump and Motor (N35ZDR, end heads to the motor case. See Figure 9 and
N45ZR, N30ZDR, N35-40ZR) Figure 10. Remove the terminal end head from
the motor case.

4. Place the motor in a vise with the terminal block 7. Remove the drive end head from the motor case.
on top and carefully clamp the vise on the motor Remove the pump seal from the drive end head.
case. See Figure 11.

5
Hydraulic Motor Repair 620 SRM 1186

1. ROTOR 5. DRIVE END HEAD

2. RETAINING RING 6. MOTOR CASE
3. DRIVE END BEARING 7. ENCODER BEARING
4. PUMP SEAL 8. TERMINAL END HEAD

Figure 11. Hydraulic Motor

CAUTION
Use an arbor press and a soft punch when re-
moving bearings to avoid damage to the bear-
ings and/or end head. Never reuse a bearing
that has been removed from a rotor.
9. Remove the rotor from the motor case.
10. Fit a bearing puller to the encoder bearing on
the end of the motor shaft. Carefully remove the
bearing from the motor shaft.

8. Remove retaining ring and bearing from drive

end head.

6
620 SRM 1186 Hydraulic Motor Repair

INSPECT shaft. Check the bearings for smooth operation. If a

Inspect the rotor and the inside of the motor case for
marks or grooves indicating contact between the ro-
tor and the motor case. Replace, if damaged. Bear-
ings should fit snug where they ride on the shaft. If
there is excessive wear, replace the bearing and/or
clean bearing does not roll smoothly, it must be re-
placed. Check that resistance between the windings
and the case is above 50,000 ohms. Resistance of the
windings (line to line) should be within specification.
See Table 2.

Table 2. Hydraulic Motor Windings

Winding to Line Resistance (Ohm)

Pump Displacement Voltage
Min Max
20cc 24 2.27 2.70
25cc 36 2.55 3.03

25cc 36 2.27 2.70

28cc 36 1.19 1.37

20cc 36 (EE) 2.27 2.70

ASSEMBLE
CAUTION
To avoid damage to the encoder bearing elec-
tronics, use a bearing driver and arbor press
to install the encoder bearing onto the rotor
shaft. Press only on the inner race of the bear-
ing during installation.
1. Install the encoder bearing onto the rotor shaft.
See Figure 11.
6. Install the four tie bar screws (6) through the
holes in the end heads. See Figure 9 and Fig-
ure 10.
7. Install the pump seal into the drive end head.
8. Install the terminal block using screws (2) as re-
moved. See Figure 9 and Figure 10.
9. Install the power leads to the terminal block. In-
stall power cable terminal nuts and torque to
15 N•m (11 lbf in).

2. Insert the rotor into the motor case.
CAUTION
Use an arbor press and a proper size driver
when installing bearings to avoid damage to
bearings and/or end head.
3. Press bearing into the drive end head. Install
retaining ring. Press only on the inner race of
the bearing.
4. Install the drive end head onto the motor case.
10. Wipe the lift pump shaft splines and the motor
input pinion clean. Apply a moderate coat of Dow
Corning® Molykote G-N paste to the shaft splines
and pinion splines with a small brush. Insert the
shaft into the pinion until the pump seats against
the motor. Align pump mounting flanges with
mounting holes in motor end head.
11. Apply Loctite® 271 to the two capscrews (3) and
install to secure the pump to the drive end head.
Tighten capscrews to 47 N•m (35 lbf in). See
Figure 9 and Figure 10.

5. Install the terminal end head over the encoder 12. Install the pump and motor assembly into the
bearing and onto the motor case. Use care when lift truck. See Hydraulic System 1900 SRM
routing the motor power leads through the end 1189 or Hydraulic System 1900 SRM 1307 for
head. installation instructions.

7
Troubleshooting
PROBLEM
Truck moves slow or in a
jerky motion.
Temperature sensor failure.
Stator shorting.
Stator open circuit.
8
Troubleshooting
POSSIBLE CAUSE
Encoder broken.
Encoder wire broken.
Temperature sensor wire damaged.
Temperature sensor malfunction.
Loss of insulation in wire.
Broken coil windings.
620 SRM 1186
PROCEDURE OR ACTION
Replace encoder bearing.
Check and repair encoder wire or re-
place encoder bearing.
Measure resistance with ohmmeter.
Resistance should be 530 ohms at
25 C (77 F). Inspect and repair tem-
perature sensor wire. The tempera-
ture sensor wire can be repaired, but
the temperature sensor must be re-
placed if faulty.
Measure resistance with ohmmeter.
If wiring is ok, resistance should be
530 ohms at 25 C (77 F). Replace the
temperature sensor.
Disconnect the battery and check re-
sistance between winding and case.
Resistance should be at 50,000 ohms
or above.
Raise drive wheel off the floor and
verify voltage at motor terminals.
Disconnect the battery and check
resistance of windings.
 TECHNICAL PUBLICATIONS

620 SRM 1186 8/09 (11/06)(10/06) Printed in U.S.A.