AC TRACTION MOTOR

REPAIR
J1.6-2.0XMT (J30-40ZT) [J160]

PART NO. 1566043 620 SRM 1115

 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 Mainte-
nance 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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
AC Traction Motor Repair Table of Contents

TABLE OF CONTENTS

Introduction........................................................................................................................................................ 1
General ........................................................................................................................................................... 1
Discharging the Capacitors........................................................................................................................... 1
Description ......................................................................................................................................................... 3
Traction Motor ............................................................................................................................................... 3
AC Motor Repair ................................................................................................................................................ 4
Remove ........................................................................................................................................................... 4
Disassemble ................................................................................................................................................... 4
Inspect ............................................................................................................................................................ 4
Assemble ........................................................................................................................................................ 6
Install ............................................................................................................................................................. 6
Troubleshooting.................................................................................................................................................. 7

This section is for the following models:

J1.6-2.0XMT (J30-40ZT) [J160]

©2006 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
620 SRM 1115 Introduction

Introduction
GENERAL to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag to
This section contains repair and maintenance proce- the steering wheel and remove the key.
dures for the AC traction motor. Additional infor-
mation concerning the traction motor may be more
closely related to other systems and included in those WARNING
sections. Sections that contain information regard- Disconnect the battery before opening the elec-
ing the traction motors include: trical compartment cover or inspecting or re-
AC Motor Controllers/Display Panel, De- pairing the electrical system. If a tool causes
scription, Checks, Adjustments, and Trou- a short circuit, the high current flow from the
bleshooting 2200 SRM 1087 battery can cause personal injury or property
Electrical System 2200 SRM 1078 damage.
Periodic Maintenance 8000 SRM 1079
WARNING
WARNING Some checks and adjustments are performed
Do not make repairs or adjustments unless you with the battery connected. Do not connect the
are properly trained and have authorization to battery until the procedure tells you to do so.
do so. Repairs and adjustments that are not Never have any metal on your fingers, arms,
correct can create dangerous operating condi- or neck. Metal items can accidentally make an
tions. Do not operate a lift truck that needs re- electrical connection and cause injury.
pairs. Report the need for repairs to your su-
pervisor immediately. If repair is necessary, at-
WARNING
tach a DO NOT OPERATE tag to the steering
wheel and remove the key. Block the lift truck drive tires to prevent unex-
pected movement before performing any tests
Throughout this section, forward will refer to travel or adjustments.
in the direction of the forks and left and right will
be determined by sitting in the seat facing forward.
See Figure 1. Troubleshooting information about the
traction motors is available through on-board diag-
nostics and may be displayed on the dash display. Re-
fer to the section AC Motor Controllers/Display
Panel, Description, Checks, Adjustments, and
Troubleshooting 2200 SRM 1087 for further expla-
nation of dash display codes concerning the traction
motors.

DISCHARGING THE CAPACITORS

WARNING
Do not make repairs or adjustments unless you
are properly trained and have authorization A. LEFT SIDE
to do so. Repairs and adjustments that are B. RIGHT SIDE
not correct can create dangerous operating C. FORWARD TRAVEL
conditions. Do not operate a lift truck that
Figure 1. Truck Orientation
needs repairs. Report the need for repairs

1
Introduction 620 SRM 1115

WARNING
The capacitor in the transistor controller can
hold an electrical charge after the battery is
disconnected. To prevent an electrical shock
and personal injury, discharge the capacitor
before inspecting or repairing any component
in the electrical compartment. Wear safety
glasses. Make certain that the battery has
been disconnected.

CAUTION
To avoid controller damage, always discon-
nect the battery and discharge the capacitor.
NEVER put power to the controller while any
power wires are disconnected. NEVER short
any controller terminal or motor terminal to
the battery. Make sure to use proper proce-
dure when servicing the controller. 1. POSITIVE CONNECTION (BT+)
2. NEGATIVE CONNECTION (B )
1. Block load wheels to prevent lift truck from mov- 3. INSULATED JUMPER WIRES
ing. 4. 200-OHM, 2-WATT RESISTOR

2. Turn key switch to OFF position and disconnect Figure 2. Discharging the Capacitors
the battery. (Standard)

3. Open the electrical compartment:

a. Remove two screws securing the electrical

compartment door.

b. Pull the compartment door open on its

hinges.

WARNING
DO NOT short across the motor controller ter-
minals with a screwdriver or jumper wire.

4. Discharge the capacitor in the controller by con-

necting a 200-ohm, 2-watt resistor across the
controller’s BT+ and B terminals for 10 seconds
using insulated jumper wires. See Figure 2.

NOTE: Some lift trucks are equipped with a premium

controller, which controls the hydraulic motor as well
as the traction motors. 1. POSITIVE CONNECTION (BT+)
2. NEGATIVE CONNECTION (B )
5. On the premium controller, also connect the 200- 3. INSULATED JUMPER WIRES
ohm, 2-watt resistor across the controller’s P+ 4. 200-OHM, 2-WATT RESISTOR
and B terminals for 10 seconds using insulated 5. POSITIVE CONNECTION (P+)
jumper wires. See Figure 3.
Figure 3. Discharging the Capacitors
6. Remove the 200-ohm, 2-watt resistor before re- (Premium)
connecting the battery.

2
620 SRM 1115 Description

Description
TRACTION MOTOR
Traction motors are mounted to the inside of each
transmission under the front end of the frame. See
Figure 4. The traction motors are three-phase AC
induction motors. DC battery current is converted
into AC current in the controller and then supplied
to the traction motors. The controller controls mo-
tor speed and direction. Each traction motor con-
tains a speed encoder device in the end head (brake)
that provides continuous motor speed and direction
information to the controller. A temperature sensor
built into the stator continually monitors motor tem-
perature. Brass terminals receive the power cables
from the controller and a small connector links the
end head (brake) wiring harness to the main wiring
harness. The rotor shaft extends out each side of the
traction motor. The splined end of the shaft engages
the input gear in the transaxle. A short, round sec-
tion of the shaft protrudes from the other side of the 1. LEFT TRANSMISSION
2. TRACTION MOTORS
motor. This end supports the parking brake hub us- 3. RIGHT TRANSMISSION
ing a woodruff key and a snap ring. See Figure 5.
Figure 4. Transmission Mounting

Figure 5. Traction Motor

3
AC Motor Repair
AC Motor Repair
REMOVE
1. Turn the key switch to the OFF position and dis-
connect the battery. Block the steer tires to pre-
vent unexpected movement.
2. Position the front of the lift truck on truck stands
or solid hardwood blocks so the front of the lift
truck is suspended off the floor approximately
300 mm (12 in.). See the section Periodic
Maintenance 8000 SRM 1079 for instructions
on putting the lift truck on blocks.
3. Remove both park brake assemblies to provide
room for traction motor removal:
a. Remove four screws, lockwashers, and wash-
ers securing the brake assembly to the trac-
tion motor. Refer to the section Brake Sys-
tem 1800 SRM 1076.
b. Slide the brake from the splined hub.
c. Remove the snap ring and slide splined hub
from the traction motor shaft and recover the
key.
d. Repeat for opposite side.
4. Remove the four capscrews and washers mount-
ing the traction motor to the transaxle.
5. Remove the traction motor from the transaxle.
Legend for Figure 6
1. END HEAD (TRANSAXLE)
2. ROTOR
3. SOCKET-HEAD CAPSCREW AND
LOCKWASHER
4
620 SRM 1115
DISASSEMBLE
1. Remove the socket-head capscrews and lock-
washers securing motor assembly together. See
Figure 6.
NOTE: Carefully tap the underside of the end head
with a soft hammer to loosen the end head from the
stator.
2. Remove the end head (brake) from the stator and
slide the end head off the rotor shaft.
3. Remove the rotor from the stator. Place the sta-
tor brake end down on the workbench.
NOTE: Carefully tap the underside of the end head
with a soft hammer to loosen the end head from the
stator.
4. Remove the end head (transaxle) from the stator.
5. If necessary, remove the nuts and washers secur-
ing the connection plate to the stator, and remove
the connection plate.
INSPECT
Inspect the rotor and the inside of the stator for
marks or grooves indicating contact between the
rotor and the stator. Replace if damaged. Check
that the bearing rolls smoothly and is not loose from
excessive wear. Replace end head (brake) assembly
if bearing is worn/damaged. If there is damage from
contact between the rotor and the stator or to other
components, replace damaged components or the
complete traction motor assembly if necessary.
4. STATOR, TERMINALS, AND HARDWARE
5. CONNECTION PLATE, SCREW, AND GROMMET
6. END HEAD (BRAKE)
7. CONNECTOR AND SCREW
620 SRM 1115 AC Motor Repair

Figure 6. AC Traction Motor

5
AC Motor Repair
ASSEMBLE
1. Install end head (transaxle) into stator as re-
moved.
2. Install rotor into stator with drive splines pro-
truding through the end head (transaxle).
3. Install connector to end head (brake) wiring har-
ness if replacing, and secure connector to end
head (brake) as removed.
4. Install connection plate to stator, if removed.
5. Install end head (brake) onto rotor shaft and into
stator as removed.
6. Install end head wiring harness into grommet
and install grommet into connector plate.
NOTE: Only torque values for nonstandard applica-
tions are specifically stated. Refer to the section Met-
ric and Inch (SAE) Fasteners 8000 SRM 231 for
standard torque specifications.
7. Install socket-head capscrews and lockwash-
ers through the end head (transaxle) and into
the end head (brake) securing motor assembly.
Torque to 14 - 16 N•m (10 - 12 lbf ft).
INSTALL
NOTE: Close clearances require the parking brake to
be installed after the traction motor is installed to
the transaxle.
1. Apply multipurpose lithium based grease with
2 - 4% molybdenum to the spines of the trac-
tion motor. Position the traction motor onto the
transaxle as removed.
6
620 SRM 1115
2. Install the four capscrews and washers mount-
ing the traction motor to the transaxle. Apply
Loctite™ 271 and torque to 48 N•m (35 lbf ft).
3. Install both park brake assemblies to the traction
motors as removed:
a. Install the splined hub and key (with coun-
terbore facing top of brake/truck center) onto
the traction motor shaft. Install the snap
ring securing the hub.
b. Install the parking brake assembly on to the
splined hub with the wiring harness toward
the operator compartment.
c. Align the brake mounting holes and install
the four capscrews, lockwashers, and wash-
ers securing the brake assembly to the drive
motor as removed. Refer to Brake System
1800 SRM 1076.
4. Connect all wiring and cables as removed. Hold
the lower nut of the terminal stud to prevent
it from turning and tighten the upper nut to
10 N•m (89 lbf in).
5. Lower the lift truck from the blocks. Refer to
Periodic Maintenance 8000 SRM 1079.
6. Turn the key switch to the ON position and con-
nect the battery. Remove the blocks from the
wheels. Test for proper operation.
620 SRM 1115 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Truck moves slow or acceler- End head (brake) wire harness dam- Check and repair end head (brake)
ates erratically. aged. wire harness or replace end head
(brake) assembly if necessary.

Main wiring harness damaged. Test traction motor circuit through

main wiring harness from connection
at controller.

Encoder bearing damaged. Replace end head (brake) - includes

encoder bearing and temperature
sensor.

Throttle position sensor broken or Troubleshoot the accelerator assem-

out of adjustment. bly.

Parking brake not releasing. Troubleshoot the parking brakes.

Temperature sensor mal- Stator wire harness damaged. Check and repair stator wire harness
function. or replace stator if necessary.

Main wiring harness damaged. Test temperature sensor circuit

through main wiring harness from
connection at controller.

Temperature sensor open or shorted. Measure resistance with ohmmeter.

Resistance should between 514 and
700 ohms. Replace stator if neces-
sary.

Traction motor does not oper- Battery lacks sufficient charge. Charge/change battery.
ate.

Throttle position sensor or neutral Troubleshoot the accelerator assem-

switch broken or out of adjustment. bly.

Electrical system malfunction. Troubleshoot the electrical system.

Operator presence switch malfunc- Check wiring/connectors. Replace

tion. switch if necessary.

Stator coil shorted to case. Check resistance between winding

and case. Resistance should be at
50,000 ohms or above. Replace sta-
tor or traction motor assembly if
necessary.

7
Troubleshooting
PROBLEM POSSIBLE CAUSE
Traction motor does not oper- Stator wires broken-open circuit.
ate. (Cont)
Parking brake not releasing/dam-
aged.
Transaxle internal damage.
Unusual noise from traction Traction motor bearing damaged.
motor.
Parking brake not releasing/dam-
aged.
Transaxle internal damage.
8
620 SRM 1115
PROCEDURE OR ACTION
Check resistance between motor
terminals U, V, and W. Resistance
should read less than 1 ohm between
each terminal. Replace stator or
traction motor assembly if necessary.
Troubleshoot the parking brakes.
Check that the transaxle rotates
smoothly.
Replace end head(s) and check stator
and rotor for damage. Replace dam-
aged components or traction motor if
necessary.
Troubleshoot the parking brakes.
Check that the transaxle rotates
smoothly.
 TECHNICAL PUBLICATIONS

620 SRM 1115 6/06 (5/06)(3/06)(8/05)(6/04) Printed in U.S.A.