AC MOTOR REPAIR

P2.0 [A290];
W45ZHD [A419]

PART NO. 4035859 0620 SRM 1513

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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 ex-
ceed 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 flamma-
ble. 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.
 Table of Contents

TABLE OF CONTENTS

General .....................................................................................................................................................................1
Accessing the Drive Unit Compartment ............................................................................................................1
Accessing the Drive Unit Compartment ............................................................................................................2
Special Precautions ................................................................................................................................................. 3
Discharging the Capacitors ................................................................................................................................ 3
Description ...............................................................................................................................................................4
AC Motor Repair ......................................................................................................................................................4
Remove ................................................................................................................................................................ 4
Disassemble .........................................................................................................................................................4
Inspect ................................................................................................................................................................. 7
Assemble ..............................................................................................................................................................7
Install ...................................................................................................................................................................7
Troubleshooting .......................................................................................................................................................8

This section is for the following models:

P2.0 [A290];
(W45ZHD) [A419]

©2015 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
0620 SRM 1513 General

General
This section contains repair and maintenance ACCESSING THE DRIVE UNIT
procedures for the AC traction motor. Additional COMPARTMENT
information concerning the traction motor may be
included in other sections when the information is The drive unit compartment is concealed behind a
more closely related to other systems. Sections that molded cover which fits securely around the drive
may contain related information include: unit and steer support to the frame.
• Periodic Maintenance 8000SRM1510
for lift truck model A290 To remove the drive unit cover, first remove the
two nuts securing the cover to the frame. Starting
• Periodic Maintenance 8000SRM1666 at the top left edge of the cover and with both
for lift truck model A419 hands pull the cover away from the frame until the
• Steering Mechanism 1600SRM1504 cover kicks out from the retaining clips. Repeat this
• Electrical System 2200SRM1508 for the right side of the cover. Work around the
edge of the cover until free from the truck. See
Figure 1.

1. DRIVE UNIT COMPARTMENT COVER 3. RETAINING CLIPS

2. NUTS 4. FRAME

Figure 1. Drive Unit Compartment Cover A290

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General 0620 SRM 1513

To install the drive unit cover, place the bottom of Remove the drive unit cover, starting at the top left
the drive unit cover onto the frame and position the edge of the cover and with both hands pull the
lower edges partially into the lower retaining clips. cover away from the frame until the cover kicks out
Align the holes in the cover with the mounting from the retaining clips. Repeat this for the right
studs attached to the frame. Push the top of the side of the cover. Work around the edge of the cover
cover partially into the upper retaining clips. Do until free from the truck. See Figure 2.
not push either edge of the cover in completely in
before starting all edges into the proper place. To install the drive unit cover, place the bottom of
When the cover is aligned and started properly, the drive unit cover onto the frame and position the
press the cover completely into the retaining clips. lower edges partially into the lower retaining clips.
Install the two nuts securing the cover to the Align the holes in the cover with the alignment pin
frame. attached to the frame. Push the top of the cover
partially into the upper retaining clips. Do not push
ACCESSING THE DRIVE UNIT either edge of the cover in completely in before
COMPARTMENT starting all edges into the proper place. When the
cover is aligned and started properly, press the
The drive unit compartment is concealed behind a cover completely into the retaining clips.
molded cover which fits securely around the drive
unit and steer support to the frame.

1. DRIVE UNIT COMPARTMENT COVER 3. RETAINING CLIPS

2. ALIGNMENT PIN 4. FRAME

Figure 2. Drive Unit Compartment Cover A419

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0620 SRM 1513 Special Precautions

Special Precautions
DISCHARGING THE CAPACITORS

WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component. Wear safety glasses.
Make certain the battery has been disconnected.
DO NOT use a screwdriver to discharge the trac-
tion motor controller.

WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments, and
connecting or disconnecting a handset or PC.

CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never put
power to the controller with any power wire dis-
connected. Never short any controller terminal or
motor terminal to battery. Make sure to use proper
procedures when servicing the controller.

1. Turn the key switch to the OFF position and

disconnect the battery. 1. CONTROLLER
2. POSITIVE CONNECTION
2. Remove the drive unit compartment cover to 3. INSULATED JUMPER WIRES
access the controller. See GeneralGeneralGen- 4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION
eral.
Figure 3. Discharging the Capacitors
3. Discharge the capacitors in the controllers by
connecting a 200-ohm, 2-watt resistor across
the controller's B+ and B− terminals using in-
sulated jumper wires. See Figure 3. DO NOT
short across the motor controller terminals
with a screwdriver or jumper wire. Remove the
200-ohm, 2-watt resistor before reconnecting
the battery.

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Description 0620 SRM 1513

Description
The traction motor is a three-phase AC induction bearing wiring harness to the main wiring harness.
motor. DC battery current is converted into AC cur- A shaft extends out the top and bottom of the trac-
rent in the controller and then supplied to the trac- tion motor. The splined end of the shaft engages
tion motor. The controller controls motor speed and the input gear in the drive unit. A short, round sec-
direction. Each traction motor contains an encoder tion of the shaft protrudes from the top of the motor
bearing in the flange (brake end) that provides con- and is secured in place with a snap ring which se-
tinuous motor speed and direction information to cures it to the flange. This end also supports the
the controller. A temperature sensor built into the parking brake hub using a woodruff key and two
stator continually monitors motor temperature. additional small snap rings.
Brass terminals receive the power cables from the
controller and a small connector links the encoder

AC Motor Repair
REMOVE 5. Remove the four capscrews and lockwashers
holding traction motor to the drive unit.
WARNING 6. Attach a sling and a lifting device to the trac-
The AC traction motor is heavy. To prevent injury, tion motor. Lift the motor from the drive unit
use a lifting device of adequate capacity for lifting and position it securely at a suitable work sta-
the assembly. tion. Remove the sling from the motor.

It is not necessary to remove the traction motor DISASSEMBLE

from the lift truck to make some repairs. Perform
only the steps necessary to safely complete the re- Some disassembly may be performed with the trac-
quired service. tion motor installed in the lift truck. Perform only
the steps necessary to safely complete the required
1. Turn the key switch to the OFF position and service.
disconnect the battery connector. Discharge the
capacitors. See Special Precautions. 1. If the traction motor is not to be removed from
the lift truck, remove the steer support from
2. Remove the steer support from the lift truck. the lift truck. Refer to Steering Mechanism
Refer to Steering Mechanism 1600SRM1504. 1600SRM1504.

2. Remove the brake and hub assembly and both

CAUTION the upper and lower snap rings from the motor
Remove the brake only as directed. Changes to shaft if installed. Refer to Brakes
adjustment screws may render the brake unusa- 1800SRM1505.
ble. The brake is factory set and cannot be adjus-
ted if altered. 3. Remove the four long screws holding the trac-
tion motor together.
NOTE: The brake may be removed at this point.
However, it is not necessary to remove the brake if 4. Remove the snap ring from the shaft securing
the motor will not be disassembled. the flange (brake end) to the shaft. Slide the
flange (brake end) off the shaft and remove
3. Remove the brake from the top of the traction from the top of the motor.
motor if necessary. See Brakes 1800SRM1505.
5. Remove the armature from the stator if neces-
4. Identify, tag, and disconnect power cables and sary.
wiring connecting traction motor to the truck
electrical system. 6. Separate the stator from the bottom flange
(drive end) if necessary.

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0620 SRM 1513 AC Motor Repair

1. ENCODER CONNECTOR (FEMALE 4 PRONG) 10. TEMP SENSOR CONNECTOR (FEMALE 2

2. ARMATURE PRONG)
3. SNAP RING 11. MOUNTING PLATE ASSEMBLY
4. SNAP RINGS (BRAKE ASSEMBLY) 12. SCREW
5. LOCKWASHER 13. GROMMET
6. ASSEMBLY SCREW 14. FLANGE (BRAKE END)
7. STATOR 15. FLANGE HOUSING
8. NUTS 16. BEARING AND WIRING
9. LOCKWASHER

Figure 4. Traction Motor Repair

5
AC Motor Repair 0620 SRM 1513

Figure 5. Traction Motor Repair (A419)

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0620 SRM 1513 AC Motor Repair

Legend for Figure 5

1. BRAKE ASSEMBLY 5. SPEED SENSOR

2. MOTOR 6. O-RING
3. SNAP RING 7. WOODRUFF KEY
4. ASSEMBLY SCREW 8. NUT

INSPECT 5. Align the motor flanges and install the four as-
sembly screws.
Inspect the armature and the inside of the stator
for marks or grooves indicating contact between the 6. Install the brake to the top of the traction mo-
rotor and the motor case. Replace if damaged. Bear- tor. Refer to Brakes 1800SRM1505.
ings should fit snug where they seat on the shaft. If
7. Install the steering support to the lift truck, if
there is excessive wear, replace the bearing and/or
removed. Refer to Steering Mechanism
shaft. Check the bearings for smooth operation. If a
1600SRM1504.
bearing does not roll smoothly, it must be replaced.
Check that resistance between the windings and INSTALL
the case is above 50,000 ohms. Resistance of the
windings (line to line) should be less than 1 ohm. 1. Apply Molykote® G-N paste to the splines of the
traction motor lower shaft.
ASSEMBLE
2. Attach a sling and a lifting device to the trac-
Partial disassembly may be have been performed tion motor. Lift the motor from the work station
with the traction motor installed in the lift truck. and position it above the drive unit. Slowly
Assemble the motor directly into the lift truck if lower the motor while turning to align the
only partially disassembled. Perform only the steps spines of the motor shaft with the drive unit.
necessary to safely complete the required service. Remove the sling from the motor.

1. Install the long screws to the flange (drive end). 3. Turn the motor to align the motor mount brack-
If assembling directly into the lift truck, posi- ets with the mounting holes of the drive unit.
tion the stator to drive unit as removed. Install the four screws to secure the motor.

2. Align the stator to the lower flange as removed. 4. Install the brake to the top of the traction mo-
tor. Refer to Brakes 1800SRM1505.
3. Install the armature down through the top of
the stator and carefully guide it through the 5. Route and connect all wiring and connectors as
stator. If assembling directly into the drive removed.
unit, apply Molykote® G-N paste to the splines 6. Install the steering support and dash assembly
of the lower shaft and install into the drive to the lift truck. Refer to Steering Mechanism
unit. Slowly lower the armature through the 1600SRM1504.
stator while turning to align the spines of the
shaft with the drive unit. 7. Connect the battery connector, turn the key
switch to the ON position, and test the lift
4. Position the flange (brake end) onto the arma- truck for proper operation. Remove the lift
ture shaft and stator as removed. Be careful not truck from blocks and return to service.
to damage the encoder bearing wiring harness
during installation.

7
Troubleshooting 0620 SRM 1513

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Unusual noise from traction mo- Parking brake not releasing/ Troubleshoot the parking brakes.
tor. damaged.

Drive unit internal damage. Check that the drive unit rotates
smoothly.

Traction motor bearing damaged. Replace end head(s) and check

stator and rotor for damage. Re-
place damaged components or
traction motor if necessary.

Truck moves slow or in a jerky mo- Encoder broken. Replace encoder bearing.
tion.

Encoder wire broken. Check and repair encoder wire or

replace encoder bearing.

Temperature sensor failure. Temperature sensor wire dam- Measure resistance with ohmme-
aged. ter. Resistance should be 530
ohms at 25 °C (77 °F). Inspect
and repair temperature sensor
wire. The temperature sensor
wire can be repaired, but the
temperature sensor must be re-
placed if faulty.

Main wiring harness damaged. Test temperature sensor circuit

through main wiring harness
from connection at controller.

Temperature sensor malfunction. Measure resistance with ohmme-

ter. If wiring is ok, resistance
should be 530 ohms at 25 °C (77
°F). Replace the temperature
sensor.

Stator shorting. Loss of insulation in wire. Disconnect the battery and check
resistance between winding and
case. Resistance should be at
50,000 ohms or above.

Stator open circuit. Broken coil windings. Raise drive wheel off the floor
and verify voltage at motor ter-
minals. Disconnect the battery
and check resistance of windings.

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0620 SRM 1513 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Traction motor does not operate. Battery lacks sufficient charge. Charge/change battery.

Throttle position sensor or neu- Troubleshoot the throttle posi-

tral switch broken or out of ad- tion sensor or neutral switch.
justment.

Stator coil shorted to case. Check resistance between wind-

ing and case. Resistance should
be at 50,000 ohms or above. Re-
place stator or traction motor as-
sembly if necessary.

Stator wires broken-open circuit. Check resistance between motor

terminals. Resistance should
read less than 1 ohm between
each terminal. Replace stator or
traction motor assembly if neces-
sary.

Electric brake assembly not re- Troubleshoot the electric brake

leasing/damaged. assembly.

Drive unit internal damage. Raise the drive tire and check
that the drive unit rotates
smoothly.

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 NOTES

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 TECHNICAL PUBLICATIONS

0620 SRM 1513 3/15 (12/13)(6/11)