Yale A955 Erp16vf Erp18vf Erp20vf Europe Forklift Service Manual

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]; ESC030-040AC [B883]; ERP40-50VM (EPR080100VM) [A985]; ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) [A938]

PART NO. 524327049

620 YRM 1385

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 Yale® 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 instructions 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 YALE 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 background.

The CAUTION symbol and word are on yellow background.

AC Motor Repair

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................

Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883)......................................................

Discharging the Capacitors (All Other Models) ...............................................................................................

Traction Motor Repair ..........................................................................................................................................

For Lift Truck Models ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883) ............................................................................................................................

Remove.......................................................................................................................................................

Disassemble ...............................................................................................................................................

Electrical Connector Repair or Replacement..............................................................................................

Clean ..........................................................................................................................................................

Inspect ........................................................................................................................................................

Assemble ....................................................................................................................................................

Install ..........................................................................................................................................................

For Lift Truck ERC22-35VG (ERC045-070VG) (A968) and ERC16-20VA (ERC030-040VA) (A969)..............

Remove.......................................................................................................................................................

Disassemble ...............................................................................................................................................

Electrical Connector Repair or Replacement..............................................................................................

Clean ..........................................................................................................................................................

Inspect ........................................................................................................................................................

Assemble ....................................................................................................................................................

Install ..........................................................................................................................................................

For Lift Truck ERP2.2-3.5VL (ERP045-070VL) (A976) ...................................................................................

Remove.......................................................................................................................................................

Disassemble ...............................................................................................................................................

Clean ..........................................................................................................................................................

Inspect ........................................................................................................................................................

Assemble ....................................................................................................................................................

Install ..........................................................................................................................................................

For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)..........................................

Remove.......................................................................................................................................................

Disassemble ...............................................................................................................................................

Electrical Connector Repair or Replacement..............................................................................................

Clean ..........................................................................................................................................................

Inspect ........................................................................................................................................................

Assemble ....................................................................................................................................................

Install ..........................................................................................................................................................

For Lift Truck ERP40-50VM (ERP080-100VM)(A985) ....................................................................................

Remove.......................................................................................................................................................

Clean ..........................................................................................................................................................

Install ..........................................................................................................................................................

Hydraulic Motor Repair........................................................................................................................................

For Lift Trucks ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), and ESC030-040AC (B883) ...................................................................................................................................

Remove.......................................................................................................................................................

Disassemble ...............................................................................................................................................

Electrical Connector Repair or Replacement..............................................................................................

Clean ..........................................................................................................................................................

Inspect ........................................................................................................................................................

Assemble ....................................................................................................................................................

Install ..........................................................................................................................................................

For Lift Truck ERC22-35VG (ERC045-070VG) (A968)....................................................................................

©2012 Yale Materials Handling Corp.

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Table of Contents

AC Motor Repair

TABLE OF CONTENTS (Continued) Remove.......................................................................................................................................................

Disassemble ...............................................................................................................................................

Standard Motor.......................................................................................................................................

Enhanced Motor .....................................................................................................................................

Electrical Connector Repair or Replacement..............................................................................................

Clean ..........................................................................................................................................................

Inspect ........................................................................................................................................................

Assemble ....................................................................................................................................................

Standard Motor.......................................................................................................................................

Enhanced Motor .....................................................................................................................................

Install ..........................................................................................................................................................

For Lift Truck Models ERP2.2-3.5VL (ERP045-070VL) (A976) and ERC16-20VA (ERC030-040VA) (A969) .............................................................................................................................................................

Remove.......................................................................................................................................................

Disassemble ...............................................................................................................................................

Electrical Connector Repair or Replacement..............................................................................................

Clean ..........................................................................................................................................................

Inspect ........................................................................................................................................................

Assemble ....................................................................................................................................................

Install ..........................................................................................................................................................

For Lift Truck Models ERP40-50VM (ERP080-100VM) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) ...........................................................................................................

Remove.......................................................................................................................................................

Disassemble ...............................................................................................................................................

Electrical Connector Repair or Replacement..............................................................................................

Clean ..........................................................................................................................................................

Inspect ........................................................................................................................................................

Assemble ....................................................................................................................................................

Install ..........................................................................................................................................................

Torque Specifications ..........................................................................................................................................

Traction Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) .............................................................................................................................................................

Traction Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968), ERC16-20VA (ERC030-040VA) (A969), and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)............................................

Traction Motor for Lift Truck ESC030-040AC (B883).......................................................................................

Hydraulic Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955).....................................................................................................................................

Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968)...........................................................

Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976) ...........................................................

Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969)............................................................

Hydraulic Motor for Lift Truck ESC030-040AC (B883) ....................................................................................

Hydraulic Motor for Lift Truck ERP40-50VM (ERP080-100VM) (A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938) ...........................................................................................................

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AC Motor Repair

Table of Contents

TABLE OF CONTENTS (Continued) This section is for the following models: 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]; ESC030-040AC [B883]; ERP40-50VM (EPR080-100VM) [A985]; ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) [A938]

iii

620 YRM 1385

General

General This section contains repair and maintenance procedures for the AC motors. Additional information concerning 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 YRM 1337 for lift truck models • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) Electrical System 2200 YRM 1369 for lift truck models • ERC22-35VG (ERC045-070VG) (A968) • ERP22-35VL (ERP045-070VL) (A976) • ERC16-20VA (ERC030-040VA) (A969) • EPR40-50VM (EPR080-100VM) (A985) • ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)

WARNING 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.

Electrical System 2200 YRM 1414 for lift truck models • ESC030-040AC (B883)

Throughout this section, forward will refer to travel in the direction of the forks and left and right will be determined by sitting in the seat facing forward. See Figure 1 or Figure 2. Troubleshooting information about the traction 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:

Periodic Maintenance 8000 YRM 1373 for lift truck models • ERP16-20VF (ERP30-40VF) (A955)

User Interface, Service-Level Functions On-Board Dash Display 2200 YRM 1417 for lift truck models • ESC030-040AC (B883)

Periodic Maintenance 8000 YRM 1339 for lift truck models • ERP15-20VT (ERP030-040VT) (G807)

User Interface, Service Technician 2200 YRM 1336 • ERP16-20VF (ERP30-40VF) (A955) • ERP15-20VT (ERP030-040VT) (G807) • ERC22-35VG (ERC045-070VG) (A968) • ERP22-35VL (ERP045-070VL) (A976) • ERC16-20VA (ERC030-040VA) (A969) • ERP40-50VM (ERP080-100VM) (A985) • ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)

Periodic Maintenance 8000 YRM 1364 for lift truck models • ERC22-35VG (ERC045-070VG) (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 (B883) Periodic Maintenance 8000 YRM 1442 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) Periodic Maintenance 8000 YRM 1541 • ERP40-50VM (ERP080-100VM) (A985) Periodic Maintenance 8000 YRM 1577 for lift truck model • ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)

A. LEFT SIDE B. RIGHT SIDE

C. FORWARD TRAVEL

Figure 1. Truck Orientation (Three-Wheel Models)

1

General

A. LEFT SIDE B. RIGHT SIDE

620 YRM 1385

C. FORWARD TRAVEL

Figure 2. Truck Orientation (Four-Wheel Models) The traction motors are mounted onto the transaxles for the following lift truck models: See Figure 3 for lift truck models • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955)

Figure 3. Traction Motors for Lift Truck ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955) Legend for Figure 3 1. LEFT TRANSAXLE 2. TRACTION MOTOR

3. RIGHT TRANSAXLE

See Figure 5 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 6 for lift truck models • ERP40-50VM (ERP080-100VM) (A985) See Figure 9 for lift truck model • ERC40-55VH, ERC50VHS ERC100VHS) (A938)

(ERC80-120VH,

For the lift truck models below, the hydraulic pump motor is mounted inside the counterweight.

• • • •

ERP15-20VT (ERP030-040VT) (G807) ERP16-20VF (ERP30-40VF) (A955) ERP22-35VL (ERP045-070VL) (A976) ERP40-50VM (ERP080-100VM) (A985)

See Figure 4 for lift truck models • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) See Figure 5 for lift truck models • ERP22-35VL (ERP045-070VL) (A976) See Figure 6 for lift truck models • ERP40-50VM (ERP080-100VM) (A985)

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1. HYDRAULIC PUMP MOTOR 2. COUNTERWEIGHT

Figure 4. Hydraulic Motor for Lift Trucks ERP15-20VT (ERP030-040VT) (G807) and ERP16-20VF (ERP30-40VF) (A955)

620 YRM 1385

1. LEFT TRACTION MOTOR 2. RIGHT TRACTION MOTOR 3. RIGHT TRANSMISSION

General

4. LEFT TRANSMISSION 5. HYDRAULIC PUMP AND MOTOR

Figure 5. Traction Motor and Hydraulic Pump Motor for Lift Truck Models ERP22-35VL (ERP045-070VL) (A976)

3

General

1. LEFT TRANSMISSION 2. RIGHT TRANSMISSION 3. TRACTION MOTOR

620 YRM 1385

4. HYDRAULIC MOTOR 5. HYDRAULIC PUMP

Figure 6. Traction and Hydraulic Pump Motor Locations, for Lift Truck Models ERP40-50VM (ERP080-100VM) (A985) For lift truck models below, the traction motor is mounted under the frame to the drive axle.

• ERC22-35VG (ERC045-070VG) (A968) • ERC16-20VA (ERC030-040VA) (A969) See Figure 7 for lift truck models • ERC22-35VG (ERC045-070VG) (A968) See Figure 8 for lift truck models • ERC16-20VA (ERC030-040VA) (A969) For lift truck models ERC22-35VG (ERC045-070VG) (A968) the hydraulic pump motor is mounted onto the frame beside the traction motor. See Figure 7.

4

For lift truck models ERC16-20VA (ERC030-040VA) (A969) and ERC40-55VH, ERC50VHS (ERC80120VH, ERC100VHS) (A938) the hydraulic pump motor is mounted onto the frame, opposite the traction motor.

See Figure 8 for lift truck model • ERC16-20VA (ERC030-040VA) (A969) See Figure 9 for lift truck model • ERC40-55VH, ERC50VHS ERC100VHS) (A938)

(ERC80-120VH,

620 YRM 1385

General

1. HYDRAULIC PUMP MOTOR 2. TRACTION MOTOR 3. FRAME

Figure 7. Traction Motor and Hydraulic Pump Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968)

1. FRAME 2. TRACTION MOTOR 3. HYDRAULIC PUMP MOTOR

Figure 8. Traction Motor and Hydraulic Pump Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969) For lift truck models below, the traction motors are mounted onto the transaxles and the hydraulic pump motor is mounted vertically to the front wall behind the front cover. • ESC030-040AC (B883)

5

General

620 YRM 1385 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 electrical 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 disconnected. 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.

2.

3.

4.

TRACTION MOTOR AUTOMATIC PARK BRAKE ACTUATOR DRIVE AXLE HYDRAULIC MOTOR

Figure 9. Traction Motor and Hydraulic Pump Motor for Lift Truck Model ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)

DISCHARGING THE CAPACITORS FOR LIFT TRUCK MODELS ESC030-040AC (B883) WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so.

Improper repairs and adjustments 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 on the steering wheel and disconnect the battery.

Disconnect the battery and allow the capacitors to discharge before opening any compartment covers or inspecting or repairing the electrical system.

6

1. To avoid injury and prevent electrical shock, perform the following steps (Step 2 through Step 7 below) to discharge the capacitors before troubleshooting, making adjustments or repairs, or connecting or disconnecting a PC service tool.

2. Turn the key or keyless switch to the OFF position and DISCONNECT THE BATTERY by pushing forward on the battery disconnect lever.

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 access the lift controller.

NOTE: The lift and traction controllers are wired parallel. 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 connecting a 200-ohm, 2-watt resistor across the lift controller’s negative (B ) and positive (B+) terminals. Wait at least 20 seconds to be sure that the capacitors are fully discharged. See Figure 10.

620 YRM 1385

1.

2.

3.

4.

B TERMINAL B+ TERMINAL JUMPER LEADS 200-OHM, 2-WATT RESISTOR

Figure 10. Lift Controller 6. If necessary to discharge the traction controllers separately from the lift controller, connect a 200ohm, 2-watt resistor across the controller’s negative (B ) and positive (B+) terminals. Wait at least 20 seconds to be sure that the capacitors are fully discharged. Repeat for the other traction controller as necessary. See Figure 11.

General

1.

2.

3.

4.

B+ TERMINAL B TERMINAL JUMPER LEADS 200-OHM, 2-WATT RESISTOR

Figure 11. Traction Controller 7. Remove the resistor from the controller(s) and reinstall the covers before returning the lift truck to service.

7

Traction Motor Repair

620 YRM 1385

DISCHARGING THE CAPACITORS (ALL OTHER MODELS) WARNING DO NOT make repairs or adjustments unless you have been properly trained and authorized to do so.

Improper repairs and adjustments 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 on the steering wheel and disconnect the battery.

Disconnect the battery and discharge the capacitors before opening any compartment covers 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 electrical 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 after the battery is disconnected. 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.

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 separating the battery connectors.

1. Ensure the capacitors are discharged by performing Step 2 through Step 6 below.

2. Turn key or keyless switch to OFF position.

3. Disconnect the battery by separating the connectors.

4. Block drive wheels to prevent lift 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. Press horn button. Wait 30 seconds to be sure capacitors are fully discharged.

Traction Motor Repair FOR LIFT TRUCK MODELS ERP15-20VT (ERP030-040VT) (G807), ERP16-20VF (ERP30-40VF) (A955), AND ESC030-040AC (B883) 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 (B883). lift truck models.

1. Disconnect manual release cable from parking brake.

2. Disconnect parking brake wire harness from main wire harness. See Figure 12.

8

3. Put lift truck on blocks so that the drive 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 (ERP030-040VT) (G807) Periodic Maintenance 8000 YRM 1373 for lift truck models • ERP16-20VF (ERP30-40VF) (A955) Periodic Maintenance 8000 YRM 1418 for lift truck models • ESC030-040AC (B883) 4. Turn the key or keyless switch to OFF position and disconnect the battery.

620 YRM 1385

Traction Motor Repair

5. Remove transaxle/traction motor/parking brake assembly from lift truck. See one of the following sections for removal instructions Transaxle 1300 YRM 1330 for lift truck models • ERP15-20VT (ERP030-040VT) (G807) • ERP16-20VF (ERP30-40VF) (A955) Transaxle 1300 YRM 1411 for lift truck models • ESC030-040AC (B883) 6. Move transaxle/traction motor/parking brake assembly 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, lockwashers, washers and parking brake from traction motor shaft. See Figure 12.

WARNING The traction motor weighs approximately 18.4 kg (40.6 lb). 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 12.

Disassemble 1. Remove four socket-head capscrews and lockwashers from brake end head and transaxle end head. See Figure 13.

8. Remove snap ring and splined hub from traction motor shaft; recover woodruff key. See Figure 12.

1.

2.

3.

4.

5.

6.

TRANSAXLE PARKING BRAKE WIRE HARNESS SOCKET HEAD CAPSCREW LOCKWASHER WASHER PARKING BRAKE

7.

8.

9.

10.

11.

TRACTION MOTOR SPLINED HUB SNAP RING WOODRUFF KEY TRACTION MOTOR MOUNTING CAPSCREW

Figure 12. Transaxle Assembly

9

Traction Motor Repair

620 YRM 1385

Figure 13. Traction Motor

10

620 YRM 1385

Traction Motor Repair

Legend for Figure 13 1. TRANSAXLE END HEAD 2. ROTOR 3. SOCKET-HEAD CAPSCREW AND LOCKWASHER 4. STATOR, TERMINALS, AND HARDWARE 5. CONNECTION PLATE, SCREW, AND GROMMET

6. BRAKE END HEAD 7. TEMP SENSOR CONNECTOR AND WIRING HARNESS 8. SNAP RING 9. BEARING

NOTE: Carefully tap underside of brake end head with a soft hammer to loosen brake end head from stator.

Clean

2. Remove brake end head from stator and slide brake end head off rotor shaft. See Figure 13.

WARNING

3. Remove rotor from stator. See Figure 13. Place stator brake end down on workbench.

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.

NOTE: Carefully tap underside of transaxle end head with a soft hammer to loosen transaxle end head from stator.

1. Clean components with a clean cloth moistened with solvent and allow to thoroughly dry. DO NOT apply liquid solvent directly to stator windings.

4. Remove transaxle end head from stator. See Figure 13.

Inspect

5. Remove snap ring from brake end head. See Figure 13.

1. Inspect rotor and inside of stator for marks or grooves indicating contact between rotor and stator. Replace if damaged.

6. Using bearing puller, carefully remove bearing from brake end head. See Figure 13.

NOTE: Perform Step 7 and Step 8 if connection plate is damaged and must be replaced.

7. Remove temp sensor wire harness from grommet.

See Figure 13.

8. Remove screws, nuts, washers, grommet, and connection plate from stator. See Figure 13.

Electrical Connector Repair or Replacement 1. If necessary, electric brake connector (see Figure 12) 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 Figure 13) may be repaired or replaced. See AMP Superseal Connector Assemblies section of Wire Harness Repair 2200 YRM 1128 manual for instructions.

2. Check that the bearings roll smoothly and are not loose from excessive wear. Replace as necessary.

Replace the bearings regardless of condition if motor 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 burnt insulation. Thermal overload will shorten the life of the stator.

4. Check stator windings resistance as indicated below. To measure continuity between U, V, and W terminals of motor use a digital multi-meter (DMM) 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 cables 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.

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Traction Motor Repair

620 YRM 1385

c. 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 cables 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 cables 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.

1. TRANSAXLE END HEAD 2. STATOR

3. ROTOR 4. DRIVE SPLINES

Figure 14. Transaxle End Head, Stator and Rotor 2. Install rotor into stator with drive splines protruding through transaxle end head. See Figure 14.

NOTE: Perform Step 3 through Step 5 if connection plate and hardware was removed.

Assemble 1. Install transaxle end head onto stator. See Figure 14.

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3. If removed, install connection plate, grommet, washers, and nuts onto stator. See Figure 15.

620 YRM 1385

Traction Motor Repair

Figure 15. Traction Motor

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Traction Motor Repair

620 YRM 1385

Legend for Figure 15 1. TRANSAXLE END HEAD 2. ROTOR 3. SOCKET-HEAD CAPSCREW AND LOCKWASHER 4. STATOR, TERMINALS, AND HARDWARE 5. CONNECTION PLATE, SCREW, AND GROMMET

6. BRAKE END HEAD 7. TEMP SENSOR CONNECTOR AND WIRING HARNESS 8. SNAP RING 9. BEARING

NOTE: Terminal studs are located on top of connection plate.

7. Install snap ring into brake end head. See Figure 15.

4. Hold lower nut of terminal stud to prevent it from turning and tighten upper nut to 12 N•m (106 lbf in).

See Figure 16.

8. Install brake end head onto rotor shaft and stator.

See Figure 15.

5. Insert temp sensor wire harness into grommet. See Figure 15.

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 15.

9. Install four lockwashers and socket-head capscrews onto transaxle end head and brake end head. See Figure 15. Tighten capscrews to 14 to 16 N•m (124 to 142 lbf in).

Install WARNING The traction motor weighs approximately 18.4 kg (40.6 lb). 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 installing motor to transaxle not to damage transaxle shaft seal.

1. Apply Dexron III 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 17. Tighten capscrews to 48 N•m (35 lbf ft).

1. TERMINAL STUD 2. LOWER NUT

3. UPPER NUT

Figure 16. Terminal Studs and Nuts

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