Section 7.Component Procedures

Model 6210 Maintenance Manual

Traction MotorElectrical Components

Traction Motor Disassembly

1.If equipped with the optional keypad, press the red OFF ( O ) key. Place the Main ON/OFF Switch in the OFF position. Disconnect the battery connector from the truck.

2.Remove the lower and grille covers.

3.Disconnect the power cables from the terminal block on the traction motor, noting their correct position.

4.Follow steps 1 through 6 in “Drive Unit Disassembly” on page7-25 to remove the top (pinion) gear attached to the motor armature shaft.

5.Remove the electromagnetic brake assembly by removing the three mounting bolts that secure the assembly to the motor end bell cover [2].

6.Remove the brake disc from the brake hub.

7.Remove the retaining ring [3] that secures the brake hub. Remove the hub and woodruff key [6].

8.Remove the four screws [1] holding the motor end bell cover [2] to the housing (stator) [11].

9.Separate the motor end bell cover [2] from the motor housing.

10.If needed, press off the bearing [5] and replace.

Traction Motor Assembly

1.Thoroughly clean all parts with solvent or other non-corrosive cleaning fluid. Air dry all parts.

NOTE: Assemble the traction motor in a dirt-free area.

2.If previously removed, install the traction motor bearing, bearing shim, and seal in the gear case.

NOTE: The seal must be replaced any time the motor is removed from the housing. The seal must be installed correctly with its open side and seal ring positioned towards the bearing.

3.Reinstall the motor end bell cover [2] on the motor armature shaft.

4.Install the brake hub, woodruff key [6], and the retaining ring [3] on the armature shaft.

5.Carefully slide the traction motor armature in the motor housing.

6.Attach the motor end bell cover [2] to the motor housing (stator) with the four cap screws [1]. Torque screws to 47.8 in. lb. (5.4Nm).

7.Follow steps 8 through 12 in “Drive Unit Assembly” on page7-25 .

8.Make sure the drive unit is filled to the correct level with gear oil. Install the fill/level plug. See “Drive Unit Housing Lubrication” on page7-27.

9.Install the brake friction disc.

10.Install the brake coil assembly and attach with three hex head cap screws. Torque screws to 47.8 in. lb. (5.4 Nm).

11.Before testing operation, move the handle from extreme left to right and down into the operating position and back several times. Check for any wire and cable interference. Repair or adjust as necessary.

NOTE: Check the traction motor cable routing. Make sure the wires are not near the drive tire. Secure wires with cable ties to prevent damage.