AC Motor Repair Hyster US-EN

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];
ESC030-040AD [C883];
ERP40-50VM, ERP50-55VM6 (ERP080-120VM,
ERP100VML) [A985];
ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) [A938]
PART NO. 524327049 0620 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 con-
tained 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 re-
move 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 man-
ual:
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
Discharging the Capacitors for Lift Truck Models ESC030-040AC (B883), ESC030-040AD (C883)....................8
Discharging the Capacitors (All Other Models) .................................................................................................... 9
Traction Motor Repair ............................................................................................................................................. 10
For Lift Truck Models , and ERP15-20VT (ERP030-040VT) (G807)...................................................................10
Remove ..........................................................................................................................................................10
Disassemble ...................................................................................................................................................11
Electrical Connector Repair or Replacement ................................................................................................. 14
Clean ..............................................................................................................................................................14
Inspect ............................................................................................................................................................14
Assemble ....................................................................................................................................................... 15
Install ..............................................................................................................................................................18
For Lift Truck ERC22-35VG (ERC045-070VG) (A968)....................................................................................... 20
Remove ..........................................................................................................................................................20
Disassemble ...................................................................................................................................................20
Clean ..............................................................................................................................................................24
Inspect ............................................................................................................................................................24
Assemble ....................................................................................................................................................... 25
Install ..............................................................................................................................................................25
For Lift Truck ERP2.2-3.5VL (ERP045-070VL) (A976)....................................................................................... 25
Remove ..........................................................................................................................................................25
Disassemble ...................................................................................................................................................25
Clean ..............................................................................................................................................................27
Inspect ............................................................................................................................................................27
Assemble ....................................................................................................................................................... 28
Install ..............................................................................................................................................................28
For Lift Truck ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)..............................................28
Remove ..........................................................................................................................................................28
Disassemble ...................................................................................................................................................29
Clean ..............................................................................................................................................................30
Inspect ............................................................................................................................................................31
Assemble ....................................................................................................................................................... 31
Install ..............................................................................................................................................................32
Traction Motor Repair For Lift Truck ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)...32
Remove ..........................................................................................................................................................32
Clean ..............................................................................................................................................................34
Install ..............................................................................................................................................................34
Hydraulic Motor Repair ........................................................................................................................................... 34
For Lift Trucks , , and ERP15-20VT (ERP030-040VT) (G807)............................................................................34
Remove ..........................................................................................................................................................34
Disassemble ...................................................................................................................................................36
Clean ..............................................................................................................................................................38
Inspect ............................................................................................................................................................38
Assemble ....................................................................................................................................................... 39
Install ..............................................................................................................................................................41
For Lift Truck ERC22-35VG (ERC045-070VG) (A968)....................................................................................... 43
Remove ..........................................................................................................................................................43
©2015 Yale Materials Handling Corp. i

Table of Contents
TABLE OF CONTENTS (Continued)
Disassemble ...................................................................................................................................................44
Standard Motor .......................................................................................................................................... 44
Enhanced Motor .........................................................................................................................................45
Clean ..............................................................................................................................................................48
Inspect ............................................................................................................................................................49
Assemble ....................................................................................................................................................... 49
Standard Motor .......................................................................................................................................... 49
Enhanced Motor .........................................................................................................................................50
Install ..............................................................................................................................................................51
For Lift Truck Models ERP2.2-3.5VL (ERP045-070VL) (A976)...........................................................................52
Remove ..........................................................................................................................................................52
Disassemble ...................................................................................................................................................52
Clean ..............................................................................................................................................................59
Inspect ............................................................................................................................................................59
Assemble ....................................................................................................................................................... 60
Install ..............................................................................................................................................................61
Hydraulic Motor Repair For 4.0-5.5T Lift Trucks ................................................................................................ 61
Remove ..........................................................................................................................................................61
Disassemble ...................................................................................................................................................61
Clean ..............................................................................................................................................................65
Inspect ............................................................................................................................................................65
Assemble ....................................................................................................................................................... 66
Install ..............................................................................................................................................................66
Torque Specifications ............................................................................................................................................. 67
Traction Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807).........................................................67
Traction Motor for Lift Truck and ERC22-35VG (ERC045-070VG) (A968), ....................................................... 67
Traction Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883).................................................. 67
Hydraulic Motor for Lift Trucks and ERP15-20VT (ERP030-040VT) (G807).......................................................67
Hydraulic Motor for Lift Truck ERC22-35VG (ERC045-070VG) (A968).............................................................. 67
Hydraulic Motor for Lift Truck ERP22-35VG (ERP045-070VG) (A976)...............................................................67
Hydraulic Motor for Lift Truck ERC16-20VA (ERC030-040VA) (A969)............................................................... 67
Hydraulic Motor for Lift Truck ESC030-040AC (B883), ESC030-040AD (C883)................................................ 67
Hydraulic Motor for Lift Truck and ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)...... 68
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];
(ESC030-040AD) [C883];
ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML) [A985];
ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) [A938]
ii
0620 YRM 1385 General
General
This section contains repair and maintenance User Interface - Technician 2200YRM2024 for lift
procedures for the AC motors. Additional information truck models
concerning the motors may be more closely related to • ESC030-040AD (C883)
other systems and included in those sections.
Sections that contain information regarding the
motors include:
Electrical System 2200YRM1414 for lift truck models

• ESC030-040AC (B883)
Electrical System 2200YRM2022 for lift truck models

• ESC030-040AD (C883)
Periodic Maintenance 8000YRM1418 for lift truck

models
• ESC030-040AC (B883)

models
• ESC030-040AD (C883) A. LEFT SIDE C. FORWARD TRAVEL
B. RIGHT SIDE
WARNING Figure 1. Truck Orientation (Three-Wheel Models)

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.
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 A. LEFT SIDE C. FORWARD TRAVEL
B. RIGHT SIDE
the motors:
Figure 2. Truck Orientation (Four-Wheel Models)
User Interface Service-Level Functions On-Board
Dash Display =>s/n B883N02978L 2200YRM1417
for lift truck models The traction motors are mounted onto the transaxle
• ESC030-040AC (B883) for the following lift truck models:
See Figure 3 for lift truck models
1
General 0620 YRM 1385
• ERP15-20VT (ERP030-040VT) (G807) For the lift truck models below, the hydraulic pump
• ERP16-20VF (ERP30-40VF) (A955) motor is mounted inside the counterweight.
See Figure 6 for lift truck models • ERP15-20VT (ERP030-040VT) (G807)

• ERP22-35VL (ERP045-070VL) (A976) • ERP16-20VF (ERP30-40VF) (A955)
• ERP22-35VL (ERP045-070VL) (A976)
See Figure 7 for lift truck models • ERP40-50VM, ERP50-55VM6
• ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML)
(ERP080-120VM, ERP100VML) (A985) • (A985)
See Figure 10 for lift truck model See Figure 4 for lift truck models
• ERC40-55VH, ERC50VHS (ERC80-120VH, • ERP15-20VT (G807) manufactured before
ERC100VHS) (A938) November, 2014
• ERP030-040VT (G807)
• ERP16-20VF (ERP30-40VF) (A955)

• ERP15-20VT (G807) manufactured after
November, 2014

• ERP22-35VL (ERP045-070VL) (A976)

• ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
1. LEFT TRANSAXLE 3. RIGHT TRANSAXLE

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

2. COUNTERWEIGHT 1. COUNTERWEIGHT
Figure 4. Hydraulic Motor for Lift Trucks
ERP15-20VT (G807) Manufactured Before Figure 5. Hydraulic Motor for Lift Trucks
November, 2014 and ERP030-040VT (G807) and ERP15-20VT (G807) Manufactured After
ERP16-20VF (ERP30-40VF) (A955) November, 2014
3
1. LEFT TRACTION MOTOR 4. LEFT TRANSMISSION

2. RIGHT TRACTION MOTOR 5. HYDRAULIC PUMP AND MOTOR
3. RIGHT TRANSMISSION
Figure 6. Traction Motor and Hydraulic Pump Motor for Lift Truck Models ERP22-35VL (ERP045-070VL)
(A976)
4
1. LEFT TRANSMISSION 4. HYDRAULIC MOTOR

2. RIGHT TRANSMISSION 5. HYDRAULIC PUMP
3. TRACTION MOTOR
Figure 7. Traction and Hydraulic Pump Motor Locations, for Lift Truck Models ERP40-50VM,
ERP50-55VM6 (ERP080-120VM, ERP100VML) (A985)
5
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)

• ERC22-35VG (ERC045-070VG) (A968)

• 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 8.
For lift truck models ERC16-20VA (ERC030-040VA)

(A969) and ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938) the hydraulic 2. TRACTION MOTOR
pump motor is mounted onto the frame, opposite the 3. FRAME
traction motor.
Figure 8. Traction Motor and Hydraulic Pump
See Figure 9 for lift truck model Motor for Lift Truck ERC22-35VG (ERC045-070VG)
(A968)
• ERC16-20VA (ERC030-040VA) (A969)
See Figure 10 for lift truck model

For lift truck models below, the traction motors are
• ERC40-55VH, ERC50VHS (ERC80-120VH,
mounted onto the transaxle and the hydraulic pump
ERC100VHS) (A938)
motor is mounted vertically to the front wall behind the
front cover.
• ESC030-040AC (B883)
6
1. TRACTION MOTOR
2. AUTOMATIC PARK BRAKE ACTUATOR
3. DRIVE AXLE
1. FRAME 4. HYDRAULIC MOTOR
2. TRACTION MOTOR
3. HYDRAULIC PUMP MOTOR Figure 10. Traction Motor and Hydraulic Pump
Motor for Lift Truck Model ERC40-55VH,
Figure 9. Traction Motor and Hydraulic Pump ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
Motor for Lift Truck ERC16-20VA (ERC030-040VA)
(A969)
7
DISCHARGING THE CAPACITORS FOR 4. Remove the electrical compartment cover to

LIFT TRUCK MODELS ESC030-040AC access the lift controller.
(B883), ESC030-040AD (C883)
NOTE: The lift and traction controllers are wired
parallel. Connecting the resistor across the lift
WARNING controller will also discharge capacitors in the traction
DO NOT make repairs or adjustments unless you controllers if they are properly connected.
have been properly trained and authorized to do
so. Improper repairs and adjustments can create 5. Discharge the capacitors in the controllers by
dangerous operating conditions. DO NOT operate connecting a 200-ohm, 2-watt resistor across the
a lift truck that needs repairs. Report the need for lift controller’s negative (B-) and positive (B+)
repairs to your supervisor immediately. If repair is terminals. Wait at least 20 seconds to be sure that
necessary, attach a DO NOT OPERATE tag on the the capacitors are fully discharged. See
steering wheel and disconnect the battery. Figure 11.
Disconnect the battery and allow the capacitors to

discharge 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 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 1. B- TERMINAL
battery has been disconnected. 2. B+ TERMINAL
3. JUMPER LEADS
DO NOT short across the motor controller 4. 200-OHM, 2-WATT RESISTOR
terminals with a screwdriver or jumper wire.
Figure 11. Lift Controller
1. To avoid injury and prevent electrical shock,
perform the following steps (Step 2 through
Step 7 below) to discharge the capacitors before 6. If necessary to discharge the traction controllers
troubleshooting, making adjustments or repairs, separately from the lift controller, connect a 200-
or connecting or disconnecting a PC service tool. ohm, 2-watt resistor across the controller’s
negative (B-) and positive (B+) terminals. Wait at
2. Turn the key or keyless switch to the OFF position least 20 seconds to be sure that the capacitors
and DISCONNECT THE BATTERY by pushing are fully discharged. Repeat for the other traction
forward on the battery disconnect lever. controller as necessary. See Figure 12.
3. Block the lift truck so the drive wheels are off the
floor to prevent lift truck from moving.
8
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

1. B+ TERMINAL terminals with a screwdriver or jumper wire.
2. B- TERMINAL
3. JUMPER LEADS Make certain the Emergency-Stop Switch has not
4. 200-OHM, 2-WATT RESISTOR been activated. This will isolate the controller and
Figure 12. Traction Controller prevent the capacitors from discharging properly.
The proper way to disconnect the battery is by
7. Remove the resistor from the controller(s) and separating the battery connectors.
reinstall the covers before returning the lift truck to 1. Ensure the capacitors are discharged by
service. performing Step 2 through Step 6 below.
DISCHARGING THE CAPACITORS (ALL 2. Turn key or keyless switch to OFF position.
OTHER MODELS)
3. Disconnect the battery by separating the
connectors.
WARNING
DO NOT make repairs or adjustments unless you 4. Block drive wheels to prevent lift truck from
have been properly trained and authorized to do moving.
so. Improper repairs and adjustments can create
dangerous operating conditions. DO NOT operate 5. Make sure the Emergency-Stop Switch HAS NOT
a lift truck that needs repairs. Report the need for been activated. If the Emergency-Stop Switch is
repairs to your supervisor immediately. If repair is activated, rotate the switch to the right until it pops
necessary, attach a DO NOT OPERATE tag on the up.
steering wheel and disconnect the battery.
6. Press horn button. Wait 30 seconds to be sure
Disconnect the battery and discharge the capacitors are fully discharged.
capacitors before opening any compartment
covers or inspecting or repairing the electrical
9
Traction Motor Repair 0620 YRM 1385
Traction Motor Repair

FOR LIFT TRUCK MODELS ERP15-20VT Periodic Maintenance 8000YRM1418 for lift truck
(ERP030-040VT) (G807), ERP16-20VF models
(ERP30-40VF) (A955), AND • ESC030-040AC (B883)
ESC030-040AC (B883)
4. Turn the key or keyless switch to OFF position
Remove and disconnect the battery.
NOTE: The procedures described in this section ap- 5. Remove transaxle/traction motor/parking brake
ply to both right and left traction motors. assembly from lift truck. See one of the following
sections for removal instructions
NOTE: Step 1 does not apply to ESC030-040AC
(B883). lift truck models. Transaxle 1300YRM1330 for lift truck models
• ERP15-20VT (ERP030-040VT) (G807)
1. Disconnect manual release cable from parking • ERP16-20VF (ERP30-40VF) (A955)
brake.
Transaxle 1300YRM1411 for lift truck models
2. Disconnect parking brake wire harness from main • ESC030-040AC (B883)
wire harness. See Figure 13.
6. Move transaxle/traction motor/parking brake as-
3. Put lift truck on blocks so that the drive tires are sembly to a bench or other suitable work surface.
suspended off the floor. See one of the following
sections for procedures: NOTE: Note placement and orientation of parking
brake prior to removal to aid in installation.
models 7. Remove four socket head capscrews, lockwash-
ers, washers and parking brake from traction mo-
• ERP15-20VT (ERP030-040VT) (G807)
tor shaft. See Figure 13.
8. Remove snap ring and splined hub from traction
models
motor shaft; recover woodruff key. See Figure 13.
• ERP16-20VF (ERP30-40VF) (A955)
10
0620 YRM 1385 Traction Motor Repair
1. TRANSAXLE 7. TRACTION MOTOR

2. PARKING BRAKE WIRE HARNESS 8. SPLINED HUB
3. SOCKET HEAD CAPSCREW 9. SNAP RING
4. LOCKWASHER 10. WOODRUFF KEY
5. WASHER 11. TRACTION MOTOR MOUNTING CAPSCREW
6. PARKING BRAKE
Figure 13. Transaxle Assembly
9. Remove four traction motor mounting capscrews,

WARNING washers, and traction motor from transaxle. See
The traction motor weighs approximately Figure 13.
18.4 kg (40.6 lb). Make sure lifting device has
enough lifting capacity to safely lift motor. Disassemble
NOTE: Use an approved lifting device to hold and lift 1. Remove four socket-head capscrews and lock-
traction motor during removal. washers from brake end head and transaxle end
head. See Figure 14.
11
Figure 14. Traction Motor
12
Legend for Figure 14
1. TRANSAXLE END HEAD 6. BRAKE END HEAD

2. ROTOR 7. TEMP SENSOR CONNECTOR AND WIRING
3. SOCKET-HEAD CAPSCREW AND LOCK- HARNESS
WASHER 8. SNAP RING
4. STATOR, TERMINALS, AND HARDWARE 9. BEARING
5. CONNECTION PLATE, SCREW, AND GROM-
MET
13
NOTE: Carefully tap underside of brake end head Clean

with a soft hammer to loosen brake end head from
stator.
WARNING
2. Remove brake end head from stator and slide Cleaning solvents can be flammable and toxic and
brake end head off rotor shaft. See Figure 14. can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
3. Remove rotor from stator. See Figure 14. Place er's recommended safety procedures.
stator brake end down on workbench.
1. Clean components with a clean cloth moistened
NOTE: Carefully tap underside of transaxle end head with solvent and allow to thoroughly dry. DO NOT
with a soft hammer to loosen transaxle end head from apply liquid solvent directly to stator windings.
stator.
Inspect
4. Remove transaxle end head from stator. See Fig-
ure 14. 1. Inspect rotor and inside of stator for marks or
grooves indicating contact between rotor and sta-
5. Remove snap ring from brake end head. See Fig-
tor. Replace if damaged.
ure 14.
2. Check that the bearings roll smoothly and are not
6. Using bearing puller, carefully remove bearing
loose from excessive wear. Replace as neces-
from brake end head. See Figure 14.
sary. Replace the bearings regardless of condi-
NOTE: Perform Step 7 and Step 8 if connection plate tion if motor has been subjected to thermal over-
is damaged and must be replaced. load (see Step 3). In case of a catastrophic bear-
ing failure, damage may result to other motor
7. Remove temp sensor wire harness from grom- components and possibly to transaxle.
met. See Figure 14.
3. Check stator windings for signs of thermal over-
8. Remove screws, nuts, washers, grommet, and load. Signs of thermal overload are dark-stained,
connection plate from stator. See Figure 14. brittle, or burnt insulation. Thermal overload will
shorten the life of the stator.
Electrical Connector Repair or Replacement
4. Check stator windings resistance as indicated be-
1. If necessary, electric brake connector (see Fig- low. To measure continuity between U, V, and W
ure 13) may be repaired or replaced. See terminals of motor use a digital multi-meter
Deutsch Connectors section of Wire Harness Re- (DMM) set to Ohms.
pair 2200YRM1128 manual for instructions.
a. Place one DMM probe on terminal U.
2. If necessary, temp sensor connector (see Fig-
ure 14) may be repaired or replaced. See AMP
Superseal 1.5 Connector Assemblies section of
Wire Harness Repair 2200YRM1128 manual for
instructions.
14
b. Place the other DMM probe on terminal V. Assemble

Meter must read less than 0.5 ohms. If the read- 1. Install transaxle end head onto stator. See Fig-
ing is more than 0.5 ohms, remove the cables ure 15.
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.
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 read-

ing is more than 0.5 ohms, remove the cables
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 read- 1. TRANSAXLE END HEAD
ing is more than 0.5 ohms, remove the cables 2. STATOR
from motor to inverter and measure again. If this 3. ROTOR
reading is other than 0.5 ohm or less, the motor 4. DRIVE SPLINES
windings in the stator have burned open and the Figure 15. Transaxle End Head, Stator and Rotor
NOTE: A likely cause of motor contamination may be

2. Install rotor into stator with drive splines protrud-
from a damaged input bearing seal on the transaxle.
ing through transaxle end head. See Figure 15.
5. Check for signs of oil or other contaminants within
NOTE: Perform Step 3 through Step 5 if connection
the motor. If contaminants are present, locate
plate and hardware was removed.
source and take corrective action.
3. If removed, install connection plate, grommet,
washers, and nuts onto stator. See Figure 16.
15
16
1. TRANSAXLE END HEAD 6. BRAKE END HEAD

2. ROTOR 7. TEMP SENSOR CONNECTOR AND WIRING
3. SOCKET-HEAD CAPSCREW AND LOCK- HARNESS
WASHER 8. SNAP RING
4. STATOR, TERMINALS, AND HARDWARE 9. BEARING
5. CONNECTION PLATE, SCREW, AND GROM-
MET
17
NOTE: Terminal studs are located on top of connec- 7. Install snap ring into brake end head. See Fig-
tion plate. ure 16.
4. Hold lower nut of terminal stud to prevent it from 8. Install brake end head onto rotor shaft and stator.
turning and tighten upper nut to See Figure 16.
12 N•m (106 lbf in). See Figure 17.
9. Install four lockwashers and socket-head cap-
screws onto transaxle end head and brake end
head. See Figure 16. 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 instal-
ling motor to transaxle not to damage transaxle shaft
seal.
1. Apply Dexron III transmission fluid to drive splines

1. TERMINAL STUD 3. UPPER NUT of traction motor and install traction motor onto
2. LOWER NUT transaxle.
Figure 17. Terminal Studs and Nuts 2. Apply Loctite® 271 to four traction motor mounting
capscrews.
5. Insert temp sensor wire harness into grommet. 3. Install four washers and traction motor mounting
See Figure 16. capscrews into traction motor and transaxle. See
Figure 18. Tighten capscrews to
48 N•m (35 lbf ft).
CAUTION
Use an arbor press and a proper size driver when 4. Install splined hub and woodruff key (with coun-
installing bearings to avoid damage to bearings terbore facing up) onto traction motor shaft. See
and/or end shields. Press only on the outer race Figure 18.
of the bearing.
5. Install snap ring onto traction motor shaft. See
6. Carefully install bearing into brake end head. See Figure 18.
Figure 16.
18
1. TRANSAXLE 7. TRACTION MOTOR

2. PARKING BRAKE WIRE HARNESS 8. SPLINED HUB
3. SOCKET-HEAD CAPSCREW 9. SNAP RING
4. LOCKWASHER 10. WOODRUFF KEY
5. WASHER 11. CAPSCREW
6. PARKING BRAKE
Figure 18. Transaxle Assembly
19
NOTE: Close clearances require parking brake to be 12. Connect battery connector and turn key or key-
installed after traction motor is installed to transaxle. less switch to the ON position. Remove the blocks
Parking brake mechanical release arm must be in ver- from the wheels. Test for proper operation.
tical position when installed.
FOR LIFT TRUCK ERC22-35VG
6. Install parking brake onto splined hub. See Fig- (ERC045-070VG) (A968) AND
ure 18. ERC16-20VA (ERC030-040VA) (A969)
7. Install four washers, lockwashers, and socket- Remove
head capscrews into parking brake and brake end
head of traction motor. See Figure 18. 1. Remove traction motor from lift truck. See Frame
0100YRM1342 for instructions.
8. Connect parking brake wire harness to main wir-
ing harness. See Figure 18.
CAUTION
NOTE: Step 9 does not apply to ESC030-040AC The traction motor can weigh as much as
(B883) lift truck models. 136 kg (300 lb). To prevent injury, use a lifting de-
9. Connect manual release cable to parking brake. vice capable of lifting the assembly.
10. Complete installation of transaxle into lift truck. 2. Place traction motor on level blocks on a flat sur-
See one of the following manuals for instructions: face with drive end pointing down. Remove floor
jack.
Disassemble
• ERP15-20VT (ERP030-040VT) (G807)
• ERP16-20VF (ERP30-40VF) (A955) 1. Remove capscrew M6, lockwasher, and speed
sensor from non-drive end head. See Figure 19.
• ESC030-040AC (B883) 2. Remove long socket-head capscrew, lockwasher,
sensor connector cover bracket, and sensor con-
11. Lower the lift truck from the blocks. Refer to one nector tab bracket from stator housing above sen-
of the following manuals for procedures: sor cable outlet. See Figure 19.
Periodic Maintenance 8000YRM1339 for lift truck 3. Remove five capscrews, lockwashers, and wash-
models ers from stator Z-nuts and non-drive end head.
See Figure 19.
• ERP15-20VT (ERP030-040VT) (G807)
4. Gently tap under non-drive end head and remove
from stator housing. See Figure 19.
models
• ERP16-20VF (ERP30-40VF) (A955) 5. Pull sensor cable outlet from stator housing (see
Figure 19) and disconnect speed sensor and tem-
Periodic Maintenance 8000YRM1418 for lift truck perature sensor connectors.
models
• ESC030-040AC (B883)
20
A. NON-DRIVE END B. DRIVE END

1. SPEED SENSOR 9. SENSOR CABLE OUTLET
2. CAPSCREW M6 10. CAPSCREW
3. LOCKWASHER 11. WASHER
4. NON-DRIVE END HEAD 12. STATOR Z-NUT
5. LONG SOCKET-HEAD CAPSCREW 13. AMP SUPERSEAL TAB ASSEMBLY
6. SENSOR CONNECTOR COVER BRACKET 14. TAB CONTACT
7. SENSOR CONNECTOR TAB BRACKET 15. WIRE SEAL
8. STATOR HOUSING
Figure 19. Traction Motor Non-Drive End Head
21
6. Using a bearing puller, remove and discard prox- 9. Remove three hex-head bolts, spring washers,
imity sensor wheel from non-drive end head. See terminal flags, terminal covers, terminal blocks,
Figure 20. and special nuts from stator housing on non-drive
end. See Figure 21.
NOTE: When replacing one bearing, it is strongly
recommended to replace both bearings. 10. Remove five capscrews, lockwashers, and wash-
ers from Z-nuts on stator housing and drive end
NOTE: Note orientation of bearing components dur- head. See Figure 21.
ing disassembly to aid in assembly.
11. Attach approved lifting device to stator housing
7. Using bearing puller, remove bearing from non- and slowly lift straight up, removing it from rotor
drive end head. See Figure 20. assembly and drive end head. See Figure 21.
8. Remove bearing preload spring from non-drive 12. Screw lifting eye into threaded hole in end of rotor
end head. See Figure 20. assembly. Attach approved lifting device and lift
rotor assembly straight up from drive end head.
See Figure 22.
NOTE: When replacing one bearing, it is strongly

recommended to replace both bearings.
NOTE: Note orientation of bearing components prior

to disassembly to aid in assembly.
13. Using bearing puller, remove bearing from drive

end head. See Figure 22.
1. PROXIMITY SENSOR WHEEL

2. NON-DRIVE END HEAD
3. BEARING
4. BEARING PRELOAD SPRING
Figure 20. Traction Motor Non-Drive End Head
Bearing
22
1. HEX-HEAD BOLT 8. LOCKWASHER

2. SPRING WASHER 9. WASHER
3. TERMINAL FLAG 10. DRIVE END HEAD
4. TERMINAL COVER 11. ROTOR ASSEMBLY
5. TERMINAL BLOCK 12. STATOR Z-NUT
6. STATOR HOUSING 13. SPECIAL NUT
7. CAPSCREW
Figure 21. Traction Motor Drive End Head
23
14. Remove and discard shaft seal from drive end tion if motor has been subjected to thermal over-
head. See Figure 22. load (see Step 3). In case of a catastrophic bear-
components and possibly to transaxle.

load. Signs of thermal overload are dark-stained,
brittle, or burnt insulation. Thermal overload will
shorten the life of the stator.
4. Check motor windings resistance as indicated be-

low. 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.

1. SHAFT SEAL 3. DRIVE END HEAD ing is more than 0.5 ohms, remove the cables
2. ROTOR ASSEMBLY 4. BEARING from motor to inverter and measure again. If this
Figure 22. Traction Motor Rotor Assembly and
Drive End Head

1. If necessary, AMP Superseal tab assembly, tab
contact, and wire seal (see Figure 19) may be re- Meter must read less than 0.5 ohms. If the read-
paired or replaced. See AMP Superseal 1.5 Con- ing is more than 0.5 ohms, remove the cables
nector Assemblies section of Wire Harness Re- from motor to inverter and measure again. If this
pair 2200YRM1128 manual for instructions. reading is other than 0.5 ohm or less, the motor
Clean motor must be repaired or replaced.

WARNING
Cleaning solvents can be flammable and toxic and f. Place the other DMM probe on terminal U.
can cause skin irritation. When using cleaning
er's recommended safety procedures.
1. Clean components with a clean cloth moistened reading is other than 0.5 ohm or less, the motor
with solvent and allow to air dry. DO NOT apply windings in the stator have burned open and the
liquid solvent directly to components. motor must be repaired or replaced.
5. Check terminal flags for cracks or other damage.

Inspect
Replace if damaged.
1. Inspect rotor assembly and inside of stator hous-
ing for marks or grooves indicating contact be-
motor. If necessary, locate source of contami-
tween rotor and stator. Replace if damaged.
nants and take corrective action.
7. Inspect all other components and replace as nec-
loose from excessive wear. Replace as neces-
essary.
24
Assemble 12. Install non-drive end head onto stator housing.

See Figure 19.
1. Using a seal driver, install new shaft seal into
drive end head. See Figure 22. 13. Install five washers, lockwashers, and capscrews
into non-drive end head and stator Z-nuts on sta-
tor housing. See Figure 19. Tighten capscrews to
CAUTION 25 to 30 N•m (18 to 22 lbf ft).
Use an arbor press and a proper size driver when
installing bearings to avoid damage to bearings 14. Install sensor connector tab bracket, sensor con-
and/or end shields. Press only on the outer race nector cover bracket, lockwasher, and long
of the bearing. Always replace bearings in sets. socket-head capscrew onto stator housing over
sensor cable outlet. See Figure 19.
2. Install bearing into drive end head as noted during
disassembly. See Figure 22. 15. Install speed sensor, lockwasher, and capscrew
M6 onto non-drive end head and stator housing.
3. Screw lifting eye into threaded hole in the end of See Figure 19.
rotor assembly. Attach approved lifting device and
lower rotor assembly onto drive end head. Ensure Install
bearing is fully seated against drive end head.
See Figure 22. 1. Install traction motor onto drive axle. See Frame
0100YRM1342 for installation instructions.
4. Remove lifting device and lifting eye from rotor
assembly. FOR LIFT TRUCK ERP2.2-3.5VL
(ERP045-070VL) (A976)
NOTE: Make sure holes for stator Z-nuts are aligned
with capscrew holes. Remove
5. Using approved lifting device, lower stator hous- NOTE: The procedures described in this section ap-
ing onto drive end head. See Figure 21. ply to both right and left traction motors.
6. Install five washers, lockwashers, and capscrews 1. Remove transaxle assembly from lift truck. See
into drive end head and stator Z-nuts on stator Transaxle 1300YRM1370 for instructions.
housing. See Figure 21. Tighten capscrews to 25
to 30 N•m (18 to 22 lbf ft). 2. Remove service and parking brake components
from traction motor housings. See Transaxle
7. Install three special nuts, terminal blocks, terminal 1300YRM1370 for instructions.
covers, terminal flags, spring washers, and hex-
head bolts onto stator housing, non-drive end. 3. Remove the AC motor to be repaired from the
See Figure 21. output housing. See Transaxle 1300YRM1370
for instructions.
8. Install bearing preload spring into non-drive end
head. See Figure 20. Disassemble
9. Install bearing into non-drive end head as noted 1. Remove nine nuts and washers from terminals on
during disassembly. See Figure 20. connection plate. See Figure 23.
10. Install new proximity sensor wheel into non-drive
11. Place sensor cable outlet into position on stator

housing (see Figure 19). Connect proximity sen-
sor and temperature sensor connectors to sensor
cable outlet.
25
1. TERMINAL 9. BRAKE END BELL

2. NUT 10. O-RING
3. WASHER 11. BEARING
4. CONNECTION PLATE 12. ROTOR
5. SCREW 13. STATOR
6. FRONT SHAFT SEAL 14. WAVE WASHER
7. REAR SHAFT SEAL 15. STATOR HOUSING
8. SNAP RING 16. DOWEL PINS
26
2. Remove two screws and connection plate from 2. Check that the bearings roll smoothly and are not
stator housing. See Figure 23. loose from excessive wear. Replace as neces-
3. Remove and discard front shaft seal from brake tion if motor has been subjected to thermal over-
end bell. See Figure 23. load (see Step 3). In case of a catastrophic bear-
4. Remove and discard rear shaft seal from stator
components and possibly to transaxle.
housing. See Figure 23.
5. Remove snap ring from rotor at brake end bell.
See Figure 23.
NOTE: Use threaded holes on the brake end bell to shorten the life of the stator.
move the end bell away from the stator housing.
6. Remove six screws, dowel pins if present, and low. To measure continuity between U, V, and W
brake end bell from stator housing. Remove and terminals of motor use a digital multi-meter
discard O-ring. See Figure 23. (DMM) set to Ohms.
7. Remove snap ring from inside brake end bell. See a. Place one DMM probe on terminal U.
Figure 23.
8. Carefully remove bearing from brake end bell.
See Figure 23.
NOTE: Bearing will remain with rotor during removal. from motor to inverter and measure again. If this
9. Remove rotor from stator housing. See Figure 23. windings in the stator have burned open and the
10. Carefully remove bearing from rotor. See Fig-
ure 23. c. Place one DMM probe on terminal V.
11. Carefully remove stator from stator housing. See d. Place the other DMM probe on terminal W.
Figure 23. Take care not to damage power leads.
12. Remove wave washer from stator housing. See ing is more than 0.5 ohms, remove the cables
Figure 23. from motor to inverter and measure again. If this
Clean windings in the stator have burned open and the
WARNING e. Place one DMM probe on terminal W.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning f. Place the other DMM probe on terminal U.
er's recommended safety procedures.
1. Clean components with a clean cloth moistened from motor to inverter and measure again. If this
with solvent and allow to thoroughly dry. DO NOT reading is other than 0.5 ohm or less, the motor
apply liquid solvent directly to stator windings. windings in the stator have burned open and the
Inspect
NOTE: A likely cause of motor contamination may be
1. Inspect rotor and inside of stator for marks or from a damaged input bearing seal on the transaxle.
grooves indicating contact between rotor and sta-
tor. Replace if damaged.
the motor. If contaminants are present, locate
source and take corrective action.
27
Assemble 10. Install new front shaft seal into brake end bell.
See Figure 23.
NOTE: The procedures described in this section ap-
ply to both right and left traction motors. 11. Using two screws, install connection plate on sta-
tor housing. Tighten screws to 3 N•m (27 lbf in).
1. Install wave washer in stator housing. See Fig- See Figure 23.
ure 23.
12. Install nine nuts and washers on terminals on
2. Carefully install stator into stator housing. See connection plate. Tighten bottom nuts to
Figure 23. Take care not to damage power leads. 8 N•m (71 lbf in). See Figure 23.
CAUTION Install
Use an arbor press and a proper size driver when NOTE: The procedures described in this section ap-
installing bearings to rotor to avoid damage to ply to both right and left traction motors.
bearing. Press only on the INNER race of the bear-
ing. Always replace bearings in sets. 1. Install repaired AC motor onto output housing.
See Transaxle 1300YRM1370 for instructions.
3. Install bearing onto rotor. See Figure 23.
2. Install parking brake and service brake compo-
4. Install rotor into stator and stator housing. See nents onto traction motor housings. See Trans-
Figure 23. axle 1300YRM1370 for instructions.
3. Install transaxle assembly onto lift truck. See

CAUTION Transaxle 1300YRM1370 for instructions.
installing bearings to avoid damage to bearing. FOR LIFT TRUCK ERC40-55VH,
Press only on the OUTER race of the bearing. Al- ERC50VHS (ERC80-120VH, ERC100VHS)
ways replace bearings in sets. (A938)
5. Install bearing into brake end bell. See Figure 23. Remove
6. Install snap ring on inside brake end bell. See Fig- 1. Remove traction motor from lift truck. See Frame
ure 23. 0100YRM1342 for instructions.
7. Install new O-ring on the brake end bell. Install

the brake end bell dowel pins and six screws into CAUTION
stator housing. Tighten the six screws to The traction motor can weigh as much as
23 N•m (204 lbf in). See Figure 23. 230 kg (507 lb). To prevent injury, use a lifting de-
vice capable of lifting the assembly.
8. Install snap ring on rotor at brake end bell. See
Figure 23. 2. Place traction motor on level blocks on a flat sur-
face with drive end pointing down. Remove floor
9. Install new rear shaft seal into stator housing. See jack.
Figure 23.
28
Disassemble 3. Remove five capscrews, lockwashers, and wash-

ers from stator Z-nuts and non-drive end head.
1. Remove capscrew M6, lockwasher, and speed See Figure 24.
sensor from non-drive end head. See Figure 24.
4. Gently tap under non-drive end head and remove
2. Remove two socket-head capscrews, two lock- from stator housing. See Figure 24.
washers, sensor connector cover bracket, and
sensor connector tab bracket from stator housing 5. Pull sensor cable outlet from stator housing (see
above sensor cable outlet. See Figure 24. Figure 24) and disconnect speed sensor and tem-
perature sensor connectors.
1. CAPSCREW 10. LONG SOCKET-HEAD CAPSCREW

2. LOCKWASHER 11. Z-NUT
3. WASHER 12. TERMINAL BOLT
4. NON-DRIVE END HEAD 13. STATOR HOUSING
5. CAPSCREW M6 14. PROXIMITY SENSOR WHEEL
6. SPEED SENSOR 15. BEARING
7. BEARING PRELOAD SPRING 16. ROTOR ASSEMBLY
8. SENSOR CONNECTOR COVER BRACKET 17. DRIVE END HEAD
9. SENSOR CONNECTOR TAB BRACKET 18. SHAFT SEAL
29
6. Using a bearing puller, remove and discard prox- 10. Remove five capscrews, lockwashers, and wash-
imity sensor wheel from non-drive end head. See ers from Z-nuts on stator housing and drive end
Figure 24. head. See Figure 24.
NOTE: When replacing one bearing, it is strongly 11. Attach approved lifting device to stator housing
recommended to replace both bearings. and slowly lift straight up, removing it from rotor
assembly and drive end head. See Figure 24.
NOTE: Note orientation of bearing components dur-
ing disassembly to aid in assembly. 12. Screw lifting eye into threaded hole in end of rotor
assembly. Attach approved lifting device and lift
7. Using bearing puller, remove bearing from non- rotor assembly straight up from drive end head.
drive end head. See Figure 24. See Figure 24.
8. Remove bearing preload spring from non-drive NOTE: When replacing one bearing, it is strongly
end head. See Figure 24. recommended to replace both bearings.
9. Remove six terminal bolts, lockwashers, terminal NOTE: Note orientation of bearing components prior
covers, and terminal blocks from stator housing. to disassembly to aid in assembly.
See Figure 25.
13. Using bearing puller, remove bearing from drive
14. Remove and discard shaft seal from drive end


1. If necessary, AMP Superseal tab assembly, tab
contact, and wire seal (see Figure 24) may be re-
paired or replaced. See AMP Superseal 1.5 Con-
nector Assemblies section of Wire Harness Re-
pair 2200YRM1128 manual for instructions.
Clean
WARNING
1. TERMINAL COVER
2. TERMINAL BOLTS solvents, always follow the solvent manufactur-
3. TERMINAL BLOCKS er's recommended safety procedures.
4. LOCK WASHER
Figure 25. Terminals with solvent and allow to air dry. DO NOT apply
liquid solvent directly to components.
30
Inspect Meter must read less than 0.5 ohms. If the read-
1. Inspect rotor assembly and inside of stator hous- from motor to inverter and measure again. If this
ing for marks or grooves indicating contact be- reading is other than 0.5 ohm or less, the motor
tween rotor and stator. Replace if damaged. windings in the stator have burned open and the
loose from excessive wear. Replace as neces- 5. Check terminal flags for cracks or other damage.
sary. Replace the bearings regardless of condi- Replace if damaged.
tion if motor has been subjected to thermal over-
load (see Step 3). In case of a catastrophic bear- 6. Check for signs of oil or other contaminants within
ing failure, damage may result to other motor motor. If necessary, locate source of contami-
components and possibly to transaxle. nants and take corrective action.
3. Check stator windings for signs of thermal over- 7. Inspect all other components and replace as nec-
load. Signs of thermal overload are dark-stained, essary.
shorten the life of the stator. Assemble
4. Check motor windings resistance as indicated be- 1. Using a seal driver, install new shaft seal into
low. To measure continuity between U, V, and W drive end head. See Figure 24.
(DMM) set to Ohms.
CAUTION
a. Place one DMM probe on terminal U. Use an arbor press and a proper size driver when
installing bearings to avoid damage to bearings
b. Place the other DMM probe on terminal V. and/or end shields. Press only on the outer race
Meter must read less than 0.5 ohms. If the read- of the bearing. Always replace bearings in sets.
ing is more than 0.5 ohms, remove the cables 2. Install bearing into drive end head as noted during
from motor to inverter and measure again. If this disassembly. See Figure 24.
windings in the stator have burned open and the 3. Screw lifting eye into threaded hole in the end of
motor must be repaired or replaced. rotor assembly. Attach approved lifting device and
lower rotor assembly onto drive end head. Ensure
c. Place one DMM probe on terminal V. bearing is fully seated against drive end head.
d. Place the other DMM probe on terminal W. See Figure 24.
Meter must read less than 0.5 ohms. If the read- 4. Remove lifting device and lifting eye from rotor
ing is more than 0.5 ohms, remove the cables assembly.
from motor to inverter and measure again. If this NOTE: Make sure holes for stator Z-nuts are aligned
reading is other than 0.5 ohm or less, the motor with capscrew holes.
motor must be repaired or replaced. 5. Using approved lifting device, lower stator hous-
ing onto drive end head. See Figure 24.
31
6. Install five washers, lockwashers, and capscrews Install

into drive end head and stator Z-nuts on stator
housing. See Figure 24. Tighten capscrews to 25 1. Install traction motor onto drive axle. See Frame
to 30 N•m (18 to 22 lbf ft). 0100YRM1342 for installation instructions.
7. Install six terminal bolts, lockwashers, terminal

covers, and terminal blocks onto stator housing,
TRACTION MOTOR REPAIR FOR LIFT
non-drive end. Tighten terminal bolts to 23 to
TRUCK ERP40-50VM, ERP50-55VM6
25 N•m (17 to 18.5 lbf ft). See Figure 24.
(ERP080-120VM, ERP100VML) (A985)
8. Install bearing preload spring into non-drive end Remove

NOTE: Disconnect all electrical connections to the
9. Install bearing into non-drive end head as noted traction motor assembly prior to removal. The proce-
during disassembly. See Figure 24. dures described in this section apply to both right and
left sides of the traction motor assembly. See Trans-
10. Install new proximity sensor wheel into non-drive axle 1300YRM1539 for preparation of the lift truck for
end head. See Figure 24. transaxle removal.
11. Place sensor cable outlet into position on stator 1. Remove the six upper nuts, six lock washers, and
housing (see Figure 24). Connect proximity sen- the lift truck power cables. See Figure 26.
sor and temperature sensor connectors to sensor
cable outlet. 2. Position power cables out of the way.
12. Install non-drive end head onto stator housing. 3. Remove transaxle assembly from lift truck. See
See Figure 24. Transaxle 1300YRM1539 for instructions.
13. Install five washers, lockwashers, and capscrews 4. Remove service and parking brake components
into non-drive end head and stator Z-nuts on sta- from traction motor housing. See Transaxle
tor housing. See Figure 24. Tighten capscrews to 1300YRM1539 for instructions.
25 to 30 N•m (18 to 22 lbf ft).
5. Remove 24 capscrews holding the traction motor
14. Install sensor connector tab bracket, sensor con- assembly to the gear box. See Figure 26.
nector cover bracket, two lockwashers, and two
6. Strike gear box and traction motor assembly join-
socket-head capscrews onto stator housing over
ing surface with soft hammer to free traction mo-
sensor cable outlet. See Figure 24.
tor assembly from the gear box.
15. Install speed sensor, lockwasher, and capscrew
7. Remove traction motor and dispose of properly.
M6 onto non-drive end head and stator housing.
See Figure 24. NOTE: Remove dowel pins or leave in gear box if
present.
32
0620 YRM 1385
1. GEAR BOX 6. TRACTION MOTOR POWER TERMINAL

2. TRACTION MOTOR ASSEMBLY 7. LOCK WASHER
3. CAPSCREW 8. WASHER
4. TRACTION MOTOR POWER CABLE 9. LOWER NUT
5. UPPER NUT
33
0620 YRM 1385
Clean 2. Connect the traction motor assembly and the gear

box.
WARNING 3. Install 24 capscrews and tighten to
Cleaning solvents can be flammable and toxic and 45 N•m (33 lbf ft). See Figure 26.
solvents, always follow the solvent manufactur- 4. Install parkbrake and service brake components
er's recommended safety procedures. onto traction motor housing. See Transaxle
1300YRM1539 for instructions.
with solvent and allow to thoroughly dry. DO NOT 5. Install transaxle assembly into lift truck. See
apply liquid solvent directly to stator windings. Transaxle 1300YRM1539 for instructions.
6. Tighten lower nuts on traction motor power termi-

Install
nals to 15 N•m (11 lbf ft). See Figure 26.
NOTE: The procedures described in this section ap-
7. Place lift truck power cables onto traction motor
ply to both right and left traction motor assembly. The
power terminals.
traction motors in this section are non-serviceable.
The entire motor assembly must be replaced. See 8. Install 6 lock washers and 6 upper nuts onto trac-
Figure 26. tion motor power terminals. Tighten to 6 to
8 N•m (53 to 71 lbf in). See Figure 26.
1. If dowel pins were removed, install dowel pins
and align with dowel holes.
Hydraulic Motor Repair

FOR LIFT TRUCKS ERP15-20VT 2. Place hydraulic pump and motor assembly on a
(ERP030-040VT) (G807), ERP16-20VF clean work bench or other suitable surface.
(ERP30-40VF) (A955), AND
ESC030-040AC (B883), ESC030-040AD 3. Remove two capscrews and drive end bracket
(C883) from hydraulic pump and motor assembly.

Remove
• ERP15-20VT (G807) manufactured before
1. Remove hydraulic pump and motor assembly November, 2014
from lift truck. See one of the following manuals
• ERP030-040VT (G807)
for removal instructions:
• ERP16-20VF (ERP30-40VF) (A955)
Hydraulic System 1900YRM1333 for models: • ESC030-040AC (B883), ESC030-040AD
• ERP15-20VT (ERP030-040VT) (G807) (C883)
• ERP16-20VF (ERP30-40VF) (A955)
Hydraulic System 1900YRM1413 for models: • ERP15-20VT (G807) manufactured after
• ESC030-040AC (B883) November, 2014
• ESC030-040AD (C883)
34
0620 YRM 1385 Hydraulic Motor Repair
4. Remove two capscrews and terminal end bracket

from hydraulic pump and motor assembly.

November, 2014
• ERP030-040VT (G807)
• ERP16-20VF (ERP30-40VF) (A955)
• ESC030-040AC (B883), ESC030-040AD
(C883)

November, 2014
1. CAPSCREWS
2. DRIVE END BRACKET
1. CAPSCREWS 3. TERMINAL END BRACKET
2. DRIVE END BRACKET 4. HYDRAULIC PUMP AND MOTOR ASSEMBLY
3. TERMINAL END BRACKET
4. HYDRAULIC PUMP AND MOTOR ASSEMBLY Figure 28. Hydraulic Pump and Motor Mounting,
Lift Truck Models ERP15-20VT (G807)
Figure 27. Hydraulic Pump and Motor Mounting, Manufactured After November, 2014
Manufactured Before November, 2014 and
ERP030-040VT (G807), ERP16-20VF (ERP30-40VF) 5. Remove two capscrews retaining hydraulic pump
(A955), ESC030-040AD (C883), and ESC030-040AC to hydraulic motor. See Figure 29.
(B883)
35
Hydraulic Motor Repair 0620 YRM 1385
4. Remove four tie rods holding non-drive end shield

and drive end shield to stator housing. See Fig-
ure 30.
CAUTION
Disposal of silicone sealant must meet local envi-
ronmental regulations.
NOTE: Note threading position and orientation of

power leads and thermal sensor connector wire
through non-drive end shield during disassembly to
aid in assembly.
NOTE: Silicone seal for power leads and thermal

sensor connector wire must be broken prior to shield
removal.
5. Remove non-drive end shield from stator housing.

See Figure 30.
1. CAPSCREWS
2. HYDRAULIC PUMP
3. HYDRAULIC MOTOR 6. Using bearing puller, remove non-drive ball bear-
ing from non-drive end shield. See Figure 30.
Figure 29. Hydraulic Pump to Hydraulic Motor
7. Remove waved spring washer from non-drive end
shield. See Figure 30.
6. Remove hydraulic pump with drive coupling from
8. Remove stator housing from drive end shield and
hydraulic motor.
rotor. See Figure 30.
Disassemble 9. Remove shaft sealing ring from drive end shield
and rotor. See Figure 30.
1. Place hydraulic motor in a vise with terminal posts
on top and carefully clamp vise onto stator hous- 10. Remove rotor from drive end shield. See Fig-
ing. ure 30.
2. Remove hex nuts and disconnect power leads 11. Remove snap ring from drive end of rotor shaft.
from terminal posts. See Figure 30. See Figure 30.
3. Remove two capscrews, terminal posts, and ter- 12. Using bearing puller, carefully remove drive end
minal post bracket from stator housing. See Fig- ball bearing from drive end shield. See Figure 30.
ure 30.
36
1. SHAFT SEALING RING 11. NON-DRIVE END SHIELD

2. DRIVE END SHIELD 12. SENSOR SCREW
3. DRIVE BALL BEARING 13. SPEED SENSOR
4. LOCKING RING 14. TIE ROD
5. TERMINAL POST 15. CAP
6. CAPSCREW 16. STATOR HOUSING
7. SNAP RING 17. TERMINAL POST BRACKET
8. ROTOR 18. SPRING WASHER
9. NON-DRIVE BALL BEARING 19. HEX NUT
10. WAVED SPRING WASHER 20. POWER LEAD
Figure 30. Hydraulic Motor Components
37
13. Remove locking ring from drive end shield. See

Figure 30. Table 2. Thermal Sensor Connector
14. Remove cap from non-drive end shield. See Fig- Pin Wire Color Description
ure 30. 1 Red Positive
Electrical Connector Repair or Replacement 2 White Negative
1. If necessary, speed sensor connector and/or ther-

mal sensor connector may be repaired or re- Clean
placed. See Figure 31. See AMP Superseal 1.5
Connector Assemblies section of Wire Harness WARNING
Repair 2200YRM1128 manual for instructions.
solvents, always follow the solvent manufac-
turer’s recommended safety procedures.

with solvent and allow to air dry. DO NOT apply
liquid solvent directly to components.

motor. If necessary, locate source of contami-
3. Clean all joints, remove all foreign matter ad con-

taminants such as release agents, grease, oil,
dust, water, protective coatings, old adhesives or
sealants, and other substances which could affect
1. SPEED SENSOR CONNECTOR silicone seal adhesion.
2. THERMAL SENSOR CONNECTOR
Figure 31. Electrical Connectors Inspect
1. Inspect rotor and inside of motor case for marks
2. Wire connections for speed sensor connector are or grooves indicating contact between rotor and
shown in Table 1. motor case. Replace if damaged.
2. Bearings should fit snugly where they ride on the

Table 1. Speed Sensor Connector shaft. If there is excessive wear, replace the bear-
ing.
Pin Wire Color Description
3. Check bearings for smooth operation. If a clean
1 Red 24V -0/+5
bearing does not roll smoothly, it must be re-
2 Blue Signal B placed.
3 White Signal A
4. Check rotor windings for signs of thermal over-
4 Black Ground load. Signs of thermal overload are dark-stained,
3. Wire connections for thermal sensor connector shorten the life of the stator housing.
are shown in Table 2.
38
5. Check motor windings resistance as indicated be- 4. Install snap ring onto drive end of rotor shaft. See
low. To measure continuity between U, V, and W Figure 32.
(DMM) set to Ohms. 5. Install rotor in drive end shield. See Figure 32.
a. Place one DMM probe on terminal U. 6. Install shaft sealing ring onto rotor and drive end
7. Install stator housing onto rotor and drive end
Meter must read less than 0.5 ohms. If the read- shield. See Figure 32.
from motor to inverter and measure again. If this 8. Install waved spring washer in non-drive end
reading is other than 0.5 ohm or less, the motor shield. See Figure 32.
CAUTION
c. Place one DMM probe on terminal V. Use an arbor press and a proper size driver when
d. Place the other DMM probe on terminal W. and/or end shields. Press only on the outer race
of the bearing. Always replace bearings in sets.
ing is more than 0.5 ohms, remove the cables 9. Carefully install non-drive end ball bearing in non-
from motor to inverter and measure again. If this drive end shield. See Figure 32.
windings in the stator have burned open and the NOTE: Take care when routing power leads and
motor must be repaired or replaced. thermal sensor through non-drive end shield as noted
during disassembly.
NOTE: Ensure waved spring washer remains in posi-
f. Place the other DMM probe on terminal U. tion during non-drive end shield installation.
Meter must read less than 0.5 ohms. If the read- 10. Install non-drive end shield onto stator housing.
ing is more than 0.5 ohms, remove the cables See Figure 32.
reading is other than 0.5 ohm or less, the motor 11. Apply neutral curing, high temperature silicone
windings in the stator have burned open and the sealant, rated for at least 260°C (500°F), between
motor must be repaired or replaced. stator housing and non-drive end shield to protect
power leads and thermal sensor.
Assemble
12. Install four tie rods in non-drive end shield and
1. Install cap in non-drive end shield. See Figure 32. drive end shield, holding stator housing between
shields. Tighten screws to 14 to 17 N•m (124 to
2. Install locking ring in drive end shield. See Fig- 150 lbf in). See Figure 32.
ure 32.
13. Install terminal post bracket, terminal posts and
two capscrews onto stator housing. See Fig-
CAUTION ure 32.
installing bearings to avoid damage to bearings 14. Connect power leads to terminal posts.
and/or end shields. Press only on the outer race
15. Install hex nuts onto terminal posts. See Fig-
ure 32. Tighten hex nuts to 14 to 16 N•m (124 to
3. Carefully install drive end ball bearing in drive end 142 lbf in).
39
1. SHAFT SEALING RING 11. NON-DRIVE END SHIELD

2. DRIVE END SHIELD 12. SENSOR SCREW
3. DRIVE BALL BEARING 13. SPEED SENSOR
4. LOCKING RING 14. TIE ROD
5. TERMINAL POST 15. CAP
6. CAPSCREW 16. STATOR HOUSING
7. SNAP RING 17. TERMINAL POST BRACKET
8. ROTOR 18. SPRING WASHER
9. NON-DRIVE BALL BEARING 19. HEX NUT
10. WAVED SPRING WASHER 20. POWER LEAD
Figure 32. Hydraulic Motor Components
40
Install 3. Install non-drive end bracket and two capscrews

onto hydraulic pump and motor assembly.
1. Install drive coupling onto rotor. Install hydraulic
pump over coupling onto hydraulic motor. See Figure 34 for lift truck models
2. Apply Loctite 271 to two capscrews and install in
November, 2014
hydraulic pump and hydraulic motor. See Fig-
ure 33. Tighten capscrews to 47 N•m (35 lbf ft). • ERP030-040VT (G807)
• ERP16-20VF (ERP30-40VF) (A955)
• ESC030-040AC (B883), ESC030-040AD
(C883)

November, 2014
4. Install drive end bracket and two capscrews onto

hydraulic pump and motor assembly.

November, 2014
• ERP030-040VT (G807)
• ERP16-20VF (ERP30-40VF) (A955)
• ESC030-040AC (B883), ESC030-040AD
(C883)
1. CAPSCREW 3. HYDRAULIC MO-
2. HYDRAULIC PUMP TOR See Figure 35 for lift truck models
Figure 33. Hydraulic Pump to Hydraulic Motor
November, 2014
41
1. CAPSCREW
3. NON-DRIVE END BRACKET
4. HYDRAULIC PUMP AND MOTOR ASSEMBLY
Figure 34. Hydraulic Pump and Motor Mounting,
Manufactured Before November, 2014 and
ERP030-040VT (G807), ERP16-20VF (ERP30-40VF)
(A955), ESC030-040AD (C883), and ESC030-040AC
(B883)
5. Install hydraulic pump and motor assembly in

counterweight. See one of the following manuals
for installation instructions: 1. CAPSCREWS
Hydraulic System 1900YRM1333 for models: 3. TERMINAL END BRACKET
• ERP15-20VT (ERP030-040VT) (G807) 4. HYDRAULIC PUMP AND MOTOR ASSEMBLY
• ERP16-20VF (ERP30-40VF) (A955) Figure 35. Hydraulic Pump and Motor Mounting,
Hydraulic System 1900YRM1413 for models: Manufactured After November, 2014
• ESC030-040AC (B883)
• ESC030-040AD (C883)
42
FOR LIFT TRUCK ERC22-35VG

(ERC045-070VG) (A968)
Remove
1. Remove hydraulic pump and motor assembly
from lift truck. See Hydraulic System
1900YRM1367 for removal instructions.
2. Place hydraulic pump and motor assembly on a

clean workbench or other suitable surface.
3. Remove five capscrews and two motor mount

brackets from hydraulic pump and motor assem-
bly. See Figure 36.
NOTE: Note orientation of fitting and suction adapter

during removal to aid in installation.
4. Remove fitting from pump. See Figure 37.
5. Remove suction adapter from pump. See Fig-

ure 37.
NOTE: Note position of inlet and outlet ports of pump

for correct alignment during installation.
6. Remove two capscrews fastening pump to motor.

Carefully remove pump from motor. See Fig-
ure 37.
NOTE: STANDARD MOTOR ASSEMBLY SHOWN.
A. FRONT VIEW B. REAR VIEW

1. HYDRAULIC PUMP AND MOTOR ASSEMBLY
2. MOTOR MOUNT BRACKET
3. MOTOR MOUNT CAPSCREW
Figure 36. Motor Mount Brackets
43
NOTE: Perform Step 7 for standard motor. Disassemble

7. Loosen two setscrews in coupling. DO NOT lose Standard Motor
two keys between coupling and shaft. Remove
coupling from motor. See Figure 37. 1. Place motor in a vise with terminal posts on top
and carefully clamp vise on stator housing.
2. Remove three hex nuts and spring washers from

terminal posts. See Figure 38.
3. Disconnect power leads from terminal posts. See

Figure 38.
4. Remove two screws, terminal posts, and terminal

post bracket from stator housing. See Figure 38.
5. Remove four tie rods holding end shields to stator

6. Remove cap from non-drive end shield. Remove

and discard O-ring from cap. See Figure 38.
CAUTION
NOTE: Note threading position and orientation of

aid in assembly.
NOTE: Silicone seal for power leads and thermal

sensor connector wire must be broken prior to shield
removal.
A. STANDARD MOTOR
B. ENHANCED MOTOR
1. PUMP 5. CAPSCREW
2. MOTOR 6. FITTING
3. COUPLING 7. SUCTION ADAPTER
4. SETSCREW
Figure 37. Pump and Motor Assembly
44
7. Remove non-drive end shield from stator housing. Enhanced Motor

See Figure 38.
1. Place motor in a vise with terminal posts on top
8. Using bearing puller, carefully remove non-drive and carefully clamp vise on stator housing.
end ball bearing from non-drive end shield. See
Figure 38. 2. Remove three hex nuts and spring washers from
terminal posts. See Figure 38.
9. Remove O-ring seal from non-drive end shield.
See Figure 38. 3. Disconnect power leads from terminal posts. See
Figure 38.
shield. See Figure 38. 4. Remove two screws, terminal posts, bracket, and
terminal post bracket from stator housing. See
11. Remove capscrew and speed sensor from non- Figure 38.
drive end shield. See Figure 38.
12. Remove drive end shield and rotor from stator CAUTION
housing. See Figure 38. Disposal of silicone sealant must meet local envi-
13. Remove woodruff key from drive end of rotor
shaft. See Figure 38. NOTE: Note threading position and orientation of
14. Remove snap ring from drive end of rotor. See through non-drive end shield during disassembly to
Figure 38. aid in assembly.
15. Remove rotor from drive end shield. See Fig- NOTE: Silicone seal for power leads and thermal
ure 38. sensor connector wire must be broken prior to shield
16. Remove locking ring from drive end shield. See removal.
Figure 38. 5. Remove four capscrews, fan cover, four washers,
17. Using bearing puller, carefully remove drive end and four spacers from non-drive end shield. See
ball bearing from drive end shield. See Figure 38. Figure 38.
45
A. STANDARD MOTOR B. ENHANCED MOTOR

1. TERMINAL POST 17. NON-DRIVE END BALL BEARING
2. HEX NUT 18. O-RING SEAL
3. SPRING WASHER 19. WAVED SPRING WASHER
4. BRACKET 20. NON-DRIVE END SHIELD
5. TERMINAL POST BRACKET 21. CAPSCREW
6. WOODRUFF KEY 22. SPEED SENSOR
7. SNAP RING 23. O-RING
8. DRIVE END SHIELD 24. CAP
9. DRIVE END BALL BEARING 25. TIE ROD
10. LOCKING RING 26. WASHER
11. STATOR HOUSING 27. FAN COVER SPACER
12. POWER LEAD 28. MOUNTING BRACKET
13. ROTOR 29. RETAINING BUSHING
14. SCREW 30. COOLING FAN
15. OIL SEAL 31. M8 X 270 SCREW
16. THERMAL SENSOR 32. FAN COVER
Figure 38. Hydraulic Motor
46
6. Remove four M8 X 270 screws holding end Electrical Connector Repair or Replacement
shields to stator housing. See Figure 38.
7. Remove cooling fan from non-drive end shield. mal sensor connector may be repaired or re-
Remove retaining bushing from fan. See Fig- placed. See Figure 39. See AMP Superseal 1.5
ure 38. Connector Assemblies section of Wire Harness
8. Remove three capscrews and mounting bracket
from non-drive end shield. See Figure 38.
9. Remove non-drive end shield from stator housing.

See Figure 38.
10. Using bearing puller, carefully remove non-drive

end ball bearing from non-drive end shield. See
Figure 38.
11. Remove O-ring seal from non-drive end shield.

See Figure 38.

13. Remove capscrew and speed sensor from non-

drive end shield. See Figure 38.
14. Remove drive end shield and rotor from stator

15. Remove snap ring from drive end of rotor. See

Figure 38.
NOTE: STANDARD MOTOR SHOWN
16. Remove rotor from drive end shield. See Fig-
ure 38. 1. SPEED SENSOR CONNECTOR
2. THERMAL SENSOR CONNECTOR
17. Remove oil seal from drive end shield. See Fig-
ure 38. Figure 39. Electrical Connectors
18. Remove locking ring from drive end shield. See

Figure 38. 2. Connections for speed sensor connector are
shown in Figure 40.
19. Using a bearing puller, carefully remove drive end
ball bearing from drive end shield. See Figure 38.
47

the motor. If necessary, locate source of contami-
3. Clean all joints, remove all foreign matter and

contaminants such as release agents, grease, oil,
silicone seal adhesion.
1. SUPPLY 3. SIGNAL A
2. SIGNAL B 4. GROUND
Figure 40. Speed Sensor Wire Connections
3. Connections for thermal sensor connector are

shown in Figure 41.
Clean
WARNING
solvents, always follow the solvent manufac- 1. GROUND 2. POSITIVE
Figure 41. Thermal Sensor Wire Connections
with solvent and allow to thoroughly dry. DO NOT
apply liquid solvent directly to rotor windings.
48
Inspect d. Place the other DMM probe on terminal W.
1. Inspect rotor and inside motor case for marks or Meter must read less than 0.5 ohms. If the read-
grooves indicating contact between rotor and mo- ing is more than 0.5 ohms, remove the cables
tor case. Replace if damaged. from motor to inverter and measure again. If this
2. Bearings should fit snugly where they ride on the windings in the stator have burned open and the
shaft. If there is excessive wear, replace bearing motor must be repaired or replaced.
and/or shaft.
bearing does not roll smoothly, it must be re- f. Place the other DMM probe on terminal U.
placed.
4. If equipped, check retaining bushing for damage. ing is more than 0.5 ohms, remove the cables
Replace if damaged. from motor to inverter and measure again. If this
5. Check rotor windings for signs of thermal over- windings in the stator have burned open and the
load. Signs of thermal overload are dark-stained, motor must be repaired or replaced.
shorten the life of the stator housing. Assemble
Standard Motor
(DMM) set to Ohms. CAUTION
a. Place one DMM probe on terminal U. Use an arbor press and a proper size driver when
b. Place the other DMM probe on terminal V. and/or end shields. Press only on the outer race
ing is more than 0.5 ohms, remove the cables 1. Carefully install drive end ball bearing in drive end
from motor to inverter and measure again. If this shield. See Figure 38.
windings in the stator have burned open and the 2. Install locking ring in drive end shield. See Fig-
motor must be repaired or replaced. ure 38.
c. Place one DMM probe on terminal V. 3. Install rotor in drive end shield. See Figure 38.
49
4. Install snap ring on drive end of rotor. See Fig- 14. Install four tie rods to hold end shields to stator
ure 38. housing. See Figure 38.
5. Install woodruff key in drive end of rotor shaft. 15. Install terminal post bracket, terminal posts, and
See Figure 38. two screws on stator housing. See Figure 38.
6. Install rotor and drive end shield in stator housing. 16. Connect power leads to terminal posts. See Fig-
See Figure 38. ure 38.
7. Install speed sensor and capscrew onto non-drive 17. Install three spring washers and hex nuts on ter-
end shield. See Figure 38. minal posts. See Figure 38. Tighten hex nuts to
14 to 16 N•m (124 to 142 lbf in).
8. Install waved spring washer in non-drive end
shield. See Figure 38. 18. Carefully remove motor from vise and place on
suitable work surface.
9. Install O-ring seal in non-drive end shield. See
Figure 38. Enhanced Motor
CAUTION CAUTION
Use an arbor press and a proper size driver when Use an arbor press and a proper size driver when
installing bearings to avoid damage to bearings installing bearings to avoid damage to bearings
and/or end shields. Press only on the outer race and/or end shields. Press only on the outer race
of the bearing. Always replace bearings in sets. of the bearing. Always replace bearings in sets.
10. Carefully install non-drive end ball bearing in non- 1. Carefully install drive end ball bearing in drive end
drive end shield. See Figure 38. shield. See Figure 38.
11. Install non-drive end shield on stator housing. See 2. Install locking ring in drive end shield. See Fig-
Figure 38. ure 38.
12. Apply neutral curing, high temperature silicone 3. Install oil seal in drive end shield. See Figure 38.
sealant (rated for at least 260°C (500°F)) between
stator housing and non-drive end shield to protect 4. Install rotor in drive end shield. See Figure 38.
power leads and thermal sensor.
5. Install snap ring on drive end of rotor. See Fig-
13. Install new O-ring on cap. Install cap in non-drive ure 38.
end shield. See Figure 38.
50
6. Install rotor and drive end shield in stator housing. 15. Install four M8 X 270 screws to hold end shields
See Figure 38. to stator housing. See Figure 38.
7. Install speed sensor and capscrew on non-drive 16. Install four spacers, four washers, fan cover, and
end shield. See Figure 38. four capscrews on non-drive end shield. See Fig-
ure 38.
8. Install waved spring washer in non-drive end
shield. See Figure 38. 17. Install terminal post bracket, bracket, terminal
posts, and two screws on stator housing. See Fig-
9. Install O-ring seal in non-drive end shield. See ure 38.
Figure 38.
18. Connect power leads to terminal posts. See Fig-
ure 38.
CAUTION
Use an arbor press and a proper size driver when 19. Install three spring washers and hex nuts to termi-
installing bearings to avoid damage to bearings nal posts. See Figure 38. Tighten hex nuts to 14
and/or end shields. Press only on the outer race to 16 N•m (124 to 142 lbf in).
20. Carefully remove motor from vise and place on
10. Carefully install non-drive end ball bearing in drive suitable work surface.
end shield. See Figure 38.
Install
11. Install non-drive end shield on stator housing. See
Figure 38. 1. Install keys onto motor shaft.
12. Apply neutral curing, high temperature silicone 2. Install coupling onto pump shaft and motor shaft.
sealant (rated for at least 260°C (500°F)) between See Figure 37.
stator housing and non-drive end shield to protect
power leads and thermal sensor. 3. Make sure the halves of the coupling are correctly
engaged. Make sure setscrews that fasten cou-
13. Install mounting bracket and three capscrews on pling to shafts are 180° opposed. See Figure 37.
non-drive end shield. See Figure 38. Tighten setscrews to 11 to 13 N•m (97 to
115 lbf in).
14. Install retaining bushing into cooling fan. Install
cooling fan in non-drive end shield. See Fig-
ure 38.
51
4. Make sure pump is aligned to motor as marked See Figure 42 for lift truck models
during removal. Install two capscrews fastening • ERP2.2-3.5VL (ERP045-070VL) (A976)
pump to motor. See Figure 37. Tighten capscrews
to 25 N•m (221 lbf in). See Figure 43 for lift truck models
NOTE: Remove plugs from pump openings and in- • ERC16-20VA (ERC030-040VA) (A969)
stall plugs in suction adapter and fitting after installa- 3. Disconnect power leads from terminal posts.
tion.
5. Install suction adapter onto hydraulic pump as no-
ted during removal. See Figure 37. Tighten • ERP2.2-3.5VL (ERP045-070VL) (A976)
adapter to 91 to 100 N•m (67 to 74 lbf ft).
6. Install fitting onto hydraulic pump. See Figure 37. • ERC16-20VA (ERC030-040VA) (A969)
Tighten fitting to 49 to 59 N•m (36 to 44 lbf ft).
4. Remove two screws, terminal posts, and terminal
7. Install hydraulic pump and motor assembly in lift post bracket and terminal strip from stator hous-
truck. See Hydraulic System 1900YRM1367 for ing.
instructions.
FOR LIFT TRUCK MODELS ERP2.2-3.5VL • ERP2.2-3.5VL (ERP045-070VL) (A976)
(ERP045-070VL) (A976) AND ERC16-20VA
(ERC030-040VA) (A969) See Figure 43 for lift truck models
• ERC16-20VA (ERC030-040VA) (A969)
Remove
NOTE: Perform Step 5 for lift truck models
1. Remove hydraulic pump and motor assembly
ERP22-35VL (ERP045-070VL) (A976) only.
from lift truck. See Hydraulic System
1900YRM1367 for removal instructions. 5. Remove three socket-head capscrews and fan
cover from non drive end shield.
clean workbench or other suitable surface. 6. Remove four tie rods holding end shields to stator
housing.
3. Remove the hydraulic pump and motor brackets.
See Hydraulic System 1900YRM1367 for re- See Figure 42 for lift truck models
moval instructions.
• ERP2.2-3.5VL (ERP045-070VL) (A976)
Disassemble See Figure 43 for lift truck models
1. Place motor in a vise with terminal posts on top • ERC16-20VA (ERC030-040VA) (A969)
and carefully clamp vise on stator housing.
2. Remove three hex nuts and lockwashers from ter-

minal posts.
52
12. Remove drive end shield and rotor from stator

CAUTION housing.
ronmental regulations. See Figure 42 for lift truck models
• ERP2.2-3.5VL (ERP045-070VL) (A976)
NOTE: during the performance of the following step,
remove only a sufficient amount of sealing material to See Figure 43 for lift truck models
allow removal of the non-drive end shield. • ERC16-20VA (ERC030-040VA) (A969)
7. Carefully remove silicone seal material from the 13. Remove and discard seal from the drive end
non-drive end shield. shield.
NOTE: Note threading position and orientation of See Figure 42 for lift truck models
through non-drive end shield during disassembly to • ERP2.2-3.5VL (ERP045-070VL) (A976)
aid in assembly. See Figure 43 for lift truck models
8. Remove non-drive end shield from stator housing. • ERC16-20VA (ERC030-040VA) (A969)
See Figure 42 for lift truck models 14. Remove lock ring, snap ring and drive end shield
• ERP2.2-3.5VL (ERP045-070VL) (A976) from the rotor.
See Figure 43 for lift truck models See Figure 42 for lift truck models
• ERC16-20VA (ERC030-040VA) (A969) • ERP2.2-3.5VL (ERP045-070VL) (A976)
9. Using bearing puller, carefully remove non-drive See Figure 43 for lift truck models
end ball bearing from rotor. • ERC16-20VA (ERC030-040VA) (A969)
10. Remove wave washer, seal, retaining bushing 15. Using bearing puller, carefully remove drive end
and fan from the non-drive end shield. Discard the ball bearing from the rotor.
seal.
See Figure 42 for lift truck models • ERP2.2-3.5VL (ERP045-070VL) (A976)
• ERP2.2-3.5VL (ERP045-070VL) (A976)
See Figure 43 for lift truck models • ERC16-20VA (ERC030-040VA) (A969)
• ERC16-20VA (ERC030-040VA) (A969)

drive end shield.
53
Figure 42. Hydraulic Motor, Lift Truck Models ERP2.2-3.5VL (ERP045-070VL) (A976)
54
1. SEAL 14. SCREW

2. LOCK RING 15. ROTOR
3. DRIVE END SHIELD 16. WAVE WASHER
4. BEARING 17. SEAL
5. SNAP RING 18. FAN
6. STATOR HOUSING 19. RETAINING BUSHING
7. THERMAL SENSOR 20. SPACER
8. CONNECTOR 21. NON-DRIVE END SHIELD
9. TERMINAL STRIP 22. SPEED SENSOR
10. TERMINAL POST BRACKET 23. SOCKET-HEAD CAPSCREW
11. TERMINAL POST 24. TIE ROD
12. LOCKWASHER 25. WASHER
13. HEX NUT 26. FAN COVER
55
Figure 43. Hydraulic Motor, Lift Truck Models ERC16-20VA (ERC030-040VA) (A969)
56
1. SEAL 13. HEX NUT

2. LOCK RING 14. SCREW
3. DRIVE END SHIELD 15. ROTOR
4. BEARING 16. WAVE WASHER
5. SNAP RING 17. SEAL
6. STATOR HOUSING 18. FAN
7. THERMAL SENSOR 19. RETAINING BUSHING
8. CONNECTOR 20. SPACER
9. TERMINAL STRIP 21. NON-DRIVE END SHIELD
10. TERMINAL POST BRACKET 22. SPEED SENSOR
11. TERMINAL POST 23. SOCKET-HEAD CAPSCREW
12. LOCKWASHER 24. TIE ROD
57
Electrical Connector Repair or Replacement 2. Connections for speed sensor connector are
shown in Figure 45.
mal sensor connector may be repaired or re-
Connector Assemblies section of Wire Harness
1. SPEED SENSOR CONNECTOR 3. Connections for thermal sensor connector are

2. THERMAL SENSOR CONNECTOR shown in Figure 46.
Figure 44. Electrical Connectors
58

with solvent and allow to thoroughly dry. DO NOT
apply liquid solvent directly to rotor windings.

the motor. If necessary, locate source of contami-

contaminants such as release agents, grease, oil,
Inspect
1. Inspect rotor and inside motor case for marks or
grooves indicating contact between rotor and mo-
tor case. Replace if damaged.

shaft. If there is excessive wear, replace bearing
and/or shaft.

1. GROUND 2. POSITIVE bearing does not roll smoothly, it must be re-
placed.
Clean brittle, or burnt insulation. Thermal overload will
shorten the life of the stator housing.
WARNING 5. Check motor windings resistance as indicated be-

Cleaning solvents can be flammable and toxic and low. To measure continuity between U, V, and W
can cause skin irritation. When using cleaning terminals of motor use a digital multi-meter
solvents, always follow the solvent manufac- (DMM) set to Ohms.
59
a. Place one DMM probe on terminal U. See Figure 43 for lift truck models
• ERC16-20VA (ERC030-040VA) (A969)
3. Install a new seal in the drive end shield.
ing is more than 0.5 ohms, remove the cables See Figure 42 for lift truck models
reading is other than 0.5 ohm or less, the motor • ERP22-35VL (ERP045-070VL) (A976)
windings in the stator have burned open and the See Figure 43 for lift truck models
• ERC16-20VA (ERC030-040VA) (A969)
4. Install drive end shield and rotor in stator housing.
Meter must read less than 0.5 ohms. If the read- • ERP22-35VL (ERP045-070VL) (A976)
from motor to inverter and measure again. If this See Figure 43 for lift truck models
reading is other than 0.5 ohm or less, the motor • ERC16-20VA (ERC030-040VA) (A969)
motor must be repaired or replaced. 5. Install speed sensor and capscrew in non-drive
end shield.
• ERP22-35VL (ERP045-070VL) (A976)
ing is more than 0.5 ohms, remove the cables See Figure 43 for lift truck models
from motor to inverter and measure again. If this • ERC16-20VA (ERC030-040VA) (A969)
windings in the stator have burned open and the 6. Install new seal, wave washer, fan, and retaining
motor must be repaired or replaced. bushing in the non-drive end shield. Discard the
seal.
Assemble
• ERP22-35VL (ERP045-070VL) (A976)
CAUTION
Use an arbor press and a proper size driver when See Figure 43 for lift truck models
installing bearings to avoid damage to bearings • ERC16-20VA (ERC030-040VA) (A969)
and/or rotor. Press only on the INNER race of the
bearing. Always replace bearings in sets.
CAUTION
1. Using a press, carefully install drive end ball bear- Use an arbor press and a proper size driver when
ing onto the rotor. installing bearings to avoid damage to bearings
bearing. Always replace bearings in sets.
• ERP22-35VL (ERP045-070VL) (A976)
7. Using a press, install non-drive end ball bearing
See Figure 43 for lift truck models onto the rotor.
• ERC16-20VA (ERC030-040VA) (A969)
2. Install drive end shield, snap ring, and lock ring on • ERP22-35VL (ERP045-070VL) (A976)
the rotor.
• ERC16-20VA (ERC030-040VA) (A969)
• ERP22-35VL (ERP045-070VL) (A976)
60
8. Install non-drive end shield onto stator housing 14. Fill the area around the power leads and thermal
and place power leads and thermal sensor in the sensor located on the non-drive end shield with
orientation and position as noted during removal. neutral curing, high temperature silicone sealant
(rated for at least 260°C (500°F).
• ERP22-35VL (ERP045-070VL) (A976) Install
See Figure 43 for lift truck models 1. Place hydraulic motor assembly on a clean work-
bench or other suitable work surface.
• ERC16-20VA (ERC030-040VA) (A969)
2. Install the hydraulic pump and motor brackets.
9. Install four tie rods holding end shields to stator
See Hydraulic System 1900YRM1367 for instal-
housing.
lation instructions.
3. Install hydraulic pump and motor assembly on the
• ERP22-35VL (ERP045-070VL) (A976) lift truck. See Hydraulic System 1900YRM1367
for installation instructions.
• ERC16-20VA (ERC030-040VA) (A969)
HYDRAULIC MOTOR REPAIR FOR
NOTE: Perform Step 10 for lift truck models 4.0-5.5T LIFT TRUCKS
ERP22-35VL (ERP045-070VL) (A976) only.
This section covers the hydraulic motor repair proce-
10. Install fan cover and three socket-head cap- dures for lift truck models:
screws on non drive end shield. See Figure 42.
• ERP40-50VM, ERP50-55VM6
11. Using two screws, install terminal strip, terminal (ERP080-120VM, ERP100VML) (A985)
post bracket, terminal posts onto stator housing. • ERC40-55VH, ERC50VHS (ERC80-120VH,
ERC100VHS) (A938)
• ERP22-35VL (ERP045-070VL) (A976) Remove
See Figure 43 for lift truck models 1. Remove hydraulic pump and motor assembly
• ERC16-20VA (ERC030-040VA) (A969) from lift truck. See Hydraulic System
1900YRM1367 for removal instructions.
12. Connect power leads from terminal posts.
See Figure 42 for lift truck models clean workbench or other suitable surface.
• ERP22-35VL (ERP045-070VL) (A976) 3. Remove the hydraulic pump and motor brackets.
See Hydraulic System 1900YRM1367 for re-
moval instructions.
• ERC16-20VA (ERC030-040VA) (A969)
Disassemble
13. Install three lockwashers and hex nuts onto termi-
nal posts.
Tighten hex nuts to 14 to 16 N•m (124 to 1. Place motor in a vise with terminal posts on top
142 lbf in). See Figure 42 for lift truck models and carefully clamp vise on stator housing.
• ERP2.2-3.5VL (ERP045-070VL) (A976) 2. Remove three hex nuts and lockwashers from ter-
minal posts. See Figure 47.
Tighten hex nuts to 14 to 16 N•m (124 to
142 lbf in). See Figure 43 for lift truck models 3. Disconnect terminal cables from terminal posts.
• ERC16-20VA (ERC030-040VA) (A969) See Figure 47.
61
0620 YRM 1385
4. Remove two screws, terminal posts, and terminal 9. Remove non-drive end shield from stator housing.
post bracket and terminal strip from stator hous- See Figure 47.
ing. See Figure 47.
10. Remove wave washer from the non-drive end
5. Remove two socket-head capscrews and fan shield. Discard the seal. See Figure 47.
cover from non drive end shield.
11. Using bearing puller, carefully remove non-drive
6. Remove four tie rods holding end shields to stator end ball bearing from rotor.
drive end shield.
CAUTION
Disposal of silicone sealant must meet local envi- 13. Remove drive end shield and rotor from stator
ronmental regulations. housing. See Figure 47.
NOTE: during the performance of the following step, 14. Remove and discard seal from the drive end
remove only a sufficient amount of sealing material to shield. See Figure 47.
allow removal of the non-drive end shield. 15. Remove drive end shield from the rotor. See Fig-
7. Carefully remove silicone seal material from the ure 47.
non-drive end shield. 16. Remove and discard O-ring from drive end shield.
8. Remove spur wheel and tolerance ring from rotor. 17. Using bearing puller, carefully remove drive end
NOTE: Note threading position and orientation of ball bearing from the rotor. See Figure 47.
aid in assembly.
62
0620 YRM 1385
1. HEX NUT 13. WAVE WASHER

2. LOCK WASHER 14. BEARING
3. WASHER 15. ROTOR
4. TERMINAL 16. STATOR
5. CYLINDER SCREW 17. DRIVE END SHIELD
6. TERMINAL BASE 18. SEAL
7. HEX SCREW 19. TEMPERATURE SENSOR
8. TERMINAL CABLE 20. TEMPERATURE SENSOR CONNECTOR
9. TIE ROD 21. SPEED SENSOR CONNECTOR
10. NON-DRIVE END PLATE 22. SPUR WHEEL
11. SPEED SENSOR 23. TOLERANCE RING
12. O-RING 24. FAN COVER
Figure 47. Hydraulic Motor, Lift Truck Models ERP40-50VM, ERP50-55VM6 (ERP080-120VM, ERP100VML)
(A985) and ERC40-55VH, ERC50VHS (ERC80-120VH, ERC100VHS) (A938)
63
0620 YRM 1385
Electrical Connector Repair or Replacement 3. Connections for thermal sensor connector are
shown in Figure 49.
mal sensor connector may be repaired or re-
Connector Assemblies section of Wire Harness
2. Connections for speed sensor connector are

shown in Figure 48.
1. GROUND 2. POSITIVE
64
0620 YRM 1385
Clean 5. Check motor windings resistance as indicated be-

WARNING (DMM) set to Ohms.
can cause skin irritation. When using cleaning a. Place one DMM probe on terminal U.
solvents, always follow the solvent manufac-
turer’s recommended safety procedures. b. Place the other DMM probe on terminal V.
1. Clean components with a clean cloth moistened Meter must read less than 0.5 ohms. If the read-
with solvent and allow to thoroughly dry. DO NOT ing is more than 0.5 ohms, remove the cables
apply liquid solvent directly to rotor windings. from motor to inverter and measure again. If this
2. Check for signs of oil or other contaminants within windings in the stator have burned open and the
the motor. If necessary, locate source of contami- motor must be repaired or replaced.
contaminants such as release agents, grease, oil, d. Place the other DMM probe on terminal W.
Inspect
1. Inspect rotor and inside motor case for marks or motor must be repaired or replaced.
grooves indicating contact between rotor and mo-
tor case. Replace if damaged.
shaft. If there is excessive wear, replace bearing Meter must read less than 0.5 ohms. If the read-
and/or shaft. ing is more than 0.5 ohms, remove the cables
bearing does not roll smoothly, it must be re-
placed.
shorten the life of the stator housing.
65
0620 YRM 1385
Assemble 10. Install spur wheel and tolerance ring onto the ro-
tor.
CAUTION 11. Install four tie rods holding end shields to stator
Use an arbor press and a proper size driver when housing. Tighten tie rods to 20 N•m (177 lbf in).
installing bearings to avoid damage to bearings See Figure 47.
bearing. Always replace bearings in sets. 12. Install fan cover and two socket-head capscrews
on non drive end shield. See Figure 47.
NOTE: Grease bearings with quality bearing grease.
13. Using two screws, install terminal strip, terminal
1. Using a press, carefully Install drive end ball bear- post bracket, terminal posts onto stator housing.
ing onto the rotor. See Figure 47. See Figure 47.
2. Install new O-ring in drive end shield. 14. Connect power leads from terminal posts. See
Figure 47
3. Install drive end shield on the rotor. See Fig-
ure 47. 15. Install three washers and hex nuts onto terminal
posts. Tighten hex nuts to 14 to 16 N•m (124 to
4. Install a new seal in the drive end shield. See Fig- 142 lbf in). See Figure 47.
ure 47.
16. Install lock three washers and hex nuts onto ter-
5. Install drive end shield and rotor in stator housing. minal posts. Tighten hex nuts to 14 to
See Figure 47. 16 N•m (124 to 142 lbf in). See Figure 47.
6. Install speed sensor and capscrew in non-drive 17. Fill the area around the power leads and thermal
end shield. See Figure 47. sensor located on the non-drive end shield with
neutral curing, high temperature silicone sealant
7. Install new seal and wave washer in the non-drive (rated for at least 260°C (500°F).
end shield. Discard the seal. See Figure 47.
Install
CAUTION 1. Place hydraulic motor assembly on a clean work-
Use an arbor press and a proper size driver when bench or other suitable work surface.
and/or rotor. Press only on the INNER race of the 2. Install the hydraulic pump and motor brackets.
bearing. Always replace bearings in sets. See Hydraulic System 1900YRM1367 for instal-
lation instructions.
NOTE: Grease bearings with quality bearing grease.
3. Install hydraulic pump and motor assembly on the
8. Using a press, install non-drive end ball bearing lift truck. See Hydraulic System 1900YRM1367
onto the rotor. See Figure 47. for installation instructions.
9. Install non-drive end shield onto stator housing
and place power leads and thermal sensor in the
orientation and position as noted during removal.
See Figure 47.
66
0620 YRM 1385 Torque Specifications
Torque Specifications
TRACTION MOTOR FOR LIFT TRUCKS HYDRAULIC MOTOR FOR LIFT TRUCK
ERP15-20VT (ERP030-040VT) (G807) AND ERC22-35VG (ERC045-070VG) (A968)
ERP16-20VF (ERP30-40VF) (A955)
Terminal Post Hex Nuts
Terminal Post Hex Nuts 14 to 16 N•m (124 to 142 lbf in)
14 to 16 N•m (124 to 142 lbf in)
Setscrews
Socket-Head Capscrews 11 to 13 N•m (97 to 115 lbf in)
14 to 16 N•m (124 to 142 lbf in)
Pump to Motor Capscrews
Mounting Capscrews 25 N•m (221 lbf in)
48 N•m (35 lbf ft)
Suction Adapter
TRACTION MOTOR FOR LIFT TRUCK 91 to 100 N•m (67 to 74 lbf ft)
ERC22-35VG (ERC045-070VG) (A968),
ERC16-20VA (ERC030-040VA) (A969), Fitting
AND ERC40-55VH, ERC50VHS 49 to 59 N•m (36 to 44 lbf ft)
(ERC80-120VH, ERC100VHS) (A938) HYDRAULIC MOTOR FOR LIFT TRUCK
End Head to Stator Housing Capscrews ERP22-35VG (ERP045-070VG) (A976)
25 to 30 N•m (18 to 22 lbf ft)
Terminal Post Hex Nuts (Lower)
TRACTION MOTOR FOR LIFT TRUCK 14 to 16 N•m (124 to 142 lbf in)
ESC030-040AC (B883), ESC030-040AD Terminal Post Hex Nuts (Upper)
(C883) 14 to 16 N•m (124 to 142 lbf in)
Terminal Post Hex Nut
14 to 16 N•m (124 to 142 lbf in)
HYDRAULIC MOTOR FOR LIFT TRUCK
ERC16-20VA (ERC030-040VA) (A969)
Socket-Head Capscrews
Terminal Post Hex Nuts (Lower)
14 to 16 N•m (124 to 142 lbf in)
14 to 16 N•m (124 to 142 lbf in)
Mounting Capscrews
Terminal Post Hex Nuts (Upper)
48 N•m (35 lbf ft)
14 to 16 N•m (124 to 142 lbf in)
HYDRAULIC MOTOR FOR LIFT TRUCKS HYDRAULIC MOTOR FOR LIFT TRUCK
ERP15-20VT (ERP030-040VT) (G807) AND ESC030-040AC (B883), ESC030-040AD
ERP16-20VF (ERP30-40VF) (A955) (C883)
Tie Bar Screws
Tie Bar Screws
14 to 17 N•m (124 to 150 lbf in)
14 to 17 N•m (124 to 150 lbf in)
14 to 16 N•m (124 to 142 lbf in)
14 to 16 N•m (124 to 142 lbf in)
47 N•m (35 lbf ft)
47 N•m (35 lbf ft)
67
Torque Specifications 0620 YRM 1385
HYDRAULIC MOTOR FOR LIFT TRUCK

ERP40-50VM, ERP50-55VM6
(ERP080-120VM, ERP100VML) (A985)
AND ERC40-55VH, ERC50VHS
(ERC80-120VH, ERC100VHS) (A938)
Tie Bar Screws
20 N•m (177 lbf in)
Suction Adapter
91 to 100 N•m (67 to 74 lbf ft)
Fitting
78 to 88 N•m (58 to 65 lbf ft)
68
0620 YRM 1385 6/15 (9/14)(12/12)(3/12)(1/11)(4/10)

AC Motor Repair Hyster US-EN

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Maintenance

PART NO. 524327049 0620 YRM 1385

©2015 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

This section is for the following models:

ERP15-20VT (ERP030-040VT) [G807];

Electrical System 2200YRM1414 for lift truck models

Electrical System 2200YRM2022 for lift truck models

Periodic Maintenance 8000YRM1418 for lift truck

Periodic Maintenance 8000YRM2025 for lift truck

WARNING Figure 1. Truck Orientation (Three-Wheel Models)

Throughout this section, forward will refer to travel in

See Figure 3 for lift truck models

See Figure 6 for lift truck models • ERP15-20VT (ERP030-040VT) (G807)

See Figure 5 for lift truck models

See Figure 6 for lift truck models

See Figure 7 for lift truck models

1. LEFT TRANSAXLE 3. RIGHT TRANSAXLE

1. HYDRAULIC PUMP MOTOR

1. LEFT TRACTION MOTOR 4. LEFT TRANSMISSION

1. LEFT TRANSMISSION 4. HYDRAULIC MOTOR

For lift truck models below, the traction motor is

See Figure 8 for lift truck models

See Figure 9 for lift truck models

For lift truck models ERC22-35VG (ERC045-070VG)

For lift truck models ERC16-20VA (ERC030-040VA)

See Figure 10 for lift truck model

DISCHARGING THE CAPACITORS FOR 4. Remove the electrical compartment cover to

Disconnect the battery and allow the capacitors to

Some checks and adjustments are performed with

Before performing any tests or adjustments, block

The capacitor in the transistor controller(s) can

system. DO NOT place tools on top of the battery.

Some checks and adjustments are performed with

Before performing any tests or adjustments, block

The capacitors in the transistor controller(s) can

DO NOT short across the motor controller

Traction Motor Repair

1. TRANSAXLE 7. TRACTION MOTOR

Figure 13. Transaxle Assembly

9. Remove four traction motor mounting capscrews,

Figure 14. Traction Motor

Legend for Figure 14

1. TRANSAXLE END HEAD 6. BRAKE END HEAD

NOTE: Carefully tap underside of brake end head Clean

b. Place the other DMM probe on terminal V. Assemble

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 read-

e. Place one DMM probe on terminal W.

f. Place the other DMM probe on terminal U.

NOTE: A likely cause of motor contamination may be

Figure 16. Traction Motor

Legend for Figure 16

1. TRANSAXLE END HEAD 6. BRAKE END HEAD

NOTE: Use an approved lifting device to lift and hold

1. Apply Dexron III transmission fluid to drive splines

1. TRANSAXLE 7. TRACTION MOTOR

Figure 18. Transaxle Assembly

A. NON-DRIVE END B. DRIVE END

Figure 19. Traction Motor Non-Drive End Head

NOTE: When replacing one bearing, it is strongly

NOTE: Note orientation of bearing components prior