Ac Motor Repair: PART NO. 1696595 0620 SRM 1385

AC MOTOR REPAIR
J1.5-2.0XNT (J30-40XNT) [K160];

J1.6-2.0XN (J30-40XN) [A935];
E2.2-3.5XN (E45-70XN) [A268];
E1.6-2.0XN (E30-40XN) [A269];
J2.2-3.5XN (J45-70XN) [A276];
E30-40HSD2 [B219];
E30HSD3, E35HSD3, E40HSD3 [C219];
J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL)
[A970];
E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS)
[A099]
PART NO. 1696595 0620 SRM 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 Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Discharging the Capacitors for Lift Truck Models E30-40HSD2 (B219), E30-40HSD3 (C219)......................9
Discharging the Capacitors (All Other Models) .............................................................................................. 10
Traction Motor Repair ...........................................................................................................................................12
For Lift Truck Models , and J1.5-2.0XNT (J30-40XNT) (K160)......................................................................12
Remove .......................................................................................................................................................... 12
Disassemble .................................................................................................................................................. 13
Electrical Connector Repair or Replacement .............................................................................................. 16
Clean ..............................................................................................................................................................16
Inspect ........................................................................................................................................................... 16
Assemble ....................................................................................................................................................... 17
Install ............................................................................................................................................................ 20
For Lift Truck E2.2-3.5XN (E45-70XN) (A268)................................................................................................22
Remove .......................................................................................................................................................... 22
Disassemble .................................................................................................................................................. 22
Clean ..............................................................................................................................................................25
Inspect ........................................................................................................................................................... 25
Assemble ....................................................................................................................................................... 26
Install ............................................................................................................................................................ 26
For Lift Truck J2.2-3.5XN (J45-70XN) (A276)................................................................................................. 26
Remove .......................................................................................................................................................... 26
Disassemble .................................................................................................................................................. 26
Clean ..............................................................................................................................................................28
Inspect ........................................................................................................................................................... 28
Assemble ....................................................................................................................................................... 29
Install ............................................................................................................................................................ 29
For Lift Truck E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099).......................................................... 29
Remove .......................................................................................................................................................... 29
Disassemble .................................................................................................................................................. 30
Clean ..............................................................................................................................................................31
Inspect ........................................................................................................................................................... 31
Assemble ....................................................................................................................................................... 32
Install ............................................................................................................................................................ 33
Traction Motor Repair For Lift Truck J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) (A970)................ 33
Remove .......................................................................................................................................................... 33
Clean ..............................................................................................................................................................35
Install ............................................................................................................................................................ 35
Hydraulic Motor Repair ........................................................................................................................................ 36
For Lift Trucks , , and J1.5-2.0XNT (J30-40XNT) (K160)............................................................................... 36
Remove .......................................................................................................................................................... 36
Disassemble .................................................................................................................................................. 37
Clean ..............................................................................................................................................................39
Inspect ........................................................................................................................................................... 40
Assemble ....................................................................................................................................................... 40
Install ............................................................................................................................................................ 42
For Lift Truck E2.2-3.5XN (E45-70XN) (A268)................................................................................................44
Remove .......................................................................................................................................................... 44
©2015 HYSTER COMPANY i

Table of Contents
TABLE OF CONTENTS (Continued)
Disassemble .................................................................................................................................................. 45
Standard Motor ........................................................................................................................................ 45
Enhanced Motor ....................................................................................................................................... 46
Clean ..............................................................................................................................................................50
Inspect ........................................................................................................................................................... 50
Assemble ....................................................................................................................................................... 50
Standard Motor ........................................................................................................................................ 50
Enhanced Motor ....................................................................................................................................... 51
Install ............................................................................................................................................................ 52
For Lift Truck Models J2.2-3.5XN (J45-70XN) (A276).................................................................................... 52
Remove .......................................................................................................................................................... 52
Disassemble .................................................................................................................................................. 52
Clean ..............................................................................................................................................................59
Inspect ........................................................................................................................................................... 60
Assemble ....................................................................................................................................................... 60
Install ............................................................................................................................................................ 61
Hydraulic Motor Repair For 4.0-5.5T Lift Trucks ...........................................................................................61
Remove .......................................................................................................................................................... 62
Disassemble .................................................................................................................................................. 62
Clean ..............................................................................................................................................................65
Inspect ........................................................................................................................................................... 65
Assemble ....................................................................................................................................................... 66
Install ............................................................................................................................................................ 66
Torque Specifications ............................................................................................................................................ 67
Traction Motor for Lift Trucks and J1.5-2.0XNT (J30-40XNT) (K160).......................................................... 67
Traction Motor for Lift Truck and E2.2-3.5XN (E45-70XN) (A268), ..............................................................67
Traction Motor for Lift Truck E30-40HSD2 (B219), E30-40HSD3 (C219)..................................................... 67
Hydraulic Motor for Lift Trucks and J1.5-2.0XNT (J30-40XNT) (K160)........................................................67
Hydraulic Motor for Lift Truck E2.2-3.5XN (E45-70XN) (A268).................................................................... 67
Hydraulic Motor for Lift Truck J2.2-3.5XN (J45-70XN) (A276)......................................................................67
Hydraulic Motor for Lift Truck E1.6-2.0XN (E30-40XN) (A269).................................................................... 67
Hydraulic Motor for Lift Truck E30-40HSD2 (B219), E30-40HSD3 (C219)...................................................67
Hydraulic Motor for Lift Truck and J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) (A970)....................67
This section is for the following models:
J1.5-2.0XNT (J30-40XNT) [K160];

J1.6-2.0XN (J30-40XN) [A935];
E2.2-3.5XN (E45-70XN) [A268];
E1.6-2.0XN (E30-40XN) [A269];
J2.2-3.5XN (J45-70XN) [A276];
(E30-40HSD2) [B219];
(E30HSD3, E35HSD3, E40HSD3) [C219];
J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) [A970];
E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) [A099]
ii
0620 SRM 1385 General
General
This section contains repair and maintenance Periodic Maintenance 8000SRM1339 for lift
procedures for the AC motors. Additional truck models
information concerning the motors may be more • J1.5-2.0XNT (J30-40XNT) (K160)
closely related to other systems and included in
those sections. Sections that contain information Periodic Maintenance 8000SRM1364 for lift
regarding the motors include: truck models
Electrical System 2200SRM1337 for lift truck • E2.2-3.5XN (E45-70XN) (A268)
models
Periodic Maintenance 8000SRM1372 for lift
• J1.5-2.0XNT (J30-40XNT) (K160) truck models
• J1.6-2.0XN (J30-40XN) (A935) • J2.2-3.5XN (J45-70XN) (A276)
Electrical System 2200SRM1369 for lift truck Periodic Maintenance 8000SRM1418 for lift
models truck models
• E2.2-3.5XN (E45-70XN) (A268) • E30-40HSD2 (B219)
• J2.2-3.5XN (J45-70XN) (A276)
• E1.6-2.0XN (E30-40XN) (A269) Periodic Maintenance 8000SRM2025 for lift
truck models
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970) • E30-40HSD3 (C219)
• E4.0-5.5XN, E5.0XNS (E80-120XN,
E100XNS) (A099) Periodic Maintenance 8000SRM1442 for lift
truck models
Electrical System 2200SRM1414 for lift truck • E1.6-2.0XN (E30-40XN) (A269)
models
• E30-40HSD2 (B219) Periodic Maintenance 8000SRM1541
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
Electrical System 2200SRM2022 for lift truck J100XNL) (A970)
models
Periodic Maintenance 8000SRM1577 for lift
• E30-40HSD3 (C219)
truck model
Periodic Maintenance 8000SRM1373 for lift • E4.0-5.5XN, E5.0XNS (E80-120XN,
truck models E100XNS) (A099)
• J1.6-2.0XN (J30-40XN) (A935)
1
General 0620 SRM 1385
WARNING
DO NOT make repairs or adjustments unless you
are properly trained and have authorization to do
so. Repairs and adjustments that are not correct
can create dangerous operating conditions. DO
NOT operate a lift truck that needs repairs. Report
the need for repairs to your supervisor
immediately. If repair is necessary, attach a DO
NOT OPERATE tag to the steering wheel and
remove the key from the key switch.
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 A. LEFT SIDE C. FORWARD TRAVEL
information about the traction motors is available B. RIGHT SIDE
through on-board diagnostics and may be displayed
on the dash display. Refer to one of the following Figure 1. Truck Orientation (Three-Wheel Models)
sections for further explanation of dash display
codes concerning the motors:
User Interface Service-Level Functions On-

Board Dash Display =>s/n B219N02184L
2200SRM1417 for lift truck models
• E30-40HSD2 (B219)
User Interface Service Technician

2200SRM1336 for lift truck models
• J1.6-2.0XN (J30-40XN) (A935)
• J1.5-2.0XNT (J30-40XNT) (K160)
• E2.2-3.5XN (E45-70XN) (A268)
• J2.2-3.5XN (J45-70XN) (A276)
• E1.6-2.0XN (E30-40XN) (A269)
A. LEFT SIDE C. FORWARD TRAVEL
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, B. RIGHT SIDE
J100XNL) (A970)
• E4.0-5.5XN, E5.0XNS (E80-120XN, Figure 2. Truck Orientation (Four-Wheel Models)
E100XNS) (A099)
2
The traction motors are mounted onto the For the lift truck models below, the hydraulic pump
transaxle for the following lift truck models: motor is mounted inside the counterweight.
See Figure 3 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160)

• J1.5-2.0XNT (J30-40XNT) (K160) • J1.6-2.0XN (J30-40XN) (A935)
• J1.6-2.0XN (J30-40XN) (A935) • J2.2-3.5XN (J45-70XN) (A276)
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
See Figure 6 for lift truck models J100XNL) (A970)
• J2.2-3.5XN (J45-70XN) (A276)
See Figure 4 for lift truck models
See Figure 7 for lift truck models • J1.5-2.0XNT (K160) manufactured before
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, November, 2014
J100XNL) (A970) • J30-40XNT (K160)
See Figure 10 for lift truck model • J1.6-2.0XN (J30-40XN) (A935)
• E4.0-5.5XN, E5.0XNS (E80-120XN, See Figure 5 for lift truck models

E100XNS) (A099)
• J1.5-2.0XNT (K160) manufactured after
November, 2014

• J2.2-3.5XN (J45-70XN) (A276)

• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
J100XNL) (A970)
1. LEFT TRANSAXLE 3. RIGHT TRANSAXLE

2. TRACTION MOTOR
Figure 3. Traction Motors for Lift Truck

J1.5-2.0XNT (J30-40XNT) (K160) and J1.6-2.0XN
(J30-40XN) (A935)
3
1. HYDRAULIC PUMP MOTOR

2. COUNTERWEIGHT 1. COUNTERWEIGHT
Figure 4. Hydraulic Motor for Lift Trucks
J1.5-2.0XNT (K160) Manufactured Before Figure 5. Hydraulic Motor for Lift Trucks
November, 2014 and J30-40XNT (K160) and J1.5-2.0XNT (K160) Manufactured After November,
J1.6-2.0XN (J30-40XN) (A935) 2014
4
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 J2.2-3.5XN (J45-70XN) (A276)
5
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 J4.0-5.0XN, J5.0-5.5XN6
(J80-120XN, J100XNL) (A970)
6
For lift truck models below, the traction motor is

mounted under the frame to the drive axle.
• E2.2-3.5XN (E45-70XN) (A268)
• E1.6-2.0XN (E30-40XN) (A269)

• E2.2-3.5XN (E45-70XN) (A268)

• E1.6-2.0XN (E30-40XN) (A269)
For lift truck models E2.2-3.5XN (E45-70XN)

(A268) the hydraulic pump motor is mounted onto
the frame beside the traction motor. See Figure 8.
For lift truck models E1.6-2.0XN (E30-40XN)

(A269) and E4.0-5.5XN, E5.0XNS (E80-120XN,
E100XNS) (A099) the hydraulic pump motor is 2. TRACTION MOTOR
mounted onto the frame, opposite the traction 3. FRAME
motor.
Figure 8. Traction Motor and Hydraulic Pump
See Figure 9 for lift truck model Motor for Lift Truck E2.2-3.5XN (E45-70XN) (A268)
• E1.6-2.0XN (E30-40XN) (A269)
See Figure 10 for lift truck model

• E4.0-5.5XN, E5.0XNS (E80-120XN,
E100XNS) (A099)
7
• E30-40HSD2 (B219)
1. TRACTION MOTOR
1. FRAME 2. AUTOMATIC PARK BRAKE ACTUATOR
2. TRACTION MOTOR 3. DRIVE AXLE
3. HYDRAULIC PUMP MOTOR 4. HYDRAULIC MOTOR
Figure 9. Traction Motor and Hydraulic Pump
Motor for Lift Truck E1.6-2.0XN (E30-40XN) (A269) Figure 10. Traction Motor and Hydraulic Pump
Motor for Lift Truck Model E4.0-5.5XN, E5.0XNS
(E80-120XN, E100XNS) (A099)
For lift truck models below, the traction motors are
mounted onto the transaxle and the hydraulic
pump motor is mounted vertically to the front wall
behind the front cover.
8
DISCHARGING THE CAPACITORS FOR 2. Turn the key or keyless switch to the OFF
LIFT TRUCK MODELS E30-40HSD2 position and DISCONNECT THE BATTERY
(B219), E30-40HSD3 (C219) by pushing forward on the battery disconnect
lever.
WARNING 3. Block the lift truck so the drive wheels are off
the floor to prevent lift truck from moving.
have been properly trained and authorized to do 4. Remove the electrical compartment cover to
so. Improper repairs and adjustments can create access the lift controller.
dangerous operating conditions. DO NOT operate
a lift truck that needs repairs. Report the need for NOTE: The lift and traction controllers are wired
repairs to your supervisor immediately. If repair is parallel. Connecting the resistor across the lift
necessary, attach a DO NOT OPERATE tag on the controller will also discharge capacitors in the
steering wheel and disconnect the battery. traction controllers if they are properly connected.
Disconnect the battery and allow the capacitors to 5. Discharge the capacitors in the controllers by
discharge before opening any compartment connecting a 200-ohm, 2-watt resistor across
covers or inspecting or repairing the electrical the lift controller’s negative (B-) and positive (B
system. DO NOT place tools on top of the battery. +) terminals. Wait at least 20 seconds to be
If a tool causes a short circuit, the high current sure that the capacitors are fully discharged.
flow from the battery can cause personal injury or See Figure 11.
property damage.
Some checks and adjustments are performed with

the battery connected. DO NOT connect the
battery until the procedure instructs you to do so.
Never wear any metallic items on your fingers,
arms, or neck. Metal items can accidentally make
an electrical connection and cause injury.
Before performing any tests or adjustments, block

the lift truck to prevent unexpected movement.
The capacitor in the transistor controller(s) can

hold an electrical charge after the battery is
disconnected. To prevent an electrical shock and
personal injury, discharge the capacitor(s) before
inspecting or repairing any component in the
drive unit compartment. Make certain that the
battery has been disconnected.
DO NOT short across the motor controller

terminals with a screwdriver or jumper wire.
1. To avoid injury and prevent electrical shock,

perform the following steps (Step 2 through
Step 7 below) to discharge the capacitors before 1. B- TERMINAL
troubleshooting, making adjustments or 2. B+ TERMINAL
repairs, or connecting or disconnecting a PC 3. JUMPER LEADS
4. 200-OHM, 2-WATT RESISTOR
service tool.
Figure 11. Lift Controller
9
6. If necessary to discharge the traction 7. Remove the resistor from the controller(s) and
controllers separately from the lift controller, reinstall the covers before returning the lift
connect a 200-ohm, 2-watt resistor across the truck to service.
controller’s negative (B-) and positive (B+)
terminals. Wait at least 20 seconds to be sure DISCHARGING THE CAPACITORS (ALL
that the capacitors are fully discharged. Repeat OTHER MODELS)
for the other traction controller as necessary.
See Figure 12. WARNING
have been properly trained and authorized to do
so. Improper repairs and adjustments can create
dangerous operating conditions. DO NOT operate
a lift truck that needs repairs. Report the need for
repairs to your supervisor immediately. If repair is
necessary, attach a DO NOT OPERATE tag on the
steering wheel and disconnect the battery.
Disconnect the battery and discharge the

capacitors before opening any compartment
covers or inspecting or repairing the electrical
system. DO NOT place tools on top of the battery.
If a tool causes a short circuit, the high current
flow from the battery can cause personal injury or
property damage.
1. B+ TERMINAL
2. B- TERMINAL
3. JUMPER LEADS
4. 200-OHM, 2-WATT RESISTOR
Figure 12. Traction Controller
10
Some checks and adjustments are performed with Make certain the Emergency-Stop Switch has not
the battery connected. DO NOT connect the been activated. This will isolate the controller and
battery until the procedure instructs you to do so. prevent the capacitors from discharging properly.
Never wear any metallic items on your fingers, The proper way to disconnect the battery is by
arms, or neck. Metal items can accidentally make separating the battery connectors.
an electrical connection and cause injury.
1. Ensure the capacitors are discharged by
Before performing any tests or adjustments, block performing Step 2 through Step 6 below.
the lift truck to prevent unexpected movement.
2. Turn key or keyless switch to OFF position.
The capacitors in the transistor controller(s) can
hold an electrical charge for about 10 seconds 3. Disconnect the battery by separating the
after the battery is disconnected. To prevent an connectors.
electrical shock and personal injury, discharge
4. Block drive wheels to prevent lift truck from
the capacitor(s) before inspecting or repairing any
moving.
component in the drive unit compartment. Make
certain that the battery has been disconnected. 5. Make sure the Emergency-Stop Switch HAS
NOT been activated. If the Emergency-Stop
DO NOT short across the motor controller
Switch is activated, rotate the switch to the
terminals with a screwdriver or jumper wire.
right until it pops up.
6. Press horn button. Wait 30 seconds to be sure

capacitors are fully discharged.
11
Traction Motor Repair 0620 SRM 1385
Traction Motor Repair

FOR LIFT TRUCK MODELS J1.5-2.0XNT Periodic Maintenance 8000SRM1418 for lift
(J30-40XNT) (K160), J1.6-2.0XN truck models
(J30-40XN) (A935) AND E30-40HSD2 • E30-40HSD2 (B219)
(B219)
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 follow-
ing sections for removal instructions
NOTE: Step 1 does not apply to E30-40HSD2
(B219) lift truck models. Transaxle 1300SRM1330 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)
1. Disconnect manual release cable from parking
brake. Transaxle 1300SRM1411 for lift truck models
2. Disconnect parking brake wire harness from • E30-40HSD2 (B219)
main wire harness. See Figure 13.
6. Move transaxle/traction motor/parking brake
3. Put lift truck on blocks so that the drive tires assembly to a bench or other suitable work sur-
are suspended off the floor. See one of the fol- face.
lowing sections for procedures:
NOTE: Note placement and orientation of parking
Periodic Maintenance 8000SRM1339 for lift brake prior to removal to aid in installation.
truck models
7. Remove four socket head capscrews, lockwash-
• J1.5-2.0XNT (J30-40XNT) (K160)
ers, washers and parking brake from traction
Periodic Maintenance 8000SRM1373 for lift motor shaft. See Figure 13.
truck models
8. Remove snap ring and splined hub from trac-
• J1.6-2.0XN (J30-40XN) (A935) tion motor shaft; recover woodruff key. See Fig-
ure 13.
12
0620 SRM 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
Disassemble
WARNING
The traction motor weighs approximately 1. Remove four socket-head capscrews and lock-
18.4 kg (40.6 lb). Make sure lifting device has washers from brake end head and transaxle
enough lifting capacity to safely lift motor. end head. See Figure 14.
NOTE: Use an approved lifting device to hold and

lift traction motor during removal.
9. Remove four traction motor mounting cap-

screws, washers, and traction motor from
transaxle. See Figure 13.
13
Figure 14. Traction Motor
14
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
15
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 with solvent and allow to thoroughly dry. DO
head with a soft hammer to loosen transaxle end NOT apply liquid solvent directly to stator
head from stator. windings.
4. Remove transaxle end head from stator. See
Inspect
Figure 14.
1. Inspect rotor and inside of stator for marks or
5. Remove snap ring from brake end head. See
grooves indicating contact between rotor and
Figure 14.
stator. Replace if damaged.
6. Using bearing puller, carefully remove bearing
2. Check that the bearings roll smoothly and are
from brake end head. See Figure 14.
not loose from excessive wear. Replace as neces-
NOTE: Perform Step 7 and Step 8 if connection sary. Replace the bearings regardless of condi-
plate is damaged and must be replaced. tion if motor has been subjected to thermal
overload (see Step 3). In case of a catastrophic
7. Remove temp sensor wire harness from grom- bearing failure, damage may result to other mo-
met. See Figure 14. tor components and possibly to transaxle.
8. Remove screws, nuts, washers, grommet, and 3. Check stator windings for signs of thermal
connection plate from stator. See Figure 14. overload. Signs of thermal overload are dark-
stained, brittle, or burnt insulation. Thermal
Electrical Connector Repair or Replacement overload will shorten the life of the stator.
1. If necessary, electric brake connector (see Fig- 4. Check stator windings resistance as indicated
ure 13) may be repaired or replaced. See below. To measure continuity between U, V,
Deutsch Connectors section of Wire Harness and W terminals of motor use a digital multi-
Repair 2200SRM1128 manual for instructions. meter (DMM) set to Ohms.
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 2200SRM1128 manual
for instructions.
16
a. Place one DMM probe on terminal U. Assemble

b. Place the other DMM probe on terminal V. 1. Install transaxle end head onto stator. See Fig-
ure 15.
Meter must read less than 0.5 ohms. If the
reading is more than 0.5 ohms, remove the ca-
bles 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.

or replaced.
e. Place one DMM probe on terminal W. 1. TRANSAXLE END HEAD

2. STATOR
f. Place the other DMM probe on terminal U. 3. ROTOR
4. DRIVE SPLINES
Figure 15. Transaxle End Head, Stator and Rotor
2. Install rotor into stator with drive splines pro-
truding through transaxle end head. See Fig-
ure 15.
or replaced.
NOTE: Perform Step 3 through Step 5 if connection
NOTE: A likely cause of motor contamination may
plate and hardware was removed.
be from a damaged input bearing seal on the trans-
axle. 3. If removed, install connection plate, grommet,
washers, and nuts onto stator. See Figure 16.
5. Check for signs of oil or other contaminants
within the motor. If contaminants are present,
locate source and take corrective action.
17
18
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
19
NOTE: Terminal studs are located on top of con- 6. Carefully install bearing into brake end head.
nection plate. See Figure 16.
4. Hold lower nut of terminal stud to prevent it 7. Install snap ring into brake end head. See Fig-
from turning and tighten upper nut to ure 16.
12 N•m (106 lbf in). See Figure 17.
8. Install brake end head onto rotor shaft and sta-
tor. See Figure 16.
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 installing motor to transaxle not to damage
1. TERMINAL STUD 3. UPPER NUT transaxle shaft seal.
2. LOWER NUT
1. Apply Dexron III transmission fluid to drive
Figure 17. Terminal Studs and Nuts splines of traction motor and install traction
motor onto transaxle.
5. Insert temp sensor wire harness into grommet. 2. Apply Loctite® 271 to four traction motor
See Figure 16. mounting capscrews.
3. Install four washers and traction motor mount-

CAUTION ing capscrews into traction motor and trans-
Use an arbor press and a proper size driver when axle. See Figure 18. Tighten capscrews to
installing bearings to avoid damage to bearings 48 N•m (35 lbf ft).
and/or end shields. Press only on the outer race
of the bearing.
20
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
21
4. Install splined hub and woodruff key (with Periodic Maintenance 8000SRM1418 for lift
counterbore facing up) onto traction motor truck models
shaft. See Figure 18. • E30-40HSD2 (B219)
5. Install snap ring onto traction motor shaft. See
12. Connect battery connector and turn key or key-
Figure 18.
less switch to the ON position. Remove the
NOTE: Close clearances require parking brake to blocks from the wheels. Test for proper opera-
be installed after traction motor is installed to tion.
transaxle. Parking brake mechanical release arm
must be in vertical position when installed.
FOR LIFT TRUCK E2.2-3.5XN (E45-70XN)
(A268) AND E1.6-2.0XN (E30-40XN) (A269)
6. Install parking brake onto splined hub. See Fig-
ure 18. Remove
7. Install four washers, lockwashers, and socket- 1. Remove traction motor from lift truck. See
head capscrews into parking brake and brake Frame 0100SRM1342 for instructions.
end head of traction motor. See Figure 18.
8. Connect parking brake wire harness to main CAUTION

wiring harness. See Figure 18. The traction motor can weigh as much as
136 kg (300 lb). To prevent injury, use a lifting de-
NOTE: Step 9 does not apply to E30-40HSD2 vice capable of lifting the assembly.
(B219) lift truck models.
2. Place traction motor on level blocks on a flat
9. Connect manual release cable to parking brake. surface with drive end pointing down. Remove
floor jack.
10. Complete installation of transaxle into lift
truck. See one of the following manuals for in- Disassemble
structions:
1. Remove capscrew M6, lockwasher, and speed
Transaxle 1300SRM1330 for lift truck models sensor from non-drive end head. See Figure 19.
• J1.5-2.0XNT (J30-40XNT) (K160)
2. Remove long socket-head capscrew, lockwasher,
• J1.6-2.0XN (J30-40XN) (A935) sensor connector cover bracket, and sensor con-
nector tab bracket from stator housing above
Transaxle 1300SRM1411 for lift truck models
sensor cable outlet. See Figure 19.
• E30-40HSD2 (B219)
3. Remove five capscrews, lockwashers, and wash-
11. Lower the lift truck from the blocks. Refer to ers from stator Z-nuts and non-drive end head.
one of the following manuals for procedures: See Figure 19.
Periodic Maintenance 8000SRM1339 for lift 4. Gently tap under non-drive end head and re-
truck models move from stator housing. See Figure 19.
• J1.5-2.0XNT (J30-40XNT) (K160)
5. Pull sensor cable outlet from stator housing
Periodic Maintenance 8000SRM1373 for lift (see Figure 19) and disconnect speed sensor and
truck models temperature sensor connectors.
• J1.6-2.0XN (J30-40XN) (A935)
22
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
6. Using a bearing puller, remove and discard

proximity sensor wheel from non-drive end
head. See Figure 20.
NOTE: When replacing one bearing, it is strongly

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

during disassembly to aid in assembly.
7. Using bearing puller, remove bearing from non-

drive end head. See Figure 20.
8. Remove bearing preload spring from non-drive

end head. See Figure 20.
1. PROXIMITY SENSOR WHEEL
2. NON-DRIVE END HEAD
3. BEARING
4. BEARING PRELOAD SPRING
Figure 20. Traction Motor Non-Drive End Head
Bearing
23
9. Remove three hex-head bolts, spring washers, NOTE: When replacing one bearing, it is strongly
terminal flags, terminal covers, terminal recommended to replace both bearings.
blocks, and special nuts from stator housing on
non-drive end. See Figure 21. NOTE: Note orientation of bearing components
prior to disassembly to aid in assembly.
ers from Z-nuts on stator housing and drive end 13. Using bearing puller, remove bearing from
head. See Figure 21. drive end head. See Figure 22.
11. Attach approved lifting device to stator housing 14. Remove and discard shaft seal from drive end
and slowly lift straight up, removing it from ro- head. See Figure 22.
tor assembly and drive end head. See Fig-
ure 21.
12. Screw lifting eye into threaded hole in end of

rotor assembly. Attach approved lifting device
and lift rotor assembly straight up from drive
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
24

bearing failure, damage may result to other mo-
tor components and possibly to transaxle.
3. Check stator windings for signs of thermal

overload. Signs of thermal overload are dark-
overload will shorten the life of the stator.
4. Check motor windings resistance as indicated

below. To measure continuity between U, V,
and W terminals of motor use a digital multi-
meter (DMM) set to Ohms.
a. Place one DMM probe on terminal U.
b. Place the other DMM probe on terminal V.

1. SHAFT SEAL 3. DRIVE END HEAD
2. ROTOR ASSEMBLY 4. BEARING Meter must read less than 0.5 ohms. If the
Figure 22. Traction Motor Rotor Assembly and bles from motor to inverter and measure
Drive End Head again. If this reading is other than 0.5 ohm or
Electrical Connector Repair or Replacement or replaced.
1. If necessary, AMP Superseal tab assembly, tab c. Place one DMM probe on terminal V.
contact, and wire seal (see Figure 19) may be
repaired or replaced. See AMP Superseal 1.5 d. Place the other DMM probe on terminal W.
Connector Assemblies section of Wire Harness
Repair 2200SRM1128 manual for instructions.
Clean
WARNING burned open and the motor must be repaired
Cleaning solvents can be flammable and toxic and or replaced.
can cause skin irritation. When using cleaning
e. Place one DMM probe on terminal W.
er's recommended safety procedures. f. Place the other DMM probe on terminal U.
1. Clean components with a clean cloth moistened Meter must read less than 0.5 ohms. If the
with solvent and allow to air dry. DO NOT ap- reading is more than 0.5 ohms, remove the ca-
ply liquid solvent directly to components. bles from motor to inverter and measure
Inspect less, the motor windings in the stator have
1. Inspect rotor assembly and inside of stator
or replaced.
housing for marks or grooves indicating contact
between rotor and stator. Replace if damaged. 5. Check terminal flags for cracks or other dam-
age. Replace if damaged.
2. Check that the bearings roll smoothly and are
not loose from excessive wear. Replace as neces- 6. Check for signs of oil or other contaminants
sary. Replace the bearings regardless of condi- within motor. If necessary, locate source of con-
tion if motor has been subjected to thermal taminants and take corrective action.
25
7. Inspect all other components and replace as 11. Place sensor cable outlet into position on stator
necessary. housing (see Figure 19). Connect proximity sen-
sor and temperature sensor connectors to sen-
Assemble sor cable outlet.
1. Using a seal driver, install new shaft seal into 12. Install non-drive end head onto stator housing.
drive end head. See Figure 22. See Figure 19.
13. Install five washers, lockwashers, and cap-

CAUTION screws into non-drive end head and stator Z-
Use an arbor press and a proper size driver when nuts on stator housing. See Figure 19. Tighten
installing bearings to avoid damage to bearings capscrews to 25 to 30 N•m (18 to 22 lbf ft).
of the bearing. Always replace bearings in sets. 14. Install sensor connector tab bracket, sensor
connector cover bracket, lockwasher, and long
2. Install bearing into drive end head as noted socket-head capscrew onto stator housing over
during disassembly. See Figure 22. sensor cable outlet. See Figure 19.
3. Screw lifting eye into threaded hole in the end 15. Install speed sensor, lockwasher, and capscrew
of rotor assembly. Attach approved lifting de- M6 onto non-drive end head and stator hous-
vice and lower rotor assembly onto drive end ing. See Figure 19.
head. Ensure bearing is fully seated against
drive end head. See Figure 22. Install
4. Remove lifting device and lifting eye from rotor 1. Install traction motor onto drive axle. See
assembly. Frame 0100SRM1342 for installation instruc-
tions.
NOTE: Make sure holes for stator Z-nuts are
aligned with capscrew holes. FOR LIFT TRUCK J2.2-3.5XN (J45-70XN)
(A276)
5. Using approved lifting device, lower stator
housing onto drive end head. See Figure 21. Remove
6. Install five washers, lockwashers, and cap- NOTE: The procedures described in this section ap-
screws into drive end head and stator Z-nuts on ply to both right and left traction motors.
stator housing. See Figure 21. Tighten cap-
screws to 25 to 30 N•m (18 to 22 lbf ft). 1. Remove transaxle assembly from lift truck. See
Transaxle 1300SRM1370 for instructions.
7. Install three special nuts, terminal blocks, ter-
minal covers, terminal flags, spring washers, 2. Remove service and parking brake components
and hex-head bolts onto stator housing, non- from traction motor housings. See Transaxle
drive end. See Figure 21. 1300SRM1370 for instructions.
8. Install bearing preload spring into non-drive 3. Remove the AC motor to be repaired from the
end head. See Figure 20. output housing. See Transaxle 1300SRM1370
for instructions.
9. Install bearing into non-drive end head as no-
ted during disassembly. See Figure 20. Disassemble
10. Install new proximity sensor wheel into non- 1. Remove nine nuts and washers from terminals
drive end head. See Figure 20. on connection plate. See Figure 23.
26
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
27
2. Remove two screws and connection plate from Inspect

stator housing. See Figure 23.
1. Inspect rotor and inside of stator for marks or
3. Remove and discard front shaft seal from brake grooves indicating contact between rotor and
end bell. See Figure 23. stator. Replace if damaged.
4. Remove and discard rear shaft seal from stator 2. Check that the bearings roll smoothly and are
housing. See Figure 23. not loose from excessive wear. Replace as neces-
sary. Replace the bearings regardless of condi-
5. Remove snap ring from rotor at brake end bell. tion if motor has been subjected to thermal
See Figure 23. overload (see Step 3). In case of a catastrophic
NOTE: Use threaded holes on the brake end bell to
move the end bell away from the stator housing.
6. Remove six screws, dowel pins if present, and
brake end bell from stator housing. Remove and
discard O-ring. See Figure 23.
7. Remove snap ring from inside brake end bell.
See Figure 23.
8. Carefully remove bearing from brake end bell. and W terminals of motor use a digital multi-
See Figure 23. meter (DMM) set to Ohms.
NOTE: Bearing will remain with rotor during re- a. Place one DMM probe on terminal U.
moval.
9. Remove rotor from stator housing. See Fig-
ure 23.
10. Carefully remove bearing from rotor. See Fig- bles from motor to inverter and measure
ure 23. again. If this reading is other than 0.5 ohm or
11. Carefully remove stator from stator housing. burned open and the motor must be repaired
See Figure 23. Take care not to damage power or replaced.
leads.
12. Remove wave washer from stator housing. See
Figure 23. d. Place the other DMM probe on terminal W.

Clean
WARNING again. If this reading is other than 0.5 ohm or
Cleaning solvents can be flammable and toxic and less, the motor windings in the stator have
can cause skin irritation. When using cleaning burned open and the motor must be repaired
solvents, always follow the solvent manufactur- or replaced.
er's recommended safety procedures.
f. Place the other DMM probe on terminal U.
with solvent and allow to thoroughly dry. DO
NOT apply liquid solvent directly to stator
windings.
28
Meter must read less than 0.5 ohms. If the 7. Install new O-ring on the brake end bell. Install
reading is more than 0.5 ohms, remove the ca- the brake end bell dowel pins and six screws
bles from motor to inverter and measure into stator housing. Tighten the six screws to
again. If this reading is other than 0.5 ohm or 23 N•m (204 lbf in). See Figure 23.
burned open and the motor must be repaired 8. Install snap ring on rotor at brake end bell. See
or replaced. Figure 23.
NOTE: A likely cause of motor contamination may 9. Install new rear shaft seal into stator housing.
be from a damaged input bearing seal on the trans- See Figure 23.
axle.
10. Install new front shaft seal into brake end bell.
5. Check for signs of oil or other contaminants See Figure 23.
within the motor. If contaminants are present,
11. Using two screws, install connection plate on
locate source and take corrective action.
stator housing. Tighten screws to
Assemble
12. Install nine nuts and washers on terminals on
NOTE: The procedures described in this section ap-
connection plate. Tighten bottom nuts to
ply to both right and left traction motors.
1. Install wave washer in stator housing. See Fig-
ure 23. Install
2. Carefully install stator into stator housing. See NOTE: The procedures described in this section ap-
Figure 23. Take care not to damage power ply to both right and left traction motors.
leads.
1. Install repaired AC motor onto output housing.
See Transaxle 1300SRM1370 for instructions.
CAUTION
2. Install parking brake and service brake compo-
Use an arbor press and a proper size driver when nents onto traction motor housings. See Trans-
installing bearings to rotor to avoid damage to axle 1300SRM1370 for instructions.
bearing. Press only on the INNER race of the bear-
ing. Always replace bearings in sets. 3. Install transaxle assembly onto lift truck. See
Transaxle 1300SRM1370 for instructions.
3. Install bearing onto rotor. See Figure 23.
FOR LIFT TRUCK E4.0-5.5XN, E5.0XNS
4. Install rotor into stator and stator housing. See
(E80-120XN, E100XNS) (A099)
Figure 23.
Remove
CAUTION 1. Remove traction motor from lift truck. See
Use an arbor press and a proper size driver when Frame 0100SRM1342 for instructions.
installing bearings to avoid damage to bearing.
Press only on the OUTER race of the bearing. Al-
ways replace bearings in sets. CAUTION
The traction motor can weigh as much as
5. Install bearing into brake end bell. See Fig- 230 kg (507 lb). To prevent injury, use a lifting de-
ure 23. vice capable of lifting the assembly.
6. Install snap ring on inside brake end bell. See 2. Place traction motor on level blocks on a flat
Figure 23. surface with drive end pointing down. Remove
floor jack.
29
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 re-
2. Remove two socket-head capscrews, two lock- move from stator housing. See Figure 24.
washers, sensor connector cover bracket, and
sensor connector tab bracket from stator hous- 5. Pull sensor cable outlet from stator housing
ing above sensor cable outlet. See Figure 24. (see Figure 24) and disconnect speed sensor and
temperature 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
30
6. Using a bearing puller, remove and discard NOTE: When replacing one bearing, it is strongly
proximity sensor wheel from non-drive end recommended to replace both bearings.
NOTE: Note orientation of bearing components
NOTE: When replacing one bearing, it is strongly prior to disassembly to aid in assembly.
recommended to replace both bearings.
13. Using bearing puller, remove bearing from
NOTE: Note orientation of bearing components drive end head. See Figure 24.
during disassembly to aid in assembly.
14. Remove and discard shaft seal from drive end
7. Using bearing puller, remove bearing from non- head. See Figure 24.
Electrical Connector Repair or Replacement
8. Remove bearing preload spring from non-drive
end head. See Figure 24. 1. If necessary, AMP Superseal tab assembly, tab
contact, and wire seal (see Figure 24) may be
9. Remove six terminal bolts, lockwashers, termi- repaired or replaced. See AMP Superseal 1.5
nal covers, and terminal blocks from stator Connector Assemblies section of Wire Harness
housing. See Figure 25. Repair 2200SRM1128 manual for instructions.
Clean
WARNING
Cleaning solvents can be flammable and toxic and
er's recommended safety procedures.

with solvent and allow to air dry. DO NOT ap-
ply liquid solvent directly to components.
Inspect
1. Inspect rotor assembly and inside of stator
housing for marks or grooves indicating contact
between rotor and stator. Replace if damaged.
1. TERMINAL COVER 3. TERMINAL BLOCKS
2. TERMINAL BOLTS 4. LOCK WASHER 2. Check that the bearings roll smoothly and are
not loose from excessive wear. Replace as neces-
Figure 25. Terminals sary. Replace the bearings regardless of condi-
tion if motor has been subjected to thermal
ers from Z-nuts on stator housing and drive end
11. Attach approved lifting device to stator housing
and slowly lift straight up, removing it from ro-
tor assembly and drive end head. See Fig-
ure 24.
12. Screw lifting eye into threaded hole in end of
rotor assembly. Attach approved lifting device
and lift rotor assembly straight up from drive
31
a. Place one DMM probe on terminal U. Assemble

b. Place the other DMM probe on terminal V. 1. Using a seal driver, install new shaft seal into
bles from motor to inverter and measure CAUTION
again. If this reading is other than 0.5 ohm or Use an arbor press and a proper size driver when
less, the motor windings in the stator have installing bearings to avoid damage to bearings
burned open and the motor must be repaired and/or end shields. Press only on the outer race
or replaced. of the bearing. Always replace bearings in sets.
c. Place one DMM probe on terminal V. 2. Install bearing into drive end head as noted
during disassembly. See Figure 24.
3. Screw lifting eye into threaded hole in the end
Meter must read less than 0.5 ohms. If the of rotor assembly. Attach approved lifting de-
reading is more than 0.5 ohms, remove the ca- vice and lower rotor assembly onto drive end
bles from motor to inverter and measure head. Ensure bearing is fully seated against
again. If this reading is other than 0.5 ohm or drive end head. See Figure 24.
burned open and the motor must be repaired 4. Remove lifting device and lifting eye from rotor
or replaced. assembly.
e. Place one DMM probe on terminal W. NOTE: Make sure holes for stator Z-nuts are
aligned with capscrew holes.
5. Using approved lifting device, lower stator
Meter must read less than 0.5 ohms. If the housing onto drive end head. See Figure 24.
bles from motor to inverter and measure 6. Install five washers, lockwashers, and cap-
again. If this reading is other than 0.5 ohm or screws into drive end head and stator Z-nuts on
less, the motor windings in the stator have stator housing. See Figure 24. Tighten cap-
burned open and the motor must be repaired screws to 25 to 30 N•m (18 to 22 lbf ft).
or replaced.
7. Install six terminal bolts, lockwashers, termi-
5. Check terminal flags for cracks or other dam- nal covers, and terminal blocks onto stator
age. Replace if damaged. housing, non-drive end. Tighten terminal bolts
to 23 to 25 N•m (17 to 18.5 lbf ft). See Fig-
6. Check for signs of oil or other contaminants ure 24.
within motor. If necessary, locate source of con-
taminants and take corrective action. 8. Install bearing preload spring into non-drive
7. Inspect all other components and replace as
necessary.
32
9. Install bearing into non-drive end head as no-

ted during disassembly. See Figure 24. TRACTION MOTOR REPAIR FOR LIFT
TRUCK J4.0-5.0XN, J5.0-5.5XN6
10. Install new proximity sensor wheel into non- (J80-120XN, J100XNL) (A970)
Remove
11. Place sensor cable outlet into position on stator
housing (see Figure 24). Connect proximity sen- NOTE: Disconnect all electrical connections to the
sor and temperature sensor connectors to sen- traction motor assembly prior to removal. The pro-
sor cable outlet. cedures described in this section apply to both right
and left sides of the traction motor assembly. See
12. Install non-drive end head onto stator housing. Transaxle 1300SRM1539 for preparation of the
See Figure 24. lift truck for transaxle removal.
13. Install five washers, lockwashers, and cap- 1. Remove the six upper nuts, six lock washers,
screws into non-drive end head and stator Z- and the lift truck power cables. See Figure 26.
nuts on stator housing. See Figure 24. Tighten
capscrews to 25 to 30 N•m (18 to 22 lbf ft). 2. Position power cables out of the way.
14. Install sensor connector tab bracket, sensor 3. Remove transaxle assembly from lift truck. See
connector cover bracket, two lockwashers, and Transaxle 1300SRM1539 for instructions.
two socket-head capscrews onto stator housing
over sensor cable outlet. See Figure 24. 4. Remove service and parking brake components
from traction motor housing. See Transaxle
15. Install speed sensor, lockwasher, and capscrew 1300SRM1539 for instructions.
M6 onto non-drive end head and stator hous-
ing. See Figure 24. 5. Remove 24 capscrews holding the traction mo-
tor assembly to the gear box. See Figure 26.
Install
6. Strike gear box and traction motor assembly
1. Install traction motor onto drive axle. See joining surface with soft hammer to free trac-
Frame 0100SRM1342 for installation instruc- tion motor assembly from the gear box.
tions.
7. Remove traction motor and dispose of properly.
NOTE: Remove dowel pins or leave in gear box if

present.
33
0620 SRM 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
34
0620 SRM 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 compo-
er's recommended safety procedures. nents onto traction motor housing. See Trans-
axle 1300SRM1539 for instructions.
with solvent and allow to thoroughly dry. DO 5. Install transaxle assembly into lift truck. See
NOT apply liquid solvent directly to stator Transaxle 1300SRM1539 for instructions.
windings.
6. Tighten lower nuts on traction motor power ter-
minals to 15 N•m (11 lbf ft). See Figure 26.
Install
7. Place lift truck power cables onto traction mo-
NOTE: The procedures described in this section ap-
tor power terminals.
ply to both right and left traction motor assembly.
The traction motors in this section are non-service- 8. Install 6 lock washers and 6 upper nuts onto
able. The entire motor assembly must be replaced. traction motor power terminals. Tighten to 6 to
See Figure 26. 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.
35
Hydraulic Motor Repair 0620 SRM 1385
Hydraulic Motor Repair

FOR LIFT TRUCKS J1.5-2.0XNT 4. Remove two capscrews and terminal end
(J30-40XNT) (K160), J1.6-2.0XN bracket from hydraulic pump and motor assem-
(J30-40XN) (A935), AND E30-40HSD2 bly.
(B219), E30-40HSD3 (C219) See Figure 27 for lift truck models
Remove • J1.5-2.0XNT (K160) manufactured before

November, 2014
1. Remove hydraulic pump and motor assembly • J30-40XNT (K160)
from lift truck. See one of the following man-
• JJ1.6-2.0XN (J30-40XN) (A935)
uals for removal instructions:
• E30-40HSD2 (B219), E30-40HSD3 (C219)
Hydraulic System 1900SRM1333 for lift truck
models See Figure 28 for lift truck models
• J1.5-2.0XNT (J30-40XNT) (K160) • J1.5-2.0XNT (K160) manufactured after
• J1.6-2.0XN (J30-40XN) (A935) November, 2014

models
• E30-40HSD2 (B219)
• E30-40HSD3 (C219)
2. Place hydraulic pump and motor assembly on a

clean work bench or other suitable surface.
3. Remove two capscrews and drive end bracket

from hydraulic pump and motor assembly.

• J1.5-2.0XNT (K160) manufactured before
November, 2014 1. CAPSCREWS
2. DRIVE END BRACKET
• J30-40XNT (K160) 3. TERMINAL END BRACKET
• JJ1.6-2.0XN (J30-40XN) (A935) 4. HYDRAULIC PUMP AND MOTOR ASSEMBLY
• E30-40HSD2 (B219), E30-40HSD3 (C219) Figure 27. Hydraulic Pump and Motor Mounting,
Lift Truck Models J1.5-2.0XNT (K160)
See Figure 28 for lift truck models Manufactured Before November, 2014 and
• J1.5-2.0XNT (K160) manufactured after J30-40XNT (K160), J1.6-2.0XN (J30-40XN) (A935),
November, 2014 E30-40HSD3 (C219), and E30-40HSD2 (B219)
36
0620 SRM 1385 Hydraulic Motor Repair
1. CAPSCREWS
2. HYDRAULIC PUMP
3. HYDRAULIC MOTOR
Figure 29. Hydraulic Pump to Hydraulic Motor
6. Remove hydraulic pump with drive coupling

from hydraulic motor.
1. CAPSCREWS Disassemble
3. TERMINAL END BRACKET 1. Place hydraulic motor in a vise with terminal
4. HYDRAULIC PUMP AND MOTOR ASSEMBLY posts on top and carefully clamp vise onto sta-
Figure 28. Hydraulic Pump and Motor Mounting, tor housing.
Manufactured After November, 2014 2. Remove hex nuts and disconnect power leads
from terminal posts. See Figure 30.
5. Remove two capscrews retaining hydraulic
pump to hydraulic motor. See Figure 29.
37
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
3. Remove two capscrews, terminal posts, and ter- NOTE: Silicone seal for power leads and thermal
minal post bracket from stator housing. See sensor connector wire must be broken prior to
Figure 30. shield removal.
4. Remove four tie rods holding non-drive end 5. Remove non-drive end shield from stator hous-
shield and drive end shield to stator housing. ing. See Figure 30.
See Figure 30.
6. Using bearing puller, remove non-drive ball
bearing from non-drive end shield. See Fig-
CAUTION ure 30.
Disposal of silicone sealant must meet local envi-
ronmental regulations. 7. Remove waved spring washer from non-drive
end shield. See Figure 30.
NOTE: Note threading position and orientation of
power leads and thermal sensor connector wire 8. Remove stator housing from drive end shield
through non-drive end shield during disassembly to and rotor. See Figure 30.
aid in assembly.
38
9. Remove shaft sealing ring from drive end shield 2. Wire connections for speed sensor connector are
and rotor. See Figure 30. shown in Table 1.
10. Remove rotor from drive end shield. See Fig-

ure 30. Table 1. Speed Sensor Connector
11. Remove snap ring from drive end of rotor shaft. Pin Wire Color Description
See Figure 30. 1 Red 24V -0/+5
12. Using bearing puller, carefully remove drive 2 Blue Signal B
end ball bearing from drive end shield. See Fig- 3 White Signal A
ure 30.
4 Black Ground
13. Remove locking ring from drive end shield. See
Figure 30.
3. Wire connections for thermal sensor connector
14. Remove cap from non-drive end shield. See Fig- are shown in Table 2.
ure 30.
Table 2. Thermal Sensor Connector
Electrical Connector Repair or Replacement
Pin Wire Color Description
1. If necessary, speed sensor connector and/or
thermal sensor connector may be repaired or 1 Red Positive
replaced. See Figure 31. See AMP Superseal 1.5 2 White Negative
Clean
WARNING
solvents, always follow the solvent manufac-
turer’s recommended safety procedures.

with solvent and allow to air dry. DO NOT ap-
ply liquid solvent directly to components.

within motor. If necessary, locate source of con-
taminants and take corrective action.
1. SPEED SENSOR CONNECTOR 3. Clean all joints, remove all foreign matter ad
2. THERMAL SENSOR CONNECTOR contaminants such as release agents, grease,
Figure 31. Electrical Connectors oil, dust, water, protective coatings, old adhe-
sives or sealants, and other substances which
could affect silicone seal adhesion.
39

1. Inspect rotor and inside of motor case for marks or replaced.
or grooves indicating contact between rotor and
motor case. Replace if damaged. Assemble
2. Bearings should fit snugly where they ride on 1. Install cap in non-drive end shield. See Fig-
the shaft. If there is excessive wear, replace the ure 32.
bearing.
2. Install locking ring in drive end shield. See Fig-
3. Check bearings for smooth operation. If a clean ure 32.
bearing does not roll smoothly, it must be re-
placed.
CAUTION
4. Check rotor windings for signs of thermal over- Use an arbor press and a proper size driver when
load. Signs of thermal overload are dark- installing bearings to avoid damage to bearings
stained, brittle, or burnt insulation. Thermal and/or end shields. Press only on the outer race
overload will shorten the life of the stator hous- of the bearing. Always replace bearings in sets.
ing.
3. Carefully install drive end ball bearing in drive
5. Check motor windings resistance as indicated end shield. See Figure 32.
and W terminals of motor use a digital multi- 4. Install snap ring onto drive end of rotor shaft.
meter (DMM) set to Ohms. See Figure 32.
a. Place one DMM probe on terminal U. 5. Install rotor in drive end shield. See Figure 32.
b. Place the other DMM probe on terminal V. 6. Install shaft sealing ring onto rotor and drive
reading is more than 0.5 ohms, remove the ca- 7. Install stator housing onto rotor and drive end
bles from motor to inverter and measure shield. See Figure 32.
less, the motor windings in the stator have 8. Install waved spring washer in non-drive end
burned open and the motor must be repaired shield. See Figure 32.
or replaced.
c. Place one DMM probe on terminal V. CAUTION

Use an arbor press and a proper size driver when
d. Place the other DMM probe on terminal W. installing bearings to avoid damage to bearings
of the bearing. Always replace bearings in sets.
bles from motor to inverter and measure 9. Carefully install non-drive end ball bearing in
again. If this reading is other than 0.5 ohm or non-drive end shield. See Figure 32.
burned open and the motor must be repaired NOTE: Take care when routing power leads and
or replaced. thermal sensor through non-drive end shield as no-
ted during disassembly.
NOTE: Ensure waved spring washer remains in
f. Place the other DMM probe on terminal U. position during non-drive end shield installation.
Meter must read less than 0.5 ohms. If the 10. Install non-drive end shield onto stator hous-
reading is more than 0.5 ohms, remove the ca- ing. See Figure 32.
40
11. Apply neutral curing, high temperature silicone 13. Install terminal post bracket, terminal posts
sealant, rated for at least 260°C (500°F), be- and two capscrews onto stator housing. See Fig-
tween stator housing and non-drive end shield ure 32.
to protect power leads and thermal sensor.
14. Connect power leads to terminal posts.
12. Install four tie rods in non-drive end shield and
drive end shield, holding stator housing be- 15. Install hex nuts onto terminal posts. See Fig-
tween shields. Tighten screws to 14 to ure 32. Tighten hex nuts to 14 to 16 N•m (124
17 N•m (124 to 150 lbf in). See Figure 32. to 142 lbf in).
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
41
Install 3. Install non-drive end bracket and two cap-

screws onto hydraulic pump and motor assem-
1. Install drive coupling onto rotor. Install hy- bly.
draulic pump over coupling onto hydraulic mo-
tor. See Figure 34 for lift truck models
2. Apply Loctite 271 to two capscrews and install
November, 2014
in hydraulic pump and hydraulic motor. See
Figure 33. Tighten capscrews to • J30-40XNT (K160)
47 N•m (35 lbf ft). • JJ1.6-2.0XN (J30-40XN) (A935)
• E30-40HSD2 (B219), E30-40HSD3 (C219)

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

onto hydraulic pump and motor assembly.

November, 2014
• J30-40XNT (K160)
• JJ1.6-2.0XN (J30-40XN) (A935)
• E30-40HSD2 (B219), E30-40HSD3 (C219)

1. CAPSCREW November, 2014
2. HYDRAULIC PUMP
3. HYDRAULIC MOTOR
Figure 33. Hydraulic Pump to Hydraulic Motor
42
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
J30-40XNT (K160), J1.6-2.0XN (J30-40XN) (A935),
E30-40HSD3 (C219), and E30-40HSD2 (B219)
1. CAPSCREWS
3. TERMINAL END BRACKET
Figure 35. Hydraulic Pump and Motor Mounting,

Manufactured After November, 2014
43
5. Install hydraulic pump and motor assembly in

counterweight. See one of the following man-
uals for installation instructions:

models
• J1.5-2.0XNT (J30-40XNT) (K160)
• J1.6-2.0XN (J30-40XN) (A935)

models
• E30-40HSD2 (B219)
• E30-40HSD3 (C219)
FOR LIFT TRUCK E2.2-3.5XN (E45-70XN)

(A268)
Remove
1. Remove hydraulic pump and motor assembly
from lift truck. See Hydraulic System
1900SRM1367 for removal instructions.

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

brackets from hydraulic pump and motor as-
sembly. See Figure 36.
NOTE: Note orientation of fitting and suction

adapter during removal to aid in installation.
NOTE: STANDARD MOTOR ASSEMBLY SHOWN.
4. Remove fitting from pump. See Figure 37.
A. FRONT VIEW B. REAR VIEW
5. Remove suction adapter from pump. See Fig-
ure 37. 2. MOTOR MOUNT BRACKET
3. MOTOR MOUNT CAPSCREW
Figure 36. Motor Mount Brackets
44
NOTE: Note position of inlet and outlet ports of Legend for Figure 37
pump for correct alignment during installation.
A. STANDARD MOTOR B. ENHANCED MO-
6. Remove two capscrews fastening pump to mo- TOR
tor. Carefully remove pump from motor. See 1. PUMP 5. CAPSCREW
Figure 37. 2. MOTOR 6. FITTING
3. COUPLING 7. SUCTION ADAPTER
NOTE: Perform Step 7 for standard motor. 4. SETSCREW
7. Loosen two setscrews in coupling. DO NOT lose

two keys between coupling and shaft. Remove
Disassemble
coupling from motor. See Figure 37.
Standard Motor
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 termi-

nal post bracket from stator housing. See Fig-
ure 38.
5. Remove four tie rods holding end shields to sta-

tor housing. See Figure 38.
6. Remove cap from non-drive end shield. Remove

and discard O-ring from cap. See Figure 38.
CAUTION
ronmental regulations.
Figure 37. Pump and Motor Assembly
45
NOTE: Note threading position and orientation of 17. Using bearing puller, carefully remove drive
power leads and thermal sensor connector wire end ball bearing from drive end shield. See Fig-
through non-drive end shield during disassembly to ure 38.
aid in assembly.
Enhanced Motor
NOTE: Silicone seal for power leads and thermal
sensor connector wire must be broken prior to 1. Place motor in a vise with terminal posts on top
shield removal. and carefully clamp vise on stator housing.
7. Remove non-drive end shield from stator hous- 2. Remove three hex nuts and spring washers
ing. See Figure 38. from terminal posts. See Figure 38.
8. Using bearing puller, carefully remove non- 3. Disconnect power leads from terminal posts.
drive end ball bearing from non-drive end See Figure 38.
shield. See Figure 38.
4. Remove two screws, terminal posts, bracket,
9. Remove O-ring seal from non-drive end shield. and terminal post bracket from stator housing.
See Figure 38. See Figure 38.
10. Remove waved spring washer from non-drive

end shield. See Figure 38. CAUTION
11. Remove capscrew and speed sensor from non- ronmental regulations.
drive end shield. See Figure 38.
12. Remove drive end shield and rotor from stator power leads and thermal sensor connector wire
housing. See Figure 38. through non-drive end shield during disassembly to
13. Remove woodruff key from drive end of rotor aid in assembly.
shaft. See Figure 38. NOTE: Silicone seal for power leads and thermal
14. Remove snap ring from drive end of rotor. See sensor connector wire must be broken prior to
Figure 38. shield removal.
15. Remove rotor from drive end shield. See Fig- 5. Remove four capscrews, fan cover, four wash-
ure 38. ers, and four spacers from non-drive end shield.
See Figure 38.
16. Remove locking ring from drive end shield. See
Figure 38.
46
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
47
6. Remove four M8 X 270 screws holding end 19. Using a bearing puller, carefully remove drive
shields to stator housing. See Figure 38. end ball bearing from drive end shield. See Fig-
ure 38.
7. Remove cooling fan from non-drive end shield.
Remove retaining bushing from fan. See Fig- Electrical Connector Repair or Replacement
ure 38.
8. Remove three capscrews and mounting bracket thermal sensor connector may be repaired or
from non-drive end shield. See Figure 38. replaced. See Figure 39. See AMP Superseal 1.5
9. Remove non-drive end shield from stator hous-
ing. See Figure 38.
10. Using bearing puller, carefully remove non-

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

See Figure 38.
12. Remove waved spring washer from non-drive

13. Remove capscrew and speed sensor from non-

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

housing. See Figure 38.
15. Remove snap ring from drive end of rotor. See

Figure 38.
16. Remove rotor from drive end shield. See Fig-

ure 38.
17. Remove oil seal from drive end shield. See Fig-
ure 38. NOTE: STANDARD MOTOR SHOWN
18. Remove locking ring from drive end shield. See 1. SPEED SENSOR CONNECTOR
2. THERMAL SENSOR CONNECTOR
Figure 38.
Figure 39. Electrical Connectors
48
2. Connections for speed sensor connector are

shown in Figure 40.
1. SUPPLY 3. SIGNAL A
2. SIGNAL B 4. GROUND 1. GROUND 2. POSITIVE
Figure 40. Speed Sensor Wire Connections Figure 41. Thermal Sensor Wire Connections
3. Connections for thermal sensor connector are

shown in Figure 41.
49
Clean b. Place the other DMM probe on terminal V.

WARNING reading is more than 0.5 ohms, remove the ca-
Cleaning solvents can be flammable and toxic and bles from motor to inverter and measure
can cause skin irritation. When using cleaning again. If this reading is other than 0.5 ohm or
solvents, always follow the solvent manufac- less, the motor windings in the stator have
turer’s recommended safety procedures. burned open and the motor must be repaired
or replaced.
with solvent and allow to thoroughly dry. DO c. Place one DMM probe on terminal V.
NOT apply liquid solvent directly to rotor wind-
ings. d. Place the other DMM probe on terminal W.
2. Check for signs of oil or other contaminants Meter must read less than 0.5 ohms. If the
within the motor. If necessary, locate source of reading is more than 0.5 ohms, remove the ca-
contaminants and take corrective action. bles from motor to inverter and measure
3. Clean all joints, remove all foreign matter and less, the motor windings in the stator have
contaminants such as release agents, grease, burned open and the motor must be repaired
oil, dust, water, protective coatings, old adhe- or replaced.
could affect silicone seal adhesion. e. Place one DMM probe on terminal W.

Inspect
1. Inspect rotor and inside motor case for marks
motor case. Replace if damaged.
2. Bearings should fit snugly where they ride on less, the motor windings in the stator have
the shaft. If there is excessive wear, replace burned open and the motor must be repaired
bearing and/or shaft. or replaced.
3. Check bearings for smooth operation. If a clean Assemble

bearing does not roll smoothly, it must be re-
placed. Standard Motor
4. If equipped, check retaining bushing for dam-
age. Replace if damaged. CAUTION
Use an arbor press and a proper size driver when
5. Check rotor windings for signs of thermal over- installing bearings to avoid damage to bearings
load. Signs of thermal overload are dark- and/or end shields. Press only on the outer race
stained, brittle, or burnt insulation. Thermal of the bearing. Always replace bearings in sets.
overload will shorten the life of the stator hous-
ing. 1. Carefully install drive end ball bearing in drive
below. To measure continuity between U, V, 2. Install locking ring in drive end shield. See Fig-
and W terminals of motor use a digital multi- ure 38.
3. Install rotor in drive end shield. See Figure 38.
50
4. Install snap ring on drive end of rotor. See Fig- Enhanced Motor
ure 38.
5. Install woodruff key in drive end of rotor shaft. CAUTION

See Figure 38. Use an arbor press and a proper size driver when
installing bearings to avoid damage to bearings
6. Install rotor and drive end shield in stator and/or end shields. Press only on the outer race
housing. See Figure 38. of the bearing. Always replace bearings in sets.
7. Install speed sensor and capscrew onto non- 1. Carefully install drive end ball bearing in drive
drive end shield. See Figure 38. end shield. See Figure 38.
8. Install waved spring washer in non-drive end 2. Install locking ring in drive end shield. See Fig-
shield. See Figure 38. ure 38.
9. Install O-ring seal in non-drive end shield. See 3. Install oil seal in drive end shield. See Fig-
Figure 38. ure 38.
4. Install rotor in drive end shield. See Figure 38.

CAUTION
Use an arbor press and a proper size driver when 5. Install snap ring on drive end of rotor. See Fig-
installing bearings to avoid damage to bearings ure 38.
of the bearing. Always replace bearings in sets. 6. Install rotor and drive end shield in stator
10. Carefully install non-drive end ball bearing in
non-drive end shield. See Figure 38. 7. Install speed sensor and capscrew on non-drive
11. Install non-drive end shield on stator housing.
See Figure 38. 8. Install waved spring washer in non-drive end
12. Apply neutral curing, high temperature silicone
sealant (rated for at least 260°C (500°F)) be- 9. Install O-ring seal in non-drive end shield. See
tween stator housing and non-drive end shield Figure 38.
to protect power leads and thermal sensor.
13. Install new O-ring on cap. Install cap in non- CAUTION

drive end shield. See Figure 38. Use an arbor press and a proper size driver when
14. Install four tie rods to hold end shields to stator and/or end shields. Press only on the outer race
housing. See Figure 38. of the bearing. Always replace bearings in sets.
15. Install terminal post bracket, terminal posts, 10. Carefully install non-drive end ball bearing in
and two screws on stator housing. See Fig- drive end shield. See Figure 38.
ure 38.
11. Install non-drive end shield on stator housing.
16. Connect power leads to terminal posts. See Fig- See Figure 38.
ure 38.
12. Apply neutral curing, high temperature silicone
17. Install three spring washers and hex nuts on sealant (rated for at least 260°C (500°F)) be-
terminal posts. See Figure 38. Tighten hex nuts tween stator housing and non-drive end shield
to 14 to 16 N•m (124 to 142 lbf in). to protect power leads and thermal sensor.
18. Carefully remove motor from vise and place on 13. Install mounting bracket and three capscrews
suitable work surface. on non-drive end shield. See Figure 38.
51
14. Install retaining bushing into cooling fan. In- 7. Install hydraulic pump and motor assembly in
stall cooling fan in non-drive end shield. See lift truck. See Hydraulic System
Figure 38. 1900SRM1367 for instructions.
15. Install four M8 X 270 screws to hold end FOR LIFT TRUCK MODELS J2.2-3.5XN
shields to stator housing. See Figure 38. (J45-70XN) (A276) AND E1.6-E2.0XN
(E30-40XN) (A269)
16. Install four spacers, four washers, fan cover,
and four capscrews on non-drive end shield. See Remove
Figure 38.
1. Remove hydraulic pump and motor assembly
17. Install terminal post bracket, bracket, terminal from lift truck. See Hydraulic System
posts, and two screws on stator housing. See 1900SRM1367 for removal instructions.
Figure 38.
18. Connect power leads to terminal posts. See Fig- clean workbench or other suitable surface.
ure 38.
3. Remove the hydraulic pump and motor brack-
19. Install three spring washers and hex nuts to ets. See Hydraulic System 1900SRM1367 for
terminal posts. See Figure 38. Tighten hex nuts removal instructions.
to 14 to 16 N•m (124 to 142 lbf in).
Disassemble
20. Carefully remove motor from vise and place on
suitable work surface. 1. Place motor in a vise with terminal posts on top
Install
2. Remove three hex nuts and lockwashers from
1. Install keys onto motor shaft. terminal posts.
2. Install coupling onto pump shaft and motor See Figure 42 for lift truck models
shaft. See Figure 37.
• J2.2-3.5XN (J45-70XN) (A276)
3. Make sure the halves of the coupling are cor-
rectly engaged. Make sure setscrews that fas- See Figure 43 for lift truck models
ten coupling to shafts are 180° opposed. See • E1.6-2.0XN (E30-40XN) (A269)
Figure 37. Tighten setscrews to 11 to
13 N•m (97 to 115 lbf in). 3. Disconnect power leads from terminal posts.
4. Make sure pump is aligned to motor as marked See Figure 42 for lift truck models
during removal. Install two capscrews fasten- • J2.2-3.5XN (J45-70XN) (A276)
ing pump to motor. See Figure 37. Tighten cap-
screws to 25 N•m (221 lbf in). See Figure 43 for lift truck models
• E1.6-2.0XN (E30-40XN) (A269)
NOTE: Remove plugs from pump openings and in-
stall plugs in suction adapter and fitting after in- 4. Remove two screws, terminal posts, and termi-
stallation. nal post bracket and terminal strip from stator
housing.
5. Install suction adapter onto hydraulic pump as
noted during removal. See Figure 37. Tighten See Figure 42 for lift truck models
adapter to 91 to 100 N•m (67 to 74 lbf ft). • J2.2-3.5XN (J45-70XN) (A276)
6. Install fitting onto hydraulic pump. See Fig- See Figure 43 for lift truck models
ure 37. Tighten fitting to 49 to 59 N•m (36 to
44 lbf ft). • E1.6-2.0XN (E30-40XN) (A269)
52
NOTE: Perform Step 5 for lift truck models See Figure 42 for lift truck models
J2.2-3.5XN (J45-70XN) (A276) only. • J2.2-3.5XN (J45-70XN) (A276)
5. Remove three socket-head capscrews and fan See Figure 43 for lift truck models
cover from non drive end shield.
• E1.6-2.0XN (E30-40XN) (A269)
tor housing. 11. Remove capscrew and speed sensor from non-
drive end shield.
• J2.2-3.5XN (J45-70XN) (A276) housing.
See Figure 43 for lift truck models See Figure 42 for lift truck models
• E1.6-2.0XN (E30-40XN) (A269) • J2.2-3.5XN (J45-70XN) (A276)

CAUTION
• E1.6-2.0XN (E30-40XN) (A269)
ronmental regulations. 13. Remove and discard seal from the drive end
shield.
NOTE: during the performance of the following
step, remove only a sufficient amount of sealing See Figure 42 for lift truck models
material to allow removal of the non-drive end
shield. • J2.2-3.5XN (J45-70XN) (A276)
7. Carefully remove silicone seal material from See Figure 43 for lift truck models
the non-drive end shield. • E1.6-2.0XN (E30-40XN) (A269)
NOTE: Note threading position and orientation of 14. Remove lock ring, snap ring and drive end
power leads and thermal sensor connector wire shield from the rotor.
through non-drive end shield during disassembly to
aid in assembly. See Figure 42 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
8. Remove non-drive end shield from stator hous-
ing. See Figure 43 for lift truck models
See Figure 42 for lift truck models • E1.6-2.0XN (E30-40XN) (A269)
• J2.2-3.5XN (J45-70XN) (A276) 15. Using bearing puller, carefully remove drive
end ball bearing from the rotor.
• E1.6-2.0XN (E30-40XN) (A269) See Figure 42 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
drive end ball bearing from rotor. See Figure 43 for lift truck models
10. Remove wave washer, seal, retaining bushing • E1.6-2.0XN (E30-40XN) (A269)
and fan from the non-drive end shield. Discard
the seal.
53
Figure 42. Hydraulic Motor, Lift Truck Models J2.2-3.5XN (J45-70XN) (A276)
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 E1.6-2.0XN (E30-40XN) (A269)
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.
thermal sensor connector may be repaired or
replaced. See Figure 44. See AMP Superseal 1.5
2. SIGNAL B 4. GROUND
Figure 45. Speed Sensor Wire Connections
1. SPEED SENSOR CONNECTOR 3. Connections for thermal sensor connector are

2. THERMAL SENSOR CONNECTOR shown in Figure 46.
Figure 44. Electrical Connectors
58
Clean
WARNING
solvents, always follow the solvent manufac-
turer’s recommended safety procedures.

NOT apply liquid solvent directly to rotor wind-
ings.

within the motor. If necessary, locate source of
contaminants and take corrective action.
3. Clean all joints, remove all foreign matter and

contaminants such as release agents, grease,
oil, dust, water, protective coatings, old adhe-
1. GROUND 2. POSITIVE
Figure 46. Thermal Sensor Wire Connections
59

1. Inspect rotor and inside motor case for marks or replaced.
motor case. Replace if damaged. Assemble
2. Bearings should fit snugly where they ride on
the shaft. If there is excessive wear, replace CAUTION
bearing and/or shaft. Use an arbor press and a proper size driver when
3. Check bearings for smooth operation. If a clean installing bearings to avoid damage to bearings
bearing does not roll smoothly, it must be re- and/or rotor. Press only on the INNER race of the
placed. bearing. Always replace bearings in sets.
4. Check rotor windings for signs of thermal over- 1. Using a press, carefully install drive end ball
load. Signs of thermal overload are dark- bearing onto the rotor.
stained, brittle, or burnt insulation. Thermal See Figure 42 for lift truck models
overload will shorten the life of the stator hous-
ing. • J2.2-3.5XN (J45-70XN) (A276)
5. Check motor windings resistance as indicated See Figure 43 for lift truck models
below. To measure continuity between U, V, • E1.6-2.0XN (E30-40XN) (A269)
meter (DMM) set to Ohms. 2. Install drive end shield, snap ring, and lock
ring on the rotor.
b. Place the other DMM probe on terminal V. • J2.2-3.5XN (J45-70XN) (A276)
Meter must read less than 0.5 ohms. If the See Figure 43 for lift truck models
bles from motor to inverter and measure • E1.6-2.0XN (E30-40XN) (A269)
3. Install a new seal in the drive end shield.
burned open and the motor must be repaired See Figure 42 for lift truck models
or replaced.
• J2.2-3.5XN (J45-70XN) (A276)
d. Place the other DMM probe on terminal W. • E1.6-2.0XN (E30-40XN) (A269)
Meter must read less than 0.5 ohms. If the 4. Install drive end shield and rotor in stator
reading is more than 0.5 ohms, remove the ca- housing.
again. If this reading is other than 0.5 ohm or See Figure 42 for lift truck models
less, the motor windings in the stator have • J2.2-3.5XN (J45-70XN) (A276)
or replaced. See Figure 43 for lift truck models
• E1.6-2.0XN (E30-40XN) (A269)
5. Install speed sensor and capscrew in non-drive
end shield.
bles from motor to inverter and measure • J2.2-3.5XN (J45-70XN) (A276)
60
See Figure 43 for lift truck models 11. Using two screws, install terminal strip, termi-
• E1.6-2.0XN (E30-40XN) (A269) nal post bracket, terminal posts onto stator
housing.
6. Install new seal, wave washer, fan, and retain-
ing bushing in the non-drive end shield. Dis- See Figure 42 for lift truck models
card the seal. • J2.2-3.5XN (J45-70XN) (A276)
See Figure 42 for lift truck models See Figure 43 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276) • E1.6-2.0XN (E30-40XN) (A269)
See Figure 43 for lift truck models 12. Connect power leads from terminal posts.
• E1.6-2.0XN (E30-40XN) (A269) See Figure 42 for lift truck models
• J2.2-3.5XN (J45-70XN) (A276)
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 • E1.6-2.0XN (E30-40XN) (A269)
and/or rotor. Press only on the INNER race of the
bearing. Always replace bearings in sets. 13. Install three lockwashers and hex nuts onto
terminal posts.
7. Using a press, install non-drive end ball bear-
ing onto the rotor. Tighten hex nuts to 14 to 16 N•m (124 to
142 lbf in). See Figure 42 for lift truck models
See Figure 42 for lift truck models • J2.2-3.5XN (J45-70XN) (A276)
• J2.2-3.5XN (J45-70XN) (A276)
Tighten hex nuts to 14 to 16 N•m (124 to
See Figure 43 for lift truck models 142 lbf in). See Figure 43 for lift truck models
• E1.6-2.0XN (E30-40XN) (A269) • E1.6-2.0XN (E30-40XN) (A269)
8. Install non-drive end shield onto stator housing 14. Fill the area around the power leads and ther-
and place power leads and thermal sensor in mal sensor located on the non-drive end shield
the orientation and position as noted during re- with neutral curing, high temperature silicone
moval. sealant (rated for at least 260°C (500°F).
See Figure 42 for lift truck models Install

• J2.2-3.5XN (J45-70XN) (A276)
1. Place hydraulic motor assembly on a clean
See Figure 43 for lift truck models workbench or other suitable work surface.
• E1.6-2.0XN (E30-40XN) (A269) 2. Install the hydraulic pump and motor brackets.
See Hydraulic System 1900SRM1367 for in-
9. Install four tie rods holding end shields to sta-
stallation instructions.
tor housing.
3. Install hydraulic pump and motor assembly on
the lift truck. See Hydraulic System
• J2.2-3.5XN (J45-70XN) (A276) 1900SRM1367 for installation instructions.
• E1.6-2.0XN (E30-40XN) (A269) HYDRAULIC MOTOR REPAIR FOR
4.0-5.5T LIFT TRUCKS
NOTE: Perform Step 10 for lift truck models
J2.2-3.5XN (J45-70XN) (A276) only. This section covers the hydraulic motor repair pro-
cedures for lift truck models:
10. Install fan cover and three socket-head cap-
• J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
screws on non drive end shield. See Figure 42.
J100XNL) (A970)
61
0620 SRM 1385
• E4.0-5.5XN, E5.0XNS (E80-120XN, NOTE: during the performance of the following

E100XNS) (A099) step, remove only a sufficient amount of sealing
material to allow removal of the non-drive end
Remove shield.
1. Remove hydraulic pump and motor assembly 7. Carefully remove silicone seal material from
from lift truck. See Hydraulic System the non-drive end shield.
1900SRM1367 for removal instructions.
8. Remove spur wheel and tolerance ring from ro-
2. Place hydraulic pump and motor assembly on a tor.
clean workbench or other suitable surface.
3. Remove the hydraulic pump and motor brack- power leads and thermal sensor connector wire
ets. See Hydraulic System 1900SRM1367 for through non-drive end shield during disassembly to
removal instructions. aid in assembly.
Disassemble 9. Remove non-drive end shield from stator hous-

ing. See Figure 47.
10. Remove wave washer from the non-drive end

1. Place motor in a vise with terminal posts on top
shield. Discard the seal. See Figure 47.
2. Remove three hex nuts and lockwashers from
drive end ball bearing from rotor.
terminal posts. See Figure 47.
12. Remove capscrew and speed sensor from non-
3. Disconnect terminal cables from terminal posts.
drive end shield.
See Figure 47.
4. Remove two screws, terminal posts, and termi-
nal post bracket and terminal strip from stator
housing. See Figure 47. 14. Remove and discard seal from the drive end
5. Remove two socket-head capscrews and fan
cover from non drive end shield. 15. Remove drive end shield from the rotor. See
Figure 47.
tor housing. See Figure 47. 16. Remove and discard O-ring from drive end
shield.
CAUTION 17. Using bearing puller, carefully remove drive
Disposal of silicone sealant must meet local envi- end ball bearing from the rotor. See Figure 47.
ronmental regulations.
62
0620 SRM 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 J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN, J100XNL) (A970) and
E4.0-5.5XN, E5.0XNS (E80-120XN, E100XNS) (A099)
63
0620 SRM 1385
Electrical Connector Repair or Replacement 3. Connections for thermal sensor connector are
shown in Figure 49.
thermal sensor connector may be repaired or
replaced. See Figure 47. See AMP Superseal 1.5
2. Connections for speed sensor connector are

shown in Figure 48.
1. GROUND 2. POSITIVE
Figure 49. Thermal Sensor Wire Connections
2. SIGNAL B 4. GROUND
Figure 48. Speed Sensor Wire Connections
64
0620 SRM 1385
Clean 4. Check rotor windings for signs of thermal over-

load. Signs of thermal overload are dark-
WARNING overload will shorten the life of the stator hous-
Cleaning solvents can be flammable and toxic and ing.
solvents, always follow the solvent manufac- 5. Check motor windings resistance as indicated
turer’s recommended safety procedures. below. To measure continuity between U, V,
1. Clean components with a clean cloth moistened meter (DMM) set to Ohms.
NOT apply liquid solvent directly to rotor wind- a. Place one DMM probe on terminal U.
ings.
within the motor. If necessary, locate source of Meter must read less than 0.5 ohms. If the
contaminants and take corrective action. reading is more than 0.5 ohms, remove the ca-
3. Clean all joints, remove all foreign matter and again. If this reading is other than 0.5 ohm or
contaminants such as release agents, grease, less, the motor windings in the stator have
oil, dust, water, protective coatings, old adhe- burned open and the motor must be repaired
sives or sealants, and other substances which or replaced.
Inspect
1. Inspect rotor and inside motor case for marks
motor case. Replace if damaged.
2. Bearings should fit snugly where they ride on again. If this reading is other than 0.5 ohm or
the shaft. If there is excessive wear, replace less, the motor windings in the stator have
bearing and/or shaft. burned open and the motor must be repaired
or replaced.
3. Check bearings for smooth operation. If a clean
bearing does not roll smoothly, it must be re- e. Place one DMM probe on terminal W.
placed.
65
0620 SRM 1385
f. Place the other DMM probe on terminal U. 8. Using a press, install non-drive end ball bear-
ing onto the rotor. See Figure 47.
reading is more than 0.5 ohms, remove the ca- 9. Install non-drive end shield onto stator housing
bles from motor to inverter and measure and place power leads and thermal sensor in
again. If this reading is other than 0.5 ohm or the orientation and position as noted during re-
less, the motor windings in the stator have moval. See Figure 47.
or replaced. 10. Install spur wheel and tolerance ring onto the
rotor.
Assemble
11. Install four tie rods holding end shields to sta-
tor housing. Tighten tie rods to
CAUTION 20 N•m (177 lbf in). See Figure 47.
Use an arbor press and a proper size driver when 12. Install fan cover and two socket-head capscrews
installing bearings to avoid damage to bearings on non drive end shield. See Figure 47.
bearing. Always replace bearings in sets. 13. Using two screws, install terminal strip, termi-
nal post bracket, terminal posts onto stator
NOTE: Grease bearings with quality bearing housing. See Figure 47.
grease.
14. Connect power leads from terminal posts. See
1. Using a press, carefully Install drive end ball Figure 47
bearing onto the rotor. See Figure 47.
15. Install three washers and hex nuts onto termi-
2. Install new O-ring in drive end shield. nal posts. Tighten hex nuts to 14 to
3. Install drive end shield on the rotor. See Fig- 16 N•m (124 to 142 lbf in). See Figure 47.
ure 47. 16. Install lock three washers and hex nuts onto
4. Install a new seal in the drive end shield. See terminal posts. Tighten hex nuts to 14 to
Figure 47. 16 N•m (124 to 142 lbf in). See Figure 47.
5. Install drive end shield and rotor in stator 17. Fill the area around the power leads and ther-
housing. See Figure 47. mal sensor located on the non-drive end shield
with neutral curing, high temperature silicone
6. Install speed sensor and capscrew in non-drive sealant (rated for at least 260°C (500°F).
Install
7. Install new seal and wave washer in the non-
drive end shield. Discard the seal. See Fig- 1. Place hydraulic motor assembly on a clean
ure 47. workbench or other suitable work surface.
2. Install the hydraulic pump and motor brackets.

CAUTION See Hydraulic System 1900SRM1367 for in-
Use an arbor press and a proper size driver when stallation instructions.
3. Install hydraulic pump and motor assembly on
the lift truck. See Hydraulic System
bearing. Always replace bearings in sets.
1900SRM1367 for installation instructions.
NOTE: Grease bearings with quality bearing
grease.
66
0620 SRM 1385 Torque Specifications
Torque Specifications
TRACTION MOTOR FOR LIFT TRUCKS Pump to Motor Capscrews
J1.5-2.0XNT (J30-40XNT) (K160) AND 25 N•m (221 lbf in)
J1.6-2.0XN (J30-40XN) (A935)
Suction Adapter
Terminal Post Hex Nuts 91 to 100 N•m (67 to 74 lbf ft)
14 to 16 N•m (124 to 142 lbf in)
Fitting
Socket-Head Capscrews 49 to 59 N•m (36 to 44 lbf ft)
14 to 16 N•m (124 to 142 lbf in)
HYDRAULIC MOTOR FOR LIFT TRUCK
Mounting Capscrews J2.2-3.5XN (J45-70XN) (A276)
48 N•m (35 lbf ft)
Terminal Post Hex Nuts (Lower)
TRACTION MOTOR FOR LIFT TRUCK 14 to 16 N•m (124 to 142 lbf in)
E2.2-3.5XN (E45-70XN) (A268), E1.6-2.0XN
(E30-40XN) (A269), AND E4.0-5.5XN, Terminal Post Hex Nuts (Upper)
E5.0XNS (E80-120XN, E100XNS) (A099) 14 to 16 N•m (124 to 142 lbf in)
End Head to Stator Housing Capscrews HYDRAULIC MOTOR FOR LIFT TRUCK
25 to 30 N•m (18 to 22 lbf ft) E1.6-2.0XN (E30-40XN) (A269)
TRACTION MOTOR FOR LIFT TRUCK Terminal Post Hex Nuts (Lower)
E30-40HSD2 (B219), E30-40HSD3 (C219) 14 to 16 N•m (124 to 142 lbf in)
Terminal Post Hex Nuts (Upper)

Terminal Post Hex Nut
14 to 16 N•m (124 to 142 lbf in)
14 to 16 N•m (124 to 142 lbf in)
Socket-Head Capscrews HYDRAULIC MOTOR FOR LIFT TRUCK

14 to 16 N•m (124 to 142 lbf in) E30-40HSD2 (B219), E30-40HSD3 (C219)
Mounting Capscrews Tie Bar Screws

48 N•m (35 lbf ft) 14 to 17 N•m (124 to 150 lbf in)
HYDRAULIC MOTOR FOR LIFT TRUCKS Terminal Post Hex Nuts

J1.5-2.0XNT (J30-40XNT) (K160) AND 14 to 16 N•m (124 to 142 lbf in)
J1.6-2.0XN (J30-40XN) (A935) Pump to Motor Capscrews
Tie Bar Screws 47 N•m (35 lbf ft)
14 to 17 N•m (124 to 150 lbf in)
Terminal Post Hex Nuts J4.0-5.0XN, J5.0-5.5XN6 (J80-120XN,
14 to 16 N•m (124 to 142 lbf in) J100XNL) (A970) AND E4.0-5.5XN,
E5.0XNS (E80-120XN, E100XNS) (A099)
Pump to Motor Capscrews
47 N•m (35 lbf ft) Tie Bar Screws
20 N•m (177 lbf in)
E2.2-3.5XN (E45-70XN) (A268) Suction Adapter
91 to 100 N•m (67 to 74 lbf ft)
Terminal Post Hex Nuts
14 to 16 N•m (124 to 142 lbf in) Fitting
78 to 88 N•m (58 to 65 lbf ft)
Setscrews
11 to 13 N•m (97 to 115 lbf in)
67
NOTES
68
TECHNICAL PUBLICATIONS
0620 SRM 1385 6/15 (9/14)(12/12)(3/12)(1/11)(4/10)

Ac Motor Repair: PART NO. 1696595 0620 SRM 1385

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AC MOTOR REPAIR

J1.5-2.0XNT (J30-40XNT) [K160];

PART NO. 1696595 0620 SRM 1385

©2015 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

This section is for the following models:

J1.5-2.0XNT (J30-40XNT) [K160];

Throughout this section, forward will refer to travel

User Interface Service-Level Functions On-

User Interface Service Technician

See Figure 3 for lift truck models • J1.5-2.0XNT (J30-40XNT) (K160)

See Figure 10 for lift truck model • J1.6-2.0XN (J30-40XN) (A935)

• E4.0-5.5XN, E5.0XNS (E80-120XN, 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

Figure 3. Traction Motors for Lift Truck

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 E2.2-3.5XN (E45-70XN)

For lift truck models E1.6-2.0XN (E30-40XN)

See Figure 10 for lift truck model

Some checks and adjustments are performed with

Before performing any tests or adjustments, block

The capacitor in the transistor controller(s) can

DO NOT short across the motor controller

1. To avoid injury and prevent electrical shock,

Disconnect the battery and discharge the

Figure 12. Traction Controller

6. Press horn button. Wait 30 seconds to be sure

Traction Motor Repair

1. TRANSAXLE 7. TRACTION MOTOR

Figure 13. Transaxle Assembly

NOTE: Use an approved lifting device to hold and

9. Remove four traction motor mounting cap-

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

2. If necessary, temp sensor connector (see Fig-

a. Place one DMM probe on terminal U. 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

e. Place one DMM probe on terminal W. 1. TRANSAXLE END HEAD

Figure 16. Traction Motor

Legend for Figure 16

1. TRANSAXLE END HEAD 6. BRAKE END HEAD

9. Install four lockwashers and socket-head cap-

NOTE: Use an approved lifting device to lift and

3. Install four washers and traction motor mount-

1. TRANSAXLE 7. TRACTION MOTOR

Figure 18. Transaxle Assembly

8. Connect parking brake wire harness to main CAUTION

• J1.6-2.0XN (J30-40XN) (A935)

A. NON-DRIVE END B. DRIVE END

Figure 19. Traction Motor Non-Drive End Head

6. Using a bearing puller, remove and discard

NOTE: When replacing one bearing, it is strongly