MOTORS

Motor Installation Positions ................................................................. 3–1

Specifications ........................................................................................... 3–1

AC Drive Motor ......................................................................................... 3–2
AC Drive Motor with Brake ....................................................................... 3–3
AC Pump Motor ........................................................................................ 3–4
DC Pump Motor ........................................................................................ 3–5
DC Steer Motor ........................................................................................ 3–6

Tightening of High-Power Motor Cable Terminals ........................... 3–7

Traction Motor & Power Steering Cable Routing ...................................... 3–7
AC Hydraulic Motor Cable Routing ........................................................... 3–8
DC Hydraulic Motor Cable Routing .......................................................... 3–8

Procedures and Suggestions for Removal and Installation of Drive Mortors ....... 3–9
3
Removal ................................................................................................... 3–9
Installation ................................................................................................ 3–9

Hydraulic Pump Motor Removal .......................................................... 3–9

Steer Pump Motor Removal ................................................................. 3 – 10

AC Motors ................................................................................................. 3 – 10
External Inspection ................................................................................... 3 – 10
Procedures and Suggestions for Disassembly and Reassembly .............. 3 – 10
AC Drive Motor ......................................................................................... 3 – 11
AC Drive Motor with Brake ....................................................................... 3 – 12

AC Pump Motor ....................................................................................... 3 – 13

Suggestions for Disassembly and Reassembly ........................................ 3 – 13

Trouble Shooting (AC Motors) .............................................................. 3 – 14

Trouble Shooting (DC Motors) .............................................................. 3 – 15
Service Data (AC Motors) ...................................................................... 3 – 23
 MOTORS

Motor Installation Positions

Specifications

Item 9” AC Drive Motor 11” AC Drive Motor w/o Brake 11” AC Drive Motor w/ Brake
Type Induction three phase Induction three phase Induction three phase
Voltage (V) 36 48 36 48 36 48
Output (kW) 6.16 kW 6.84 kW 10.2 kW 12.81 kW 10.2 kW 12.81 kW
(S2-60 min) (S2-60 min) (S2-60 min) (S2-60 min) (S2-60 min) (S2-60 min)
Weight kg (lb) 80 (176) 136 (299) 136 (299)

Item 8” AC Pump Motor 9” AC Pump Motor

Type Induction three phase Induction three phase
Voltage (V) 36 48 36 48
Output (kW) 7.41 kW 6.84 kW 10.2 kW 12.81 kW
(S3-15%) (S3-15%) (S3-15%) (S3-15%)
Weight kg (lb) 55 (121) 75 (165)

Item 8” DC Pump Motor 9” DC Pump Motor DC Steering Pump Motor

Type Series Series Permanent Magnet
Voltage (V) 36 48 36 48 36 48
Output (kW) 10 kW 14 kW 15.1 kW 22.1 kW 0.69 kW 0.93 kW
(S3-20%) (S3-20%) (S3-20%) (S3-20%) (S2-60 min) (S2-60 min)
Weight kg (lb) 52 (114) 78 (172) 14 (30)

3-1
MOTORS

Structures

AC Drive Motor

U, V, W Terminals

3-2
 MOTORS

Structures

AC Drive Motor with Brake

U, V, W Terminals

3-3
MOTORS

Structures

AC Pump Motor

U, V, W Terminals

3-4
 MOTORS

Structures

DC Pump Motor

3-5
MOTORS

Structures

DC Steer Motor

3-6
 MOTORS

Tightening of High-Power Motor Cable Terminals

! CAUTION
Truck Size Number of Terminals Tightening Torque
If the high-power cable terminals of the battery 1 Ton 11.3 ± 1.1 N•m
operated vehicle are not tightened properly, the Drive 3 (1.2 ± 0.1 kgf•m)
increased contact resistance causes excessive & Pump [8.33 lbf•ft]
heat generation, and could cause a fire in the 2 / 3 Ton 14.7 ± 1.1 N•m
worst case. To prevent accidents and equipment Drive 3 (1.5 ± 0.1 kgf•m)
problems, be sure to regularly check the & Pump [11 lbf•ft]
tightening torque of the high power cable
terminals. Do not pull the cables to check
connections or during adjustment. If the cable
terminal sections are moved, re-tighten the

Traction Motor & Power Steer Motor Cable Routing

3-7
MOTORS

Tightening of High-Power Motor Cable Terminals

AC Hydraulic Motor Cable Routing

DC Hydraulic Motor Cable Routing

3-8
 MOTORS

Procedures and Suggestions for Hydraulic Pump Motor Removal

Removal and Installation of Drive
Motors Removal
(1) Disconnect the battery from the truck.
Removal
(2) Disconnect the hoses attached to the pump fittings.
(1) Disconnect the battery plug.
(3) Disconnect the power cables and wire leads from
(2) Using a crane, remove the batteries. the pump motor.
(3) Remove the floor plate and battery cover. (4) Raise the truck enough to allow the pump and
(4) Disconnect the power cables connected to the motor assembly to be removed from below the
motor. truck. Make sure that the truck is stable and
secure
(5) Remove the drain plug on the front axle housing
to let the oil drain out. in the raised position.

(6) Disconnect the connectors of the traction motor (5) Secure the motor from above with a crane, hoist,
harness and pulse generator harness. or other adequate device, or support it at its

(7) Remove the traction motor, Reduction and

Deferential Assembly and transfer assembly as
one unit, from the front axle housing.
(8) Seperate the three assemblies removed in step (7)
from each other.
(9) Using a crane, lift the drive motor to suspend it.

NOTE

Position the hook above the gravitational center

of the drive motor.
Each motor is equipped with the provision of an
installing and lifting hook for motor removal and
installation.

Installation
Follow the removal sequence in reverse.

Installation
Follow the removal sequence in reverse.

3-9
MOTORS

Steer Pump Motor Removal AC Motors

(1) Remove the battery. External Inspection

(2) Remove the acid tray. External Inspection should include:
(3) Disconnect the cables and wires from the steer
(1) Check terminal studs and mounting bolts to
pump motor. Mark the wire leads and cables so
ensure they are clean and tight.
they can be correctly reconnected.
(2) Check all cooling openings to ensure they are free
(4) Disconnect the hydraulic lines from the pump.
of any debris or restrictions that could prevent
(5) Remove the pump motor. proper airflow and hinder cooling.
(3) Lubricate internal and external spline couplings.
(4) Check for any oil leaks and make any corrections
or repairs immediately.

Disassembly and Reassembly

(1) Remove the bolts holding the drive end bell and
rear end bell in place and remove the rear end
bell with wavy spring from the stator assembly.
The drive end bell and rotor assembly with the
rear bearing will remain inside the stator
assembly.
(2) Remove the drive end bell and rotor assembly
from the stator assembly.
(3) Remove drive end bell from the rotor assembly.
(4) Use a bearing puller to remove rear bearing from
the rotor assembly. Discard the bearing.
Installation (5) Remove the bolts holding the bearing pressure
plate in place and remove the bearing press plate.
Follow the removal sequence in reverse. Use a sleeve to press the bearing out of the drive
end bell-bearing bore and discard the bearing.
(6) Carefully blow out any accumulated dust and dirt
from the end bells and stator assembly using
clean, oil free, compressed air.
(7) If the stator assembly requires maintenance, see
Trouble Shooting Section.
(8) Press a new bearing into the rotor assembly rear
end, pressing on the inner-race only.
(9) Replace the sensor bearing on the drive end bell,
pressing on the outer race only. Then screw the
bearing press plate in place.
(10) Press the drive end bell into the rotor assembly
and tighten the screws with the stator assembly.
(11) Place the wavy washer into the bearing bore of

3-10
 MOTORS

AC Motors

Disassembly and Reassembly AC Drive Motor

(12) Connect the motor to an AC supply and run the ITEM DESCRIPTION
motor at 25 volts, 50 Hz for 30 minutes.
1 Seal
(13) Repair or replace headband (if necessary) and 2 Bolt
install the headband on the motor (if applicable).
3 Lock Washer
(14) If applicable, place a small drop on the lip of the
seal for optimum seal life before replacing the oil 4 Drive End Bell
seal. If the shaft has a keyway, protect the lip of 5 EE Motor Kit (headband)
the seal from being cut on the keyway edge. 6 Sensor Bearing Kit
7 Thermal Sensor Repair Kit
Suggestion for Disassembly and 8 Stator
Reassembly 9 Terminal Block Assembly
10 Rotor
Ball bearings at both ends are maintenance free. If it is 11 Rear End Bearing
necessary to remove the bearing when repairing the
12 Rear End Bell
motor, the bearings and seals must be replaced.
13 Bolt
If a bearing which is said to be replaced has only one
sealing lip, it should be greased with quality bearing
grease when installing it.
Replace the bearings and the seals after approximately
10,000 operating hours.

AC DRIVE MOTOR

3-11
MOTORS

AC Motors

AC Drive Motor with Brakes ITEM DESCRIPTION

1 Seal
2 Bolt
3 Lock Washer
4 Drive End Bell
5 Sensor Bearing Kit
6 EE Motor Kit (headband)
7 Thermal Sensor Repair Kit
8 Stator
9 Terminal Block Assembly
10 Rotor
11 Key C8X20
12 Brake End Bearing
13 Brake End Bell
14 Bolt
15 Brake Pad

AC DRIVE MOTOR with BRAKES

3-12
 MOTORS

AC Pump Motor

ITEM DESCRIPTION
1 Bolt
2 Lock Washer
3 Drive End Bell
4 EE Motor Kit (headband)
5 Sensor Bearing Kit
6 Thermal Sensor Repair Kit
7 Thermal Block Assembly
8 Stator
9 Rotor
10 Rear End Bearing
11 Rear End Bell

AC PUMP MOTOR

3-13
MOTORS

Trouble Shooting

AC Motor

Faulty thermal sensor or Repair or replace

thermal sensor connection

Faulty sensor bearing or Repair or replace

bearing sensor connection

Low supply voltage Charge battery and improve power

supply condition
Motor does not start.
Blown fuse Replace

Excess load Reduce load

Faulty wire connection Repair, or re-tighten wire connections

Broken wire in control device Repair or replace

Broken wire in stator coil Repair or replace

Low supply voltage Charge battery and improve power

Motor starts but does supply condition
not run at rated
speed. Excessive resistance to Remove resistance
rotation

Defective bearings Replace bearings

Motor produces
abnormal vibrations Loose mounting bolts Retighten bolts and nuts
and noise.
Contact between rotor and stator Repair or replace

Incorrect installatioin Correct installation condition

Severe external vibration Remove the cause of vibration, or

take appropriate vibration-insulating
Bearing overheats. measures

Defective bearings Replace

Oil degradation or shortage in Replace

bearings

3-14
 MOTORS

Trouble Shooting

DC Motor

SUCCESSFUL INSULATION SYSTEM

COMMUTATION REQUIREMENTS
• Good contact between commutator and brush
• Mechanically true commutator
• Brushes free to move in holders
• Copper-Oxide-Carbon film (as opposed to pure
copper surface) noted by color variations
• Insulation resistance - 0.10 Mega-ohm (or greater)
• Less than 0.10 Mega-ohm, investigate:
– Excessive dirt
– Moisture
– Insulation breaK down
For moisture, bake in an oven at 90 degrees C (190F)

• Commutator surface should be clean and smooth • 600V - 60HZ - 1 minute

• Clean commutator • Test old motors at 75% of above values

NOTE: Refer to the next following pages for charts

on “Unsatisfactory Brush Performance” and ARMATURE WINDING PROBLEMS
illustrations of “Commutator Surfaces” which show
the main patterns of film build-up on commutators, • Open Circuit
and indicate the type of brush/commutator – Thin red sparks encircling commutator
interaction which give rise to each pattern. – Blackens or flattens commutator bars,
especially at edges

SPARKING AT BRUSHES • Short Circuit

– Blue spark in vicinity of brush holder
• Commutator in poor condition
– Commutator bars oxidize or burn
• Eccentric or rough commutator
• Grounded
• Excessive vibration – High current draw
– Rapid brush wear
• Broken or sluggish spring

• Brushes to short

• Machine overloaded

• Short circuit in armature

3-15
MOTORS
Trouble Shooting
Unsatisfactory Brush Performance
TABLE ONE – PRIMARY SOURCES OF UNSATISFACTORY BRUSH PERFORMANCE
Preparation and Care of Motor
Mechanical Fault in Motor
Electric Fault in Motor
Load or Service Condition
Disturbing External Condition
• Poor operation of commutator surface
• High mica
• Side mica
• Need for periodic cleaning
• Clogged ventilating ducts
• Brushes tight in holders
• Brushes too loose in holders
• Brush holders loose at mounting
• Loose pole pieces
• Loose or worn bearings
• Dynamic imbalance
• Variable angular velocity
• Open or high resistance connection at commutator
• Connection at series terminal
• Short circuit in field or armature winding
• Ground in field or armature winding
• Reversed polarity on main pole
• Overload
• Dynamic braking
• Low average current density in brushes
• Contaminated atmosphere
• “Contact positions”
• Oil on commutator or oil mist in air
• Abrasive dust in air
• Humidity too high
• Humidity too low
• Silicone contamination
• Loose or damaged motor mounting
• External source of vibration
• External short circuit
• Contact drop of brushes too high
• Contact drop of brushes too low
• Lack of film-forming properties in brush
• Lack of polishing action in brush
• Brushes too abrasive
• Lack of carrying capacity
3-16
 MOTORS

Trouble Shooting

Unsatisfactory Brush Performance

TABLE TWO – INDICATIONS APPEARING AT BRUSHES

INDICATION
Indication IMMEDIATE CAUSES
Immediate Causes PRIMARY FAULTS
Primary Faults

Sparking Commutator surface condition • Poor operation of commutator surface

• High mica
• Side mica
• Low average current density in brushes
• Contaminated atmosphere
• Contact positions
• Oil on commutator or oil mist in air
• Humidity too low
• Lack of film-forming properties in brush
• Lack of polishing action in brush

Mechanical fault in motor • Clogged ventilating ducts

• Brushes tight in holders
• Brushes too loose at mounting
• Loose pole pieces
• Loose or worn bearings
• Dynamic unbalance
• Incorrect spring tension

Electrical fault in motor • Open or high resistance connection

at commutator
• Short circuit in field or armature winding
• Ground in field or armature winding
• Reversed polarity on main pole

Bad load condition • Overload

• Rapid change of load

Vibration • Loose or damaged motor mountings

• External source of vibration

Chattering of brushes • See Chattering or Noisy Brushes

Wrong brush grade for • Lack of film-forming properties in brush

application

Other • Silicone contamination

Etched or Burned Embedded copper • See Copper in Brush Face

Bands on Brush Face

Rapid Brush Wear Commutator surface condition • See specific surface fault in evidence
• Silicone contamination

Severe sparking • See Sparking

3-17
MOTORS

Trouble Shooting

Unsatisfactory Brush Performance

TABLE TWO – INDICATIONS APPEARING AT BRUSHES (CONT’D)

INDICATION IMMEDIATE CAUSES PRIMARY FAULTS

Rapid Brush Wear Imperfect contact w/commutator • Incorrect spring tension

(cont’d) • Brushes tight in holders
• Brushes too loose in holders
• Brushes holders loose at mounting
• Loose or damaged motor mountings
• External source of vibration

Wrong brush grade f/application • Lack of film-forming properties in brush

Copper in Brush Face Commutator surface condition • High mica

• Side mica

Bad service condition • Oil on commutator or oil mist in air

• Abrasive dust in air
• Humidity too high
• Humidity too low

Wrong brush grade f/application • Lack of film-forming properties in brush

• Brushes too abrasive

Chattering or Commutator surface condition • Raised Commutator Bars

Noisy Brushes

Looseness in motor • Brushes too loose in holders

• Brushes holders loose at mounting
• Incorrect spring tension

High friction • Clogged ventilating ducts

• Contact poisons
• Humidity too low
• External source of vibration

Wrong brush grade f/application • Lack of film-forming properties in brush

3-18
 MOTORS

Trouble Shooting

Unsatisfactory Brush Performance

TABLE THREE – INDICATIONS APPEARING AS HEATING

INDICATION IMMEDIATE CAUSES PRIMARY FAULTS

Heating in Windings Severe load conbdition • Overload

(Field or Armature) • External short circuit
• Stalled motor

Unbalanced magnetic field • Loose or worn bearings

• Short circuit in field or armature winding

Lack of ventilation

Heating at Commutator Severe load condition • Overload

Severe sparking • Contact positions

• See Sparking

High friction • Incorrect spring tension

• Contact poisons
• Humidity too low
• Lack of film-forming properties in brush

Poor commutator surface • See specific surface fault in evidence

Depreciation • Clogged ventilating ducts

High contact resistance • Contact drop of brushes too high

Heating at Brushes Severe load condition • Overload

Faulty motor adjustment • Incorrect spring tension

Severe sparking • See Sparking

Raw streaks on commutator • See Streaking or Threading of Surface

Embedded copper • See Copper in Brush Face

Wrong brush grade f/application • Contract drop of brushes too low

• Lack of film-forming properties in brush
• Brushes too abrasive
• Lack of carrying capacity

3-19
MOTORS

Trouble Shooting

Unsatisfactory Brush Performance

TABLE FOUR – INDICATIONS APPEARING AT COMMUTATOR SURFACE

INDICATION IMMEDIATE CAUSES PRIMARY FAULTS

Bar Marking at Sparking • Lack of polishing action in brush

Slot Pitch Spacing • Lack of film-forming properties in brush

Flat Spot Sparking • Open or high resistance connection at

commutator
• Stalled motor

Discoloration of High temperature • See Heating at Commutator

Surface
Atmospheric condition • Contaminated atmosphere
• Oil in commutator or oil mist in air

Wrong brush grade f/application • Lack of polishing action in brush

• Lack of film-forming properties in brush

Raw Copper Surface Embedded copper • See Copper in Brush Face

Bad service condition • Contact positions

• Abrasive dust in air
• Humidity too low

Wrong brush grade f/application • Lack of film-forming properties in brush

• Brushes too abrasive

Rapid Commutator Burning • High mica

Wear with • Side mica
Blackened Surface • Incorrect spring tension
• Brushes tight in holders
Severe sparking • See Sparking

Rapid Commutator Foreign material in brush face • Contact positions

Wear with • Abrasive dust in air
Bright Surface • Humidity too low
• Brushes too abrasive

Wrong brush grade f/application • Brushes too abrasive

• Lack of film-forming properties

Copper Dragging Brush Vibration • External source of vibration

• Lack of film-forming properties in brush

3-20

Trouble Shooting
Unsatisfactory Brush Performance
COMMUTATOR SURFACES
GOOD CONDITION
LIGHT FILM
Uniform coloring indicates
satisfactory operation of
machine and brushes. Film color
is largely an effect of thickness,
therefore provided the film is
uniform it is perfectly
acceptable.
SATISFACTORY CONDITION
LIGHT AND DARK PATTERN
This is not a good condition but
in our experience it is known
that machines having this
commutator pattern have
operated with satisfactory
results for long periods of time.
This condition can appear in
alternating bars as shown or
every 3rd or 4th bar, etc. This is
related to the winding design of
the armature. Difficulty caused
from split windings crossing in
UNSATISFACTORY CONDITION
STREAKY FILM WITH NO
COMMUTATOR WEAR
Frequently due to under-loaded
operation, machine grossly over-
brushed or brush grade incorect
for particular machine
appliction. Atmosphere and
environmental conditions can
contribute.
3-21
MOTORS
UNSATISFACTORY CONDITION
UNEVEN FILM
Patchy colors of varying densities
and shape. Due to unclean
operating conditions or incorrect
physical condition of commutator.
UNSATISFACTORY CONDITION
FILM WITH DARK AREAS
These areas can be isolated or
regular. Commutator out of
round. This can be caused by
vibration or mechanical
deficiencies in equipment
operation, bearings, couplings,
etc.
UNSATISFACTORY CONDITION
EXAMPLE OF POOR
COMMUTATOR
MACHINING
Bars are low on entry and
leaving edges giving rise to the
brushes riding on the middle of
the bars.
MOTORS
Trouble Shooting
Unsatisfactory Brush Performance
COMMUTATOR SURFACES
UNSATISFACTORY CONDITION
EXAMPLE OF POOR
COMMUTATOR
MACHINING
Bars are low in the middle giving
rise to the brushes riding on
entry and leaving bar edges.
This and the previous illustration
indicate the need for better
maintenance.
UNSATISFACTORY CONDITION
STREAKY FILM WITH
COMMUTATOR WEAR
This is a further development of
the third example, previous
page. Brush grade, machine
applications and working
environment all suspect. Earlier
corrective action should have
been taken.
UNSATISFACTORY CONDITION
DOUBLE POLE PITCH
Darkening of commutator in
sequences two pole pitches
apart is due to armature fault,
defective coil, riser bars or
equalizer connections.
3-22
UNSATISFACTORY CONDITION
BRUSH CONTACT MARK
Storage of machines, for lengthy
periods, with brushes in position.
This can also result from
operation of machine in
prolonged stall conditions.
UNSATISFACTORY CONDITION
BAR EDGE BURNING
CAUSE HIGH MICA
Illustration shows high mica in
every slot. Same effect can
occur on one bar only. Similar
conditions can be caused by a
high or low bar.
UNSATISFACTORY CONDITION
SMALL BRIGHT SPOTS
Related to over-loaded machines
and low brush pressure. Due to
sparking under brush which
gives rise to spots being of a
random distribution. If not
corrected, will result in scored
commutator.
 MOTORS

Service Data

AC Motor

Truck Models
1 Ton Class 2 / 3 Ton Class
Item
Stator Coil Insulation Resistance 1MΩ min. 1MΩ min.
AC Drive Motor and Pump Motor

U-V 0 0
Drive Motor
Terminal Conductivity V-W 0 0
(Ω) Pump Motor
W-U 0 0

N•m 11.3 ± 1.1 N•m 14.7 ± 1.1 N•m

Cable Terminal Tightening Torque (kgf•m) (1.2 ± 0.1 kgf•m) (1.5 ± 0.1 kgf•m)
[lbf•ft] [8.33 lbf•ft] [11 lbf•ft]

DC Motor

Truck Models
1 Ton Class 2 / 3 Ton Class
Item
0Ω 0Ω
Pump Motor

Resistance between PA1 & PS2

6.8 N•m 13.5 N•m
DC Pump Motor

Cable Terminal tightening torque 0.69kgf•m 1.4 kgf•m

5 lbf•ft 10 lbf•ft
Resistance between Neg. & Pos. 0Ω 0Ω
Steer Pump
Motor

6.8 N•m 6.8 N•m

Cable Terminal tightening torque 0.69 kgf•m 0.69 kgf•m
5 lbf•ft 5 lbf•ft

3-23
 ®
Lift
Trucks

Mitsubishi Caterpillar Forklift America Inc.

2121 W. Sam Houston Parkway N.
Houston, TX 77043-2305

Copyright © 2008 by MCFA. All Rights Reserved.

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