Maintenance

A/C MOTOR REPAIR S/N A474N03000L=>

S/N A497N030000L=> S/N D801N02161L=>
S/N E826N01917L=>
NDR035EB, NR045EB [D861];
NDR030EB, NR035/040EB [E815];
NDR030DB, NR035/040DB [B295];
SS030BF [A474];
FS030BF [A497];
OS030EF [D801];
OS030BF [E826];
MPC060-VG [A372];
MPC080-VG [A283];
MPE060-VG [B292];
MPE080-VG [B287];
MTR005-F, MTR007-F [C903]

PART NO. 550073166 0620 YRM 1621

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
A/C Motor Repair S/N A474N03000L=> S/N A497N030000L=> S/N D801N02161L=> S/N E826N01917L=>
Table of Contents

TABLE OF CONTENTS

General ..................................................................................................................................................................... 1
Special Precautions .................................................................................................................................................. 2
Discharging the Capacitors .................................................................................................................................. 2
Traction Motor Repair ............................................................................................................................................... 2
Remove ................................................................................................................................................................ 2
Disassemble ......................................................................................................................................................... 4
Clean/Inspect ........................................................................................................................................................8
Assemble ..............................................................................................................................................................8
Install .................................................................................................................................................................... 9
Hydraulic Motor Repair ........................................................................................................................................... 11
Disassemble ....................................................................................................................................................... 11
Inspect ................................................................................................................................................................ 14
Assemble ............................................................................................................................................................14
Special Tools .......................................................................................................................................................... 15
Tool Chart ...........................................................................................................................................................15
Troubleshooting ...................................................................................................................................................... 15

This section is for the following models:

(NDR035EB, NR045EB) [D861];

(NDR030EB, NR035/040EB) [E815];
(NDR030DB, NR035/040DB) [B295];
(SS030BF) [A474];
(FS030BF) [A497];
(OS030EF) [D801];
(OS030BF) [E826];
(MPC060-VG) [A372];
(MPC080-VG) [A283];
(MPE060-VG) [B292];
(MPE080-VG) [B287];
(MTR005-F, MTR007-F) [C903]

©2014 Yale Materials Handling Corp. i

0620 YRM 1621
General
This section contains repair and maintenance
procedures for the AC traction and hydraulic motors.
Additional information concerning the traction motor
may be included in other sections when the
information is more closely related to other systems.
For lift truck models NDR035EB, NR045EB (D861),
NDR030EB, NR035-040EB (E815) and NDR030DB,
NR035-040DB (B295) see:
• Periodic Maintenance 8000YRM1617
• Electrical System 2200YRM1612
• Master Drive Unit S/N D801N03000L=> S/N
A474N03000L=> S/N A497N030000L=> S/N
E826N03000L=> 0630YRM1609
For lift truck models SS030BF (A474), FS030BF
(A497), OS030EF (D801) and OS030BF (E826) see:
• Periodic Maintenance 8000YRM1472
• Electrical System 2200YRM1467
• Electrical System 2200YRM1468
• Master Drive Unit S/N D801N03000L=> S/N
A474N03000L=> S/N A497N030000L=> S/N
E826N03000L=> 0630YRM1609
General
For lift truck models MPC060-VG (A372) and
MPC080-VG (A283) see:
• Periodic Maintenance 8000YRM1635
• Electrical System 2200YRM1632
• Master Drive Unit S/N D801N03000L=> S/N
A474N03000L=> S/N A497N030000L=> S/N
E826N03000L=> 0630YRM1609
For lift truck model MPE060-VG (B292) and MPE080-
VG (B287) see:
• Periodic Maintenance 8000YRM1644
• Electrical System 2200YRM1640
• Master Drive Unit * (With EPAS)
0630YRM0961
• Master Drive Unit S/N D801N03000L=> S/N
A474N03000L=> S/N A497N030000L=> S/N
E826N03000L=> 0630YRM1609
1
Special Precautions 0620 YRM 1621

Special Precautions
DISCHARGING THE CAPACITORS 3. Discharge the capacitors in the controllers by con-
necting a 200-ohm, 2-watt resistor across the
controller's B+ and B− terminals using insulated
WARNING jumper wires. See Figure 1. DO NOT short across
The capacitor in the transistor controller can hold the motor controller terminals with a screwdriver
an electrical charge after the battery is disconnec- or jumper wire. Remove the 200-ohm, 2-watt re-
ted. To prevent electrical shock and personal in- sistor before reconnecting the battery.
jury, discharge the capacitor before inspecting or
repairing any component. Wear safety glasses.
Make certain the battery has been disconnected.
DO NOT use a screwdriver to discharge the trac-
tion motor controller.

WARNING
To avoid personal injury and prevent electrical
shock, perform the following steps before per-
forming any troubleshooting or adjustments, and
connecting or disconnecting a handset or PC.

CAUTION
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never put
power to the controller with any power wire dis-
connected. Never short any controller terminal or
motor terminal to battery. Make sure to use proper
procedures when servicing the controller.
1. NEGATIVE CONNECTION
1. Turn the key switch to the OFF position and dis- 2. POSITIVE CONNECTION
connect the battery. 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
2. Remove the electrical compartment cover for ac-
cess to the traction motor controller. Remove the Figure 1. Discharging the Capacitors
capscrews retaining the cover to the frame.

Traction Motor Repair

REMOVE
WARNING
Capacitors inside the controllers can hold an elec-
trical charge after the battery is disconnected. dis-
charge the capacitors before servicing the electri-
cal system to prevent injury or electronic damage.
WARNING
The AC traction motor is heavy. To prevent injury,
use a lifting device of adequate capacity for lifting
the assembly.
It is not necessary to remove the traction motor from
the lift truck to make some repairs. Perform only the
steps necessary to safely complete the required serv-
ice.

2
0620 YRM 1621 Traction Motor Repair

See Hydraulic System 1900YRM1639 lift truck

WARNING model MPE060-VG (B292) and MPE080-VG
Disconnect the battery and separate the connec- (B287).
tor before opening the drive unit compartment
door and before inspecting or repairing the elec- 5. Remove steer motor from lift truck.
trical system. If a tool causes a short circuit, the
See Steering System 1600YRM1610 for lift truck
high-current flow from the battery can cause in-
models NDR035EB, NR045EB (D861),
jury or parts damage
NDR030EB, NR035-040EB (E815) and
1. Turn the key switch to the OFF position and dis- NDR030DB, NR035-040DB (B295).
connect the battery connector. Discharge the ca-
See Steering System 1600YRM1462 for lift truck
pacitors. See Special Precautions in this manual.
models SS030BF (A474), FS030BF (A497),
2. Remove the operator cover or electrical compart- OS030EF (D801) and OS030BF (E826).
ment cover, depending on your model lift truck.
See Steering Mechanism 1600YRM1627 for lift
See Frame 0100YRM1615, Covers, Panels, and truck models MPC060-VG (A372) and MPC080-VG
Plates Repair for lift truck models NDR035EB, (A283).
NR045EB (D861), NDR030EB, NR035-040EB
See Steering Mechanism 1600YRM1637 lift truck
(E815) and NDR030DB, NR035-040DB (B295).
model MPE060-VG (B292) and MPE080-VG
See Frame 0100YRM0760, Frame Repair for lift (B287).
truck models SS030BF (A474), FS030BF (A497),
NOTE: The brake may be removed at this point.
OS030EF (D801) and OS030BF (E826).
However, it is not necessary to remove the brake if
See FRAME 0100YRM1580, Covers for lift truck the motor will not be disassembled.
models MPC060-VG (A372) and MPC080-VG
6. Remove brake from the top of the traction motor if
(A283).
necessary.
See Frame 0100YRM1636, Covers for lift truck
See Brake System 1800YRM1188 for lift truck
model MPE060-VG (B292) and MPE080-VG
models NDR035EB, NR045EB (D861),
(B287).
NDR030EB, NR035-040EB (E815) and
3. Open the drive unit compartment doors and fas- NDR030DB, NR035-040DB (B295).
ten each door so that they are fully open.
See Brake System 1800YRM1463 for lift truck
4. Remove the hydraulic motor and hydraulic tank models SS030BF (A474), FS030BF (A497),
from lift truck. OS030EF (D801) and OS030BF (E826)

See Hydraulic System 1900YRM1616 for lift truck See Brakes 1800YRM1628 for lift truck models
models NDR035EB, NR045EB (D861), MPC060-VG (A372) and MPC080-VG (A283).
NDR030EB, NR035-040EB (E815) and
See Brakes 1800YRM1638 lift truck model
NDR030DB, NR035-040DB (B295).
MPE060-VG (B292) and MPE080-VG (B287).
See Hydraulic System 1900YRM1464 or Hy-
7. Identify, tag, and disconnect the power cables
draulic System 1900YRM1465 for lift truck models
and wiring connecting the traction motor to the
SS030BF (A474), FS030BF (A497), OS030EF
truck electrical system.
(D801) and OS030BF (E826)

See Walkie Hydraulic System 1900YRM1629 for

lift truck models MPC060-VG (A372) and MPC080-
VG (A283).

3
Traction Motor Repair
WARNING
The AC traction motor weighs 42.2 kg (93 lb). To
prevent injury, use a lifting device of adequate ca-
pacity for lifting the assembly.
WARNING
There are close clearances between the MDU,
drive motor and truck frame, which can cause se-
rious injury. NEVER put hands, arms, head, or
legs between these parts unless there are blocks
in place to prevent movement. If the drive motor
falls, it can cause an injury. Support the drive mo-
tor vertically using an overhead hoist and rated
lifting device to prevent it from falling.
CAUTION
Clean the motor housing and drive unit (MDU)
mating surfaces prior to removing the drive mo-
tor. Use clean cloths and suitable spray cleaner.
DO NOT use pressure washing methods to clean
MDU and motor compartment. Use care when lift-
ing drive motor to prevent dirt from entering MDU.
CAUTION
Use care when removing the drive motor. Some
slight rotation of the motor may be required to al-
low pinion gear to exit the internal gear of MDU.
Protect the drive motor input pinion gear from
damage.
8. Remove the capscrews and lockwashers that fas-
ten the traction motor to the adapter ring on the
MDU.
9. Using Ring Eye Adapter lifting device, screw
adapter into threads of rotor shaft.
CAUTION
The traction motor should always be lifted and
lowered vertically. Failure to do so may lead to
damage of the drive pinion gear.
NOTE: A plastic mallet may be required to free the
drive motor from the MDU.
10. Attach an overhead hoist through overhead guard
to ring adapter so as to allow for a straight re-
moval of the drive motor.
4
0620 YRM 1621
CAUTION
Place a suitable plug or other cover over MDU to
prevent contamination from entering the gearbox.
11. Apply slight pressure with the overhead lift to the
Ring Eye Adapter while tapping gently on the
lower motor housing with plastic mallet and
slightly rotating the sling and Ring Eye Adapter
until the motor is free of the MDU adapter ring
and bearing. Carefully lift the motor straight up out
of the way of the MDU and frame. Place the mo-
tor on a work bench or other suitable support so
as not to damage the bearing housing and pinion
gear. Protect the gear and bearing with a suitable
cover to prevent dirt and debris from entering the
bearing assembly and possibly causing damage.
If replacing the bearing housing see Disassemble
section of this manual for repair instructions.
DISASSEMBLE
WARNING
The drive end bearing retainer assembly and
seals are serviceable parts. The non-drive end
bearing is not a serviceable part. The AC traction
motor weighs 42.2 kg (93 lb). To prevent injury,
use a lifting device of adequate capacity for lifting
the assembly.
NOTE: The sensor connector cover only needs to be
removed if connectors are damaged and need to be
replaced.
See Wire Harness Repair 2200YRM1128 for lift truck
models NDR035EB, NR045EB (D861), NDR030EB,
NR035-040EB (E815) and NDR030DB,
NR035-040DB (B295).
See Wire Guidance 2200YRM1471 for lift truck mod-
els SS030BF (A474), FS030BF (A497), OS030EF
(D801) and OS030BF (E826).
NOTE: Step 1 applies to 24/36V Traction Motor As-
sembly.
1. Remove two capscrews, two washers and sensor
connector cover from side of traction motor. See
Figure 2.
0620 YRM 1621 Traction Motor Repair

1. BEARING AND SEAL ASSEMBLY 14. LOCKWASHER

2. DRIVE END COVER 15. CAPSCREW
3. O-RING 16. NUT
4. PINION 17. INSULATOR BLOCK
5. SLOTTED NUT 18. TERMINAL COVER
6. BOLT 19. NON-DRIVE END COVER
7. LOCKWASHER 20. SPEED ENCODER
8. WASHER 21. SCREW
9. WOODRUFF KEY 22. WHEEL
10. BRACKET 23. NON-DRIVE END BEARING ASSEMBLY
11. FASTENER 24. SET SCREW
12. CLIP 25. TRACTION MOTOR
13. SENSOR CONNECTOR COVER
Figure 2. Traction Motor Assembly (24/36 Volt)

5
Traction Motor Repair 0620 YRM 1621

1. BEARING AND SEAL ASSEMBLY 10. FASTENER

2. DRIVE END COVER 11. INSULATOR BLOCK
3. O-RING 12. NUT
4. PINION 13. LOCKWASHER
5. SLOTTED NUT 14. NON-DRIVE END COVER
6. BOLT 15. SPEED ENCODER
7. WASHER 16. SET SCREW
8. WOODRUFF KEY 17. NON-DRIVE END BEARING ASSEMBLY
9. BRACKET 18. TRACTION MOTOR
Figure 3. Traction Motor Assembly (15 Volt)

6
0620 YRM 1621 Traction Motor Repair

2. Remove set screw and speed encoder from trac-

tion motor. See Figure 2 or Figure 3.

NOTE: Secure traction motor shaft on the non-drive

end to prevent motor shaft from rotating during re-
moval of slotted nut.

3. Using special tool, remove slotted nut from drive

end of traction motor shaft. See Figure 4.

4. Remove input pinion and woodruff key from drive

end of traction motor. See Figure 4.

NOTE: SOME COMPONENTS SHOWN FOR REF-

ERENCE PURPOSES ONLY.

1. OUTER SNAP RING

2. INNER SNAP RING
3. BEARING AND SEAL ASSEMBLY
4. O-RING
5. TRACTION MOTOR

Figure 5. Drive-End Bearing and Seal Removal

1. SLOTTED NUT 3. WOODRUFF KEY

2. INPUT PINION 4. TRACTION MOTOR

Figure 4. Slotted Nut/Pinion Removal

WARNING
The bearing and seal assembly is installed with a
snap ring. Applying force on the bearing without
first removing the snap ring could cause damage
to the traction motor or personal injury.

NOTE: The bearing and seal assembly, O-ring and

snap ring is serviced as a single part number. If any
component is damaged and needs to be replaced, the
assembly will need to be replaced. 1. HEX BOLT 4. DRIVE END COVER
2. FLAT WASHER 5. TRACTION MOTOR
5. Remove snap ring and bearing and seal assem- 3. LOCK WASHER
bly from traction motor. See Figure 5.
Figure 6. Drive End Cover

7
Traction Motor Repair 0620 YRM 1621

NOTE: Note position of non-drive end cover in rela- Inspect terminal insulators and terminal insulator
tion to alignment arrows and "U", "V" and "W" mark- blocks for damage or wear. Replace components as
ings on non-drive head end cover, to help during as- necessary. See Figure 8.
sembly.

6. Remove four hex bolts, four lock washers, and

four flat washers from non-drive end cover. See
Figure 7.

7. Remove non-drive end cover assembly from trac-

tion motor. See Figure 7.

NOTE: SOME COMPONENTS REMOVED FOR

CLARITY.

1. TERMINAL COVER
2. TERMINAL FLAG
1. HEX BOLT 3. TERMINAL INSULATOR
2. LOCK WASHER 4. SPRING WASHER
3. FLAT WASHER 5. HEX HEAD BOLT
4. NON-DRIVE END COVER 6. TRACTION MOTOR HOUSING
5. TRACTION MOTOR
Figure 7. Non-Drive End Cover Removal Figure 8. Terminal Insulator Components

CLEAN/INSPECT
Inspect the drive motor bearing and seal housing for
damage to gear teeth. Any gear teeth that are chip-
ped or worn is cause for replacement of the gear. In-
spect the bearing retainer by rotating the bearing re-
tainer housing. Any roughness in the bearing retainer
housing is cause for replacement. Inspect the O-ring
groove in the bearing retainer housing for nicks or
damage. Once the motor is removed the original O-
ring should be discarded and replaced.
Inspect the motor housing surfaces for any cracks or
damage that may prevent reassembly. Inspect the up-
per motor stator shaft to brake mounting splines for
damage. If worn excessively or damaged the motor
should be replaced.
ASSEMBLE
NOTE: Position non-drive end cover as noted during
removal.
1. Install non-drive end cover assembly onto traction
motor. See Figure 7.
2. Install four flat washers, four lock washers and
four hex head bolts into non-drive end cover and
traction motor. Torque bolts to 18 to 22 N•m (13
to 16 lbf ft). See Figure 7.
3. Install traction motor drive end cover, four lock
washers, four flat washers and four hex bolts onto
traction motor. Torque bolts to 18 to 22 N•m (13
to 16 lbf ft). See Figure 6.

8
0620 YRM 1621
4. Using special tool and the following procedure, in-
stall bearing and seal assembly onto drive end of
traction motor.
• Place bearing and seal assembly onto
shaft at drive end of traction motor.
• Place special tool against bearing and seal
assembly onto shaft at drive end of traction
motor.
• Thread center rod of special tool onto end
of shaft at drive end of traction motor.
• Slide press collar over center rod and onto
main body of special tool.
• Thread a M16x1.5 nut until the nut is snug
against press collar. Continue to torque the
nut against the press collar and special tool
until bearing and seal assembly is fully
seated onto shoulder of shaft on drive end
of traction motor.
1. MAIN BODY
2. CENTER ROD
3. PRESS COLLAR
4. BEARING AND SEAL ASSEMBLY
5. SHAFT
Figure 9. Bearing and Seal Assembly Installation
5. Remove special tool and install snap ring onto
drive end of traction motor. See Figure 5.
6. Install woodruff key and input pinion onto drive
end of traction motor. See Figure 4.
NOTE: Secure traction motor shaft on non-drive end
to prevent motor shaft from rotating during assembly.
Traction Motor Repair
7. Using special tool, install slotted nut onto drive
end of traction motor. Torque nut to
55 N•m (40.6 lbf ft). See Figure 4.
8. Install speed encoder and set screw into side of
traction motor. See Figure 2 or Figure 3.
NOTE: The sensor connector cover only needs to be
removed if connectors are damaged and need to be
replaced.
See Wire Harness Repair 2200YRM1128 for lift truck
models NDR035EB, NR045EB (D861), NDR030EB,
NR035-040EB (E815) and NDR030DB,
NR035-040DB (B295).
See Wire Guidance 2200YRM1471 for lift truck mod-
els SS030BF (A474), FS030BF (A497), OS030EF
(D801) and OS030BF (E826).
NOTE: Step 9 applies to 24/36V Traction Motor As-
sembly.
9. Install sensor connector cover, two washers and
two capscrews onto side of traction motor. See
Figure 2 .
INSTALL
WARNING
There are close clearances between the MDU,
drive motor and truck frame, which can cause se-
rious injury. NEVER put hands, arms, head, or
legs between these parts unless there are blocks
in place to prevent movement. If the drive motor
falls, it can cause an injury. Support the drive mo-
tor vertically using an overhead hoist and rated
lifting device to prevent it from falling.
CAUTION
Use care when installing the drive motor. Some
slight rotation of the motor rotor may be required
to allow the pinion gear to enter the internal gear
of the MDU. The motor gear must be installed
from a vertical position to prevent damage to the
motor gear teeth. Protect the drive motor input
pinion gear from damage during installation.
1. Remove the protective cover from the MDU and
inspect the gearbox adapter ring bore for any dirt,
or damage. Lightly lubricate the adapter ring bore
with a coat of gearbox oil.
9
Traction Motor Repair 0620 YRM 1621

7. Install the steer motor.

WARNING
The AC traction motor weighs 42.2 kg (93 lb). To See Steering System 1600YRM1610 for lift truck
prevent injury, use a lifting device of adequate ca- models NDR035EB, NR045EB (D861),
pacity for lifting the assembly. NDR030EB, NR035-040EB (E815) and
NDR030DB, NR035-040DB (B295).
NOTE: Ensure that the O-ring placed into the groove
of the bearing and seal assembly is properly seated in See Steering System 1600YRM1462 for lift truck
place and lubricated prior to motor being installed into models SS030BF (A474), FS030BF (A497),
MDU. OS030EF (D801) and OS030BF (E826).

2. Using the overhead hoist and sling and the ring
eye adapter, lower the drive motor carefully until
the pinion gear makes contact with the MDU pin-
ion gear. A slight rotation of the sling and ring eye
adapter to allow indexing of the gear teeth may be
necessary. Verify a slight backlash in the gear
teeth before lowering the motor completely.
3. Slightly tap on the motor housing with the plastic
mallet to seat the motor housing ring in the MDU
turntable bearing. A slight gap may remain which
can be removed by installing the motor cap
screws and washers and tightening the bolts
equally in a cross pattern until the motor housing
is seated in the MDU housing.
4. Install the four capscrews, lockwashers, and
washers to secure the motor. Tighten alternately
to half torque, then to full torque 23 N•m (17 lbf ft).
5. Connect the drive motor wiring and power cable
connections.
6. Install the drive motor brake.
See Steering System 1600YRM1610 for lift truck
models NDR035EB, NR045EB (D861),
NDR030EB, NR035-040EB (E815) and
NDR030DB, NR035-040DB (B295).
See Steering System 1600YRM1462 for lift truck
models SS030BF (A474), FS030BF (A497),
OS030EF (D801) and OS030BF (E826).
See Brakes 1800YRM1628 for lift truck models
MPC060-VG (A372) and MPC080-VG (A283).
See Brakes 1800YRM1638 lift truck model
MPE060-VG (B292) and MPE080-VG (B287).
See Steering Mechanism 1600YRM1627 for lift
truck models MPC060-VG (A372) and MPC080-VG
(A283).
See Steering Mechanism 1600YRM1637 lift truck
model MPE060-VG (B292) and MPE080-VG
(B287).
8. Install the hydraulic tank and hydraulic motor.
See Hydraulic System 1900YRM1616 for lift truck
models NDR035EB, NR045EB (D861),
NDR030EB, NR035-040EB (E815) and
NDR030DB, NR035-040DB (B295).
See Hydraulic System 1900YRM1464 or Hy-
draulic System 1900YRM1465 for lift truck models
SS030BF (A474), FS030BF (A497), OS030EF
(D801) and OS030BF (E826)
See Walkie Hydraulic System 1900YRM1629 for
lift truck models MPC060-VG (A372) and MPC080-
VG (A283)
See Hydraulic System 1900YRM1639 lift truck
model MPE060-VG (B292) and MPE080-VG
(B287).
9. Install the operator cover.
See Frame 0100YRM1615, Covers, Panels, and
Plates RepairCovers, Panels, and Plates Repair for
lift truck modelsNDR035EB, NR045EB (D861),
NDR030EB, NR035-040EB (E815) and
NDR030DB, NR035-040DB (B295).
See Frame 0100YRM0760, Frame Repair for lift
truck models SS030BF (A474), FS030BF (A497),
OS030EF (D801) and OS030BF (E826).

10
0620 YRM 1621 Hydraulic Motor Repair

See FRAME 0100YRM1580, Covers for lift truck
models MPC060-VG (A372) and MPC080-VG
(A283).
See Frame 0100YRM1636 lift truck model
MPE060-VG (B292) and MPE080-VG (B287).
10. Route and connect all wiring and connectors as
removed.
11. Connect the battery connector, turn the key
switch to the ON position, and test the lift truck for
proper operation. Remove the lift truck from
blocks and return to service.

Hydraulic Motor Repair

DISASSEMBLE
1. Remove the pump and motor assembly from the
lift truck.

See Hydraulic System 1900YRM1616 for lift truck

models NDR035EB, NR045EB (D861),
NDR030EB, NR035-040EB (E815) and
NDR030DB, NR035-040DB (B295).

See Hydraulic System 1900YRM1464 or Hy-

draulic System 1900YRM1465 for lift truck models
SS030BF (A474), FS030BF (A497), OS030EF
(D801) and OS030BF (E826)

See Walkie Hydraulic System 1900YRM1629 for

lift truck models MPC060-VG (A372) and MPC080-
VG (A283)

See Hydraulic System 1900YRM1639 lift truck

model MPE060-VG (B292) and MPE080-VG 1. POWER CABLE TERMINAL NUT
(B287). 2. SCREW
3. CAPSCREW
2. For the hydraulic motor repair procedure on lift 4. LOCKWASHER
truck models SS030BF (A474), FS030BF (A497), 5. TERMINAL END HEAD
OS030EF (D801) and OS030BF (E826) see the 6. DRIVE END HEAD
7. TIE BAR SCREW
section AC Motor Repair 0620YRM1461, Hy- 8. MOTOR CASE
draulic Motor Repair. 9. LIFT PUMP
3. Place the pump and motor assembly on a clean Figure 10. Hydraulic Pump and Motor (NDR030EB,
work bench or other suitable surface. NR035/040EB, NDR035EB, NR045EB)
4. Remove the two capscrews and two lockwashers
holding the pump to the motor. See Figure 10 and
Figure 11. Remove the pump.

11
Hydraulic Motor Repair 0620 YRM 1621

6. Loosen and remove the power cable terminal

nuts. Remove the power leads from the terminal
block and remove the screws (2) retaining the ter-
minal block to the motor case. See Figure 10 and
Figure 11. Remove the terminal block.

7. Unscrew the four tie bar screws (6) holding the

end heads to the motor case. See Figure 10 and
Figure 11. Remove the terminal end head from
the motor case.

8. Remove the drive end head from the motor case.

Remove the pump seal from the drive end head.
See Figure 12.

CAUTION
Use an arbor press and a soft punch when remov-
ing bearings to avoid damage to the bearings
and/or end head. Never reuse a bearing that has
been removed from a rotor.
1. POWER CABLE TERMINAL NUT
2. DRIVE END HEAD 9. Remove retaining ring and bearing from drive end
3. CAPSCREW head.
4. TERMINAL END HEAD
5. LIFT PUMP 10. Remove the rotor from the motor case.
6. MOTOR CASE
7. TIE BAR SCREW 11. Fit a bearing puller to the encoder bearing on the
Figure 11. Hydraulic Pump and Motor (NDR030DB, end of the motor shaft. Carefully remove the bear-
NR035/040DB) ing from the motor shaft.

5. Place the motor in a vise with the terminal block

on top and carefully clamp the vise on the motor
case.

12
0620 YRM 1621 Hydraulic Motor Repair

1. ROTOR 5. DRIVE END HEAD

2. RETAINING RING 6. MOTOR CASE
3. DRIVE END BEARING 7. ENCODER BEARING
4. PUMP SEAL 8. TERMINAL END HEAD

Figure 12. Hydraulic Motor

13
Hydraulic Motor Repair
INSPECT
Inspect the rotor and the inside of the motor case for
marks or grooves indicating contact between the rotor
and the motor case. Replace, if damaged. Bearings
should fit snug where they ride on the shaft. If there is
excessive wear, replace the bearing and/or shaft.
Check the bearings for smooth operation. If a clean
bearing does not roll smoothly, it must be replaced.
Check that resistance between the windings and the
case is above 50,000 ohms.
ASSEMBLE
CAUTION
To avoid damage to the encoder bearing electron-
ics, use a bearing driver and arbor press to install
the encoder bearing onto the rotor shaft. Press
only on the inner race of the bearing during instal-
lation.
1. Install the encoder bearing onto the rotor shaft.
See Figure 12.
2. Insert the rotor into the motor case.
CAUTION
Use an arbor press and a proper size driver when
installing bearings to avoid damage to bearings
and/or end head.
3. Press bearing into the drive end head. Install re-
taining ring. Press only on the inner race of the
bearing.
4. Install the drive end head onto the motor case.
5. Install the terminal end head over the encoder
bearing and onto the motor case. Use care when
routing the motor power leads through the end
head.
6. Install the four tie bar screws (6) through the
holes in the end heads. See Figure 10 and Fig-
ure 11.
14
0620 YRM 1621
7. Install the pump seal in the drive end head.
8. Install the terminal block using screws (2) as re-
moved. See Figure 10 and Figure 11.
9. Install the power leads to the terminal block. In-
stall power cable terminal nuts and torque to
15 N•m (11 lbf in).
NOTE: Step 10 applies to lift truck models
(NDR030DB, NR035/040DB) only.
10. Wipe the lift pump shaft tangs clean. Apply a
moderate coat of Dow Corning® Molykote G-N
paste to the shaft tangs and pinion splines with a
small brush. Insert the shaft until the pump seats
against the motor. Align pump mounting flanges
with mounting holes in motor end head.
11. Apply Loctite® 271 to the two capscrews. Install
two lockwashers and two capscrews to secure the
pump to the drive end head. Tighten capscrews to
47 N•m (35 lbf in). See Figure 10 and Figure 11.
12. Install the pump and motor assembly in the lift
truck.
See Hydraulic System 1900YRM1616 for lift truck
models NDR035EB, NR045EB (D861),
NDR030EB, NR035-040EB (E815) and
NDR030DB, NR035-040DB (B295).
See Hydraulic System 1900YRM1464 or Hy-
draulic System 1900YRM1465 for lift truck models
SS030BF (A474), FS030BF (A497), OS030EF
(D801) and OS030BF (E826)
See Walkie Hydraulic System 1900YRM1629 for
lift truck models MPC060-VG (A372) and MPC080-
VG (A283).
See Hydraulic System 1900YRM1639 lift truck
model MPE060-VG (B292) and MPE080-VG
(B287).
0620 YRM 1621 Special Tools

Special Tools
TOOL CHART

No. Instrument Name Application Illustration

Remove and install slotted nut

1 Slotted Nut Socket
off/on traction motor shaft.

AC Motor Bearing and Seal In- Install bearing and seal assembly
2
stallation Tool onto traction motor shaft.

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

AC Motor is noisy Loose or damaged hardware. Repair or replace hardware or

components as necessary.

Gearbox or hydraulic oil may be Check gearbox or hydraulic oil

low. level, add oil as needed.

Drive Motor is noisy Drive motor is not flush and not
fully seated to MDU. There should
be no clearance between motor
and MDU interface.
Look for clearance between drive
motor flange and MDU mounting
face. Look for loose Drive Motor
mounting bolts. Mounting bolt tor-
que to be 23 N•m (17 lbf ft). Re-
move the drive motor, refer to
Traction Motor Repair for proce-
dures, and look for burrs and
raised areas along the drive flange
pilot diameter. Repair or replace as
necessary.

Improper installation or damage to Check installation for proper align-

input gear teeth. ment and check input gear teeth
for damaged or missing teeth. Re-
place input gear if necessary.

15
Troubleshooting 0620 YRM 1621

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Worn drive tire or load wheel dam- Check drive tire for wear and load
age. wheel for damage. Replace if nec-
essary.

Damage to MDU. Inspect MDU for damage and re-

place if necessary.

Improper side to side clearance of Adjust caster side to side clear-

caster. ance as needed.

AC Motor will not turn or turns very AC Motor and MDU may be as- Check for proper assembly, disas-
slowly or vibrates. sembled incorrectly. semble and reassemble as nee-
ded.

AC Motor gears or MDU gear box Disassemble AC Motor or MDU to

gears may be binding. inspect gears for proper assembly
and installation. Replace gears as
needed.

Drive Motor Brake may not be op- Inspect the brake for proper opera-
erating properly. tion and installation.

Improper installation of motor ca- Reinstall motor cables if neces-

bles or improper orientation of sary. Reorient phase terminal lugs
phase terminal lugs U, V, and W. if necessary.

Motor encoder connections and Remove and install motor encoder

temperature connections are in- connections and temperature con-
stalled incorrectly. nections properly.

AC Motor controller may be in poor Inspect condition of AC Motor con-

condition. troller, replace if necessary.

16
0620 YRM 1621
PROBLEM POSSIBLE CAUSE
AC Motor controller has no power
or bus bar connections may be
faulty.
Handle throttle is not responding to
commands.
Lift truck battery is not properly
charged or serviced.
AC Motor encoder and proximity
switch wheel is damaged or conta-
minated.
AC Motor power cables may be
loose or damaged.
Phase current at motor terminals
U, V, and W may be incorrect.
Troubleshooting
PROCEDURE OR ACTION
Check for power to AC Motor con-
troller and check bus bar connec-
tions for proper contact.
Check handle throttle response
commands using lift truck diagnos-
tics.
Ensure lift truck battery is properly
charged and serviced.
Disassemble components and in-
spect AC Motor encoder or proxim-
ity switch wheel for damage or
contamination. Clean or replace
components as needed.
Inspect power cables for proper in-
stallation or damage. Resistance
should be less than 1 Ohm meas-
ured from each end of the cable
terminal lugs.
If any one leg is low or high , re-
move that cable and move all ca-
bles one position. If the phase ab-
normality stays with the cable, the
motor controller may be defective.
If the phase abnormality stays with
the motor terminal lug, there is a
possible short in the AC Motor.
Some slight gear noise is consid-
ered normal if the motor pinion
gear was replaced or if the MDU
has been replaced. One hundred
hours of break in time should be
allowed for the gear teeth to set
their gear pattern.
17
 NOTES

18