AC MOTOR REPAIR

N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265]

PART NO. 1590934 620 SRM 1186

AC Motor Repair Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Traction Motor Repair ....................................................................................................................................... 2
Disassemble ................................................................................................................................................... 2
Inspect ............................................................................................................................................................ 2
Assemble ........................................................................................................................................................ 3
Drive End Bearing, Replace.......................................................................................................................... 4
Hydraulic Motor Repair..................................................................................................................................... 5
Disassemble ................................................................................................................................................... 5
Inspect ............................................................................................................................................................ 6
Assemble ........................................................................................................................................................ 7
Troubleshooting.................................................................................................................................................. 8

This section is for the following models:

N35ZDR, N45ZR [C264];

N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265]

2006 HYSTER COMPANY i

620 SRM 1186 General

General
This section describes disassembly, assembly, inspec-
tion, and checks for malfunctions of AC motors.

AC traction motors and AC hydraulic pump motors

are similar in function. See Figure 1, Figure 2, and
Figure 3. Disassembly and repair of these motors is
similar.

Figure 2. AC Hydraulic Motor (N35ZDR,

N45ZR, N30ZDR, N35-40ZR)

Figure 1. AC Traction Motor

Figure 3. AC Hydraulic Motor (N30ZDRS,

N35-40ZRS)

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Traction Motor Repair 620 SRM 1186

Traction Motor Repair

DISASSEMBLE
WARNING
The bearings and seals on the traction motor
are serviceable parts. The AC traction motor
weighs 109 kg (240 lb). To prevent injury, use
a lifting device of adequate capacity for lifting
the assembly.
NOTE: When replacing the encoder bearing, also re-
place the bearing on the drive end of the motor.
1. Remove traction motor from the lift truck. See
Master Drive Unit 630 SRM 1022 for removal
information.
2. Screw lifting eye into the threaded hole in the
end of the rotor shaft and connect a chain to the
lifting eye.
3. Remove temperature sensor wire and encoder
wire from holding bracket. See Figure 4.
CAUTION
Never reuse a bearing that has been removed
from a rotor shaft.
12. Using a bearing puller, remove bearing from
drive end of rotor shaft.
INSPECT
Inspect the rotor and the inside of the motor case for
marks or grooves indicating contact between the ro-
tor and the motor case. Replace if damaged. Bear-
ings should fit snug where they seat on the shaft. If
there is excessive wear, replace the bearing and/or
shaft. Check the bearings for smooth operation. If a
bearing does not roll smoothly, it must be replaced.
Check that resistance between the windings and the
case is above 50,000 ohms. Resistance of the wind-
ings (line to line) should be within specification. See
Table 1.

4. Remove screws from the non drive rear end bell.

5. Place alignment marks on the end bell and motor

case. Marks will be used to correctly align the
end bell on the motor case during assembly.

6. Lift end bell and rotor assembly from AC motor

case. Place horizontally on a flat surface.

7. Remove chain and lifting eye.

8. Remove screws from air guide.

9. Remove end bell from rotor assembly. See Fig-

ure 5.

10. Remove air guide, being careful not to damage

encoder bearing wire.

CAUTION
Never reuse a bearing that has been removed
from a rotor shaft.

NOTE: Before removing the encoder bearing, note its

orientation and install the new encoder bearing in
1. END BELL
the same orientation. 2. SCREW
3. ENCODER WIRE
11. Using a bearing puller, remove encoder bearing. 4. TEMPERATURE SENSOR WIRE
See Figure 6. 5. HOLDING BRACKET

Figure 4. AC Motor Assembly

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620 SRM 1186 Traction Motor Repair

ASSEMBLE

CAUTION
To avoid damage to the encoder bearing elec-
tronics, use a bearing driver and arbor press.
Press only on the inner race of the bearing.

1. Install the bearing on the drive end of the rotor

shaft using a bearing driver and arbor press.

NOTE: The encoder bearing must be oriented as

noted during removal.

2. Using a bearing driver and arbor press, install

the encoder bearing as noted during removal.
Press only on the inner race of the bearing dur-
ing installation.

3. Place encoder wire through air guide and move

1. SCREW 3. END BELL SLOT air guide back over encoder bearing. See Fig-
2. AIR GUIDE 4. ENCODER WIRE ure 7.

Figure 5. Rotor Disassembly 4. Place end bell on rotor assembly.

1. ENCODER 2. BEARING PULLER

BEARING 3. ENCODER WIRE

Figure 6. Bearing Removal

Table 1. Traction Motor Windings

Winding to Line Resistance

Voltage (Ohm)
1. ENCODER WIRE
Min Max 2. AIR GUIDE
3. ENCODER BEARING
24 3.22 3.83
36 3.22 3.83 Figure 7. Alignment of Air Guide and End Bell

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Traction Motor Repair 620 SRM 1186

1. Follow Step 1 through Step 10 of Disassemble

CAUTION
To prevent damage to the encoder bearing, en-
sure encoder wire is inserted in end bell slot
when air guide is attached to the end bell.
5. Insert encoder wire in the end bell slot and attach
air guide to end bell.
6. Install eyebolt into end bell and rotor assembly
and connect a chain to the lifting eye.
7. Lift the end bell and rotor assembly to a vertical
position.
procedure.
CAUTION
Never reuse a bearing that has been removed
from a motor.
2. Using a bearing puller, remove drive end bearing
from shaft. See Figure 8.
3. Using a bearing driver and arbor press, install
drive end bearing. Press only on the inner race
of the bearing during installation.

4. Follow Step 3 through Step 12 of the Assemble

CAUTION procedure.
To prevent damage to the encoder wire, line up
end bell and rotor assembly slot with visible
mark to guide encoder wire into end bell and
rotor assembly case.

8. Using the alignment marks made during disas-

sembly, line up the end bell and rotor assembly
with the motor case.

9. Lower the end bell and rotor assembly back into

the case and place the encoder bearing and tem-
perature sensor wires into position.

10. Attach end bell and rotor assembly to AC motor

case.

11. Install temperature sensor wire and encoder

wire onto holding bracket.

12. Remove chain and lifting eye.

13. Install motor into the lift truck. See Master 1. END BELL SLOT
Drive Unit 630 SRM 1022 for your lift truck 2. AIR GUIDE
model for installation information. 3. DRIVE END BEARING
4. ENCODER WIRE
DRIVE END BEARING, REPLACE Figure 8. Alignment of End Shaft Bearing
NOTE: Drive end bearing is to be replaced if worn or
damaged.

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620 SRM 1186 Hydraulic Motor Repair

Hydraulic Motor Repair

DISASSEMBLE
1. Remove the pump and motor assembly from the
lift truck. See Hydraulic System 1900 SRM
1189 or Hydraulic System 1900 SRM 1307 for
instructions on removing the pump and motor
assembly.
2. Place the pump and motor assembly on a clean
work bench or other suitable surface.
3. Remove the two capscrews (3) retaining the
pump to the motor. See Figure 9 and Figure 10.
Remove the pump.
4. Place the motor in a vise with the terminal block
on top and carefully clamp the vise on the motor
case.
5. Loosen and remove the power cable terminal
nuts. Remove the power leads from the terminal
block and remove the screws (2) retaining the
terminal block to the motor case. See Figure 9
and Figure 10. Remove the terminal block.
6. Unscrew the four tie bar screws (6) holding the
end heads to the motor case. See Figure 9 and
Figure 10. Remove the terminal end head from
the motor case.
7. Remove the drive end head from the motor case.
Remove the pump seal from the drive end head.
See Figure 11.

1. POWER CABLE TERMINAL NUT

2. SCREW
3. CAPSCREW
4. TERMINAL END HEAD 1. POWER CABLE TERMINAL NUT
5. DRIVE END HEAD 2. DRIVE END HEAD
6. TIE BAR SCREW 3. CAPSCREW
7. MOTOR CASE 4. TERMINAL END HEAD
8. LIFT PUMP 5. LIFT PUMP
6. MOTOR CASE
Figure 9. Hydraulic Pump and Motor (N35ZDR, 7. TIE BAR SCREW
N45ZR, N30ZDR, N35-40ZR)
Figure 10. Hydraulic Pump and Motor
(N30ZDRS, N35-40ZRS)

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Hydraulic Motor Repair 620 SRM 1186

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 11. Hydraulic Motor

CAUTION
Use an arbor press and a soft punch when re-
moving bearings to avoid damage to the bear-
ings and/or end head. Never reuse a bearing
that has been removed from a rotor.
8. Remove retaining ring and bearing from drive
end head.
9. Remove the rotor from the motor case.
10. Fit a bearing puller to the encoder bearing on
the end of the motor shaft. Carefully remove the
bearing from the motor shaft.
INSPECT
Inspect the rotor and the inside of the motor case for
marks or grooves indicating contact between the ro-
tor and the motor case. Replace, if damaged. Bear-
ings 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 re-
placed. Check that resistance between the windings
and the case is above 50,000 ohms. Resistance of the
windings (line to line) should be within specification.
See Table 2.

6
620 SRM 1186 Hydraulic Motor Repair

Table 2. Hydraulic Motor Windings

Winding to Line Resistance (Ohm)

Pump Displacement Voltage
Min Max
20cc 24 2.27 2.70
25cc 36 2.55 3.03

25cc 36 2.27 2.70

28cc 36 1.19 1.37

20cc 36 (EE) 2.27 2.70

ASSEMBLE routing the motor power leads through the end

CAUTION
To avoid damage to the encoder bearing elec-
tronics, use a bearing driver and arbor press
to install the encoder bearing onto the rotor
shaft. Press only on the inner race of the bear-
ing during installation.
1. Install the encoder bearing onto the rotor shaft.
See Figure 11.
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
retaining ring. Press only on the inner race of
the bearing.
4. Install the drive end head onto the motor case.
head.
6. Install the four tie bar screws (6) through the
holes in the end heads. See Figure 9 and Fig-
ure 10.
7. Install the pump seal into the drive end head.
8. Install the terminal block using screws (2) as re-
moved. See Figure 9 and Figure 10.
9. Install the power leads to the terminal block. In-
stall power cable terminal nuts and torque to
15 Nm (11 lbf in).
10. Apply Loctite 271 to the two capscrews (3) and
install the pump to the drive end head. Tighten
capscrews to 47 Nm (35 lbf in). See Figure 9 and
Figure 10.
11. Install the pump and motor assembly into the
lift truck. See Hydraulic System 1900 SRM
1189 or Hydraulic System 1900 SRM 1307 for
installation instructions.

5. Install the terminal end head over the encoder

bearing and onto the motor case. Use care when

7
Troubleshooting
PROBLEM
Truck moves slow or in a
jerky motion.
Temperature sensor failure.
Stator shorting.
Stator open circuit.
Troubleshooting
POSSIBLE CAUSE
Encoder broken.
Encoder wire broken.
Temperature sensor wire damaged.
Temperature sensor malfunction.
Loss of insulation in wire.
Broken coil windings.
620 SRM 1186
PROCEDURE OR ACTION
Replace encoder bearing.
Check and repair encoder wire or re-
place encoder bearing.
Measure resistance with ohmmeter.
Resistance should be 530 ohms at
25 C (77 F). Inspect and repair tem-
perature sensor wire. The tempera-
ture sensor wire can be repaired, but
the temperature sensor must be re-
placed if faulty.
Measure resistance with ohmmeter.
If wiring is ok, resistance should be
530 ohms at 25 C (77 F). Replace the
temperature sensor.
Disconnect the battery and check re-
sistance between winding and case.
Resistance should be at 50,000 ohms
or above.
Raise drive wheel off the floor and
verify voltage at motor terminals.
Disconnect the battery and check
resistance of windings.