AC MOTOR REPAIR

J2.00-3.20XM (J40-65Z) [A416]

PART NO. 1534732

620 SRM 1053

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• 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 Mainte-
nance 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 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 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 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
manual:

WARNING

Indicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

AC Motor Repair

Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

AC Motor Repair ................................................................................................................................................

Disassemble ...................................................................................................................................................

Assemble ........................................................................................................................................................

Drive End Bearing, Replace..........................................................................................................................

Troubleshooting..................................................................................................................................................

This section is for the following models:

J2.00-3.20XM (J40-65Z) [A416]

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

620 SRM 1053

General

This section describes disassembly and assembly, in-
spection, and checks for malfunctions of AC motors.

AC traction motors and AC hydraulic pump motors
are similar in design. Older model lift trucks are
equipped with an AC traction and AC hydraulic
pump motor that is shown in Figure 1. Newer model
lift trucks are equipped with an AC traction and AC
hydraulic pump motor that is shown in Figure 2.
For both types of motors, the AC hydraulic pump
motor is a smaller version of the AC traction motor.
Disassembly and repair of these motors is similar.

NOTE: AC HYDRAULIC PUMP MOTOR USED ON
OLDER MODEL J2.00-3.20XM (J40-65Z) (A416)
TRUCKS SHOWN.

AC HYDRAULIC PUMP MOTOR

Figure 1. AC Hydraulic Pump Motor (Shown)

NOTE: AC TRACTION MOTOR USED ON NEWER
MODEL J2.00-3.20XM (J40-65Z) (A416) TRUCKS
SHOWN.

Figure 2. AC Traction Motor

AC Motor Repair

620 SRM 1053

AC Motor Repair

DISASSEMBLE

WARNING

The bearing and seal on the AC traction motor
are serviceable parts, while the only service-
able part on the AC hydraulic pump motor is
the bearing. Be careful to not damage bearings
when replacing. The AC hydraulic pump motor
weighs 46 kg (101 lb) and the AC traction motor
weighs 109 kg (240 lb). To prevent injury, use a
lifting device capable of lifting the assembly.

NOTE: When replacing one bearing, it is strongly rec-
ommended to replace both bearings and the seal of
the AC traction motor.

Remove motor from the lift truck. See the Frame
SRM for your lift truck model for removal infor-
mation.

Screw lifting eye into the threaded hole in the
end of the rotor shaft and connect a chain to the
lifting eye.

Remove temperature sensor wire and encoder
wire from holding bracket.

See Figure 3 and

Figure 4.

Note placement of wires in rubber

gasket that surrounds stator wires.

Remove screws from the nondrive rear end bell.

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.

Lift end bell and rotor assembly from AC motor
case. Place horizontally on a flat surface and re-
move rubber gasket that covers three field wires.

Remove chain and lifting eye.

Remove screws from air guide.

Remove end bell from rotor assembly. See Fig-
ure 5.

10. Remove air guide, being careful not to damage

encoder bearing wire.

NOTE: Before removing the encoder bearing, note its
orientation and install the new encoder bearing in
the same orientation.

11. Using a bearing puller, remove encoder bearing.

See Figure 6.

12. Using a bearing puller, remove bearing from

drive end of rotor shaft.

ASSEMBLE

CAUTION

To avoid damage to the encoder bearing elec-
tronics, use a bearing driver and arbor press.

Install the bearing on the drive end of the rotor
shaft using a bearing driver and arbor press.

NOTE: AC HYDRAULIC PUMP MOTOR USED ON
OLDER MODEL J2.00-3.20XM (J40-65Z) (A416)
TRUCKS SHOWN.

END BELL

SCREW

ENCODER WIRE

TEMPERATURE SENSOR WIRE

RUBBER GASKET

HOLDING BRACKET

Figure 3. AC Motor Assembly (Hydraulic Pump

Motor Shown)

620 SRM 1053

AC Motor Repair

NOTE: AC TRACTION MOTOR USED ON NEWER
MODEL J2.00-3.20XM (J40-65Z) (A416) TRUCKS
SHOWN.

END BELL

SCREW

ENCODER BEARING CONNECTOR

CONNECTOR COVER

TEMPERATURE SENSOR

Figure 4. AC Motor Assembly (Traction Motor

Shown)

NOTE: The encoder bearing must be oriented as
noted during removal.

Using a bearing driver and arbor press, install
the encoder bearing as noted during removal.

Place encoder wire through air guide and move
air guide back over encoder bearing. See Fig-
ure 7.

Place end bell on rotor assembly.

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.

Insert encoder wire in the end bell slot and attach
air guide to end bell.

Install eyebolt into end bell and rotor assembly
and connect a chain to the lifting eye.

SCREW

AIR GUIDE

END BELL SLOT

ENCODER WIRE

Figure 5. Rotor Disassembly

ENCODER BEARING

BEARING PULLER

ENCODER WIRE

Figure 6. Bearing Removal

AC Motor Repair

620 SRM 1053

ENCODER WIRE

AIR GUIDE

ENCODER BEARING

Figure 7. Alignment of Air Guide and End Bell

Lift the end bell and rotor assembly to a vertical
position.

CAUTION

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.

Using the alignment marks made during disas-
sembly, line up the end bell and rotor assembly
with the motor case.

Lower the end bell and rotor assembly back into
the case and place the encoder bearing and tem-
perature sensor wires into position on the rubber
gasket.

10. Replace rubber gasket that covers the field wires.

11. Attach end bell and rotor assembly to AC motor

case.

12. Install temperature sensor wire and encoder

wire onto holding bracket.

13. Remove chain and lifting eye.

14. Install motor into the lift truck. See the Frame

SRM for your lift truck model for installation in-
formation.

DRIVE END BEARING, REPLACE

NOTE: Drive end bearing is to be replaced if worn or
damaged.

Follow Step 1 through Step 10 of Disassemble
procedure.

Using a bearing puller, remove drive end bearing
from shaft. See Figure 8.

Using a bearing driver and arbor press, install
drive end bearing.

Follow Step 3 through Step 13 of the Assemble
procedure.

END BELL SLOT

AIR GUIDE

DRIVE END BEARING

ENCODER WIRE

Figure 8. Alignment of End Shaft Bearing

620 SRM 1053

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Truck moves slow or in a
jerky motion.

Encoder broken.

Replace encoder bearing.

Encoder wire broken.

Check and repair encoder wire or re-
place encoder bearing.

Temperature

sensor

wire

fails.

Measure resistance with ohmmeter.
Resistance should be 530 ohms at 25

C (77 F). Repair temperature sensor

wire. The temperature sensor wire
can be repaired, but the temperature
sensor cannot be repaired.

Stator wires fail.

Loss of insulation in wire.

Check resistance between winding
and case.

Resistance should be at

50,000 ohms or above.

NOTES

____________________________________________________________

TECHNICAL PUBLICATIONS

620 SRM 1053

7/05 (4/05)(1/04)(11/03)(3/03) Printed in United Kingdom

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