Hyster N35ZDR User manual

AC MOTOR REPAIR
N35ZDR, N45ZR [C264];
N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265]
PART NO. 1590934 620 SRM 1186
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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
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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 1. AC Traction Motor
Figure 2. ACHydraulicMotor(N35ZDR,
N45ZR, N30ZDR, N35-40ZR)
Figure 3. AC Hydraulic Motor (N30ZDRS,
N35-40ZRS)
1
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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
aliftingdev
ice 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 DriveUnit630 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.
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
the same orientation.
11. Using a bearing puller, remove encoder bearing.
SeeFigure6.
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.
1. END BELL
2. SCREW
3. ENCODER WIRE
4. TEMPERATURE SENSOR WIRE
5. HOLDING BRACKET
Figure 4. AC Motor Assembly
2
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620 SRM 1186 Traction Motor Repair
1. SCREW
2. AIR GUIDE
3. END BELL SLOT
4. ENCODER WIRE
Figure 5. Rotor Disassembly
1. ENCODER
BEARING
2. BEARING PULLER
3. ENCODER WIRE
Figure 6. Bearing Removal
Table 1. Traction Motor Windings
Winding to Line Resistance
(Ohm)
Voltage
Min Max
24 3.22 3.83
36 3.22 3.83
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
air guide back over encoder bearing. See Fig-
ure 7.
4. Place end bell on rotor assembly.
1. ENCODER WIRE
2. AIR GUIDE
3. ENCODER BEARING
Figure 7. Alignment of Air Guide and End Bell
3
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