Maintenance

AC MOTOR REPAIR
MP20 [A249];
MPB045VG [A245]

PART NO. 550036879 0620 YRM 1513

 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.
 Table of Contents

TABLE OF CONTENTS

General ..................................................................................................................................................................... 1
Accessing the Drive Unit Compartment ................................................................................................................1
Accessing the Drive Unit Compartment ................................................................................................................2
Special Precautions .................................................................................................................................................. 3
Discharging the Capacitors .................................................................................................................................. 3
Description ................................................................................................................................................................4
AC Motor Repair ....................................................................................................................................................... 4
Remove ................................................................................................................................................................ 4
Disassemble ......................................................................................................................................................... 4
Inspect .................................................................................................................................................................. 7
Assemble ..............................................................................................................................................................7
Install .................................................................................................................................................................... 7
Troubleshooting ........................................................................................................................................................ 8

This section is for the following models:

(MP20) [A249];
(MPB045VG) [A245]

©2015 Yale Materials Handling Corp. i

0620 YRM 1513
General
This section contains repair and maintenance
procedures for the AC traction motor. Additional
information concerning the traction motor may be
included in other sections when the information is
more closely related to other systems. Sections that
may contain related information include:
• Periodic Maintenance 8000YRM1510
for lift truck model A249
• Periodic Maintenance 8000YRM1666
for lift truck model A245
• Steering Mechanism 1600YRM1504
• Electrical System 2200YRM1508
1. DRIVE UNIT COMPARTMENT COVER
2. NUTS
Figure 1. Drive Unit Compartment Cover A249
General
ACCESSING THE DRIVE UNIT
COMPARTMENT
The drive unit compartment is concealed behind a
molded cover which fits securely around the drive unit
and steer support to the frame.
To remove the drive unit cover, first remove the two
nuts securing the cover to the frame. Starting at the
top left edge of the cover and with both hands pull the
cover away from the frame until the cover kicks out
from the retaining clips. Repeat this for the right side
of the cover. Work around the edge of the cover until
free from the truck. See Figure 1.
3. RETAINING CLIPS
4. FRAME
1
General
To install the drive unit cover, place the bottom of the
drive unit cover onto the frame and position the lower
edges partially into the lower retaining clips. Align the
holes in the cover with the mounting studs attached to
the frame. Push the top of the cover partially into the
upper retaining clips. Do not push either edge of the
cover in completely in before starting all edges into
the proper place. When the cover is aligned and
started properly, press the cover completely into the
retaining clips. Install the two nuts securing the cover
to the frame.
ACCESSING THE DRIVE UNIT
COMPARTMENT
The drive unit compartment is concealed behind a
molded cover which fits securely around the drive unit
and steer support to the frame.
1. DRIVE UNIT COMPARTMENT COVER
2. ALIGNMENT PIN
Figure 2. Drive Unit Compartment Cover A245
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0620 YRM 1513
Remove the drive unit cover, starting at the top left
edge of the cover and with both hands pull the cover
away from the frame until the cover kicks out from the
retaining clips. Repeat this for the right side of the
cover. Work around the edge of the cover until free
from the truck. See Figure 2.
To install the drive unit cover, place the bottom of the
drive unit cover onto the frame and position the lower
edges partially into the lower retaining clips. Align the
holes in the cover with the alignment pin attached to
the frame. Push the top of the cover partially into the
upper retaining clips. Do not push either edge of the
cover in completely in before starting all edges into
the proper place. When the cover is aligned and
started properly, press the cover completely into the
retaining clips.
3. RETAINING CLIPS
4. FRAME
0620 YRM 1513 Special Precautions

Special Precautions
DISCHARGING THE CAPACITORS

WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
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. Turn the key switch to the OFF position and dis-

connect the battery. 1. CONTROLLER
2. POSITIVE CONNECTION
2. Remove the drive unit compartment cover to ac- 3. INSULATED JUMPER WIRES
cess the controller. See GeneralGeneralGeneral. 4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION
3. Discharge the capacitors in the controllers by con- Figure 3. Discharging the Capacitors
necting a 200-ohm, 2-watt resistor across the
controller's B+ and B− terminals using insulated
jumper wires. See Figure 3. DO NOT short across
the motor controller terminals with a screwdriver
or jumper wire. Remove the 200-ohm, 2-watt re-
sistor before reconnecting the battery.

3
Description
Description
The traction motor is a three-phase AC induction mo-
tor. DC battery current is converted into AC current in
the controller and then supplied to the traction motor.
The controller controls motor speed and direction.
Each traction motor contains an encoder bearing in
the flange (brake end) that provides continuous motor
speed and direction information to the controller. A
temperature sensor built into the stator continually
monitors motor temperature. Brass terminals receive
the power cables from the controller and a small con-
AC Motor Repair
REMOVE
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.
1. Turn the key switch to the OFF position and dis-
connect the battery connector. Discharge the ca-
pacitors. See Special Precautions.
2. Remove the steer support from the lift truck. Refer
to Steering Mechanism 1600YRM1504.
CAUTION
Remove the brake only as directed. Changes to
adjustment screws may render the brake unusa-
ble. The brake is factory set and cannot be adjus-
ted if altered.
NOTE: The brake may be removed at this point.
However, it is not necessary to remove the brake if
the motor will not be disassembled.
3. Remove the brake from the top of the traction mo-
tor if necessary. See Brakes 1800YRM1505.
4. Identify, tag, and disconnect power cables and
wiring connecting traction motor to the truck elec-
trical system.
4
0620 YRM 1513
nector links the encoder bearing wiring harness to the
main wiring harness. A shaft extends out the top and
bottom of the traction motor. The splined end of the
shaft engages the input gear in the drive unit. A short,
round section of the shaft protrudes from the top of
the motor and is secured in place with a snap ring
which secures it to the flange. This end also supports
the parking brake hub using a woodruff key and two
additional small snap rings.
5. Remove the four capscrews and lockwashers
holding traction motor to the drive unit.
6. Attach a sling and a lifting device to the traction
motor. Lift the motor from the drive unit and posi-
tion it securely at a suitable work station. Remove
the sling from the motor.
DISASSEMBLE
Some disassembly may be performed with the trac-
tion motor installed in the lift truck. Perform only the
steps necessary to safely complete the required serv-
ice.
1. If the traction motor is not to be removed from the
lift truck, remove the steer support from the lift
truck. Refer to Steering Mechanism
1600YRM1504.
2. Remove the brake and hub assembly and both
the upper and lower snap rings from the motor
shaft if installed. Refer to Brakes 1800YRM1505.
3. Remove the four long screws holding the traction
motor together.
4. Remove the snap ring from the shaft securing the
flange (brake end) to the shaft. Slide the flange
(brake end) off the shaft and remove from the top
of the motor.
5. Remove the armature from the stator if neces-
sary.
6. Separate the stator from the bottom flange (drive
end) if necessary.
0620 YRM 1513 AC Motor Repair

1. ENCODER CONNECTOR (FEMALE 4 PRONG) 10. TEMP SENSOR CONNECTOR (FEMALE 2

2. ARMATURE PRONG)
3. SNAP RING 11. MOUNTING PLATE ASSEMBLY
4. SNAP RINGS (BRAKE ASSEMBLY) 12. SCREW
5. LOCKWASHER 13. GROMMET
6. ASSEMBLY SCREW 14. FLANGE (BRAKE END)
7. STATOR 15. FLANGE HOUSING
8. NUTS 16. BEARING AND WIRING
9. LOCKWASHER

Figure 4. Traction Motor Repair

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AC Motor Repair 0620 YRM 1513

Figure 5. Traction Motor Repair (A245)

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0620 YRM 1513 AC Motor Repair

Legend for Figure 5

1. BRAKE ASSEMBLY 5. SPEED SENSOR

2. MOTOR 6. O-RING
3. SNAP RING 7. WOODRUFF KEY
4. ASSEMBLY SCREW 8. NUT

INSPECT 5. Align the motor flanges and install the four as-
sembly screws.
Inspect the armature and the inside of the stator for
marks or grooves indicating contact between the rotor 6. Install the brake to the top of the traction motor.
and the motor case. Replace if damaged. Bearings Refer to Brakes 1800YRM1505.
should fit snug where they seat on the shaft. If there is
7. Install the steering support to the lift truck, if re-
excessive wear, replace the bearing and/or shaft.
moved. Refer to Steering Mechanism
Check the bearings for smooth operation. If a bearing
1600YRM1504.
does not roll smoothly, it must be replaced. Check
that resistance between the windings and the case is INSTALL
above 50,000 ohms. Resistance of the windings (line
to line) should be less than 1 ohm. 1. Apply Molykote® G-N paste to the splines of the
traction motor lower shaft.
ASSEMBLE
2. Attach a sling and a lifting device to the traction
Partial disassembly may be have been performed motor. Lift the motor from the work station and po-
with the traction motor installed in the lift truck. As- sition it above the drive unit. Slowly lower the mo-
semble the motor directly into the lift truck if only parti- tor while turning to align the spines of the motor
ally disassembled. Perform only the steps necessary shaft with the drive unit. Remove the sling from
to safely complete the required service. the motor.

1. Install the long screws to the flange (drive end). If 3. Turn the motor to align the motor mount brackets
assembling directly into the lift truck, position the with the mounting holes of the drive unit. Install
stator to drive unit as removed. the four screws to secure the motor.

2. Align the stator to the lower flange as removed.
3. Install the armature down through the top of the
stator and carefully guide it through the stator. If
assembling directly into the drive unit, apply Moly-
kote® G-N paste to the splines of the lower shaft
and install into the drive unit. Slowly lower the ar-
mature through the stator while turning to align
the spines of the shaft with the drive unit.
4. Position the flange (brake end) onto the armature
shaft and stator as removed. Be careful not to
damage the encoder bearing wiring harness dur-
ing installation.
4. Install the brake to the top of the traction motor.
Refer to Brakes 1800YRM1505.
5. Route and connect all wiring and connectors as
removed.
6. Install the steering support and dash assembly to
the lift truck. Refer to Steering Mechanism
1600YRM1504.
7. 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.

7
Troubleshooting
Troubleshooting
PROBLEM POSSIBLE CAUSE
Unusual noise from traction motor. Parking brake not
damaged.
Drive unit internal damage.
Traction motor bearing damaged.
Truck moves slow or in a jerky mo- Encoder broken.
tion.
Encoder wire broken.
Temperature sensor failure. Temperature sensor wire dam-
aged.
Main wiring harness damaged.
Temperature sensor malfunction.
Stator shorting. Loss of insulation in wire.
Stator open circuit. Broken coil windings.
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0620 YRM 1513
PROCEDURE OR ACTION
releasing/ Troubleshoot the parking brakes.
Check that the drive unit rotates
smoothly.
Replace end head(s) and check
stator and rotor for damage. Re-
place damaged components or
traction motor if necessary.
Replace encoder bearing.
Check and repair encoder wire or
replace encoder bearing.
Measure resistance with ohmme-
ter. Resistance should be 530
ohms at 25 °C (77 °F). Inspect and
repair temperature sensor wire.
The temperature sensor wire can
be repaired, but the temperature
sensor must be replaced if faulty.
Test temperature sensor circuit
through main wiring harness from
connection at controller.
Measure resistance with ohmme-
ter. If wiring is ok, resistance
should be 530 ohms at 25 °C (77
°F). Replace the temperature sen-
sor.
Disconnect the battery and check
resistance 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.
0620 YRM 1513 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Traction motor does not operate. Battery lacks sufficient charge. Charge/change battery.

Throttle position sensor or neutral Troubleshoot the throttle position

switch broken or out of adjustment. sensor or neutral switch.

Stator coil shorted to case. Check resistance between winding

and case. Resistance should be at
50,000 ohms or above. Replace
stator or traction motor assembly if
necessary.

Stator wires broken-open circuit. Check resistance between motor

terminals. Resistance should read
less than 1 ohm between each ter-
minal. Replace stator or traction
motor assembly if necessary.

Electric brake assembly not releas- Troubleshoot the electric brake as-
ing/damaged. sembly.

Drive unit internal damage. Raise the drive tire and check that
the drive unit rotates smoothly.

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 NOTES

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0620 YRM 1513 3/15 (12/13)(4/12)