Motor

Objectives
After completing this topic, participants should be able to:

Identify

• the location and the individual components of the motor

Know

• the proper handling methods for the sensor bearing

Perform

• the Inspection and Adjustments for the motors

AC Motors and EPS Motor location
 Specification of the Motors
Traction Motor
Applicable Model Type Rating
1.4 / 1.6 ton AT60D2 6.0kW, 30V, 60 min
2.0 ton AT70D2 7.0 kW, 30V, 60 min

Hydraulic Motor
Applicable Model Type Rating
1.4 / 1.6 / 2.0 ton AH120C2CD 12.0kW, 30V, 10 min

EPS Motor
Applicable Model Part No. Rating
1.4 / 1.6 / 2.0 ton 70000-05230 0.55kW, 48V, 3340rpm 60 min
 Components of the Traction Motor
Sensor
Housing Traction motor
sensor bearing
End Cover
Terminal Comp.

Stator Comp.

• Take caution when replacing the sensor

bearing, be very careful not to damage the
sensor. If the sensor is damaged, the motor will
Rotor sub Ass’y not operate correctly i.e. jerky or slow travel.
• The sensor bearing is very sensitive, do not
touch any connector pins of the lead wire
terminal directly
End Cover(D) – Wear Anti-static wrist strap / rubber gloves
Components of the Hydraulic Motor
Sensor
Housing
End Cover

Terminal Comp.

Stator Comp.

Rotor sub Ass’y

Bearing
[No Sensor]

End Cover(D)
Components of the EPS Motor
Spring
Commutator cover
Brush
Yoke Ass’y
Shim
Armature
Comp.

End Cover
Ass’y (C)
Brush Holder
Ass’y

Bearing

Oil Seal

End Cover(D)
 Inspection of Rotor Comp (AC motors)
 Inspection of Damage
 Check the rotor comp. for damage i.e. burn marks
 Inspection of Spline
 Check the spline for signs of wear
 Inspection of Ball Bearings
 Check fitting parts in “End Cover” and “End Cover(D)” for any looseness
Inspection of Armature Comp (DC motor)
 Inspection of Damage
 Check the rotor comp. for damage
i.e. burn marks
 Inspection of Spline
 Check the spline for signs of wear
 Inspection of Ball Bearings
 Check fitting parts in “End
Cover(D)” and “End Cover(C)
Ass’y” for any looseness
Inspection of Armature Comp (DC motor)
 Inspection of Insulation
 Measure the insulation
between the commutator and
armature shaft
<Specifications>
Tool Specific Resistance
Tester ∞ (Infinite at x1kΩ range)
Megger 0.5MΩ or greater (DC500V)

Clean up by compressed air

before measuring
 Inspection of Brush Wear (EPS motor)
 Raise up whirl spring (A) and then pull out
the carbon brush (B) to check the length.
 Measure dimension (C), If dimension (C) is
less than the wear limit, replace all brushes
of the motor.

<Specifications>
Applicable Model Normal dimension Wearing limit
(H) (C)
RBF14CA/16CA/20CA 20mm 9mm
 Inspection of Brush Contacting Surface
 If the contacting surface is not good,
repair it as follows:
1. Insert a sandpaper between
Commutator and Brush. (Face the
file side to the brush
2. Polish the contacting surface of
the brush by moving the
sandpaper or rotating the
commutator by hand.
3. Blow the dust out with compressed
air after repairing.
Inspection of Brush Holder Spring Force
 Hook a spring scale to the brush spring and
pull, check if both springs have the same
tension. Then make sure that the force on the
2 springs are equal.

Motor Specific force of Spring

EPS Motor 5-8N (0.5-0.8kg∙f)

If spring and/or brush holder

were rusted, replace them.
 Inspection of AC Motors (TRV)
Abnormal Noise Check Traction Motor
 Operate the motor/ Make sure there is
no abnormal noise. 1. Connect the U1 cable from the chassis
to the U1 terminal in the motor.
1. Be sure to secure the motor
ass’y to a work bench. 2. Connect the V1 cable from the chassis
to the V1 terminal in the motor.
2. Use the battery of the forklift
truck to carry out the testing. 3. Connect the W1 cable from the
chassis to the W1 terminal in the
3. Connect wires as shown.
motor.
4. Operate traction and hydraulic
4. Connect the lead wire for the speed
motor slowly at the chassis side,
make sure the motors are sensor from the chassis (water proof
performing without abnormal type 4P) to the lead wire for the speed
noise. sensor in the motor (water proof type
4P).

When performing a motor test, be sure to securely fix the motor to

a work bench. The motor will move suddenly when it is started.
 Inspection of AC Motors (HYD)
Abnormal Noise Check Hydraulic Motor
 Operate the motor/ Make sure there is
no abnormal noise. 1. Connect the U2 cable from the chassis
to the U2 terminal in the motor.
1. Be sure to secure the motor
ass’y to a work bench. 2. Connect the V2 cable from the chassis
to the V2 terminal in the motor.
2. Use the battery of the forklift
truck to carry out the testing. 3. Connect the W2 cable from the
chassis to the W2 terminal in the
3. Connect wires as shown.
motor.
4. Operate traction and hydraulic
4. Connect the lead wire for the speed
motor slowly at the chassis side,
make sure the motors are sensor from the chassis (water proof
performing without abnormal type 4P) to the lead wire for the speed
noise. sensor in the motor (water proof type
4P).

When performing a motor test, be sure to securely fix the motor to

a work bench. The motor will move suddenly when it is started.
 Inspection of AC Motors (TRV/HYD)
Insulation Check
 Measure the insulation between terminals of the connector and stator comp.
with Megger.
1. Apply earth probe (negative [-]) of Megger to the stator comp.
2. Apply line probe (positive [+]) of Megger to each terminal.

<Specifications>
Tool Specific Resistance
Tester ∞ (Infinite at x1kΩ range)
Megger 0.5MΩ or greater (DC500V)
 Inspection of DC Motor (EPS)
Abnormal Noise & Arc (Spark) Check EPS Motor
 Operate the motor, make sure there is 1. Connect WHITE wire with the positive
no abnormal noise and sparks seen (+) terminal of the battery
coming from the brushes. 2. Connect BLACK wire with the negative
1. Be sure to secure the EPS motor (-) terminal of the battery
ass’y to a work bench.
2. Apply ¼ voltage of the battery
(about 12V) to carry out testing.
3. Connect wires as shown.

When performing a motor test, be sure to securely fix the motor to

a work bench. The motor will move suddenly when it is started.
 Inspection of DC Motor (EPS)
Insulation Check
 Measure the insulation between the terminals of the connector and the yoke
with Megger.
1. Apply earth probe (negative [-]) of Megger to the yoke.
2. Apply line probe (positive [+]) of Megger to each terminal of the
connector plug.

<Specifications>
Tool Specific Resistance
Megger 0.1MΩ or greater (DC500V)
 Inspection of DC Motor (EPS)
Oil seal and Permanent magnet check
 Oil Seal
 Check oil seal for wear and damage.
 Replace if worn or damaged.
 Permanent Magnet
 Check permanent magnets of yoke for damage or sticking metallic dust.
 If sticking metallic dust are found, remove it with compressed air.
 If damaged, replace the assembly.