MASTER DRIVE UNIT S/N A169N01536L=>

S/N A169N01537L=> S/N H118N01715L=>

N30ZDR2, N35-40ZR2 [E470];
N30ZDRS2, N35-40ZRS2 [B265];
N35ZDR2, N45ZR2 [D264];
R30XMF3 [A169];
R30XMA3 [A185];
R30XMS3 [E174];
R30XM3 [H118]

PART NO. 897861 0630 SRM 0613

 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 Hyster®
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 in-
structions contained 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 HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed 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 flamma-
ble. 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 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.
Master Drive Unit S/N A169N01536L=> S/N A169N01537L=> S/N H118N01715L=> Table of Contents

TABLE OF CONTENTS

HFK400 Master Drive Unit ....................................................................................................................................1

General ................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Drive Unit Maintenance and Repair ................................................................................................................. 2
Remove ............................................................................................................................................................ 2
Install .............................................................................................................................................................. 3
Disassemble .................................................................................................................................................... 3
Assemble ......................................................................................................................................................... 8
Troubleshooting .................................................................................................................................................17
GK Master Drive Unit ...........................................................................................................................................18
General .............................................................................................................................................................. 18
Description ........................................................................................................................................................ 18
Maintenance ......................................................................................................................................................20
Changing the Oil ...........................................................................................................................................20
Traction Motor and Drive Unit Splines .......................................................................................................20
Remove .............................................................................................................................................................. 20
Assemble ............................................................................................................................................................21
Mounting Electric Motor .............................................................................................................................. 21
Pivoted Connection ....................................................................................................................................... 22
Disassemble .......................................................................................................................................................22
Install .................................................................................................................................................................22
Troubleshooting .................................................................................................................................................23
Master Drive Unit ................................................................................................................................................. 24
General .............................................................................................................................................................. 24
Description ........................................................................................................................................................ 24
Maintenance ......................................................................................................................................................26
Changing the Oil ...........................................................................................................................................26
Remove .............................................................................................................................................................. 26
Disassemble .......................................................................................................................................................28
Clean and Inspect ............................................................................................................................................. 30
Assemble ............................................................................................................................................................30
Install .................................................................................................................................................................34

This section is for the following models:

(N30ZDR2, N35-40ZR2) [E470];

(N30ZDRS2, N35-40ZRS2) [B265];
(N35ZDR2, N45ZR2) [D264];
(R30XMF3) [A169];
(R30XMA3) [A185];
(R30XMS3) [E174];
(R30XM3) [H118]

©2014 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
0630 SRM 0613 HFK400 Master Drive Unit

HFK400 Master Drive Unit

GENERAL

CAUTION
Some of the hardware used on the MDU and
traction motor is metric. Use the correct tool to
avoid damage.

This section contains a description, repair, and

adjustment procedures for the parts of the HFK400
master drive unit (MDU) used on the narrow aisle
and grocery reach lift trucks. The traction motor,
steering, and brake repair information are in
separate manuals.

DESCRIPTION
The main component parts of the MDU are the
case, the motor pinion and large gear set, the
pinion and spiral bevel gear set, the bearings, the
axle, and the wheel. See Figure 1. The traction
motor fastens to an adapter ring fastened to the
MDU. This adapter ring is part of the large ball
bearing and allows the MDU to turn on the axis of
the traction motor for steering. The traction motor
does not turn with the MDU.

Six capscrews fasten the large ball bearing and

MDU to the articulating axle. There is a small
pinion gear on the traction motor armature shaft.
This gear turns a large gear on the pinion shaft in
the MDU. The pinion shaft turns a spiral bevel
gear on the axle to turn the drive wheel. The brake
is fastened to the other end of the traction motor
shaft and provides friction for braking to stop
rotation of the shaft. The braking action works
through the gears to stop the unit.
Figure 1. Master Drive Unit With Motor and Wheel

1
HFK400 Master Drive Unit 0630 SRM 0613

DRIVE UNIT MAINTENANCE AND REPAIR drain plug. After the oil has completely
drained, install the drain plug. Tighten the
Remove drain plug to 22 N•m (16 lbf ft).

6. Remove the six capscrews and lockwashers that

WARNING fasten the traction motor to the adapter ring on
The lift truck and components are heavy. Be sure the MDU. Carefully lift the motor and set the
that all lifting devices (hoists, cables, chains, motor out of the way. DO NOT damage the
slings, etc.) are suitable and of adequate capacity pinion gear on the motor shaft. Use a rope to
to lift the lift truck or component. The lift truck can fasten the motor to prevent the motor from
weigh up to approximately 3541 kg (7800 lb) falling. See Figure 2.
empty.

1. Move the steering control so the drive wheel is

in a position for straight travel.

WARNING
Disconnect the battery and separate the
connector before opening the drive unit
compartment door and before inspecting or
repairing the electrical system. If a tool causes a
short circuit, the high-current flow from the
battery can cause injury or parts damage.

2. Disconnect and remove the battery. Use the

battery removal procedure described in either
the Operating Manual or the section .

3. Remove the electrical compartment cover for

access to the traction motor controller. Remove
the capscrews retaining the cover to the frame.

WARNING
The capacitor in the traction motor controller can
hold an electrical charge after the battery is
disconnected. To prevent electrical shock or
injury, discharge the capacitor before inspecting
or repairing any component. Wear safety glasses. 1. TRACTION MOTOR 8. LOCKWASHER
Make certain the battery has been disconnected. 2. CAPSCREW 9. NUT
3. LOCKWASHER 10. WHEEL NUT
Discharge the capacitors in the controller by 4. CAPSCREW 11. WHEEL
connecting a load (such as a contactor coil or 5. LOCKWASHER 12. DRIVE UNIT
horn) across the controller's B+ and B- terminals 6. O-RING 13. FRAME
(center two terminals). DO NOT use a screwdriver 7. PINION GEAR
to discharge the traction motor controller.
Figure 2. Separating Traction Motor
4. Discharge the traction motor controller by
connecting a load across terminals B+ and B-.
7. Loosen the lock nut at the chain anchor for the
5. Open the drive unit compartment door. Fasten steering chain. Remove the capscrew at the
the door so that it is fully open. Put a pan chain anchor. Put a mark on the MDU for the
under the MDU drain plug and remove the location of the pin that fastens the chain anchor
to the sprocket. Remove the pin. Carefully
remove the chain anchor and chain from the
sprocket. Refer to the section .

2
0630 SRM 0613 HFK400 Master Drive Unit

4. Install the six capscrews and lockwashers that

WARNING fasten the adapter ring and MDU to the frame
There are close clearances between the MDU, or axle plate. Use a cross pattern to tighten the
drive chassis, and base arm that can cause capscrews to 25 N•m (18 lbf ft). Make sure the
serious injury. NEVER put hands, arms, head, or large ball bearing and adapter ring are in the
legs between these parts unless the parts have correct position around the complete
blocks to prevent movement. If the MDU falls, it circumference. Use the cross pattern to tighten
can cause an injury. Support the MDU vertically to the capscrews to 68 N•m (50 lbf ft).
prevent it from falling.
5. If the pinion gear on the motor shaft was
8. Place a sling under the lift truck frame on the removed, install the key, gear, lockwasher, and
mast side of the MDU. Make sure the lifting nut. Tighten the nut to 54 N•m (40 lbf ft). If an
device and sling have the ability to lift impact wrench is used, make sure it does not
approximately 3541 kg (7800 lb). tighten the nut to more than the correct torque.

9. Remove the six capscrews and lockwashers that 6. Install a new O-ring on the motor using O-ring
fasten the adapter ring and MDU to the lubricant. Carefully install and align the motor
articulating axle. on the adapter ring and MDU. DO NOT
damage the pinion gear on the motor shaft or
10. Hold the MDU and raise the truck frame so the large gear of the MDU. Install the six
that the MDU is free. The steer axle will pivot capscrews and lockwashers. Tighten the
on the articulation shaft. Lower the MDU to capscrews to 20 N•m (15 lbf ft).
the floor and move it from under the lift truck.
Lower the lift truck frame on blocks. 7. Make sure the MDU is in the position for
straight travel with the tire to the left of the
Install case (facing MDU). Carefully install the
steering chain. Use the pin to install the chain
anchor on the adapter ring. Use the capscrew to
WARNING fasten the two chain anchors together. Adjust
The lift truck and components are heavy. Be sure the steering chain, steering potentiometer, and
that all lifting devices (hoists, cables, chains, limit switches using the procedures in the
slings, etc.) are suitable and of adequate capacity section .
to lift the lift truck or component. The lift truck can
weigh up to approximately 3541 kg (7800 lb)
empty. CAUTION
The steering system MUST be adjusted before
1. Use a crane and chain or sling with a capacity operating the lift truck.
rating of 3541 kg (7800 lb) to lift the frame. Lift
the frame for clearance to slide the MDU under 8. Lubricate the large ball bearing using the
the frame or steer axle. Temporarily install proper grease. Fill the MDU to the level/fill
blocks under the frame to prevent lowering. plug using the proper oil. The proper lubricants
Lay the MDU on the floor. Slide the MDU are listed in the Operating Manual or the
under the drive chassis. section . Add oil slowly. The oil passes through
the bearings to the lower part of the MDU.
2. Move the MDU into approximate alignment
under the frame or axle plate. 9. Install the battery and close the drive unit
compartment doors. Install the electrical
3. Hold the MDU in the vertical position through compartment cover. Connect the battery
the hole in the plate. DO NOT put any part of connector.
your body between the MDU and the frame or
axle plate. Carefully raise the frame and Disassemble
remove the blocks. Carefully lower the frame
and align the capscrew holes in the large ball 1. Remove the wheel nuts and the drive/steer
bearing, adapter ring, and frame or axle plate. wheel.

3
HFK400 Master Drive Unit 0630 SRM 0613

2. Remove the nine capscrews that fasten the Legend for Figure 3
lower housing to the upper housing. Remove
the four capscrews inside the upper housing. 1. TOP CASE
2. CAPSCREWS INSIDE TOP CASE
See Figure 3. There are also two capscrews 3. BOTTOM CASE
inside the case that are secured with washers 4. CAPSCREWS (3 EACH SIDE)
and nuts on the opposite side of the upper 5. CAPSCREW (CENTER)
housing. Make certain to remove the capscrews, 6. CAPSCREW IN PIN
lockwashers, and nuts before attempting to 7. SPACER
separate the upper housing from the lower
housing.
3. The upper housing is retained to the lower
housing with two dowel pins. Use a plastic
hammer against the lower portion of the upper
housing to separate the upper housing from the
lower housing. Carefully slide the upper
housing for clearance between the upper
housing and helical gear. Remove the upper
housing.

CAUTION
The helical gear and pinion shaft assembly can
only be removed after the bevel gear and axle
shaft have been removed from the drive unit lower
housing.

4. Remove the capscrews retaining the drive unit

cover. Remove the drive unit cover.

5. Install two wheel nuts on to the wheel bolts.

Position a piece of wood or bar between the
nuts to retain the drive axle while removing the
special capscrew retaining the bevel gear to the
axle shaft. Remove the special capscrew (24
mm) and the special washer.

Figure 3. Separating Cases

4
0630 SRM 0613 HFK400 Master Drive Unit

8. If necessary, remove the bearing cones from the

WARNING axle shaft, the bevel gear, and the bevel pinion
Toxic vapors may be generated by heating the shaft. To remove the bearing cone from the axle
axle shaft to remove the Loctite® adhesive. Wear a shaft, it is necessary to cut the bearing cage,
protective mask during this operation. Use gloves then open the cage and remove the rollers. Use
to remove the bevel gear if it has been heated. a puller to remove the cage from the axle shaft.

NOTE: The bevel gear is secured to the axle shaft 9. Remove the bearing shield from the lower
using Loctite® 270. It may be necessary to use a housing using a plastic hammer. See Figure 4.
welding torch to heat the bevel gear to 100 to
120°C (212 to 248°F) to free the bevel gear from the
axle shaft.

6. Use a strap wrench or place a wood wedge

under the helical gear to keep the gear from
rotating. Remove the nut retaining the helical
spur gear. Use a gear puller to remove the
helical gear from the pinion shaft. Carefully
remove the pinion shaft and bearing cone from
the lower housing. Use a plastic hammer, if Figure 4. Removing Bearing Shield
necessary. Remove the spacer bushing from the
pinion shaft.
10. If necessary, remove the motor nut, lockwasher,
7. Use a copper mandrel and a plastic hammer to bevel pinion, and key from the motor shaft.
drive the axle shaft out of the lower housing. Remove the O-ring from the motor.
Remove the bevel pinion out of the lower
housing. 11. Remove the wheel bolts from the axle shaft,
using a hydraulic press, if necessary. See
Figure 5.
CAUTION
Keep all shim sets together and labeled for
correct location and installation during assembly.

NOTE: If the bevel pinion and gear set will NOT

be replaced, the same shim sets can be used during
assembly. Adjustment will not be necessary.

5
HFK400 Master Drive Unit 0630 SRM 0613

Figure 5. Master Drive Unit Parts

6
0630 SRM 0613 HFK400 Master Drive Unit

Legend for Figure 5

1. SCREW 13. SEAL RING 25. WHEEL STUD

2. CENTERING RING 14. LUBE FITTING 26. SEALING RING
3. SOCKET HEAD SCREW 15. PINION GEAR 27. BEARING
4. WASHER 16. LOCK NUT 28. SHIM
5. NUT 17. GEAR 29. OIL RING
6. SOCKET HEAD SCREW 18. BEARING 30. SEALING RING
7. SOCKET HEAD SCREW 19. SHIM 31. CAPSCREW
8. SOCKET HEAD SCREW 20. PLUG/OIL DRAIN 32. DISK
9. DOWEL PIN 21. SEAL RING 33. RING AND PINION
10. UPPER HOUSING 22. CAPSCREW 34. BEARING
11. BREATHER VALVE 23. COVER 35. SHIM
12. PLUG/OIL FILL 24. WHEEL SHAFT 36. LOWER HOUSING

12. If necessary, remove the bearing cups. See

Figure 6. Use a puller or copper mandrel and a
plastic hammer. DO NOT damage or lose the
shims between the cups and the bore in the
case. Keep each set of shims together and
separate from the other sets of shims. Put a
label on each set so that the sets can be
installed in the correct position during
assembly. Measure the distance between the
edge of the case and the inner seal ring at the
axle bore. The replacement seal ring MUST be
installed in the same position as the old seal.
Remove the seal ring.

1. UPPER PINION BEARING CUP

2. LOWER PINION BEARING CUP
3. INNER AXLE SHAFT BEARING CUP
4. OUTER AXLE SHAFT BEARING CUP
5. UPPER PINION BEARING SHIMS
6. LOWER PINION BEARING SHIMS
7. INNER AXLE SHAFT SHIMS
8. OUTER AXLE SHAFT SHIMS
9. INNER SEAL RING
10. BEARING SHIELD

Figure 6. Bearing and Shim Location

7
HFK400 Master Drive Unit 0630 SRM 0613

Assemble 2. Check all parts for damage or cracks. Replace

any damaged parts.
WARNING
Cleaning solvents can be flammable and toxic and CAUTION
can cause skin irritation. When using cleaning The axle and gear assemblies are installed and
solvents, always follow the recommendations of removed several times during this procedure. Be
the manufacturer. Wear eye protection. careful not to damage the seals.

NOTE: The helical pinion and gear and the bevel

CAUTION pinion shaft and bevel gear are matched sets and
Some of the hardware used on the master drive MUST be replaced as sets. When replacing the
unit (MDU) and traction motor is metric. Use the gear sets, always replace the tapered roller
correct tool to avoid damage. bearings. The bearing cup and bearing cone MUST
be from the same manufacturer. Lubricate the
NOTE: The pinion gear and the large gear MUST bearings with clean transmission oil prior to
be replaced as a set. The spiral bevel pinion and assembly.
gear set MUST be replaced as a set.
NOTE: Assembly of the drive unit requires the use
NOTE: The large ball bearing is part of the top of a standard micrometer, torque wrench, and dial
case. The top case and the ball bearing are replaced indicator. The procedure below specifies the use of
as a unit. a special measuring tool (Hyster P/N 2036120) and
a special clamping tool (Hyster P/N 2036121). The
1. Clean all components thoroughly. Use Loctite®
measuring tool can be fabricated, if desired, as
Fast Cleaner No. 706 to remove all traces of follows: Make a bushing to fit the bore of the lower
adhesive from the lower housing in the area pinion shaft bearing. The bushing must have an
where the thread-protecting shield had been outside diameter of 51.5 mm (2.03 in.) and a length
located. Spray the cleaner from a distance of of 67.5 mm (2.66 in.). The special clamping tool can
approximately 30 cm (12 in.) while holding the be used to facilitate easy assembly.
can upright. Allow the cleaner to work; then
thoroughly remove the dissolved dirt from the 3. Insert the special measuring tool in the pinion
lower housing using a clean cloth. Spray the shaft lower bearing bore. Determine the correct
surface with the cleaner again and allow to air- thickness for the lower bearing shim set
dry. (dimension X) as follows (see Figure 7):

8
0630 SRM 0613 HFK400 Master Drive Unit

NOTE: THERE ARE TWO NUMBERS STAMPED ON THE BEVEL PINION SHAFT. THERE ARE ALSO TWO
NUMBERS STAMPED ON THE BEVEL GEAR. ONE NUMBER ON EACH PART IS THE SET NUMBER. THESE
NUMBERS MUST BE THE SAME. CHECK THAT THE BEVEL PINION SHAFT AND THE BEVEL GEAR ARE A
MATCHED SET BY COMPARING THE SET NUMBERS. THE SECOND NUMBER ON THE BEVEL PINION
SHAFT IS THE ASSEMBLY DIMENSION OF THE SHAFT (DIMENSION B, BELOW). THE SECOND NUMBER
ON THE BEVEL GEAR IS THE GEAR CLEARANCE NUMBER.

1. BEVEL PINION SHAFT 6. LOWER BEARING SHIM SET

2. SPACER 7. UPPER BEARING SHIM SET
3. SPECIAL MEASURING TOOL 8. UPPER BEARING
4. LOWER CASE 9. DIMENSION B (MM) STAMPED ON END OF
5. LOWER BEARING BEVEL PINION SHAFT
Figure 7. Bevel Pinion Shaft Installation

9
HFK400 Master Drive Unit 0630 SRM 0613

a. Measure dimension F (the difference

between the axle bearing bore and the end of
the bushing).

b. Subtract the value F from the length (L) of

the bushing.

c. Add the value of d/2. The result is dimension

E. E = L - F + d/2 L = bushing length F = the
difference between the bearing bore for the
axle and the end of the bushing d/2 =
45.00 mm (1.7716 in.)

d. Measure dimension T (the width of the lower

bearing).

e. Subtract assembly dimension B (stamped on

the bevel pinion shaft) from dimension E
(found in Step c, above). Then subtract
dimension T. The result is dimension X (the 1. BEARING CUP
correct thickness of the lower bearing shim 2. WHEEL SHAFT INNER BEARING BORE SHIM
set). X = E - B - T E = the value found in SET
Step c B = the number stamped on the pinion 3. WHEEL SHAFT OUTER BEARING BORE SHIM
shaft T = the total thickness of the bearing SET

Figure 8. Wheel Shaft Shim Sets

4. Assemble the proper combination of shims to
equal the correct thickness for the lower
bearing shim set, as determined above
NOTE: DO NOT install the wheel shaft seal until
[±0.05 mm (0.002 in.)]. Install the lower bearing
after the adjustment procedure has been
shim set into the lower bearing bore. Press the
completed.
lower bearing cup into the bore.
7. Press the taper roller bearing cone up to the
stop on the pinion shaft.
CAUTION
DO NOT use damaged or distorted shims in the 8. Lubricate the bearing cup with transmission
following steps. oil. Install the pinion shaft into the housing and
preload it against the bearing cup with the
5. Install the shim set removed during special clamping tool or a piece of wood.
disassembly from the inner bearing bore of the
wheel shaft into the inner bearing bore. This 9. Measure distance A between the top of the
shim set will be used for the preliminary shoulder of the pinion shaft and the bottom of
adjustment of the wheel shaft. Drive the inner the bore for the upper bearing. See Figure 9.
bearing cup into the inner bearing bore. See
Figure 8.

6. Install the shim set removed during

disassembly from the outer bearing bore of the
wheel shaft into the outer bearing bore. This
shim set will be used for the preliminary
adjustment of the wheel shaft. Press the outer
bearing cup into the outer bearing bore. See
Figure 8.

10
0630 SRM 0613 HFK400 Master Drive Unit

Figure 9. Shim Measurement Figure 10. Pinion Shaft Bearing Clearance Check

10. Add 0.02 mm (0.00079 in.) to the value of

dimension A and install a shim set equal to 16. Remove the pinion shaft and bearing. Remove
that sum into the bearing bore. Shim set (mm) the upper bearing cup. Additional shims must
= A + 0.02 mm be added to the upper bearing bore to preload
the bearing. To determine the correct amount of
11. Press the upper bearing cup into the bearing additional shims, add 0.07 mm (0.0028 in.) to
bore. Press the upper bearing cone onto the the clearance value measured in Step 15.
pinion shaft up to the stop. Install shims equal to that sum into the bearing
bore with the shims installed earlier.
12. Place the helical gear onto the pinion shaft and Additional shim set (mm) = value measured on
install the nut. Hold the helical gear with a dial indicator + 0.07 mm
strap wrench and tighten the nut to a torque
value of 150 N•m (111 lbf ft). DO NOT stake If no clearance was measured, add a total of
the nut. The bearing clearance must be checked 0.02 mm (0.00079 in.) to the shims installed
and adjusted before staking the nut. earlier.

13. Remove the special clamping tool or piece of 17. Install the pinion shaft. Press the upper
wood holding the pinion shaft in place. bearing cup into the bearing bore. Press the
upper bearing cone onto the pinion shaft up to
14. Press the pinion shaft downward by hand while the stop.
turning the shaft several times to align the
taper rollers within the bearing. 18. Cover the splines of the helical gear with a thin
coat of Loctite® 270. Wipe off any excess with a
15. Place the dial indicator on the housing as rag.
shown in Figure 10. Adjust the dial to indicate
zero. Mark the point of measurement on the 19. Place the helical gear onto the pinion shaft and
helical spur gear with a colored pencil. Lift the install the nut. Hold the helical gear with a
pinion shaft upward by carefully prying up strap wrench and tighten the nut to a torque
beneath the helical spur gear with two levers. value of 150 N•m (111 lbf ft). Stake the nut to
Read any deflection on the dial indicator. This the pinion shaft.
value is the bearing clearance. Repeat the
procedure to be sure to obtain the correct value.

11
HFK400 Master Drive Unit 0630 SRM 0613

20. Press the wheel bolts into the wheel shaft until
the bolt contacts the stop. Be sure the flattened
side of the bolt faces the wheel shaft center.

21. Push the sealing ring onto the wheel shaft.

Press the outer wheel bearing cone onto the
wheel shaft until the bearing contacts the stop.
Wait to grease the bearing until after the
preload adjustments are performed.

NOTE: After the proper backlash has been

obtained, grease the seal ring and fill the outer
bearing cone using Shell Alvania R3 grease prior to
assembly.

22. Press the inner wheel bearing cone onto the

1. SPIRAL BEVEL GEAR
bevel gear until the bearing cone contacts the 2. DIAL INDICATOR
stop. 3. WOOD WEDGE
23. Insert the bevel gear into the MDU housing. Figure 11. Checking Backlash
NOTE: DO NOT install the inner seal ring until
the bearing preload has been adjusted. 27. Adjust the dial indicator to zero. Turn the
24. Insert the wheel shaft into the housing and wheel shaft in both directions to measure any
engage the splines of the shaft into the bevel deflection. The admissible range for backlash is
gear. Secure the bevel gear on the wheel shaft between 0.03 to 0.11 mm (0.0012 to 0.0043 in.).
using the M16 capscrew and special washer. Backlash is adjusted by adding or removing
shims beneath the inner wheel bearing cup.
25. Prevent the axle from turning. Tighten the M16 The ideal backlash is 0.07 mm (0.028 in.).
capscrew to 245 N•m (181 lbf ft).
28. Check the tooth contact pattern by coating
26. Use a dial indicator to check the backlash three to four tooth flanks of the bevel gear with
between the bevel gear and the pinion. The ink. Mesh the coated teeth with the pinion gear
backlash is the clearance between the teeth of several times and then inspect the wear
the bevel gear and the teeth of the pinion gear. pattern of the ink on the coated teeth. Slight
See Figure 11. Position the dial indicator on the deviations from the ideal tooth contact pattern
housing so that the dial indicator foot is as are admissible. Significant tooth contact
close as possible to being perpendicular to the pattern misalignment is an indication that a
tooth flank of the bevel gear. Install a wood mistake was made at an earlier step in the
wedge under the large gear at the top of the procedure and will necessitate repeating the
MDU to keep the gear and pinion from moving. assembly procedure. See Table 1.

12
0630 SRM 0613 HFK400 Master Drive Unit

Table 1. Tooth Contact Pattern

Correct Contact Pattern Step 1. Apply a colored dye or grease to

approximately 12 of the teeth of the spiral
bevel gear.
Step 2. Apply a small friction load to the
edge of the gear so that the gear does not
turn easily. Rotate the gear one revolution
by turning the large gear on the spiral bevel
pinion.
Step 3. Check the tooth contact pattern on
the spiral bevel gear. Make sure that the
pattern is checked on the side of the tooth
where the pinion teeth apply the force.
Wrong Tooth Contact Pattern
Tip Contact The spiral bevel pinion is too far from the
center of the spiral bevel gear. Some
movement in the direction of the arrows can
be necessary. Adjust the thickness of the
shim as described in the assembly
procedure.

Base Contact The spiral bevel pinion is too close to the

center of the spiral bevel gear. Some
movement in the direction of the arrows can
be necessary. Adjust the thickness of the
shim sets as described in the assembly
procedure.

Inner Contact The spiral bevel pinion is too far from the
center of the spiral bevel pinion. Some
movement of the spiral gear away from the
spiral bevel pinion can be necessary. Adjust
the shim sets at the spiral bevel gear as
described in the assembly procedure.

Outer Contact The spiral bevel pinion is too far from the
center of the spiral bevel pinion. Some
movement of the spiral gear toward the
spiral bevel pinion can be necessary. Adjust
the shim sets at the spiral bevel gear as
described in the assembly procedure.

13
HFK400 Master Drive Unit 0630 SRM 0613

29. Check the wheel bearing clearance. Press down preload set in the previous step in
on the wheel shaft by hand and rotate it several 0.01 mm (0.00039 in.) increments until the
times. Arrange the dial indicator on the wheel shaft can be turned by hand.
housing as shown in Figure 12. Adjust the dial
to indicate zero. Lift the wheel shaft upward by 32. After the bearing preload has been properly set,
carefully prying up beneath the bevel gear with check the backlash again. Use a dial indicator
two levers. Read any deflection on the dial to check the backlash between the bevel gear
indicator. This value is the bearing clearance. and the pinion. The backlash is the clearance
Repeat the procedure to be sure to obtain the between the teeth of the bevel gear and the
correct value. teeth of the pinion gear. See Figure 11. Position
the dial indicator on the housing so that the
dial indicator foot is as close as possible to
being perpendicular to the tooth flank of the
bevel gear. Install a wood wedge under the
large gear at the top of the MDU to keep the
gear and pinion from moving.

33. Adjust the dial indicator to zero. Turn the

wheel shaft in both directions to measure any
deflection. The admissible range for backlash is
between 0.03 to 0.11 mm (0.0012 to 0.0043 in.).
If the backlash needs to be adjusted at this
point, the total thickness of the outer plus the
inner shims must remain constant (i.e., if you
Figure 12. Wheel Shaft Bearing Clearance Check remove a shim from beneath the inner bearing
cup, you must add it to the shims beneath outer
bearing cup). The ideal backlash is
30. Remove the wheel shaft and outer bearing. 0.07 mm (0.003 in.).
Remove the outer bearing cup. Add or remove
shims as required to obtain a bearing clearance 34. After the proper backlash and preload have
of 0.02 mm (0.00079 in.). Install the outer been obtained, remove the bevel gear and wheel
bearing cup, bearing, and wheel shaft. Repeat shaft in order to mount the thread-protective
Step 29. After the bearing clearance is shield and the radial shaft seal.
confirmed to be 0.02 mm (0.00079 in.), remove 35. Thoroughly clean the seat of the thread-
the wheel shaft, outer bearing, and outer
protective shield on the housing with Loctite®
bearing cup again. Add 0.10 mm (0.004 in.)
Fast Cleaner 706 or equivalent.
additional shims to the outer bearing bore to
preload the bearing. 36. Coat the seat of the thread-protective shield
31. Install the outer bearing cup, outer bearing, with Loctite® 270. Press the thread-protective
and wheel shaft. Verify that the wheel shaft shield on the lower housing as far as possible.
can be turned by hand. If not, reduce the See Figure 13.

14
0630 SRM 0613 HFK400 Master Drive Unit

1. M16 CAPSCREW 5. WHEEL SHAFT

2. SPECIAL WASHER 6. GREASE
3. BEVEL GEAR 7. LOCTITE® 270
4. HOUSING
Figure 14. Wheel Shaft Assembly
1. RADIAL SHAFT SEAL
2. THREAD-PROTECTIVE SHIELD

Figure 13. Inner Seal Installation 40. Insert the wheel shaft into the housing and
engage the splines of the shaft into the bevel
gear. Remove excess with a clean cloth.
37. Remove the outer bearing cup and shims.
41. Secure the bevel gear on the wheel shaft using
Thinly coat the radial shaft seal with Loctite® the M16 capscrew and special washer. Prevent
574. Install the inner seal into the lower the axle from turning. Tighten the M16
housing. The inner seal should be capscrew to 245 N•m (181 lbf ft).
3.0 mm (0.118 in.) below the bottom edge of the
outer bearing bore, when properly installed. 42. Coat the flat housing surface with Loctite® 574
See Figure 13. Install the shims and outer before mounting the housing cover. Apply one
bearing cup. drop of Loctite® 243 to the threads of each of
38. Coat the entire surface of the inner splines of the housing cover mounting bolts and install
the bolts.
the bevel gear with Loctite® 270. Insert the
bevel gear in the housing. See Figure 13. NOTE: If the tapped holes in the bottom of the
lower housing extend through the housing,
39. Fill the inner seal ring and the cone on the
wheel shaft with Shell Alvania R3 grease. See completely seal the capscrews with Loctite®
Figure 14. adhesive to prevent oil from leaking from around
the threads.

43. Tighten the housing cover capscrews to

9.5 N•m (7 lbf ft).

15
HFK400 Master Drive Unit 0630 SRM 0613

44. Inspect the upper part of the MDU. The upper 48. Install the drive venting filter as far as possible
part of the MDU must be replaced if: into the upper part of the MDU. Install grease
fitting. See Figure 16.
a. The caulked cover plate on the trunnion
bearing has separated. Check visually.

b. The trunnion bearing is difficult to turn or

binds. Check manually.

c. The maximum trunnion bearing clearance is

exceeded. Check the clearance as described
below.

45. Clamp the upper part of the MDU to an

assembly table. Install three eyebolts into the
outer race of the trunnion bearing and rotate
the bearing several times. See Figure 15.

1. DRIVE VENTING FILTER

2. GREASE FITTING

Figure 16. Drive Venting Filter and Grease Fitting

Installation

49. Use Loctite® 574 to install the upper housing on

the lower housing. Make sure the upper
housing is aligned correctly and use a punch to
install the two dowels if removed. Install the
capscrews. Tighten the 8 mm capscrews to
23 N•m (17 lbf ft). Tighten the 10 mm
capscrews to 46 N•m (34 lbf ft). Install the
socket head capscrews, the washers, and the
nuts. Tighten the nuts to 23 N•m (17 lbf ft).
Figure 15. Wheel Shaft Assembly
50. Install the wheel and the lug nuts. Tighten the
nuts in a cross pattern to one-half the torque
46. Install a cable in each eye bolt. Position three value specified in Section 2. Tighten the lug
dial indicators on the trunnion bearing and set nuts again using the cross pattern to obtain the
the indicators to zero. Mark the position of one proper torque.
dial indicator on the trunnion bearing with a
marking pen. 51. Lubricate trunnion bearing using the
recommended grease listed in Section 2. Add
47. Raise the upper housing using a lifting device the grease through both fittings. Slowly rotate
and a spring balance to obtain approximately the MDU while filling the fittings with grease.
50 kg (110 lb) of force. Rotate the trunnion A dry bearing will take approximately
bearing several times and position at the mark 55 grams (0.12 lb) of grease to fill the bearing
again. The maximum bearing clearance is completely.
0.03 mm (0.0012 in.). If the bearing clearance is
more than the recommended clearance, the 52. Fill the MDU to the level/fill plug using the
trunnion bearing and upper housing must be recommended oil listed in Section 2. Add the oil
replaced. slowly. The oil must go through the bearings to
the lower part of the MDU. Fill until the oil just
NOTE: The large ball bearing is part of the upper starts to run out. Install the plug and tighten to
housing. The upper housing and the ball bearing 22 N•m (16 lbf ft).
are replaced as a unit.

16
0630 SRM 0613 HFK400 Master Drive Unit

TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Lift truck will not move. Traction motor not operating. Repair or replace traction motor.

Damaged gears or bearings. Replace gears or bearings.

MDU makes noise. Insufficient lubricant or incorrect Lubricate as needed.

lubricant.

Dry, damaged, or incorrect Lubricate as needed.

bearings.

Bearing preload or backlash not Adjust backlash.

properly adjusted.

Worn or damaged gears. Replace gears.

Oil leaks at the housing cover. Housing cover is not sealed or Seal properly.
properly seated.

Capscrews not sealed off or not Tighten to appropriate torque.

tightened to specified torque.

Oil leaks at the wheel shaft. Shaft seal incorrectly mounted or Replace shaft seal.
damaged.

Surface of axle shaft damaged. Replace axle shaft.

Oil leaks at the filler plug or drain Dirt between sealing ring and Clean sealing ring and housing.
plug. housing.

Plugs not tightened to specified Tighten plugs to appropriate

torque. torque.

Oil leakage between lower and Sealing surface not sealed off. Seal properly.
upper housings.

Capscrews not tightened to Tighten to appropriate torque.

specified torque.

17
GK Master Drive Unit 0630 SRM 0613

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Oil leaks in motor compartment. Too much oil in MDU. Drain excess oil.

Breather defective. Clean or replace breather.

Traction motor seal defective. Replace motor seal.

Trunnion bearing difficult to turn, Centering ring separated, Torque capscrews holding
binds, or exceeds maximum allowing dirt to penetrate into centering ring to MDU.
clearance. bearing.

Cage segments are damaged. Replace cage segments.

Deformation of the balls or ball Replace balls and ball races.

races.

Bearing not properly lubricated. Lubricate as needed.

GK Master Drive Unit

GENERAL The GK MDU is vertically installed in the truck
and allows an effective utilization of space. The
This section contains a description, repair, and ad- compact, one-piece housing is made of high-duty
justment procedures for the parts of the GK master nodular iron; thus having a high rigidity and opti-
drive unit (MDU) used on the narrow aisle lift mum guiding precision. This allows a fully integra-
trucks. The traction motor, steering, and brake re- ted bearing of the helical spur gear stage with a
pair information are in separate manuals. very high running smoothness; i.e., no drive pinion
on the motor shaft of the electric motor. See Fig-
DESCRIPTION ure 17.

The MDU consists of two ratio steps. Gear ratio 1 is

CAUTION designed as helical spur gear stage and perma-
Certain specifications and procedures differ de- nently integrated in the housing. Gear ratio 2 is de-
pending upon the type of master drive unit. Verify signed as Gleason bevel gearing of the hypoid type
the type of MDU by inspecting the housing. with offset bevel pinion shaft.
Some of the hardware used on the MDU and trac-
tion motor is metric. Use the correct tool to avoid
damage.

18
0630 SRM 0613 GK Master Drive Unit

1. MDU HOUSING 6. WHEEL SHAFT

2. VENT HOLE 7. INPUT PINION
3. GEAR RIM 8. HOUSING COVER
4. STEERING PINION 9. OIL FILLER PLUG
5. STEERING BEARING 10. OIL DRAIN PLUG

Figure 17. GK Master Drive Unit

19
GK Master Drive Unit 0630 SRM 0613

MAINTENANCE 1. Move the steering control so the drive wheel is

in a position for straight travel.
Changing the Oil
NOTE: The oil used in the master drive unit should WARNING
be drained and replaced after 350 hours of initial Disconnect the battery and separate the connec-
operation in accordance with the maintenance tor before opening the drive unit compartment
schedule. After the initial oil change, the master door and before inspecting or repairing the elec-
drive unit requires only the addition of the recom- trical system. If a tool causes a short circuit, the
mended oil to maintain the oil at the proper level. high-current flow from the battery can cause in-
jury or parts damage.
Drain the oil when it is warm by removing the
drain and fill plugs. Use a drain pan under the 2. Disconnect and remove the battery. Use the
drain to keep oil off the floor. Install the drain plug battery removal procedure described in either
and fill the unit by adding oil slowly. Allow enough the Operating Manual or the section , , Peri-
time for the oil to flow through the bearings to fill odic Maintenance 8000SRM1472.
the reservoir. The correct level is at the bottom of
3. Remove the electrical compartment cover for
the fill plug hole.
access to the traction motor controller.
Traction Motor and Drive Unit Splines
WARNING
CAUTION The capacitor in the traction motor controller can
hold an electrical charge after the battery is dis-
The traction motor is only allowed to be lifted with
connected. To prevent electrical shock or injury,
soft ropes or belts, never with steel cables or
discharge the capacitor before inspecting or re-
chains. Care must be taken during transport to
pairing any component. Wear safety glasses.
avoid shocks.
Make certain the battery has been disconnected.
NOTE: The traction motor shaft and MDU input
4. Discharge the capacitor in the controller by con-
pinion splines should be lubricated every 2000
necting a 200-ohm, 2-watt resistor across the
hours.
controller's a load across the B+ and B- termi-
nals of the motor controller for 10 seconds. Re-
To lubricate the traction motor shaft and MDU in-
move the resistor after discharging the capaci-
put pinion, remove the traction motor from the
tor See Figure 18.
drive unit. Wipe the motor shaft splines and the
drive unit input pinion clean. Apply Dow Corning® 5. Open the drive unit compartment doors and
Molykote G-N paste (or equivalent) (Hyster P/N fasten them so that they are fully open. Put a
0339068) with a small brush to moderately coat in- pan under the MDU drain plug and remove the
ternal MDU splines and external drive motor plug. After the oil has completely drained, rein-
splines before reinstalling motor to the drive unit. stall the drain plug. Tighten to
Refer to Remove and Assemble for instructions on 22 N•m (16 lbf ft).
removing and installing the traction motor.

REMOVE WARNING
The motor is heavy. Use appropriate lifting equip-
ment to avoid personal injury.
WARNING
The lift truck and components are heavy. All lift- 6. Remove the capscrews and lockwashers that
ing devices (hoists, cables, chains, slings, etc.) fasten the traction motor to the MDU. Care-
must be suitable and of adequate capacity to lift fully lift and sit the motor out of the way. Use
the lift truck or component. The lift truck can rope to fasten the motor to prevent it from fall-
weigh up to approximately 3541 kg (7800 lb) ing.
empty.

20
0630 SRM 0613 GK Master Drive Unit

9. Hold the MDU and raise the truck frame so

that the MDU is free. Move the MDU from un-
der the lift truck. Lower the lift truck frame on
blocks.

ASSEMBLE

CAUTION
The MDU is only allowed to be lifted with soft
ropes or belts, never with steel cables or chains.
Care must be taken during transport to avoid
shocks. This is especially important pertaining to
wheel bolts, the electric motor, and accessories.

The corrosion protection can only be removed

from the connecting points using a suitable
cleaner. Never use benzene, solvents, or other
combustible substances for cleaning. Use only
nontoxic, noncombustible, and commercially per-
missible cleaning agents. Wear safety gloves and
1. NEGATIVE CONNECTION (B-) goggles!
2. POSITIVE CONNECTION (B+)
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR DO NOT drain cleaners into the soil. DO NOT al-
low cleaners to contact rubber parts, electrical con-
Figure 18. Discharging the Capacitors - R30XMF3, nections of accessories, or the motor ventilation.
R30XMA3, R30XMS3, and R30XM3
Mounting Electric Motor
1. Wipe the motor shaft splines and the drive unit
WARNING input pinion clean. Apply Dow Corning® Moly-
There are close clearances between the MDU, kote G-N paste (or equivalent)(Hyster P/N
drive chassis, and base arm that can cause seri- 0339068) with a small brush to moderately coat
ous injury. NEVER put hands, arms, head, or legs internal drive pinion splines and external mo-
between these parts unless there are blocks in tor shaft splines before installing motor to the
place to prevent movement. If the MDU falls, it can drive unit.
cause an injury. Support the MDU vertically to
prevent it from falling. NOTE: Applying lubrication paste is critical to the
splines of the drive motor and MDU shaft. Prema-
7. Place a sling under the lift truck frame on the ture gear shaft failure may result if lubrication
mast side of the MDU. Make sure the lifting de- paste is not applied.
vice and sling have the ability to lift approxi-
mately 3541 kg (7800 lb). 2. Assemble the electric motor into the centering
seat of the steering bearing and cautiously join
8. Remove the capscrews and lockwashers that it with the splined hub connection of the drive
fasten the MDU to the truck frame. pinion.

3. Turn the hole pattern of the steering bearing so

WARNING that it is aligned with the electric motor.
The MDU is heavy. It can weigh approximately
4. Install the six capscrews and lockwashers that
52 kg (114.6 lb). Use appropriate lifting equipment
fasten the electric motor and tighten to appro-
to avoid personal injury.
priate torque.

21
GK Master Drive Unit 0630 SRM 0613

Pivoted Connection NOTE: Use Loctite® adhesive as needed. During

disassembly and later reuse of the screws, the ad-
1. Make sure that the gear rim is clean and pay hesive remaining on the thread must be removed
attention that no foreign substances or cleaning and new screws must be used.
agents get through the threaded boreholes of
the connecting structure into the transmission The fixing bolts should be checked at fixed inter-
interior. See Figure 19. vals or operating hours, especially in case of high
breakdown torque load or suspended axial load.

DISASSEMBLE
To disassemble, reverse the assembly process ex-
plained in previous section.

INSTALL

WARNING
The lift truck and components are heavy. Be sure
that all lifting devices (hoists, cables, chains,
slings, etc.) are suitable and of adequate capacity
to lift the lift truck or component to avoid personal
injury.

1. Use a crane and chain or sling with appropriate

capacity to lift the frame. Lift the frame for
enough clearance to slide the MDU under the
frame. Temporarily install blocks under the
frame to prevent lowering. Lay the MDU under
the drive chassis.

2. Move the MDU into approximate alignment un-

der the frame.

3. Align both the MDU with the screw holes and

the steer gear with the axle pilot hole. Carefully
raise the frame and remove the blocks. Lower
1. BOREHOLES the frame and align the capscrew holes in the
2. GEAR RIM large ball bearing and the frame.
3. STEERING BEARING
4. CAPSCREWS 4. Install the capscrews and lockwashers that fas-
Figure 19. Steering ten the MDU to the frame. Use cross pattern to
tighten the capscrews to the appropriate tor-
que. Make sure the steering bearing is in the
2. Align the gear rim and bolt holes with the correct position around the complete circumfer-
threaded boreholes of the connecting structure. ence.
Install the steering bearing on the correct side
and turn it so the bolt holes are aligned with 5. Fill the MDU to the level/fill plug using the
the hole pattern of the gear rim and the hous- proper oil. The proper lubricants are listed in
ing. the Operating Manual or the section , Peri-
odic Maintenance 8000SRM1472. Add oil
3. Install capscrews to 34 N•m (25 lbf ft) to fasten slowly. The oil passes through the bearings to
the steering bearing and the gear rim onto the the lower part of the MDU.
connecting structure.

22
0630 SRM 0613 Master Drive Unit

TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Lift truck will not move. Traction motor not operating. Repair or replace traction motor.

Damaged gears or bearings. Replace drive unit.

Master drive unit makes noise. Insufficient lubricant or incorrect Lubricate as needed.
lubricant.

Dry, damaged, or incorrect bear- Lubricate as needed.

ings.

Worn or damaged gears. Replace drive unit.

Oil leaks at the wheel shaft. Shaft seal incorrectly mounted or Replace drive unit.
damaged.

Surface of axle shaft damaged. Replace drive unit.

Oil leaks at the filler plug or drain Dirt between sealing ring and Clean sealing ring and housing.
plug. housing.

Plugs not tightened to specified Tighten to appropriate torque.

torque.

Oil leaks in motor compartment. Too much oil in MDU. Drain excess oil.

Breather defective. Clean or replace breather.

Steering bearing difficult to turn, Centering ring separated, allow- Torque capscrews holding center-
binds, or exceeds maximum clear- ing dirt to penetrate into bearing. ing ring to MDU.
ance.

Cage segments are damaged. Replace steering bearing.

Deformation of the balls or ball Replace steering bearing.

races.

Bearing not properly lubricated. Replace steering bearing.

23
Master Drive Unit 0630 SRM 0613

Master Drive Unit

GENERAL • Periodic Maintenance 8000SRM1472
• Steering System 1600SRM1462
This section contains a description, repair, and ad-
justment procedures for the parts of the GK master • Brake System 1800SRM1463
drive unit (MDU) used on the narrow aisle lift
trucks. DESCRIPTION

Additional information concerning the MDU may CAUTION

be included in other manuals when the information
Certain specifications and procedures differ de-
is more closely related to other systems.
pending upon the type of master drive unit. Verify
the type of MDU by inspecting the housing.
For lift truck models N35ZDR2, N45ZR2 (D264),
N30ZDR2, N35-40ZR2 (E470) and N30ZDRS2, Some of the hardware used on the MDU and trac-
N35-40ZRS2 (B265) see: tion motor is metric. Use the correct tool to avoid
• A/C Motor Repair S/N A169N03000L=> damage.
S/N A185N03000L=> S/N H118N03000L=>
S/N E174N03000L=> 0620SRM1621 The GK MDU is vertically installed in the truck
• Electrical System 2200SRM1612 and allows an effective utilization of space. The
compact, one-piece housing is made of high-duty
• Periodic Maintenance 8000SRM1617 nodular iron; thus having a high rigidity and opti-
• Steering System 1600SRM1610 mum guiding precision. This allows a fully integra-
• Brake System 1800SRM1188 ted bearing of the helical spur gear stage with a
very high running smoothness; i.e., no drive pinion
For lift truck models R30XNF3 (A169), R30XMA3 on the motor shaft of the electric motor. See Fig-
(A185), R30XMS3 (E174) and R30XM3 (H118) see: ure 20.

• AC Motor Repair 0620SRM1461 The MDU consists of two ratio steps. Gear ratio 1 is
• A/C Motor Repair S/N A169N03000L=> designed as helical spur gear stage and perma-
S/N A185N03000L=> S/N H118N03000L=> nently integrated in the housing. Gear ratio 2 is de-
S/N E174N03000L=> 0620SRM1621 signed as Gleason bevel gearing of the hypoid type
• Electrical System 2200SRM1467 with offset bevel pinion shaft.

• Electrical System 2200SRM1468

24
0630 SRM 0613 Master Drive Unit

1. MDU HOUSING 6. INPUT PINION

2. GEAR RIM 7. HOUSING COVER
3. STEERING PINION 8. OIL FILLER PLUG
4. STEERING BEARING 9. OIL DRAIN PLUG
5. WHEEL SHAFT

Figure 20. Master Drive Unit

25
Master Drive Unit 0630 SRM 0613

MAINTENANCE 3. Remove the electrical compartment cover for

access to the traction motor controller. Remove
Changing the Oil the capscrews holding the cover to the frame.

NOTE: After the initial oil change, the master

drive unit requires only the addition of the recom- WARNING
mended oil to maintain the oil at the proper level. The capacitor in the traction motor controller can
hold an electrical charge after the battery is dis-
Drain the oil when it is warm by removing the connected. To prevent electrical shock or injury,
drain and fill plugs. Use a drain pan under the discharge the capacitor before inspecting or re-
drain to keep oil off the floor. Install the drain plug pairing any component. Wear safety glasses.
and fill the unit by adding oil slowly. Allow enough Make certain the battery has been disconnected.
time for the oil to flow through the bearings to fill
the reservoir. The correct level is at the bottom of 4. Discharge the capacitor in the controller by con-
the fill plug hole. necting a 200-ohm, 2-watt resistor across the
controller's a load across the B+ and B- termi-
REMOVE nals of the motor controller for 10 seconds. Re-
move the resistor after discharging the capaci-
tor. See Figure 21.
WARNING
The lift truck and components are heavy. All lift-
ing devices (hoists, cables, chains, slings, etc.)
must be suitable and of adequate capacity to lift
the lift truck or component. The lift truck can
weigh up to approximately 3541 kg (7800 lb)
empty.

1. Move the steering control so the drive wheel is

in a position for straight travel.

WARNING
Disconnect the battery and separate the connec-
tor before opening the drive unit compartment
door and before inspecting or repairing the elec-
trical system. If a tool causes a short circuit, the
high-current flow from the battery can cause in-
jury or parts damage.

2. Disconnect and remove the battery. Use the

battery removal procedure described in either 1. POSITIVE CONNECTION (B+)
the Operating Manual or 2. NEGATIVE CONNECTION (B-)
3. INSULATED JUMPER WIRES
• Periodic Maintenance 8000SRM1617 4. 200-OHM, 2-WATT RESISTOR
for lift truck models N35ZDR2, N45ZR2
(D264), N30ZDR2, N35-40ZR2 (E470) and Figure 21. Discharging the Capacitors
N30ZDRS2, N35-40ZRS2 (B265)
• Periodic Maintenance 8000SRM1472 5. Open the drive unit compartment door and fas-
for lift truck models R30XNF3 (A169), ten the door so that it is fully open. Put a pan
R30XMA3 (A185), R30XMS3 (E174) and under the MDU drain plug and remove the
R30XM3 (H118) plug. After the oil has completely drained, rein-
• for lift ruck models stall the drain plug. Tighten to
• 22 N•m (16 lbf ft).
for lift truck models B60ZHD (B262) and
B80ZHD (B257)

26
0630 SRM 0613 Master Drive Unit

8. Remove capscrews and lockwashers that hold

WARNING the adapter ring and MDU to the truck frame.
The motor is heavy. Use appropriate lifting equip- See Figure 22.
ment to avoid personal injury.

NOTE: After traction motor is removed place a cap

over the bearing input pinion opening to prevent
dirt and contamination from entering the MDU.

6. Remove the traction motor from the MDU.

See A/C Motor Repair S/N A169N03000L=>

S/N A185N03000L=> S/N H118N03000L=>
S/N E174N03000L=> 0620SRM1621 for lift
truck models N35ZDR2, N45ZR2 (D264),
N30ZDR2, N35-40ZR2 (E470), N30ZDRS2,
N35-40ZRS2 (B265), C60ZHD (A373),C80ZHD
(A282), B60ZHD (B262) and B80ZHD (B257).

See AC Motor Repair 0620SRM1461 for lift

truck models R30XNF3 (A169), R30XMA3
(A185), R30XMS3 (E174) and R30XM3 (H118).

WARNING
There are close clearances between the MDU,
drive chassis, and base arm that can cause seri-
ous injury. NEVER put hands, arms, head, or legs
between these parts unless there are blocks in
place to prevent movement. If the MDU falls, it can
cause an injury. Support the MDU vertically to 1. TRACTION MOTOR
prevent it from falling. 2. CAPSCREW
3. LOCKWASHER
7. Raise the truck up high enough to allow re- 4. WHEEL NUT
5. WHEEL
moval of the MDU with approved lifting devices 6. MASTER DRIVE UNIT (MDU)
able to support up to 4536 kg (10,000 lb) and 7. MDU MOUNTING PLATE
secure the truck with supports. If the truck has
a mast over 3.66 m (144 in.) collapsed height, it Figure 22. Drive Unit Assembly
is recommended the mast be removed before
raising the truck.

See Mast 4000SRM1194 for lift truck models WARNING

N35ZDR2, N45ZR2 (D264), N30ZDR2, The MDU is heavy. It can weigh approximately
N35-40ZR2 (E470) and N30ZDRS2, N35-40ZRS2 52 kg (114.6 lb). Use appropriate lifting equipment
(B265). to avoid personal injury.
See MAST 4000SRM0763 for lift truck models 9. Hold the MDU and raise the truck frame so
R30XNF3 (A169), R30XMA3 (A185), R30XMS3 that the MDU is free. Move the MDU from un-
(E174) and R30XM3 (H118). der the lift truck. Lower the lift truck frame on
blocks.
Use approved lifting slings rated to lift the truck.

27
Master Drive Unit 0630 SRM 0613

DISASSEMBLE

CAUTION
The MDU is only allowed to be lifted with soft ropes or belts, never with steel cables or chains. Care must
be taken during transport to avoid shocks. This is especially important pertaining to wheel bolts, the elec-
tric motor, and accessories.

The corrosion protection can only be removed from the connecting points using a suitable cleaner. Never
use benzene, solvents, or other combustible substances for cleaning. Use only nontoxic, noncombusti-
ble, and commercially permissible cleaning agents. Wear safety gloves and goggles!

CAUTION
After removal of the drive motor, cover the MDU bearing input opening with a cap to prevent dirt or con-
tamination from entering the MDU.

DO NOT drain cleaners into the soil. DO NOT allow cleaners to contact rubber parts, electrical connections
of accessories, or the motor ventilation.

NOTE: Only disassemble the MDU to the extent required to replace the damaged component. Some parts
may be removed without complete disassembly. Disassembly and repair of the MDU requires special tools,
equipment and training to perform properly. Only properly trained and equipped repair personnel should at-
tempt disassembly of the internal gears, bearings and seals.

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.

NOTE: Position a drain underneath MDU with

enough capacity for your lift truck model.

STEP 1.
Remove oil drain plug and oil fill plug from MDU
assembly.

1. OIL FILL PLUG 3. MDU ASSEMBLY

2. OIL DRAIN PLUG

28
0630 SRM 0613 Master Drive Unit

NOTE: For STEP 2 and STEP 3, support the MDU

in a vertical position.

STEP 2.
Remove twelve hexagon screws, steering bearing,
capscrew, lock nut and steering gear from top of
MDU.

1. HEXAGON SCREWS
2. STEERING BEARING
3. CAPSCREW
4. LOCK NUT
5. STEERING GEAR

CAUTION
DO NOT damage surface area around sealing cap
during removal.

NOTE: Remove breather valve from sealing cap

and set aside to be installed into new sealing cap.

STEP 3.
Remove and discard sealing cap from top of MDU
housing.

1. MDU HOUSING 3. BREATHER CAP

2. SEALING CAP

29
Master Drive Unit 0630 SRM 0613

NOTE: For STEP 4, place MDU on a solid work

surface and the housing cover and side cover facing
up.

STEP 4.
Remove ten capscrews and side cover from MDU
housing.

1. CAPSCREW 2. SIDE COVER

CLEAN AND INSPECT Clean all sealing surfaces as needed.

Inspect all contact surfaces and wear surfaces for

damage and cracks. Replace as necessary.

ASSEMBLE
STEP 1.
Fill each capscrew through hole with Loctite 243®
and place a bead of Loctite 5910® on the MDU
sealing surface for side cover. Using ten cap-
screws, install side cover onto MDU assembly.
Torque to 9.5 N•m (7 lbf ft) using installation pat-
tern in adjacent diagram.

STEP 2.
Install breather valve removed during Disassem-
ble, into sealing cap.

1. BREATHER VALVE 2. SEALING RING

30
0630 SRM 0613 Master Drive Unit

STEP 3.
Install steering gear onto MDU assembly. Rotate
steering gear as needed to line up threaded holes
and cutout for sealing ring breather valve.

1. STEERING GEAR

STEP 4.
Using twelve hexagon screws, install steering
bearing onto steering gear and MDU assembly.
Torque hexagon screws to 34 N•m (25 lbf ft). Use
tightening sequence pattern outlined in graphic.

1. HEXAGON SCREW

31
Master Drive Unit 0630 SRM 0613

STEP 5.
Install oil drain plug into MDU assembly. Torque
to 30 N•m (22 lbf ft).

32
0630 SRM 0613 Master Drive Unit

STEP 6.
Install fill plug into MDU assembly. Torque to
30 N•m (22 lbf ft).

33
Master Drive Unit 0630 SRM 0613

INSTALL • Periodic Maintenance 8000SRM1472

for lift truck models R30XNF3 (A169),
R30XMA3 (A185), R30XMS3 (E174) and
WARNING R30XM3 (H118)
The lift truck and components are heavy. Be sure
• for lift ruck models C60ZHD (A373) and
that all lifting devices (hoists, cables, chains,
slings, etc.) are suitable and of adequate capacity C80ZHD (A282)
to lift the lift truck or component to avoid personal • for lift truck models B60ZHD (B262) and
injury.
B80ZHD (B257)
1. Use a crane and chain or sling with appropriate .
capacity to lift the frame. Lift the frame for
enough clearance to slide the MDU under the Add oil slowly. The oil passes through the bear-
frame. Temporarily install blocks under the ings to the lower part of the MDU.
frame to prevent lowering. Lay the MDU under
the drive chassis. WARNING
2. Move the MDU into approximate alignment un- The motor is heavy. Use appropriate lifting equip-
der the frame. ment to avoid personal injury.

3. Align both the MDU with the screw holes and 6. Install the traction motor onto the MDU.
the steer gear with the axle pilot hole. Carefully
See A/C Motor Repair S/N A169N03000L=>
raise the frame and remove the blocks. Lower
S/N A185N03000L=> S/N H118N03000L=>
the frame and align the capscrew holes in the
S/N E174N03000L=> 0620SRM1621 for lift
large ball bearing steering gear and the frame.
truck models N35ZDR2, N45ZR2 (D264),
4. Install the capscrews and lockwashers that fas- N30ZDR2, N35-40ZR2 (E470), N30ZDRS2,
ten the steering gear and MDU to the frame. N35-40ZRS2 (B265), C60ZHD (A373),C80ZHD
Use cross pattern to tighten the capscrews to (A282), B60ZHD (B262) and B80ZHD (B257).
the appropriate torque. Make sure the steering
bearing is in the correct position around the See AC Motor Repair 0620SRM1461 for lift
complete circumference. See Figure 22. truck models R30XNF3 (A169), R30XMA3
(A185), R30XMS3 (E174) and R30XM3 (H118).
5. Fill the MDU to the level/fill plug using the
proper oil. The proper lubricants are listed in
the Operating Manual or the section
• Periodic Maintenance 8000SRM1617
for lift truck models N35ZDR2, N45ZR2
(D264), N30ZDR2, N35-40ZR2 (E470)
and N30ZDRS2, N35-40ZRS2 (B265)

34
 TECHNICAL PUBLICATIONS

0630 SRM 0613 2/14 (8/09)(4/09)(11/06)(10/06)(8/04)