MASTER DRIVE UNIT

N25XMDR3, N30-40XMR3 [C470];

N50XMA3 [C471];
N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265];
N30XMDR3, N45XMR3 [G138];
N30XMXDR3, N45XMXR3 [B264];
N35ZDR, N45ZR [C264]

PART NO. 1523820 630 SRM 1022

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic 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 exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a 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 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 ............................................................................................................................................... 4
Assemble .................................................................................................................................................... 7
Troubleshooting ............................................................................................................................................. 15
GK Master Drive Unit ....................................................................................................................................... 17
General ........................................................................................................................................................... 17
Description ..................................................................................................................................................... 17
Maintenance .................................................................................................................................................. 18
Changing the Oil ....................................................................................................................................... 18
Traction Motor and Drive Unit Splines.................................................................................................... 18
Remove ........................................................................................................................................................... 18
Assemble ........................................................................................................................................................ 19
Mounting Electric Motor........................................................................................................................... 20
Pivoted Connection - Geared Steering ..................................................................................................... 20
Disassemble ................................................................................................................................................... 21
Install ............................................................................................................................................................. 21
Troubleshooting ............................................................................................................................................. 22

This section is for the following models:

N25XMDR3, N30-40XMR3 [C470];

N50XMA3 [C471];
N30ZDR, N35-40ZR [D470];
N30ZDRS, N35-40ZRS [A265];
N30XMDR3, N45XMR3 [G138];
N30XMXDR3, N45XMXR3 [B264];
N35ZDR, N45ZR [C264]

©2009 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
630 SRM 1022 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 ad-

justment 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 sepa-
rate 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, and the axle and
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 630 SRM 1022

DRIVE UNIT MAINTENANCE AND REPAIR
Remove
6. Remove the six capscrews and lockwashers that
WARNING
The lift truck and components are heavy.
Be sure that all lifting devices (hoists, ca-
bles, chains, slings, etc.) are 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.
drain plug. Tighten the drain plug to 22 N•m
(16 lbf ft).
fasten the traction motor to the adapter ring on
the MDU. Carefully lift the motor and set the mo-
tor out of the way. DO NOT damage the pinion
gear on the motor shaft. Use a rope to fasten the
motor to prevent the motor from falling. See Fig-
ure 2.

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

a position for straight travel.

WARNING
Disconnect the battery and separate the con-
nector before opening the drive unit compart-
ment 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 Periodic
Maintenance 8000 SRM 970.

3. Remove the electrical compartment cover for ac-

cess 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 1. TRACTION MOTOR 8. LOCKWASHER
or injury, discharge the capacitor before in- 2. CAPSCREW 9. NUT
specting or repairing any component. Wear 3. LOCKWASHER 10. WHEEL NUT
4. CAPSCREW 11. WHEEL
safety glasses. Make certain the battery has 5. LOCKWASHER 12. DRIVE UNIT
been disconnected. Discharge the capacitors 6. O-RING 13. ARTICULATING
in the controller by connecting a load (such as 7. PINION GEAR AXLE
a contactor coil or horn) across the controller’s
B+ and B terminals (center two terminals). Figure 2. Separating Traction Motor
DO NOT use a screwdriver to discharge the
7. Loosen the lock nut at the chain anchor for the
traction motor controller.
steering chain. Remove the capscrew at the
4. Discharge the traction motor controller by con- chain anchor. Put a mark on the MDU for the
necting a load across terminals B+ and B . location of the pin that fastens the chain anchor
to the sprocket. Remove the pin. Carefully
5. Open the drive unit compartment door. Fasten remove the chain anchor and chain from the
the door so that it is fully open. Put a pan under sprocket. Refer to the section Steering System
the MDU drain plug and remove the drain plug. 1600 SRM 974.
After the oil has completely drained, install the

2
630 SRM 1022
WARNING
There are close clearances between the MDU,
drive chassis, and base arm that can cause se-
rious injury. NEVER put hands, arms, head, or
legs between these parts unless the parts have
blocks to prevent movement. If the MDU falls,
it can cause an injury. Support the MDU verti-
cally to prevent it from falling.
8. Place a sling under the lift truck frame on the
mast side of the MDU. Make sure the lifting de-
vice and sling have the ability to lift approxi-
mately 3541 kg (7800 lb).
9. Remove the six capscrews and lockwashers that
fasten the adapter ring and MDU to the articu-
lating axle.
10. Hold the MDU and raise the truck frame so that
the MDU is free. The steer axle will pivot on the
articulation shaft. Lower the MDU to the floor
and move it from under the lift truck. Lower the
lift truck frame on blocks.
Install
WARNING
The lift truck and components are heavy.
Be sure that all lifting devices (hoists, ca-
bles, chains, slings, etc.) are 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. Use a crane and chain or sling with a capacity
rating of 3541 kg (7800 lb) to lift the frame. Lift
the frame for clearance to slide the MDU un-
der the frame or steer axle. Temporarily install
blocks under the frame to prevent lowering. Lay
the MDU on the floor. Slide the MDU under the
drive chassis.
2. Move the MDU into approximate alignment un-
der the frame or axle plate.
3. Hold the MDU in the vertical position through
the hole in the plate. DO NOT put any part
of your body between the MDU and the frame
or axle plate. Carefully raise the frame and re-
move the blocks. Carefully lower the frame and
align the capscrew holes in the large ball bear-
ing, adapter ring, and frame or axle plate.
HFK400 Master Drive Unit
4. Install the six capscrews and lockwashers that
fasten the adapter ring and MDU to the frame
or axle plate. Use a cross pattern to tighten the
capscrews to 25 N•m (18 lbf ft). Make sure the
large ball bearing and adapter ring are in the cor-
rect position around the complete circumference.
Use the cross pattern to tighten the capscrews to
68 N•m (50 lbf ft).
5. If the pinion gear on the motor shaft was re-
moved, install the key, gear, lockwasher, and nut.
Tighten the nut to 54 N•m (40 lbf ft). If an impact
wrench is used, make sure it does not tighten the
nut to more than the correct torque.
6. Install a new O-ring on the motor using O-ring
lubricant. Carefully install and align the motor
on the adapter ring and MDU. DO NOT damage
the pinion gear on the motor shaft or the large
gear of the MDU. Install the six capscrews and
lockwashers. Tighten the capscrews to 20 N•m
(15 lbf ft).
7. Make sure the MDU is in the position for straight
travel with the tire to the left of the case (facing
MDU). Carefully install the steering chain. Use
the pin to install the chain anchor on the adapter
ring. Use the capscrew to fasten the two chain
anchors together. Adjust the steering chain,
steering potentiometer, and limit switches using
the procedures in the section Steering System
1600 SRM 974.
CAUTION
The steering system MUST be adjusted before
operating the lift truck.
8. Lubricate the large ball bearing using the proper
grease. 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 8000 SRM 970. Add oil slowly.
The oil passes through the bearings to the lower
part of the MDU.
9. Install the battery and close the drive unit com-
partment doors. Install the electrical compart-
ment cover. Connect the battery connector.
3
HFK400 Master Drive Unit 630 SRM 1022

Disassemble 3. The upper housing is retained to the lower hous-

1. Remove the wheel nuts and the drive/steer
wheel.
2. Remove the nine capscrews that fasten the lower
housing to the upper housing. Remove the four
capscrews inside the upper housing. See Fig-
ure 3. There are also two capscrews inside the
case that are secured with washers and nuts on
the opposite side of the upper housing. Make
certain to remove the capscrews, lockwashers,
and nuts before attempting to separate the up-
per housing from the lower housing.
ing with two dowel pins. Use a plastic hammer
against the lower portion of the upper housing to
separate the upper housing from the lower hous-
ing. Carefully slide the upper housing for clear-
ance 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. Po-

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

WARNING
Toxic vapors may be generated by heating the
axle shaft to remove the Loctite® adhesive.
Wear a protective mask during this operation.
Use gloves to remove the bevel gear if it has
been heated.

NOTE: The bevel gear is secured to the axle shaft us-

ing Loctite® 270. It may be necessary to use a weld-
ing 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
1. TOP CASE shaft and bearing cone from the lower housing.
2. CAPSCREWS INSIDE TOP CASE Use a plastic hammer, if necessary. Remove the
3. BOTTOM CASE spacer bushing from the pinion shaft.
4. CAPSCREWS (3 EACH SIDE)
5. CAPSCREW (CENTER) 7. Use a copper mandrel and a plastic hammer to
6. CAPSCREW IN PIN drive the axle shaft out of the lower housing. Re-
7. SPACER
move the bevel pinion out of the lower housing.
Figure 3. Separating Cases

4
630 SRM 1022
CAUTION
Keep all shim sets together and labeled for cor-
rect 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 as-
sembly. Adjustment will not be necessary.
8. If necessary, remove the bearing cones from the
axle shaft, the bevel gear, and the bevel pinion
shaft. To remove the bearing cone from the axle
shaft, it is necessary to cut the bearing cage, then
open the cage and remove the rollers. Use a
puller to remove the cage from the axle shaft.
9. Remove the bearing shield from the lower hous-
ing using a plastic hammer. See Figure 4.
Figure 4. Removing Bearing Shield
HFK400 Master Drive Unit
10. If necessary, remove the motor nut, lockwasher,
bevel pinion, and key from the motor shaft. Re-
move the O-ring from the motor.
11. Remove the wheel bolts from the axle shaft, us-
ing a hydraulic press, if necessary. See Figure 5.
12. If necessary, remove the bearing cups. See Fig-
ure 6. Use a puller or copper mandrel and a plas-
tic 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. Re-
move the seal ring.
5
HFK400 Master Drive Unit 630 SRM 1022

Figure 5. Master Drive Unit Parts

6
630 SRM 1022 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
Assemble

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer. Wear eye
protection.

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

NOTE: The pinion gear and the large gear MUST be

replaced as a set. The spiral bevel pinion and gear
set MUST be replaced as a set.

NOTE: The large ball bearing is part of the top case.

The top case and the ball bearing are replaced as a
unit.

1. Clean all components thoroughly. Use Loctite®

Fast Cleaner No. 706 to remove all traces of ad-
1. UPPER PINION BEARING CUP hesive from the lower housing in the area where
2. LOWER PINION BEARING CUP the thread-protecting shield had been located.
3. INNER AXLE SHAFT BEARING CUP
4. OUTER AXLE SHAFT BEARING CUP Spray the cleaner from a distance of approxi-
5. UPPER PINION BEARING SHIMS mately 30 cm (12 in.) while holding the can up-
6. LOWER PINION BEARING SHIMS right. Allow the cleaner to work; then thoroughly
7. INNER AXLE SHAFT SHIMS remove the dissolved dirt from the lower housing
8. OUTER AXLE SHAFT SHIMS using a clean cloth. Spray the surface with the
9. INNER SEAL RING
10. BEARING SHIELD cleaner again and allow to air-dry.

Figure 6. Bearing and Shim Location 2. Check all parts for damage or cracks. Replace
any damaged parts.

7
HFK400 Master Drive Unit 630 SRM 1022

indicator. The procedure below specifies the use of

CAUTION
The axle and gear assemblies are installed and
removed several times during this procedure.
Be careful not to damage the seals.
NOTE: The helical pinion and gear and the bevel
pinion shaft and bevel gear are matched sets and
MUST be replaced as sets. When replacing the gear
sets, always replace the tapered roller bearings. The
bearing cup and bearing cone MUST be from the
same manufacturer. Lubricate the bearings with
clean transmission oil prior to assembly.
NOTE: Assembly of the drive unit requires the use
of a standard micrometer, torque wrench, and dial
a special measuring tool (Hyster P/N 2036120) and
a special clamping tool (Hyster P/N 2036121). The
measuring tool can be fabricated, if desired, as fol-
lows: Make a bushing to fit the bore of the lower pin-
ion shaft bearing. The bushing must have an out-
side diameter of 51.5 mm (2.03 in.) and a length of
67.5 mm (2.66 in.). The special clamping tool can be
used to facilitate easy assembly.
3. Insert the special measuring tool in the pinion
shaft lower bearing bore. Determine the correct
thickness for the lower bearing shim set (dimen-
sion X) as follows (see Figure 7):

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

8
630 SRM 1022 HFK400 Master Drive Unit

a. Measure dimension F (the difference be-

tween 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
correct thickness of the lower bearing shim
set).
X=E B T
E = the value found in Step c
B = the number stamped on the pinion shaft
T = the total thickness of the bearing
4. Assemble the proper combination of shims to
equal the correct thickness for the lower bear-
ing shim set, as determined above [±0.05 mm
(0.002 in.)]. Install the lower bearing shim set
into the lower bearing bore. Press the lower
bearing cup into the bore.
1. BEARING CUP
2. WHEEL SHAFT INNER BEARING BORE SHIM
SET
3. WHEEL SHAFT OUTER BEARING BORE SHIM
SET
Figure 8. Wheel Shaft Shim Sets
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.
NOTE: DO NOT install the wheel shaft seal until
after the adjustment procedure has been completed.

7. Press the taper roller bearing cone up to the stop

CAUTION
DO NOT use damaged or distorted shims in the
following steps.
5. Install the shim set removed during disassembly
from the inner bearing bore of the wheel shaft
into the inner bearing bore. This shim set will be
used for the preliminary adjustment of the wheel
shaft. Drive the inner bearing cup into the inner
bearing bore. See Figure 8.
on the pinion shaft.
8. Lubricate the bearing cup with transmission
oil. Install the pinion shaft into the housing
and preload it against the bearing cup with the
special clamping tool or a piece of wood.
9. Measure distance A between the top of the shoul-
der of the pinion shaft and the bottom of the bore
for the upper bearing. See Figure 9.

9
HFK400 Master Drive Unit
Figure 9. Shim Measurement
10. Add 0.02 mm (0.00079 in.) to the value of dimen-
sion A and install a shim set equal to that sum
into the bearing bore.
Shim set (mm) = A + 0.02 mm
11. Press the upper bearing cup into the bearing
bore. Press the upper bearing cone onto the
pinion shaft up to the stop.
12. Place the helical gear onto the pinion shaft and
install the nut. Hold the helical gear with a strap
wrench and tighten the nut to a torque value of
150 N•m (111 lbf ft). DO NOT stake the nut. The
bearing clearance must be checked and adjusted
before staking the nut.
13. Remove the special clamping tool or piece of wood
holding the pinion shaft in place.
14. Press the pinion shaft downward by hand while
turning the shaft several times to align the taper
rollers within the bearing.
15. Place the dial indicator on the housing as shown
in Figure 10. Adjust the dial to indicate zero.
Mark the point of measurement on the helical
spur gear with a colored pencil. Lift the pinion
shaft upward by carefully prying up beneath the
helical spur gear with two levers. Read any de-
flection on the dial indicator. This value is the
bearing clearance. Repeat the procedure to be
sure to obtain the correct value.
10
630 SRM 1022
Figure 10. Pinion Shaft Bearing Clearance
Check
16. Remove the pinion shaft and bearing. Remove
the upper bearing cup. Additional shims must
be added to the upper bearing bore to preload
the bearing. To determine the correct amount
of additional shims, add 0.07 mm (0.0028 in.) to
the clearance value measured in Step 15. Install
shims equal to that sum into the bearing bore
with the shims installed earlier.
Additional shim set (mm) = value measured on
dial indicator + 0.07 mm
If no clearance was measured, add a total of
0.02 mm (0.00079 in.) to the shims installed
earlier.
17. Install the pinion shaft. Press the upper bearing
cup into the bearing bore. Press the upper bear-
ing cone onto the pinion shaft up to the stop.
18. Cover the splines of the helical gear with a thin
coat of Loctite® 270. Wipe off any excess with a
rag.
19. Place the helical gear onto the pinion shaft and
install the nut. Hold the helical gear with a strap
wrench and tighten the nut to a torque value of
150 N•m (111 lbf ft). Stake the nut to the pinion
shaft.
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.
630 SRM 1022 HFK400 Master Drive Unit

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 bevel
gear until the bearing cone contacts the stop.

23. Insert the bevel gear into the MDU housing.

NOTE: DO NOT install the inner seal ring until the

bearing preload has been adjusted.
24. Insert the wheel shaft into the housing and en-
gage the splines of the shaft into the bevel gear.
Secure the bevel gear on the wheel shaft using
the M16 capscrew and special washer.
25. Prevent the axle from turning. Tighten the M16
capscrew to 245 N•m (181 lbf ft).
26. Use a dial indicator to check the backlash
between the bevel gear and the pinion. The
backlash is the clearance between the teeth of
the bevel gear and the 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.
1. SPIRAL BEVEL GEAR
2. DIAL INDICATOR
3. WOOD WEDGE
Figure 11. Checking Backlash
27. 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.).
Backlash is adjusted by adding or removing
shims beneath the inner wheel bearing cup. The
ideal backlash is 0.07 mm (0.028 in.).
28. Check the tooth contact pattern by coating three
to four tooth flanks of the bevel gear with ink.
Mesh the coated teeth with the pinion gear sev-
eral times and then inspect the wear pattern of
the ink on the coated teeth. Slight deviations
from the ideal tooth contact pattern are admis-
sible. Significant tooth contact pattern misalign-
ment is an indication that a mistake was made
at an earlier step in the procedure and will ne-
cessitate repeating the assembly procedure. See
Table 1.

11
HFK400 Master Drive Unit 630 SRM 1022

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.

29. Check the wheel bearing clearance. Press down levers. Read any deflection on the dial indicator.
on the wheel shaft by hand and rotate it several This value is the bearing clearance. Repeat the
times. Arrange the dial indicator on the housing procedure to be sure to obtain the correct value.
as shown in Figure 12. Adjust the dial to indi-
cate zero. Lift the wheel shaft upward by care-
fully prying up beneath the bevel gear with two

12
630 SRM 1022 HFK400 Master Drive Unit

a shim from beneath the inner bearing cup, you

must add it to the shims beneath outer bearing
cup). The ideal backlash is 0.07 mm (0.003 in.).

34. After the proper backlash and preload have been

obtained, remove the bevel gear and wheel shaft
in order to mount the thread-protective shield
and the radial shaft seal.

35. Thoroughly clean the seat of the thread-protec-

tive shield on the housing with Loctite® Fast
Cleaner 706 or equivalent.

36. Coat the seat of the thread-protective shield with

Figure 12. Wheel Shaft Bearing Clearance
Loctite® 270. Press the thread-protective shield
Check
on the lower housing as far as possible. See Fig-
30. Remove the wheel shaft and outer bearing. Re- ure 13.
move the outer bearing cup. Add or remove
shims as required to obtain a bearing clear-
ance of 0.02 mm (0.00079 in.). Install the outer
bearing cup, bearing, and wheel shaft. Repeat
Step 29. After the bearing clearance is confirmed
to be 0.02 mm (0.00079 in.), remove the wheel
shaft, outer bearing, and outer bearing cup
again. Add 0.10 mm (0.004 in.) additional shims
to the outer bearing bore to preload the bearing.

31. Install the outer bearing cup, outer bearing, and

wheel shaft. Verify that the wheel shaft can be
turned by hand. If not, reduce the preload set
in the previous step in 0.01 mm (0.00039 in.) in-
crements until the wheel shaft can be turned by
hand.

32. After the bearing preload has been properly set,

check the backlash again. Use a dial indicator to
check the backlash between the bevel gear and
the pinion. The backlash is the clearance be-
tween the teeth of the bevel gear and the 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 deflec-
tion. The admissible range for backlash is be-
tween 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 remove
1. RADIAL SHAFT SEAL
2. THREAD-PROTECTIVE SHIELD
Figure 13. Inner Seal Installation
37. Remove the outer bearing cup and shims. Thinly
coat the radial shaft seal with Loctite® 574. In-
stall the inner seal into the lower housing. The
inner seal should be 3.0 mm (0.118 in.) below
the bottom edge of the outer bearing bore, when
properly installed. See Figure 13. Install the
shims and outer bearing cup.
38. Coat the entire surface of the inner splines of the
bevel gear with Loctite® 270. Insert the bevel
gear in the housing. See Figure 13.

13
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
39. Fill the inner seal ring and the cone on the wheel
shaft with Shell Alvania R3 grease. See Fig-
ure 14.
40. Insert the wheel shaft into the housing and en-
gage the splines of the shaft into the bevel gear.
Remove excess with a clean cloth.
41. Secure the bevel gear on the wheel shaft using
the M16 capscrew and special washer. Prevent
the axle from turning. Tighten the M16 capscrew
to 245 N•m (181 lbf ft).
42. Coat the flat housing surface with Loctite® 574
before mounting the housing cover. Apply one
drop of Loctite® 243 to the threads of each of
the housing cover mounting bolts and install the
bolts.
NOTE: If the tapped holes in the bottom of the lower
housing extend through the housing, completely seal
the capscrews with Loctite® adhesive to prevent oil
from leaking from around the threads.
43. Tighten the housing cover capscrews to 9.5 N•m
(7 lbf ft).
44. Inspect the upper part of the MDU. The upper
part of the MDU must be replaced if:
a. The caulked cover plate on the trunnion bear-
ing has separated. Check visually.
b. The trunnion bearing is difficult to turn or
binds. Check manually.
14
630 SRM 1022
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.
Figure 15. Wheel Shaft Assembly
46. Install a cable in each eye bolt. Position three
dial indicators on the trunnion bearing and set
the indicators to zero. Mark the position of one
dial indicator on the trunnion bearing with a
marking pen.
47. Raise the upper housing using a lifting device
and a spring balance to obtain approximately
50 kg (110 lb) of force. Rotate the trunnion
bearing several times and position at the mark
again. The maximum bearing clearance is
0.03 mm (0.0012 in.). If the bearing clearance
is more than the recommended clearance, the
trunnion bearing and upper housing must be
replaced.
NOTE: The large ball bearing is part of the upper
housing. The upper housing and the ball bearing are
replaced as a unit.
48. Install the drive venting filter as far as possible
into the upper part of the MDU. Install grease
fitting. See Figure 16.
630 SRM 1022 HFK400 Master Drive Unit

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).

50. Install the wheel and the lug nuts. Tighten the
nuts in a cross pattern to one-half the torque
value specified in Section 2. Tighten the lug nuts
again using the cross pattern to obtain the proper
torque.

51. Lubricate trunnion bearing using the recom-

1. DRIVE VENTING FILTER
2. GREASE FITTING
Figure 16. Drive Venting Filter and Grease
Fitting Installation
52. Fill the MDU to the level/fill plug using the rec-
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
mended grease listed in Section 2. Add the
grease through both fittings. Slowly rotate the
MDU while filling the fittings with grease. A
dry bearing will take approximately 55 grams
(0.12 lb) of grease to fill the bearing completely.
ommended oil listed in Section 2. Add the oil
slowly. The oil must go through the bearings to
the lower part of the MDU. Fill until the oil just
starts to run out. Install the plug and tighten to
22 N•m (16 lbf ft).

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 lu- Lubricate as needed.

bricant.

Dry, damaged, or incorrect bearings. Lubricate as needed.

Bearing preload or backlash not Adjust backlash.

properly adjusted.

Worn or damaged gears. Replace gears.

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

Capscrews not sealed off or not tight- Tighten to appropriate torque.

ened to specified torque.

15
HFK400 Master Drive Unit 630 SRM 1022

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Oil leaks at the housing

cover. (Cont.)

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 Dirt between sealing ring and hous- Clean sealing ring and housing.
drain plug. ing.

Plugs not tightened to specified Tighten plugs to appropriate torque.

torque.

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

Capscrews not tightened to specified Tighten to appropriate torque.

torque.

Oil leaks in motor compart- Too much oil in MDU. Drain excess oil.
ment.

Breather defective. Clean or replace breather.

Traction motor seal defective. Replace motor seal.

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

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.

16
630 SRM 1022 GK Master Drive Unit

GK Master Drive Unit

GENERAL
This section contains a description, repair, and ad-
justment procedures for the parts of the GK master
drive unit (MDU) used on the narrow aisle lift trucks.
The traction motor, steering, and brake repair infor-
mation are in separate manuals.
DESCRIPTION
CAUTION
Certain specifications and procedures differ
depending upon the type of master drive unit.
Verify the type of MDU by inspecting the hous-
ing.
Some of the hardware used on the MDU and
traction motor is metric. Use the correct tool
to avoid damage.
The GK MDU is vertically installed in the truck and
allows an effective utilization of space. The com-
pact, one-piece housing is made of high-duty nodular
iron; thus having a high rigidity and optimum guid-
ing precision. This allows a fully integrated bearing
of the helical spur gear stage with a very high run-
ning smoothness; i.e., no drive pinion on the motor
shaft of the electric motor. See Figure 17.

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

The MDU consists of two ratio steps. Gear ratio 1 is Gleason bevel gearing of the hypoid type with offset
designed as helical spur gear stage and permanently bevel pinion shaft.
integrated in the housing. Gear ratio 2 is designed as

17
GK Master Drive Unit 630 SRM 1022

MAINTENANCE
Changing the Oil
NOTE: The oil used in the master drive unit should be
drained and replaced after 150 to 250 hours of initial
operation in accordance with the maintenance sched-
ule. After the initial oil change, the master drive unit
requires only the addition of the recommended oil to
maintain the oil at the proper level.
Drain the oil when it is warm by removing the drain
and fill plugs. Use a drain pan under the drain to
keep oil off the floor. Install the drain plug and fill the
unit by adding oil slowly. Allow enough time for the
oil to flow through the bearings to fill the reservoir.
The correct level is at the bottom of the fill plug hole.
Traction Motor and Drive Unit Splines
WARNING
Disconnect the battery and separate the con-
nector before opening the drive unit compart-
ment 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 Peri-
odic Maintenance 8000 SRM 970 or Periodic
Maintenance 8000 SRM 1197.
3. Remove the electrical compartment cover for ac-
cess to the traction motor controller. Remove the
capscrews retaining the cover to the frame. See
Figure 18.

CAUTION
The traction motor 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.

NOTE: The traction motor shaft and MDU input pin-

ion splines should be lubricated every 3000 hours.

To lubricate the traction motor shaft and MDU input

pinion, remove the traction motor from the drive
unit. Wipe the motor shaft splines and the drive unit
input pinion clean. Apply Dow Corning® Molykote
G-N paste (or equivalent)(Hyster P/N 0339068) with
a small brush to moderately coat internal MDU
splines and external drive motor splines before re-
installing motor to the drive unit. Refer to Remove
and Assemble for instructions on removing and
installing the traction motor.

REMOVE

WARNING 1. TRACTION MOTOR 6. WHEEL NUT

2. CAPSCREW 7. WHEEL
The lift truck and components are heavy. All 3. LOCKWASHER 8. DRIVE UNIT
lifting devices (hoists, cables, chains, slings, 4. CAPSCREW 9. ARTICULATING
etc.) must be suitable and of adequate capac- 5. LOCKWASHER AXLE
ity to lift the lift truck or component. The lift
truck can weigh up to approximately 3541 kg Figure 18. Drive Unit Assembly
(7800 lb) empty.

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

a position for straight travel.

18
630 SRM 1022
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 inspect-
ing or repairing any component. Wear safety
glasses. Make certain the battery has been dis-
connected.
4. Discharge the capacitor in the controller by
connecting a 200-ohm, 2-watt resistor across
the controller’s a load across the B+ and B
terminals of the motor controller for 10 seconds.
Remove the resistor after discharging the capac-
itor See Figure 19.
1. POSITIVE CONNECTION (B+)
2. NEGATIVE CONNECTION (B )
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
Figure 19. Discharging the Capacitors
5. Open the drive unit compartment door and fas-
ten the door so that it is fully open. Put a pan
under the MDU drain plug and remove the plug.
After the oil has completely drained, reinstall the
drain plug. Tighten to 22 N•m (16 lbf ft).
WARNING
The motor is heavy. Use appropriate lifting
equipment to avoid personal injury.
6. Remove the capscrews and lockwashers that fas-
ten the traction motor to the adapter ring on the
GK Master Drive Unit
MDU. Carefully lift and sit the motor out of the
way. Use rope to fasten the motor to prevent it
from falling.
WARNING
There are close clearances between the MDU,
drive chassis, and base arm that can cause se-
rious 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 prevent it from falling.
7. Place a sling under the lift truck frame on the
mast side of the MDU. Make sure the lifting de-
vice and sling have the ability to lift approxi-
mately 3541 kg (7800 lb).
8. Remove capscrews and lockwashers that fasten
the adapter ring and MDU to the articulating
axle or truck frame.
WARNING
The MDU is heavy. It can weigh approximately
52 kg (114.6 lb). Use appropriate lifting equip-
ment to avoid personal injury.
9. Hold the MDU and raise the truck frame so that
the MDU is free. Move the MDU from under 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 commer-
cially permissible cleaning agents. Wear safety
gloves and goggles!
DO NOT drain cleaners into the soil. DO NOT al-
low cleaners to contact rubber parts, electrical con-
nections of accessories, or the motor ventilation.
19
GK Master Drive Unit 630 SRM 1022

Mounting Electric Motor

1. Wipe the motor shaft splines and the drive
unit input pinion clean. Apply Dow Corning®
Molykote G-N paste (or equivalent)(Hyster P/N
0339068) with a small brush to moderately coat
internal drive pinion splines and external motor
shaft splines before installing motor to the drive
unit.

NOTE: Applying lubrication paste is critical to the

splines of the drive motor and MDU shaft. Prema-
ture gear shaft failure may result if lubrication paste
is not applied.

2. Assemble the electric motor into the centering

seat of the steering bearing and cautiously join
it with the splined hub connection of the drive
pinion.

3. Turn the hole pattern of the steering bearing so

that it is aligned with the electric motor.

4. Install the six capscrews and lockwashers that

fasten the electric motor and tighten to appropri-
ate torque.

Pivoted Connection - Geared Steering

1. Make sure that the gear rim is clean and pay 1. BOREHOLES 3. STEERING
attention that no foreign substances or cleaning 2. GEAR RIM BEARING
agents get through the threaded boreholes of the 4. CAPSCREWS
connecting structure into the transmission inte-
rior. See Figure 20. Figure 20. Geared Steering

20
630 SRM 1022
2. Align the gear rim and bolt holes with the
threaded boreholes of the connecting structure.
Install the steering bearing on the correct side
and turn it so the bolt holes are aligned with the
hole pattern of the gear rim and the housing.
3. Install capscrews to 34 N•m (25 lbf ft) to fasten
the steering bearing and the gear rim onto the
connecting structure.
NOTE: Use Loctite® adhesive as needed. During dis-
assembly and later reuse of the screws, the adhesive
remaining on the thread must be removed and new
screws must be used.
The fixing bolts should be checked at fixed inter-
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, ca-
bles, chains, slings, etc.) are suitable and of
adequate capacity to lift the lift truck or com-
ponent to avoid personal injury.
GK Master Drive Unit
1. Use a crane and chain or sling with appropri-
ate capacity to lift the frame. Lift the frame for
enough clearance to slide the MDU under the
frame or steer axle. 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 or axle plate.
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 the
frame and align the capscrew holes in the large
ball bearing, adapter ring, and the frame or axle
plate.
4. Install the capscrews and lockwashers that fas-
ten the adapter ring and MDU to the frame or
axle plate. Use cross pattern to tighten the cap-
screws to the appropriate torque. Make sure the
large ball bearing and adapter ring are in the cor-
rect position around the complete circumference.
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 Peri-
odic Maintenance 8000 SRM 970 or Periodic
Maintenance 8000 SRM 1197. Add oil slowly.
The oil passes through the bearings to the lower
part of the MDU.
21
GK Master Drive Unit 630 SRM 1022

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 Insufficient lubricant or incorrect lu- Lubricate as needed.
noise. bricant.

Dry, damaged, or incorrect bearings. Lubricate as needed.

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 Dirt between sealing ring and hous- Clean sealing ring and housing.
drain plug. ing.

Plugs not tightened to specified Tighten to appropriate torque.

torque.

Oil leaks in motor compart- Too much oil in MDU. Drain excess oil.
ment.

Breather defective. Clean or replace breather.

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

Cage segments are damaged. Replace trunnion bearing.

Deformation of the balls or ball Replace trunnion bearing.

races.

Bearing not properly lubricated. Replace trunnion bearing.

22
 TECHNICAL PUBLICATIONS

630 SRM 1022 8/09 (4/09)(11/06)(10/06)(8/04)(9/03) Printed in U.S.A.