MASTER DRIVE UNIT

S/N A169N03000L=>
S/N A185N03000L=>
S/N H118N03000L=>
S/N E174N03000L=>
N30ZDR2, N35-40ZR2 [E470];
N30ZDRS2, N35-40ZRS2 [B265];
N35ZDR2, N45ZR2 [D264];
R30XMF3 [A169];
R30XMA3 [A185];
R30XMS3 [E174];
R30XM3 [H118];
B60ZHD [B262];
B80ZHD [B257];
C60ZHD [A373];
C80ZHD [A282];
T5ZAC, T7ZAC [C477]

PART NO. 4075032 0630 SRM 1609

 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 A169N03000L=> S/N A185N03000L=> S/N H118N03000L=> S/N E174N03000L=>
Table of Contents

TABLE OF CONTENTS

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

General ................................................................................................................................................................ 1
Description .......................................................................................................................................................... 2
Maintenance ........................................................................................................................................................3
Changing the Oil .............................................................................................................................................3
Remove ................................................................................................................................................................ 3
Disassemble .........................................................................................................................................................5
Clean and Inspect ............................................................................................................................................... 7
Assemble ..............................................................................................................................................................7
Install .................................................................................................................................................................11
Troubleshooting .....................................................................................................................................................12

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];
(B60ZHD) [B262];
(B80ZHD) [B257];
(C60ZHD) [A373];
(C80ZHD) [A282];
(T5ZAC, T7ZAC) [C477]

©2014 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
0630 SRM 1609
Master Drive Unit
GENERAL
This section contains a description, repair, and
adjustment procedures for the parts of the GK
master drive unit (MDU) used on the narrow aisle
lift trucks.
Additional information concerning the MDU may
be included in other manuals when the information
is more closely related to other systems.
For lift truck models N35ZDR2, N45ZR2 (D264),
N30ZDR2, N35-40ZR2 (E470) and N30ZDRS2,
N35-40ZRS2 (B265) see:
• A/C Motor Repair S/N A169N03000L=>
S/N A185N03000L=> S/N H118N03000L=>
S/N E174N03000L=> 0620SRM1621
• Electrical System 2200SRM1612
• Periodic Maintenance 8000SRM1617
• Steering System 1600SRM1610
• Brake System 1800SRM1188
For lift truck models R30XNF3 (A169), R30XMA3
(A185), R30XMS3 (E174) and R30XM3 (H118) see:
• AC Motor Repair 0620SRM1461
• A/C Motor Repair S/N A169N03000L=>
S/N A185N03000L=> S/N H118N03000L=>
S/N E174N03000L=> 0620SRM1621
Master Drive Unit
• Electrical System 2200SRM1467
• Electrical System 2200SRM1468
• Periodic Maintenance 8000SRM1472
• Steering System 1600SRM1462
• Brake System 1800SRM1463
For lift truck models B60ZHD (B262) and B80ZHD
(B257) see:
• A/C Motor Repair S/N A169N03000L=>
S/N A185N03000L=> S/N H118N03000L=>
S/N E174N03000L=> 0620SRM1621
• Electrical System 2200SRM1640
• Periodic Maintenance 8000SRM1644
• Steering Mechanism 1600SRM1637
• Brakes 1800SRM1638
For lift truck models C60ZHD (A373) and C80ZHD
(A282) see:
• A/C Motor Repair S/N A169N03000L=>
S/N A185N03000L=> S/N H118N03000L=>
S/N E174N03000L=> 0620SRM1621
• Electrical System 2200SRM1632
• Periodic Maintenance 8000SRM1635
• Steering Mechanism 1600SRM1627
• Brakes 1800SRM1628
1
Master Drive Unit 0630 SRM 1609

DESCRIPTION nodular iron; thus having a high rigidity and

CAUTION
Certain specifications and procedures differ
depending upon the type of master drive unit.
Verify the type of MDU by inspecting the housing.
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
compact, one-piece housing is made of high-duty
optimum guiding precision. This allows a fully
integrated bearing of the helical spur gear stage
with a very high running smoothness; i.e., no drive
pinion on the motor shaft of the electric motor. See
Figure 1.
The MDU consists of two ratio steps. Gear ratio 1 is
designed as helical spur gear stage and
permanently integrated in the housing. Gear ratio
2 is designed as Gleason bevel gearing of the
hypoid type with offset bevel pinion shaft.

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 1. Master Drive Unit

2
0630 SRM 1609 Master Drive Unit

MAINTENANCE • Periodic Maintenance 8000SRM1635

Changing the Oil
NOTE: 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.
REMOVE
WARNING
The lift truck and components are heavy. All
lifting 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.
for lift ruck models C60ZHD (A373) and
C80ZHD (A282)
• Periodic Maintenance 8000SRM1644
for lift truck models B60ZHD (B262) and
B80ZHD (B257)
3. Remove the electrical compartment cover for
access to the traction motor controller. Remove
the capscrews holding 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.
Make certain the battery has been disconnected.
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
capacitor. See Figure 2.

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

• Periodic Maintenance 8000SRM1617

for lift truck models N35ZDR2, N45ZR2
(D264), N30ZDR2, N35-40ZR2 (E470) and
N30ZDRS2, N35-40ZRS2 (B265)
• Periodic Maintenance 8000SRM1472 1. POSITIVE CONNECTION (B+)
for lift truck models R30XNF3 (A169), 2. NEGATIVE CONNECTION (B-)
3. INSULATED JUMPER WIRES
R30XMA3 (A185), R30XMS3 (E174) and 4. 200-OHM, 2-WATT RESISTOR
R30XM3 (H118)
Figure 2. Discharging the Capacitors

3
Master Drive Unit 0630 SRM 1609

5. Open the drive unit compartment door and
fasten 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.
NOTE: After traction motor is removed place a cap
over the bearing input pinion opening to prevent
dirt and contamination from entering the MDU.
See MAST 4000SRM0763 for lift truck models
R30XNF3 (A169), R30XMA3 (A185), R30XMS3
(E174) and R30XM3 (H118).
Use approved lifting slings rated to lift the truck.
8. Remove capscrews and lockwashers that hold
the adapter ring and MDU to the truck frame.
See Figure 3.
WARNING
The MDU is heavy. It can weigh approximately
52 kg (114.6 lb). Use appropriate lifting equipment
to avoid personal injury.

6. Remove the traction motor from the MDU. 9. Hold the MDU and raise the truck frame so
that the MDU is free. Move the MDU from
See A/C Motor Repair S/N A169N03000L=> under the lift truck. Lower the lift truck frame
S/N A185N03000L=> S/N H118N03000L=> on blocks.
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
serious 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. Raise the truck up high enough to allow

removal of the MDU with approved lifting
devices able to support up to
4536 kg (10,000 lb) and secure the truck with
supports. If the truck has a mast over
3.66 m (144 in.) collapsed height, it is
recommended the mast be removed before
1. TRACTION MOTOR
raising the truck. 2. CAPSCREW
3. LOCKWASHER
See Mast 4000SRM1194 for lift truck models 4. WHEEL NUT
N35ZDR2, N45ZR2 (D264), N30ZDR2, 5. WHEEL
N35-40ZR2 (E470) and N30ZDRS2, N35-40ZRS2 6. MASTER DRIVE UNIT (MDU)
(B265). 7. MDU MOUNTING PLATE

Figure 3. Drive Unit Assembly

4
0630 SRM 1609 Master Drive Unit

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
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 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
contamination 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
attempt 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

2. OIL DRAIN PLUG
3. MDU ASSEMBLY

5
Master Drive Unit 0630 SRM 1609

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
2. SEALING CAP
3. BREATHER CAP

6
0630 SRM 1609 Master Drive Unit

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
capscrews, install side cover onto MDU assembly.
Torque to 9.5 N•m (7 lbf ft) using installation
pattern in adjacent diagram.

7
Master Drive Unit 0630 SRM 1609

STEP 2.
Install breather valve removed during
Disassemble, into sealing cap.

1. BREATHER VALVE
2. SEALING RING

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

8
0630 SRM 1609 Master Drive Unit

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

9
Master Drive Unit 0630 SRM 1609

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

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

10
0630 SRM 1609
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
under 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
the frame and align the capscrew holes in the
large ball bearing steering gear and the frame.
4. Install the capscrews and lockwashers that
fasten the steering gear and MDU to the frame.
Use cross pattern to tighten the capscrews to
the appropriate torque. Make sure the steering
bearing is in the correct position around the
complete circumference. See Figure 3.
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)
Master Drive Unit
• Periodic Maintenance 8000SRM1472
for lift truck models R30XNF3 (A169),
R30XMA3 (A185), R30XMS3 (E174) and
R30XM3 (H118)
• Periodic Maintenance 8000SRM1635
for lift ruck models C60ZHD (A373) and
C80ZHD (A282)
• Periodic Maintenance 8000SRM1644
for lift truck models B60ZHD (B262) and
B80ZHD (B257)
.
Add oil slowly. The oil passes through the
bearings to the lower part of the MDU.
WARNING
The motor is heavy. Use appropriate lifting
equipment to avoid personal injury.
6. Install the traction motor onto 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).
11
Troubleshooting 0630 SRM 1609

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. Internal drive train, gear, or Replace master drive unit..
bearing noise.

Oil leaks at the wheel shaft. Radial sealing ring damaged or Replace master drive unit.
worn.

Damaged race on input- and/or Replace master drive unit.

wheel 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 to appropriate torque.

torque.

Sealing ring worn Install new sealing ring

Oil leaks in Breather. Excessive oil level. Check oil level.

Breather defective. Clean or replace breather.

Oil Leaks at Housing Cover. Screws not tightened with the Tighten screws with the specified
specified tightening torque tightening torque

O-Ring sealing defective Replace O-Ring

Oil Leaks at Side Cover Screws not tightened according to Tighten screws according to cor-
sequence of tightening and the rect sequence of tightening and
tightening torque. with the tightening torque speci-
fied.

No uniform adhesive application Apply LOCTITE 5910™ evenly

of LOCTITE 5910™ and continuously

12
0630 SRM 1609 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Steering bearing difficult to turn, Cover disc has loosened and dirt Replace pivoted steering bearing.
binds, or exceeds maximum clear- got into bearing.
ance.

Cage segments are damaged. Replace Trunnion bearing.

Deformation of the balls or ball Replace Trunnion bearing.

races.

Bearing not properly lubricated. Replace Trunnion bearing.

13
 NOTES

14
 TECHNICAL PUBLICATIONS

0630 SRM 1609 2/14 (10/13)(7/13)