Maintenance

0$67(5 '5,9( 81,7

OS030EC [C801];
OS/SS030BE [D826]

PART NO. 524166249 630 YRM 1021

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

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks.

• Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to 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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Master Drive Unit Table of Contents

TABLE OF CONTENTS

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

General ........................................................................................................................................................... 1
Description ...................................................................................................................................................... 1
Drive Unit Maintenance and Repair ................................................................................................................ 1
Remove....................................................................................................................................................... 1
Install .......................................................................................................................................................... 3
Disassemble ............................................................................................................................................... 3
Assemble .................................................................................................................................................... 6
Troubleshooting ............................................................................................................................................... 14
GK Master Drive Unit........................................................................................................................................... 15
General ........................................................................................................................................................... 15
Description ...................................................................................................................................................... 15
Maintenance and Repair ................................................................................................................................. 15
Install............................................................................................................................................................... 17
Assemble ........................................................................................................................................................ 18
Mounting Electric Motor .............................................................................................................................. 18
Pivoted Connection - Geared Steering ....................................................................................................... 18
Check the Backlash .................................................................................................................................... 18
Disassemble.................................................................................................................................................... 19
Troubleshooting ............................................................................................................................................... 19

This section is for the following models:

OS030EC [C801];
OS/SS030BE [D826]

©2002 Yale Materials Handling Corp. i

630 YRM 1021 HFK400 Master Drive Unit

HFK400 Master Drive Unit

GENERAL

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

The HFK400 is used on the NDR030AE, NR035/040/

045AE, NS040AF, NS050AF, NDR030CB, NR045CB,
NDR030GB, NR045GB, OS030EC, and OS/SS030BE
models.

This manual has a description and the repair and ad-

justment procedures for the parts of the master drive
unit (MDU) used on the narrow aisle and grocery reach
series of lift trucks. The traction motor, steering, and
brake repair procedures 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, 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

DRIVE UNIT MAINTENANCE AND REPAIR

Remove
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. 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 connector
before opening the drive unit compartment door
and before inspecting or repairing the electri-
cal 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 Operat-
ing Manual or Periodic Maintenance 8000 YRM
924.

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HFK400 Master Drive Unit 630 YRM 1021

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 discon-
nected. To prevent electrical shock or injury, dis-
charge the capacitor before inspecting or repairing
any component. Wear safety glasses. Make cer-
tain the battery has been disconnected. Discharge
the capacitors in the controller by connecting a load
(such as a contactor coil or horn) across the con-
troller’s B+ and B− terminals (center two terminals).
DO NOT use a screwdriver to discharge the traction
motor controller.
8. Place a sling under the lift truck frame on the mast
side of the MDU. Make sure the lifting device and
sling have the ability to lift approximately 3541 kg
(7800 lb).
9. Remove the six capscrews and lockwashers that
fasten the adapter ring and MDU to the articulating
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.

4. Discharge the traction motor controller by connect-

ing a load across terminals B+ and B−.

5. Open the drive unit compartment door. Fasten the

door so that it is fully open. Put a pan under the
MDU drain plug and remove the drain plug. After
the oil has completely drained, install the drain plug.
Tighten the drain plug to 22 N•m (16 lbf ft).

6. Remove the six capscrews and lockwashers that

fasten the traction motor to the adapter ring on the
MDU. Carefully lift the motor and set the motor out
of the way. Do not damage the pinion gear on the
motor shaft. Use a rope to fasten the motor to pre-
vent the motor from falling. See Figure 2.

7. Loosen the lock nut at the chain anchor for the

steering chain. Remove the capscrew at the chain
anchor. Put a mark on the MDU for 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
Steering System 1600 YRM 691.
1. TRACTION MOTOR 8. LOCKWASHER
2. CAPSCREW 9. NUT
WARNING 3. LOCKWASHER 10. WHEEL NUT
There are close clearances between the MDU, drive 4. CAPSCREW 11. WHEEL
chassis, and base arm that can cause serious in- 5. LOCKWASHER 12. DRIVE UNIT
jury. NEVER put hands, arms, head, or legs be- 6. O-RING 13. ARTICULATING
7. PINION GEAR AXLE
tween these parts unless the parts have blocks to
prevent movement. If the MDU falls, it can cause an Figure 2. Separating Traction Motor
injury. Support the MDU vertically to prevent it from
falling.

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630 YRM 1021
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. The lift truck can
weigh up to approximately 3541 kg (7800 lb) empty.
1. Use a crane and chain or sling with a capacity rat-
ing of 3541 kg (7800 lb) to lift the frame. Lift the
frame for clearance to slide the MDU under the
frame or steer axle. Temporarily install blocks un-
der 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 under
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 remove the blocks.
Carefully lower the frame and align the capscrew
holes in the large ball bearing, adapter ring, and
frame or axle plate.
4. Install the six capscrews and lockwashers that fas-
ten 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 correct posi-
tion 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 removed,
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 lu-
bricant. Carefully install and align the motor on the
adapter ring and MDU. Do NOT damage the pin-
ion 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
HFK400 Master Drive Unit
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 poten-
tiometer, and limit switches using the procedures in
section Steering System 1600 YRM 691.
CAUTION
The steering system MUST be adjusted before op-
erating 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 Periodic Maintenance 8000
YRM 924. 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 compartment
cover. Connect the battery connector.
Disassemble
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 Figure 3.
There are also two capscrews inside the case that
are secured with washers and nuts on the oppo-
site side of the upper housing. Make certain to re-
move the capscrews, lockwashers, and nuts before
attempting to 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. Care-
fully 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.
3
HFK400 Master Drive Unit 630 YRM 1021

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. Re-
move 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 necessary. Remove the spacer bushing
from the pinion shaft.

7. Use a copper mandrel and a plastic hammer to

drive the axle shaft out of the lower housing. Re-
move the bevel pinion out of the lower housing.

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 re-
placed, the same shim sets can be used during assem-
bly. 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
1. TOP CASE 5. CAPSCREW
2. CAPSCREWS (CENTER) open the cage and remove the rollers. Use a puller
INSIDE TOP CASE 6. CAPSCREW IN PIN to remove the cage from the axle shaft.
3. BOTTOM CASE 7. SPACER
4. CAPSCREWS (3 9. Remove the bearing shield from the lower housing
EACH SIDE) using a plastic hammer. See Figure 4.

Figure 3. Separating Cases
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 re-
taining the bevel gear to the axle shaft. Remove the
special capscrew (24 mm) and the special washer.
10. If necessary, remove the motor nut, lockwasher,
bevel pinion, and key from the motor shaft. Remove
the O-ring from the motor.
11. Remove the wheel bolts from the axle shaft, using
a hydraulic press, if necessary. See Figure 5.

WARNING
Toxic vapors may be generated by heating the axle
shaft to remove the Loctite. 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 using

Loctite No. 270. It may be necessary to use a welding Figure 4. Removing Bearing Shield

4
630 YRM 1021 HFK400 Master Drive Unit

Figure 5. Master Drive Unit Parts

5
HFK400 Master Drive Unit 630 YRM 1021

Legend for Figure 5

1. SCREW 8. SOCKET HEAD 17. GEAR 27. BEARING
2. CENTERING RING SCREW 18. BEARING 28. SHIM
3. SOCKET HEAD 9. DOWEL PIN 19. SHIM 29. OIL RING
SCREW 10. UPPER HOUSING 20. PLUG/OIL DRAIN 30. SEALING RING
4. WASHER 11. BREATHER VALVE 21. SEAL RING 31. CAPSCREW
5. NUT 12. PLUG/OIL FILL 22. CAPSCREW 32. DISK
6. SOCKET HEAD 13. SEAL RING 23. COVER 33. RING AND PINION
SCREW 14. LUBE FITTING 24. WHEEL SHAFT 34. BEARING
7. SOCKET HEAD 15. PINION GEAR 25. WHEEL STUD 35. SHIM
SCREW 16. LOCK NUT 26. SEALING RING 36. LOWER HOUSING

12. If necessary, remove the bearing cups. See Fig- remove the dissolved dirt from the lower housing
ure 6. Use a puller or copper mandrel and a plastic using a clean cloth. Spray the surface with the
hammer. Do NOT damage or lose the shims be- cleaner again and allow to air-dry.
tween the cups and the bore in the case. Keep
each set of shims together and separate from the 2. Check all parts for damage or cracks. Replace any
other sets of shims. Put a label on each set so that damaged parts.
the sets can be installed in the correct position dur-
ing 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.

Assemble

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations 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. 1. UPPER PINION BEARING CUP
The top case and the ball bearing are replaced as a 2. LOWER PINION BEARING CUP
unit. 3. INNER AXLE SHAFT BEARING CUP
4. OUTER AXLE SHAFT BEARING CUP
1. Clean all components thoroughly. Remove all 5. SHIMS - UPPER PINION BEARING
traces of Loctite. Use Loctite Fast Cleaner No. 6. SHIMS - LOWER PINION BEARING
7. SHIMS - INNER AXLE SHAFT
706 to remove Loctite from the lower housing in 8. SHIMS - OUTER AXLE SHAFT
the area where the thread-protecting shield had 9. INNER SEAL RING
been located. Spray the cleaner from a distance of 10. BEARING SHIELD
approximately 30 cm (12 in.) while holding the can
upright. Allow the cleaner to work; then thoroughly Figure 6. Bearing and Shim Location

6
630 YRM 1021 HFK400 Master Drive Unit

NOTE: Assembly of the drive unit requires 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 pin-
ion shaft and bevel gear are matched sets and MUST
be replaced as sets. When replacing the gear sets, al-
ways replace the tapered roller bearings. The bearing
cup and bearing cone MUST be from the same manu-
facturer. Lubricate the bearings with clean transmission
oil prior to assembly.
a standard micrometer, torque wrench, and dial indica-
tor. The procedure below specifies the use of a spe-
cial measuring tool (Yale P/N 518096888) and a spe-
cial clamping tool (Yale P/N 518096890). The measur-
ing tool can be fabricated, if desired, as follows: Make a
bushing to fit the bore of the lower pinion shaft bearing.
The bushing must have an outside diameter of 51.5 mm
(2.03 in.) and a length of 67.5 mm (2.66 in.). The spe-
cial clamping tool can be used to facilitate easy assem-
bly.
3. Insert the special measuring tool in the pinion shaft
lower bearing bore. Determine the correct thick-
ness for the lower bearing shim set (dimension 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

7
HFK400 Master Drive Unit 630 YRM 1021

a. Measure dimension F (the difference between 7. Press the taper roller bearing cone up to the stop
the axle bearing bore and the end of the bush- on the pinion shaft.
ing).

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 bearing 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
8. Lubricate the bearing cup with transmission oil. In-
stall 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-

CAUTION der of the pinion shaft and the bottom of the bore
Do not use damaged or distorted shims in the fol- for the upper bearing. See Figure 9.
lowing 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.

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.
Figure 9. Shim Measurement

8
630 YRM 1021
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 in-
stall 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 deflection on the dial indi-
cator. This value is the bearing clearance. Repeat
the procedure to be sure to obtain the correct value.
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
HFK400 Master Drive Unit
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 bearing 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 Loctite with a
rag.
19. Place the helical gear onto the pinion shaft and in-
stall 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.
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 engage
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 cap-
screw 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
9
HFK400 Master Drive Unit
the teeth of the pinion gear. See Figure 11. Po-
sition 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 ad-
justed 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 several times
and then inspect the wear pattern of the ink on the
coated teeth. Slight deviations from the ideal tooth
contact pattern are admissible. Significant tooth
contact pattern misalignment is an indication that
a mistake was made at an earlier step in the proce-
dure and will necessitate repeating the assembly
procedure. See Table 1.
29. Check the wheel bearing clearance. Press down
on the wheel shaft by hand and rotate it several
times. Arrange the dial indicator on the housing
10
630 YRM 1021
as shown in Figure 12. Adjust the dial to indicate
zero. Lift the wheel shaft upward by carefully prying
up beneath the bevel gear with two levers. Read
any deflection on the dial indicator. This value is
the bearing clearance. Repeat the procedure to be
sure to obtain the correct value.
Figure 12. Wheel Shaft Bearing Clearance Check
30. Remove the wheel shaft and outer bearing. Re-
move the outer bearing cup. Add or remove
shims as required to obtain a bearing clearance 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.) incre-
ments 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 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.
630 YRM 1021
Table 1. Tooth Contact Pattern
Correct Contact Pattern
Wrong Tooth Contact Pattern
Tip Contact
Base Contact
Inner Contact
Outer Contact
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 thick-
ness of the outer plus the inner shims must remain
constant (i.e., if you remove 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.).
HFK400 Master Drive Unit
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.
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.
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.
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.
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.
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-protective
shield on the housing with Loctite Fast Cleaner 706
or equivalent.
11
HFK400 Master Drive Unit
36. Coat the seat of the thread-protective shield with
Loctite No. 270. Press the thread-protective shield
on the lower housing as far as possible. See Fig-
ure 13.
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 No. 574. In-
stall the inner seal into the lower housing. The in-
ner seal should be 3.0 mm (0.118 in.) below the
bottom edge of the outer bearing bore, when prop-
erly 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 No. 270. Insert the bevel
gear in the housing. See Figure 13.
39. Fill the inner seal ring and the cone on the wheel
shaft with Shell Alvania R3 grease. See Figure 14.
40. Insert the wheel shaft into the housing and engage
the splines of the shaft into the bevel gear. Remove
excess Loctite 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).
12
630 YRM 1021
42. Coat the flat housing surface with Loctite No. 574
before mounting the housing cover. Apply one drop
of Loctite No. 243 to the threads of each of the
housing cover mounting bolts and install the bolts.
1. M16 CAPSCREW 5. WHEEL SHAFT
2. SPECIAL WASHER 6. GREASE
3. BEVEL GEAR 7. LOCTITE NO. 270
4. HOUSING
Figure 14. Wheel Shaft Assembly
NOTE: If the tapped holes in the bottom of the lower
housing extend through the housing, completely seal
the capscrews with Loctite 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 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.
630 YRM 1021 HFK400 Master Drive Unit

46. Install a cable in each eye bolt. Position three dial 52. Fill the MDU to the level/fill plug using the recom-
indicators on the trunnion bearing and set the indi- mended oil listed in Section 2. Add the oil slowly.
cators to zero. Mark the position of one dial indica- The oil must go through the bearings to the lower
tor on the trunnion bearing with a marking pen. 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).
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 hous-

ing. The upper housing and the ball bearing are re-
placed 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.

49. Use Loctite 574 to install the upper housing on the Figure 15. Wheel Shaft Assembly
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).

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

51. Lubricate trunnion bearing using the recommended

grease listed in Section 2. Add the grease through
1. DRIVE VENTING FILTER
both fittings. Slowly rotate the MDU while filling the 2. GREASE FITTING
fittings with grease. A dry bearing will take approx-
imately 55 grams (0.12 lb) of grease to fill the bear- Figure 16. Drive Venting Filter and Grease Fitting
ing completely. Installation

13
HFK400 Master Drive Unit 630 YRM 1021

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 lubri- Lubricate as needed.

cant.

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

Bearing preload or backlash not prop- Adjust backlash.

erly adjusted.

Worn or damaged gears. Replace gears.

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

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

ened to specified torque.

Oil leaks at the wheel shaft. Shaft seal incorrectly mounted or dam- Replace shaft seal.
aged.

Surface of axle shaft damaged. Replace axle shaft.

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

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.

14
630 YRM 1021
PROBLEM POSSIBLE CAUSE
Trunnion bearing difficult to Centering ring separated, allowing dirt
turn, binds, or exceeds maxi- to penetrate into bearing.
mum clearance.
Cage segments are damaged.
Deformation of the balls or ball races.
Bearing not properly lubricated.
GK Master Drive Unit
GENERAL
This section contains a description, repair, and adjust-
ment procedures for the parts of the GK master drive
unit (MDU) used on the narrow aisle lift trucks. The trac-
tion motor, steering, and brake repair information are in
separate manuals.
DESCRIPTION
CAUTION
Certain specifications and procedures differ de-
pending upon the type of master drive unit. Verify
the type of MDU by inspecting the housing.
CAUTION
Some of the hardware used on the MDU and trac-
tion motor is metric. Use the correct tool to avoid
damage.
The GK MDU is vertically installed in the truck and al-
lows an effective utilization of space. The compact,
one-piece housing is made of high-duty nodular iron;
thus having a high rigidity and optimum guiding preci-
sion. 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 17.
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
GK Master Drive Unit
PROCEDURE OR ACTION
Torque capscrews holding centering
ring to MDU.
Replace cage segments.
Replace balls and ball races.
Lubricate as needed.
Gleason bevel gearing of the hypoid type with offset
bevel pinion shaft.
MAINTENANCE AND REPAIR
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.
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 electri-
cal 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 Opera-
tor Manual or Periodic Maintenance 8000 YRM
924.
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.
15
GK Master Drive Unit 630 YRM 1021

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

WARNING
The capacitor in the traction motor controller can
hold an electrical charge after the battery is discon-
nected. To prevent electrical shock or injury, dis-
charge the capacitor before inspecting or repairing
any component. Wear safety glasses. Make cer-
tain the battery has been disconnected. Discharge
the capacitors in the controller by connecting a load
(such as the contactor coil or horn) across the con-
troller’s B+ and B− terminals (center two terminals).
Do NOT use a screwdriver to discharge the traction
motor controller.
4. Discharge the traction motor controller by connect-
ing a load across terminals B+ and B−.
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 equip-
ment to avoid personal injury.
6. Remove the three capscrews and lockwashers that
fasten the traction motor to the adapter ring on the
MDU. Carefully lift and sit the motor out of the way.
Use rope to fasten the motor to prevent it from
falling.

16
630 YRM 1021 GK Master Drive Unit

WARNING
The MDU is heavy. It can weigh approximately
52 kg (114.6 lb). Use appropriate lifting equipment
to avoid personal injury.

9. 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, 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 ca-

pacity to lift the frame. Lift the frame for enough
1. TRACTION MOTOR 6. WHEEL NUT clearance to slide the MDU under the frame or steer
2. CAPSCREW 7. WHEEL axle. Temporarily install blocks under the frame
3. LOCKWASHER 8. DRIVE UNIT
4. CAPSCREW 9. ARTICULATING to prevent lowering. Lay the MDU under the drive
5. LOCKWASHER AXLE chassis.

Figure 18. Drive Unit Assembly 2. Move the MDU into approximate alignment under
the frame or axle plate.

WARNING
There are close clearances between the MDU, drive
chassis, and base arm that can cause serious in-
jury. NEVER put hands, arms, head, or legs be-
tween 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 device and
sling have the ability to lift approximately 3541 kg
(7800 lb).
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 bear-
ing, adapter ring, and the frame or axle plate.
4. Install the capscrews and lockwashers that fasten
the adapter ring and MDU to the frame or axle
plate. Use cross pattern to tighten the capscrews
to the appropriate torque. Make sure the large ball
bearing and adapter ring are in the correct position
around the complete circumference. Use the cross
pattern to tighten the capscrews.

8. Remove capscrews and lockwashers that fasten

the adapter ring and MDU to the articulating axle.

17
GK Master Drive Unit 630 YRM 1021

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.

CAUTION
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!

Do not drain cleaners into the soil. Do not allow clean-

ers to contact rubber parts, electrical connections of ac-
cessories, or the motor ventilation.

Mounting Electric Motor

1. Apply a thin coat of lubrication grease onto the
splined shaft-hub connection.

2. Assemble the electric motor into the centering seat

of the steering bearing and cautiously join it with the
1. BOREHOLES 3. STEERING
splined hub connection of the drive pinion. 2. GEAR RIM BEARING
4. CAPSCREWS
3. Turn the hole pattern of the steering bearing so that
it is aligned with the electric motor. Figure 19. Geared Steering
4. Install the six capscrews and lockwashers that fas- 3. Install capscrews to 34 N•m (25 lbf ft) to fasten the
ten the electric motor and tighten to appropriate steering bearing and the gear rim onto the connect-
torque. ing structure.

Pivoted Connection - Geared Steering
1. Make sure that the gear rim is clean and pay atten-
tion that no foreign substances or cleaning agents
get through the threaded boreholes of the connect-
ing structure into the transmission interior. See Fig-
ure 19.
NOTE: Use Loctite as needed. During disassembly and
later reuse of the screws, the Loctite remaining on the
thread must be removed and new screws must be used.
The fixing bolts should be checked at fixed intervals
or operating hours, especially in case of high break-
down torque load or suspended axial load.

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.
Check the Backlash
Ensure that a sufficient backlash is available for the in-
stallation of the toothed pivoted connections and the ap-
propriate steering pinion. This should be checked as
follows:

1. Calculate specified value (0.03 to 0.04 x module).

18
630 YRM 1021 GK Master Drive Unit

2. Determine the existing value of the backlash at that DISASSEMBLE

point of the maximum eccentricity or the narrowest
point of the teeth using a feeler gauge. To disassemble, reverse the assembly process ex-
plained in previous section.
3. Compare specified value with determined value.

4. If the actual value differs from the calculated spec-

ified value, adjust the backlash as required.

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.

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

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

Bearing preload or backlash not prop- Adjust backlash.

erly adjusted.

Worn or damaged gears. Replace gears.

Oil leaks at the wheel shaft. Shaft seal incorrectly mounted or dam- Replace shaft seal.
aged.

Surface of axle shaft damaged. Replace axle shaft.

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

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.

19
GK Master Drive Unit 630 YRM 1021

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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

Cage segments are damaged. Replace caged segments.

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

Bearing not properly lubricated. Lubricate as needed.

20
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

630 YRM 1021 7/02 Printed in U.S.A.