NACCO MATERIALS HANDLING GROUP, INC.

Familiarization
 Familiarization

NACCO MATERIALS HANDLING GROUP, INC.

©NMHG 2014
1400 Sullivan Drive
Greenville, NC 27834-2011
252.931.5100
Rev 2

This document does not replace the Service Manual for this product. Refer to
the Service Manual for complete maintenance and safety procedures prior to
performing ANY service or maintenance on these lift trucks.

NMHG Technical Training

 Familiarization

Table of Contents
Introduction ........................................................................................................... 1
Learning Objectives........................................................................................... 1
Skill Objectives .................................................................................................. 1
Series Code / Model Nomenclature ...................................................................... 2
Retail and Americas .............................................................................................. 2
Serial Number Location ........................................................................................ 3
Standard Features – All ........................................................................................ 3
Retail (B265 / B295) Features .............................................................................. 4
Americas Small (E470 / E815) Features ............................................................... 4
Americas Large / Grocery (D264 / D861) Features............................................... 5
Upgrades from Previous Models ........................................................................... 6
Carry Over From Previous Models........................................................................ 6
Operator Compartment ......................................................................................... 7
Forward Stance ................................................................................................. 7
Aft Travel Control Handle .................................................................................. 8
Side Stance ....................................................................................................... 9
Covers ................................................................................................................ 10
Truck Walk Around ............................................................................................. 11
Brake System...................................................................................................... 11
Control System – CAN Devices .......................................................................... 11
Motor Controllers and IFB ............................................................................... 12
CAN I/O Module, Steering Motor Controllers .................................................. 12
Display ............................................................................................................ 13
Remote CAN Module ...................................................................................... 13
External Termination Resistor ......................................................................... 14
Impact Sensor ................................................................................................. 14
Electrical System ................................................................................................ 15
Contactor ......................................................................................................... 15
Battery Connector ........................................................................................... 15
Ignition Switch, E-Stop Switch ......................................................................... 16
Fans and Horn................................................................................................. 16
Floor Plate Switches........................................................................................ 17
Heated Floor Plates......................................................................................... 17
Floor Plate Heater Options .......................................................................... 18
Floor Plate Heated Switches........................................................................ 18
Operator Comfort Package / Heated Floor Plate ......................................... 19
Mast Sensor .................................................................................................... 20
Optional Reduced Travel Speed with Carriage Extended ............................... 20
Retail Models ............................................................................................... 20
Optional Reduced Travel Speed with Carriage Extended ............................... 21
Americas Models ......................................................................................... 21
Optional Carry Level Proximity Sensor ............................................................ 21
Optional Return To Set Tilt .............................................................................. 22

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Optional Option Module ................................................................................... 22

Optional Height Encoder ................................................................................. 23
Optional Camera and Monitor - Camera ......................................................... 23
Optional Camera and Monitor - Monitor .......................................................... 24
Optional Laser ................................................................................................. 25
Optional Load Weight Display ......................................................................... 26
Americas ...................................................................................................... 26
Retail ........................................................................................................... 26
Hydraulic Systems .............................................................................................. 27
Americas ...................................................................................................... 27
Retail ........................................................................................................... 28
Carriage Functions – All .................................................................................. 28
Steering System.................................................................................................. 29
Optional Steer Caster Assembly ..................................................................... 30
Traction System .................................................................................................. 31
Traction Motors ............................................................................................... 31
Pinion Gears.................................................................................................... 31
Master Drive Unit............................................................................................. 32
Module Summary ................................................................................................ 33
Learning Objectives......................................................................................... 33
Skill Objectives ................................................................................................ 33

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 Familiarization

Introduction
This module will familiarize the service technician with Hyster i3 Technology™ /
Yale iSi Technology™ Class II Narrow Aisle models.

Learning Objectives
Upon completion of this module, you will be able to:

 Describe the location of the components used in this truck series.

 Understand how the components interact with each other in this truck
series.

Skill Objectives
Upon completion of this module, you will be able to:

 Identify the components used in the Hyster i3 Technology™ / Yale iSi

Technology™.

 Operate the truck.

1 Technical Training
 Familiarization

Series Code / Model Nomenclature

In 2013, NACCO Materials Handling Group, Inc. began to commonize the control
system for several Class I, II, and III models. The first vehicles released with the
Hyster i3 Technology™ / Yale iSi Technology™ are the Class II Narrow Aisle
models. Each brand (Hyster, Yale) has its own marketing term to designate the
control system.

Hyster – i3 Technology™
Yale – iSi Technology™

The series codes and model nomenclature for these models are listed below.

Hyster
B265……….. N35-40ZRS2, N30ZDRS2………...Retail
E470……….. N35-40ZR2, N30ZDR2…………… Americas Small
D264……….. N45ZR2, NDR35ZDR2…………… Americas Large / Grocery

Yale
B295……….. NR035-040DB, NDR030DB…….. Retail
E815……….. NR035-040EB, NDR030EB…….. Americas Small
D861……….. NR040EB, NDR035EB………….. Americas Large / Grocery

Retail and Americas

On some of the service information, the terms Large Standard Americas and
Retail are used. These terms apply to specific models. These terms and the
models they define are listed above.

Example of terms Large Standard Americas and Retail, from the electrical schematic

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Serial Number Location

The serial number for a truck is located on the data plate and stamped in the
frame plate that the drive unit compartment door fastens to.

Serial number location on data plates

Hyster data plate Yale data plate

Standard Features – All

For these models the following systems and devices are standard:

 AC Hydraulic Motor
 AC Steering Motor
 AC Traction Motor
 Articulating Caster Wheel
 CANbus Communication
 Multi-Function Display
 Sealed Battery Rollers
 Standard Construction (32°F to 120°F)
 Tilt 3° Forward / 4° Back
 UL E

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Retail (B265 / B295) Features

The following items are some of the standard features for B265 / B295 models:

 24V Electrical System with a SB350 Red Connector

 Drive Tire, Rubber, 12” x 5.5” x 8”
 Mast, 3 Stage Full Free Lift (91” Lowered, 203” Maximum Fork Height
(MFH) 52” Free Lift)
 Proportional Lift / Lower

The following items are some of the optional features for Retail (B265 / B295)
models:

 Cooler / Freezer Construction (0°F to 120°F)

 Steered Caster Wheel (36V vehicle only)

Americas Small (E470 / E815) Features

The following items are some of the standard features for E470 / E815 models:

 36V Electrical System with a SB350 Gray Connector

 Auxiliary Pump
 Drive Tire, Poly, 12” x 5.5” x 8”
 Mast, 3 Stage Full Free Lift (91” Lowered, 203” MFH, 52” Free Lift)
 Powered Lowering – Unloaded
 Regenerative Lowering – Loaded

The following items are some of the optional features for Americas Small (E470 /
E815) models:

 Cooler / Freezer Construction (0°F to 120°F)

 High Speed Lift † – applies to unloaded lifting only
 Steered Caster Wheel
 Sub-Zero Construction (-40°F to 120°F)
 Sub-Zero Construction with Heated Floor Plate (-40°F to 120°F)
 UL EE

† - increases unloaded lifting speed to 114 feet per minute from 100 feet per
minute

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Americas Large / Grocery (D264 / D861) Features

The following items are some of the standard features for D264 / D861 models:

 36V Electrical System with a SB350 Gray Connector

 Auxiliary Pump
 Drive Tire, Vulkollan, 13.5” x 5.5” x 10.8”
 Mast, 3 Stage Full Free Lift (91” Lowered, 212” MFH, 56” Free Lift)
 Powered Lowering – Unloaded
 Regenerative Lowering – Loaded

The following items are some of the optional features for Americas Large /
Grocery (D264 / D861) models:

 Cooler / Freezer Construction (0°F to 120°F)

 High Speed Lift and Travel † – applies to unloaded lift speed, travel speed
loaded
 Steered Caster Wheel
 Sub-Zero Construction (-40°F to 120°F)
 Sub-Zero Construction with Heated Floor Plate (-40°F to 120°F)
 UL EE

† - increases unloaded lifting speed to 130 feet per minute from 114 feet per
minute and travel speed to 8.0 mph from 7.4 mph with a load up 2500 pounds

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Upgrades from Previous Models

Several upgrades were made to control system and other devices for these new
Class II Narrow Aisle, i3 Technology™ / iSi Technology™ models.

 Control System
o CAN I/O Module replaces Master Controller, CAN I/O Module
vendor is Zapi

 Display
o Change to Zapi from Danaher
o One “software” display, no longer a “standard” or “premium” display

 Hydraulic System
o Hydraulic Motor Controller – change to Zapi from Danaher

 MDU
o GK20 and GK25 improved by ZF, no oil change required

 Steering System
o Steering Control Unit – Hall Effect sensor with (6) pin connector

 Traction System
o Traction Motor – tapered drive shaft with pinion
o Traction Motor Controller – change to Zapi from Danaher

Carry Over From Previous Models

Some components remain unchanged from previous models, these are:

 Auxiliary Pump Motor (Americas models only)

 Drive Tires
 Hydraulic Tank
 Hydraulic Valve (Retail model only)
 Integrated Fuse Boards
 Load Wheels
 Pump Motor
 Remote CAN Module (Americas models only)
 Standard Caster Wheel Assembly
 Valves on Carriage
 Optional Steer Caster Wheel Assembly

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Operator Compartment
There are two operator compartments, Forward Stance and Side Stance. The
main difference between the two is the control handle. The side stance handle is
a new design.

Forward Stance Side Stance

Forward Stance
The forward stance handle is listed as Fore/Aft Handle on the electrical
schematic. Operators must push or pull the forward stance handle to actuate
travel. The actuator for lift and lower is the rocker switch on the face of the
handle. The rocker switch on the back of the handle actuates carriage extension
and retraction. The four push buttons on the face of the handle are for tilt and
side shift. Side shift is an option unless the truck is equipped with a double reach
carriage. The horn button is also on the face of the handle.

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Aft Travel Control Handle

The Aft Travel Control Handle is optional only for Forward Stance configured
models. A rocker switch on the handle provides direction control.

Direction switch

Aft Travel Control Handle

A specific series of actions are required by the operator to enable the Aft Travel
Control Handle. These are:

 Prior to beginning activation sequence, lower

mast to carry height

 Truck must be at rest (stationary)

 If released, floor plate switches must be

depressed

 Grasp Aft Travel Control Handle with left hand

to activate optical sensor

 Press horn, handle is now enabled to control

travel

Optical sensor

CAUTION:
Operator should verify vehicle steers in desired
manner, automotive type steering or reverse steering.

When the operator’s hand is removed from the optical

sensor, the handle’s ability to control travel is
disabled.

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Side Stance
Travel is actuated by moving the side stance handle left and right. Lift and
lowering is actuated by moving the side stance handle up and down. There is a
four way switch on the side stance handle for carriage functions. Tilt, extend,
and retract are standard. Side shift is optional for single reach carriages; side
shift comes with all double reach carriages. To actuate side shift, the trigger
must be depressed prior to selecting side shift on the four way switch.

Trigger for Side Shift Horn Lift, Lower Forward, Reverse

Tilt Up, Down

Side Shift Four Way Switch Extend, Retract

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Covers
For most repair jobs, it will be necessary to remove the covers to access
components for troubleshooting and or replacement.

Front Frame Panels Operator Backrest / Armrest Pad

Left and Right

Operator Compartment Cover Caster Wheel Cover

Door with Door Pad

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Truck Walk Around

Now we will begin to illustrate the location of components on the truck. The walk
around will include all the components of the brake system, control system,
electrical system, hydraulic systems, steering system, and traction system.
Technical data for components is not presented in this module.

Brake System
The same electromechanical brake is used for all of these models. The brake
fastens to the top of the traction motor. The brake is spring applied, electrically
released when travel is requested by the operator.

Electromechanical Brake

Control System – CAN Devices

The control system consists of CAN devices and the Integrated Fuse Board
(IFB). CAN devices are:

 Auxiliary Pump Motor (Americas only)

 CAN I/O Module
 Control Handle
 Display
 PC Service Tool Connector
 Pump Motor Controller
 Remote CAN Module (Americas only)
 Steering Motor Controller
 Traction Motor Controller
 Optional Impact Monitor
 Optional Steer Caster Motor Controller

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Motor Controllers and IFB

The traction motor controller, pump motor controller, and Integrated Fuse Board
(IFB) fasten to the frame front plate under the operator compartment cover.
Facing the motor controllers, the traction motor controller is the left hand
controller. The IFB is to the right of the motor controllers. The motor controllers
and IFB vary according to truck voltage and options chosen by the customer.

Traction and pump motor controllers Integrated Fuse Board (IFB)

Traction Pump

Optional Steer Caster Motor Controller

Steer Motor Controller CAN I/O Module

CAN I/O Module, Steering Motor Controllers

The CAN I/O Module and Steer Motor Controller fasten to a panel that fastens to
the left side of the frame behind the traction motor. If the truck is equipped with
the optional steer caster, the steer caster motor controller fastens to the top of
the panel.

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Display
The display consists of a LCD screen, five push buttons, and five warning lights.
Buttons 1 – 4 are labeled; the button in the center is designated as number 5.
There is a Forward Stance display and a Side Stance display.

LCD (5) Warning Lights (5) Push Buttons

Forward Stance Display Side Stance Display

Remote CAN Module

Americas models (listed below) require a CAN device designated as the Remote
CAN Module. It fastens to the fork carriage near the front selector valve.

Remote CAN Module Front Selector Valve

Fork carriage

Hyster Americas models – [E470] N35-40ZR2, N30ZDR2 and [D264] N45ZR2, N35ZDR2
Yale Americas models – [E815] NR035-040EB, NDR030EB and [D861] NR045EB, NDR035EB

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External Termination Resistor

Termination resistors are required to reduce noise on the CANbus. All of the
models require two termination resistors. For Americas models, the termination
resistors are inside the display and Remote CAN Module. Retail models (listed
below) require an external 120Ω, ½ watt termination resistor. The resistor
connects to a connector on the chassis harness. It is located under the operator
compartment in the right corner of the frame near the battery connector. The
other termination resistor is in the display.

Battery Connector

Termination Resistor
Hyster Retail models – [B265] N35-40ZRS2, N30ZDRS2
Yale Retail models – [B295] NR035-040DB, NDR030DB

Impact Sensor
An impact sensor is optional for all models. The sensor is located under the
operator compartment cover, beside the hydraulic tank. The same sensor is
used for all models.

Impact Sensor

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Electrical System
The standard battery connector for these models is a SB350 battery connector.
The color of the connector designates the voltage of the truck’s electrical system.
A red connector designates a 24 volt system, a gray connector designates a 36
volt system.

Contactor
These models only require one contactor. The contactor is under the operator
compartment. Buss bars connect the contactor to the motor controllers. The
contactor is voltage specific.

Motor Controllers

Contactor, 24V or 36V

UL E or UL EE

Battery Connector

The color of the connector indicates the voltage

of the vehicle’s electrical system.

 Red – 24V
 Gray – 36V

SB350 Red / Gray Battery Connector

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Ignition Switch, E-Stop Switch

The location of the ignition switch and E-Stop switch depends on the
configuration of the operator compartment, Forward Stance or Side Stance. For
Forward Stance, the switches are positioned above the display. For Side
Stance, the ignition switch is below the control handle and the E-Stop switch is
on top of the control handle cover.

Ignition E-Stop Ignition E-Stop

Forward Stance Side Stance

Fans and Horn

There are two 24 volt cooling fans. One is located behind the door; the other fan
is located behind the left front cover. The fans remove heat from the motor
controller heat sink and from the CAN I/O Module and Steer Motor Controller.

The horn is also located behind the left front cover.

Horn

(2) Fans
Front Cover Removed Door Removed

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Floor Plate Switches

There are two switches that fasten to the bottom of the floor plate. The switch
closest to the operator entry opening is the foot switch. The switch in the right
corner of the floor plate is the operator sensing switch.

At start up, do not depress either switch

until the LCD on the display indicates the
vehicle is ready for operation. When the
vehicle is ready for operation, depress the
operator sensing switch, then the foot
switch.

Foot Switch Operator Sensing Switch

Heated Floor Plates

Trucks with heated floor
plates require two relays
and two thermostats.

The relays fasten to the

frame behind the caster
wheel cover.

One thermostat fastens to

the frame behind the front
right cover.

The other thermostat

fastens to the bottom of the
floor plate near the
Operator Sensing Switch.

The relays and thermostats

are required regardless of
heater configuration.

Thermostat (100°F) Thermostat (50°F)

17 Technical Training
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Floor Plate Heater Options

There are two floor plate heater options. Terms used to identify these options
are floor plate heated switches and operator comfort package - heated floor
plate.

Floor Plate Heated Switches

For trucks used in a cooler or sub-zero application, floor plate heaters are
required to prevent condensation from accumulating in the floor plate switches.
This option is available for all Reach trucks. The heaters are voltage specific, 24
volts or 36 volts. The heaters do not provide heat for the operator.

Heater, 24V or 36V, depends on truck voltage

Thermostat (100°F)

Heater, 24V or 36V, depends on truck voltage

Heater brackets removed from illustration above

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Operator Comfort Package / Heated Floor Plate

An operator comfort package is only available for Americas models. The heater
is located in between the two metal plates that make up the floor plate assembly.
The heater provides heat for operator foot comfort and prevents condensation
from accumulating in floor plate switches.

Heater, 36V Thermostat (100°F)

Operator Comfort / Comfort Package / Heated Floor Plate

Limited to Americas models listed below

Hyster Yale
[E470] N35-40ZR2, N30ZDR2 [E815] NR035-040EB, NDR030EB
[D264] N45ZR2, N35ZDR2 [D861] NR045EB, NDR035EB

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Mast Sensor
The control system uses a proximity sensor to determine when the mast is above
free lift. Facing the mast, the sensor is on the right hand side. The sensor is
visible with the battery removed. The connector for the sensor is near the motor
controller’s cooling fan behind the front left cover.

Sensor Connector

Sensor

Optional Reduced Travel Speed with Carriage Extended

Retail Models
Reduced Travel Speed with Carriage Extended is an available option for these
models. Different sensors are used for Retail and Americas models. On Retail
models a proximity sensor is used. On Americas models a rotary type Hall Effect
sensor is used. Both of these devices are located at the top of the carriage
frame. To access these sensors, it is necessary to extend the carriage.

Retail models arrangement – Reduced Travel Speed with Carriage Extended

Back of carriage frame Sensor for Retail models

Hyster Retail models – [B265] N35-40ZRS2, N30ZDRS2
Yale Retail models – [B295] NR035-040DB, NDR030DB

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Optional Reduced Travel Speed with Carriage Extended

Americas Models

Back of carriage frame Rotary type Hall Effect sensor

Hyster Americas models – [E470] N35-40ZR2, N30ZDR2 and [D264] N45ZR2, N35ZDR2
Yale Americas models – [E815] NR035-040EB, NDR030EB and [D861] NR045EB, NDR035EB

Optional Carry Level Proximity Sensor

Carry Level is an available option for Americas models only. This feature
requires a proximity sensor at the bottom of the carriage frame. The sensor is
visible when the carriage is extended. There are three settings:

 Off – disabled
 Halt – during lowering, mast stops at approximately 12 inches above floor
 Beep – during lowering, alarm sounds when forks are approximately 12
inches above the floor, mast continues lowering at a reduced speed

Proximity Sensor
Hyster Americas models – [E470] N35-40ZR2, N30ZDR2 and [D264] N45ZR2, N35ZDR2
Yale Americas models – [E815] NR035-040EB, NDR030EB and [D861] NR045EB, NDR035EB

21 Technical Training
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Optional Return To Set Tilt

Return to Set Tilt (RTST) is another option that is only available for Americas
models. A Hall Effect position sensor is used to monitor tilt position of the
carriage. The sensor fastens to the fork carriage.

Return to Set Tilt sensor

Optional Option Module

If the truck is equipped with RTST, camera or laser, the option module is
required. The option module fastens to the plate that protects the front selector
valve. The option module is accessible with the carriage extended.

Back of front selector valve plate

Option Module

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Optional Height Encoder

An optional height encoder is available for all models. The encoder is located at
the top of the mast. The encoder requires a timing belt to determine fork height.
This would be for either the Fork Height Display or the Shelf Height Selector.

Height Encoder and Timing Belt

Optional Camera and Monitor - Camera

A color camera and monitor system is available for Americas Large / Grocery
models only. In addition to the camera and monitor, the system requires two
converters. The camera and one converter are on a carriage mounted bracket.
Converter

Camera Bracket attaches to carriage

Camera, Monitor option only available for Americas Large / Grocery models
Hyster [D264] N45ZR2, N35ZDR2, Yale [D861] NR045EB, NDR035EB

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Optional Camera and Monitor - Monitor

The monitor fastens to the overhead guard and the other converter is located
under the operator compartment cover near the battery connector.

Monitor

Converter

The monitor is a 7 inch color LCD

monitor. When the traction motor is
over 200 RPM, the monitor is disabled.

The camera system is installed and

tested at the factory. The camera and
monitor are removed for shipping.
Dealerships are required to reinstall
components that were removed for
shipping.

Freezer and sub-zero freezer

application trucks require a different
camera and monitor group.

The differences between standard

application and freezer sub-zero
application camera and monitor groups
are:

 Monitor
 Monitor harness
 Camera operating manual
 Installation guide

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Optional Laser
An optional fork mounted laser is available for all Americas models. The laser
projects a solid line on the racks. The laser is installed and tested at the factory,
then removed for shipping. Dealerships are required to reinstall components that
were removed for shipping.

Laser and bracket

Laser

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Optional Load Weight Display

Optional Load Weight Display is available for all models.

Americas
For Americas models, the option requires software only. Americas models are
equipped with a pressure transducer that the control system uses for powered
lowering and regen lowering. When Load Weight Display is ordered, a file is
loaded into the control system to use the signal from the pressure transducer to
display the weight of the load.

Retail
For Retail models, the pressure transducer and software file are required. The
pressure transducer is added to the hydraulic control valve below the hydraulic
pump and motor assembly.

Pressure Transducer, same part for Americas and Retail

Americas Retail

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Hydraulic Systems
There are two unique hydraulic systems, one for Americas models and one for
Retail models.

Americas
Americas models have two separate hydraulic circuits, one for lift and lower and
the other for auxiliary carriage functions. Flow for lift and lower is provided by the
main pump and motor located beside the hydraulic tank. The pump is equipped
with an integral valve. Flow for auxiliary carriage functions is provided by an
auxiliary pump motor below the main pump and motor.

Main Pump and Motor Integral Valve Hydraulic Tank

Auxiliary Pump and Motor

For the Americas models, there are two performance options for the main
hydraulic pump motor and a UL EE rated motor for EE applications. The
difference in the motors is power and overall length (OAL). The UL EE motor is
an enclosed motor.

Series Codes Std.Perf. / OAL Hi-Perf. / OAL UL EE / OAL

†
E470 / E815 11 Kw / 12.14” 13.4 Kw / 13.77” 13.4 Kw / 13.32”
Δ
D264 / D861 13.4 Kw / 13.77” 15.4 Kw / 15.74” 13.4 Kw / 13.32”

†High performance motor increases unloaded lift speed to 114 fpm, from 100 fpm
Δ
High performance motor increase unloaded lift speed to 130 fpm, from 114 fpm

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Retail
The pump and motor for Retail models are located beside the hydraulic tank. A
proportional hydraulic control valve fastens to the frame directly below the pump
and motor. Only a 24 volt pump motor is available. Retail models can have a 36
volt or 24 volt traction motor.

Pump and Motor Hydraulic Tank

Proportional Hydraulic Control Valve

Carriage Functions – All

For carriage functions, flow is directed to
selector valves on the carriage. These
selector valves are designated as the rear
selector valve and front selector in the
Service Manual. The valves are
accessible with the carriage extended, and
guard plates removed as shown.

Rear Selector Valve

Front Selector Valve

All carriages are equipped with a tilt

cylinder. Side shift is optional for single
reach carriages, double reach carriages
come with side shift.

Tilt Cylinder

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Steering System
The steering system consists of the steer assembly, steering motor and proximity
sensor, and caster wheel. There are two steer assemblies, fixed and adjustable.
Adjustable steering has a pull knob that enables operators to pull up to move the
center of rotation. Both fixed and adjustable steer assemblies have a Dual Hall
Effect steering control unit. The steering control unit fastens to the base of the
steer assembly.

Steer Assembly

Steering Control Unit Elastomer Spring

Dual Hall Effect

Steer Motor and Proximity Sensor Caster Wheel

(Standard shown)

The steer motor mounts to the same plate as the traction motor. The proximity
sensor is used at start up to set the vehicle for straight travel. The standard
caster wheel rotates as the vehicle is steered. All caster wheels (standard and
steered caster) have an adjustable elastomer spring that requires periodic
inspection.

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Optional Steer Caster Assembly

The optional steer caster assembly also has a proximity sensor that is used at
start up to set the vehicle (caster) for straight travel. The steer motor fastens to
the caster wheel assembly, the controller for the motor is on the panel located
behind the traction motor.

Elastomer Spring

Proximity Sensor Steer Motor

Optional Steer Caster

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Traction System
An AC powered traction motor and a master drive unit (MDU) make up the
traction system. The traction motor does not rotate during steering. The traction
motors feature a temperature sensor, an external mounted speed sensor, and a
tapered drive shaft. The temperature sensor is not serviceable. The traction
motors insulation rating is Class F.

Speed Sensor

Connector for Temperature Sensor

Connector for Speed Sensor

Traction Motors
Different traction motors are available for
these models.

Retail Traction Motors, B265 / B295

Traction motors for Retail models can
either be 36 volts or 24 volts.

Americas Small, E470 / E815

There are two 36 volts traction motor
options: standard and UL EE rated.

Americas Large / Grocery, D264 / D861

There are three 36 volts traction motor
options: standard, high performance and
UL EE rated.

Pinion Gears
The drive shafts of the traction motors are tapered. A pinion gear on the drive
shaft engages a gear in the MDU. As the motor rotates, the pinion gear drives
the gear in the MDU for travel. The pinion gear on the shaft is dictated by the
gear in the drive unit not the motor.

Retail Americas Small Americas Large / Grocery

Pinion
B265 / B295 E470 / E815 D264 / D861
Teeth 24 29 20
Ratio 25.4:1 19.8:1 22.9:1

31 Technical Training
 Familiarization

Master Drive Unit

The MDU fastens to the frame plate with six bolts. There are three MDU’s. The
MDU’s are model specific and have different gear ratios. The MDU’s do not
require an oil change, but the correct oil level must be maintained. Check the oil
level every 500 hours or 3 months, whichever comes first. The correct oil level is
when oil is flush with the bottom of fill level plug.

Fill / Level Plugs

Retail Americas Small Americas Large / Grocery

B265 / B295 E470 / E815 D264 / D861
GK20 GK20 GK25
25.4:1 19.8:1 22.9:1

NMHG 32
 Familiarization

Module Summary
This module familiarizes service technicians with Hyster i3 Technology™ / Yale
iSi Technology™ Class II Narrow Aisle models.

Learning Objectives
You should now be able to:

 Describe the location of the components used in these models.

 Understand how the components interact with each other in these models.

Skill Objectives
You should now be able to:

 Identify the components used in the Hyster i3 Technology™ / Yale iSi

Technology™.

 Operate the truck.

33 Technical Training
NMHG • 1400 Sullivan Drive • Greenville, NC • 27834 (10/14)