Maintenance

MASTER DRIVE UNIT

S/N D801N03000L=>
S/N A474N03000L=>
S/N A497N030000L=>
S/N E826N03000L=>
NDR030EB, NR035-040EB [E815];
NDR030DB, NR035-040DB [B295];
NDR035EB, NR045EB [D861];
SS030BF [A474];
FS030BF [A497];
OS030EF [D801];
OS030BF [E826];
MPC060-VG [A372];
MPC080-VG [A283];
MPE060-VG [B292];
MPE080-VG [B287];
MTR005-F, MTR007-F [C903];
MPR080VG, MPR100VG [A284]

PART NO. 550073167 0630 YRM 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 Yale® 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 instructions con-
tained 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 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 re-
move 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 man-
ual:

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.
 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:

(NDR030EB, NR035-040EB) [E815];

(NDR030DB, NR035-040DB) [B295];
(NDR035EB, NR045EB) [D861];
(SS030BF) [A474];
(FS030BF) [A497];
(OS030EF) [D801];
(OS030BF) [E826];
(MPC060-VG) [A372];
(MPC080-VG) [A283];
(MPE060-VG) [B292];
(MPE080-VG) [B287];
(MTR005-F, MTR007-F) [C903];
(MPR080VG, MPR100VG) [A284]

©2014 Yale Materials Handling Corp. i

0630 YRM 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 NDR035EB, NR045EB (D861),
NDR030EB, NR035-040EB (E815) and NDR030DB,
NR035-040DB (B295) see:
• A/C Motor Repair S/N A474N03000L=> S/N
A497N030000L=> S/N D801N02161L=> S/N
E826N01917L=> 0620YRM1621
• Electrical System 2200YRM1612
• Periodic Maintenance 8000YRM1617
• Steering System 1600YRM1610
• Brake System 1800YRM1188
For lift truck models SS030BF (A474), FS030BF
(A497), OS030EF (D801) and OS030BF (E826) see:
• AC Motor Repair 0620YRM1461
Master Drive Unit
• A/C Motor Repair S/N A474N03000L=> S/N
A497N030000L=> S/N D801N02161L=> S/N
E826N01917L=> 0620YRM1621
• Electrical System 2200YRM1467
• Electrical System 2200YRM1468
• Periodic Maintenance 8000YRM1472
• Steering System 1600YRM1462
• Brake System 1800YRM1463
For lift truck models MPR080VG, MPR100VG (A284)
see:
• AC Motor Repair 0620YRM1695
• Electrical System 2200YRM1701
• Periodic Maintenance 8000YRM1705
• Steering Mechanism 1600YRM1696
• Brake System 1800YRM1697
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Master Drive Unit 0630 YRM 1609

DESCRIPTION The compact, one-piece housing is made of high-duty

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.
nodular iron; thus having a high rigidity and 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

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0630 YRM 1609 Master Drive Unit

MAINTENANCE • Periodic Maintenance 8000YRM1644

for lift truck models MPE060-VG (B292) and
Changing the Oil MPE080-VG (B287)

NOTE: After the initial oil change, the master drive • Periodic Maintenance 8000YRM1705
unit requires only the addition of the recommended oil for lift truck models MPR080VG,
to maintain the oil at the proper level. MPR100VG (A284)

3. Remove the electrical compartment cover for

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.
1. Move the steering control so the drive wheel is in
a position for straight travel.
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.

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 8000YRM1617 for

lift truck models NDR035EB, NR045EB
(D861), NDR030EB, NR035-040EB (E815)
and NDR030DB, NR035-040DB (B295)
• Periodic Maintenance 8000YRM1472
for lift truck models SS030BF (A474), 1. POSITIVE CONNECTION (B+)
FS030BF (A497), OS030EF (D801) and 2. NEGATIVE CONNECTION (B-)
OS030BF (E826) 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
• Periodic Maintenance 8000YRM1635
for lift ruck models MPC060-VG (A372) and Figure 2. Discharging the Capacitors
MPC080-VG (A283)

3
Master Drive Unit 0630 YRM 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).
See MAST 4000YRM0763 for lift truck models
SS030BF (A474), FS030BF (A497), OS030EF
(D801) and OS030BF (E826).
Use approved lifting slings rated to lift the truck.

8. Remove capscrews and lockwashers that hold

WARNING the adapter ring and MDU to the truck frame. See
The motor is heavy. Use appropriate lifting Figure 3.
equipment to avoid personal injury.

NOTE: After traction motor is removed place a cap WARNING

over the bearing input pinion opening to prevent dirt The MDU is heavy. It can weigh approximately
and contamination from entering the MDU. 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
See A/C Motor Repair S/N A474N03000L=> S/N the MDU is free. Move the MDU from under the
A497N030000L=> S/N D801N02161L=> S/N lift truck. Lower the lift truck frame on blocks.
E826N01917L=> 0620YRM1621 for lift truck
models NDR035EB, NR045EB (D861),
NDR030EB, NR035-040EB (E815), NDR030DB,
NR035-040DB (B295), MPC060-VG (A372),
MPC080-VG (A283), MPE060-VG (B292) and
MPE080-VG (B287).

See AC Motor Repair 0620YRM1461 for lift truck

models SS030BF (A474), FS030BF (A497),
OS030EF (D801) and OS030BF (E826).

See AC Motor Repair 0620YRM1695 for lift truck

models MPR080VG, MPR100VG (A284).

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 1. TRACTION MOTOR
3.66 m (144 in.) collapsed height, it is 2. CAPSCREW
recommended the mast be removed before 3. LOCKWASHER
4. WHEEL NUT
raising the truck. 5. WHEEL
6. MASTER DRIVE UNIT (MDU)
See Mast 4000YRM1194 for lift truck models 7. MDU MOUNTING PLATE
NDR035EB, NR045EB (D861), NDR030EB,
NR035-040EB (E815) and NDR030DB, Figure 3. Drive Unit Assembly
NR035-040DB (B295).

4
0630 YRM 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 YRM 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 YRM 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 YRM 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 YRM 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 YRM 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 YRM 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 8000YRM1617 for
lift truck models NDR035EB, NR045EB
(D861), NDR030EB, NR035-040EB (E815)
and NDR030DB, NR035-040DB (B295)
Master Drive Unit
• Periodic Maintenance 8000YRM1472
for lift truck models SS030BF (A474),
FS030BF (A497), OS030EF (D801) and
OS030BF (E826)
• Periodic Maintenance 8000YRM1635
for lift ruck models MPC060-VG (A372)
and MPC080-VG (A283)
• Periodic Maintenance 8000YRM1644
for lift truck models MPE060-VG (B292)
and MPE080-VG (B287)
• Periodic Maintenance 8000YRM1705
for lift truck models MPR080VG,
MPR100VG (A284)
.
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 A474N03000L=> S/N
A497N030000L=> S/N D801N02161L=> S/N
E826N01917L=> 0620YRM1621 for lift truck
models NDR035EB, NR045EB (D861),
NDR030EB, NR035-040EB (E815), NDR030DB,
NR035-040DB (B295), MPC060-VG (A372),
MPC080-VG (A283), MPE060-VG (B292) and
MPE080-VG (B287).
See AC Motor Repair 0620YRM1461 for lift truck
models SS030BF (A474), FS030BF (A497),
OS030EF (D801) and OS030BF (E826).
See AC Motor Repair 0620YRM1695 for lift truck
models MPR080VG, MPR100VG (A284).
11
Troubleshooting 0630 YRM 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 bearing Replace master drive unit.
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 of Apply LOCTITE 5910™ evenly

LOCTITE 5910™. and continuously.

12
0630 YRM 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