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];OS
030EF [D801];OS030BF [E826];MPC060-
VG [A372];MPC080-VG [A283];MPE060-
VG [B292];MPE080-VG [B287];MTR005-F, MTR007-
F [C903];MPR080VG,
MPR100VG [A284];MEP060VH [C292];MPE080VH [C28
7]
PART NO. 550073167 0630 YRM 1609
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use 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 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 ............................................................................................................................................................ 1
Maintenance ......................................................................................................................................................... 2
Changing the Oil ............................................................................................................................................... 2
Remove .................................................................................................................................................................2
Disassemble ......................................................................................................................................................... 5
Clean and Inspect ................................................................................................................................................. 7
Assemble .............................................................................................................................................................. 8
Install ...................................................................................................................................................................10
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];
(MEP060VH) [C292];
(MPE080VH) [C287]
©2018 Yale Materials Handling Corp. i
0630 YRM 1609 Master Drive Unit
Master Drive Unit
GENERAL For lift truck models MPE060VG (B292) and MPE080-
VG (B287) see:
This section contains a description, repair, and
adjustment procedures for the parts of the GK master • A/C Motor Repair S/N A474N03000L=> S/N
drive unit (MDU) used on the narrow aisle lift trucks. A497N030000L=> S/N D801N02161L=> S/N
E826N01917L=> 0620YRM1621
Additional information concerning the MDU may be Electrical System 2200YRM1640
•
included in other manuals when the information is
more closely related to other systems. • Periodic Maintenance 8000YRM1644
• Steering Mechanism 1600YRM1637
For lift truck models NDR035EB, NR045EB (D861),
NDR030EB, NR035-040EB (E815) and NDR030DB, • Brakes 1800YRM1638
NR035-040DB (B295) see: For lift truck models MPE060VH (C292) and
• A/C Motor Repair S/N A474N03000L=> S/N MPE080VH (C287) see:
A497N030000L=> S/N D801N02161L=> S/N A/C Motor Repair S/N A474N03000L=> S/N
•
E826N01917L=> 0620YRM1621 A497N030000L=> S/N D801N02161L=> S/N
• Electrical System 2200YRM1612 E826N01917L=> 0620YRM1621
• Periodic Maintenance 8000YRM1617 • Electrical System 2200YRM2102
• Steering System 1600YRM1610 • Periodic Maintenance 8000YRM2105
• Brake System 1800YRM1188 • Steering Mechanism 1600YRM2101
For lift truck models SS030BF (A474), FS030BF • Brakes 1800YRM1638
(A497), OS030EF (D801) and OS030BF (E826) see:
• AC Motor Repair 0620YRM1461
DESCRIPTION
• A/C Motor Repair S/N A474N03000L=> S/N
A497N030000L=> S/N D801N02161L=> S/N CAUTION
E826N01917L=> 0620YRM1621 Certain specifications and procedures differ
• Electrical System [D801 (OS030EF)] depending upon the type of master drive unit.
2200YRM1467 Verify the type of MDU by inspecting the housing.
• Electrical System 2200YRM1468
Some of the hardware used on the MDU and
• Periodic Maintenance 8000YRM1472 traction motor is metric. Use the correct tool to
• Steering System 1600YRM1462 avoid damage.
• Brake System 1800YRM1463 The GK MDU is vertically installed in the truck and
For lift truck models MPR080VG, MPR100VG (A284) allows an effective utilization of space. The compact,
see: one-piece housing is made of high-duty nodular iron;
thus having a high rigidity and optimum guiding
• AC Motor Repair 0620YRM1695
precision. This allows a fully integrated bearing of the
• Electrical System 2200YRM1701 helical spur gear stage with a very high running
• Periodic Maintenance 8000YRM1705 smoothness; i.e., no drive pinion on the motor shaft of
• Steering Mechanism 1600YRM1696 the electric motor. See Figure 1.
• Brake System 1800YRM1697
1
Master Drive Unit 0630 YRM 1609
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
The MDU consists of two ratio steps. Gear ratio 1 is REMOVE
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 WARNING
bevel pinion shaft. The lift truck and components are heavy. All lifting
devices (hoists, cables, chains, slings, etc.) must
MAINTENANCE be suitable and of adequate capacity to lift the lift
truck or component. The lift truck can weigh up to
Changing the Oil approximately 3541 kg (7800 lb) empty.
NOTE: After the initial oil change, the master drive
unit requires only the addition of the recommended oil 1. Move the steering control so the drive wheel is in
to maintain the oil at the proper level. a position for straight travel.
Drain the oil when it is warm by removing the drain
and fill plugs. Use a drain pan under the drain to keep WARNING
oil off the floor. Install the drain plug and fill the unit by Disconnect the battery and separate the connector
adding oil slowly. Allow enough time for the oil to flow before opening the drive unit compartment door
through the bearings to fill the reservoir. The correct and before inspecting or repairing the electrical
level is at the bottom of the fill plug hole. system. If a tool causes a short circuit, the high-
current flow from the battery can cause injury or
parts damage.
2
0630 YRM 1609 Master Drive Unit
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), 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 8000YRM2105 for lift
truck models MPE060VH (C292) and
MPE080VH (C287)
• Periodic Maintenance 8000YRM1705 for lift 1. POSITIVE CONNECTION (B+)
truck models MPR080VG, MPR100VG (A284) 2. NEGATIVE CONNECTION (B-)
3. INSULATED JUMPER WIRES
3. Remove the electrical compartment cover for 4. 200-OHM, 2-WATT RESISTOR
access to the traction motor controller. Remove
the capscrews holding the cover to the frame. Figure 2. Discharging the Capacitors
5. Open the drive unit compartment door and fasten
WARNING the door so that it is fully open. Put a pan under
the MDU drain plug and remove the plug. After
The capacitor in the traction motor controller can
the oil has completely drained, reinstall the drain
hold an electrical charge after the battery is
plug. Tighten to 22 N•m (16 lbf ft).
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.
WARNING
The motor is heavy. Use appropriate lifting
4. Discharge the capacitor in the controller by equipment to avoid personal injury.
connecting a 200-ohm, 2-watt resistor across the
controller's a load across the B+ and B- terminals NOTE: After traction motor is removed place a cap
of the motor controller for 10 seconds. Remove over the bearing input pinion opening to prevent dirt
the resistor after discharging the capacitor. See and contamination from entering the MDU.
Figure 2. 6. Remove the traction motor from 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),
MPE080-VG (B287), MPE060VH (C292) and
MPE080VH (C287) .
3
Master Drive Unit 0630 YRM 1609
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
3.66 m (144 in.) collapsed height, it is
recommended the mast be removed before
raising the truck.
See Mast 4000YRM1194 for lift truck models
NDR035EB, NR045EB (D861), NDR030EB,
1. TRACTION MOTOR
NR035-040EB (E815) and NDR030DB, 2. CAPSCREW
NR035-040DB (B295) . 3. LOCKWASHER
4. WHEEL NUT
See MAST 4000YRM0763 for lift truck models 5. WHEEL
SS030BF (A474), FS030BF (A497), OS030EF 6. MASTER DRIVE UNIT (MDU)
(D801) and OS030BF (E826) . 7. MDU MOUNTING PLATE
Use approved lifting slings rated to lift the truck. Figure 3. Drive Unit Assembly
8. Remove capscrews and lockwashers that hold
the adapter ring and MDU to the truck frame. See
Figure 3.
WARNING
The MDU is heavy. It can weigh approximately
52 kg (114.6 lb). Use appropriate lifting equipment
to avoid personal injury.
9. Hold the MDU and raise the truck frame so that
the MDU is free. Move the MDU from under the
lift truck. Lower the lift truck frame on blocks.
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
6
0630 YRM 1609 Master Drive Unit
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
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.
7
Master Drive Unit 0630 YRM 1609
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.
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).
INSTALL 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.
WARNING Temporarily install blocks under the frame to
The lift truck and components are heavy. Be sure prevent lowering. Lay the MDU under the drive
that all lifting devices (hoists, cables, chains, chassis.
slings, etc.) are suitable and of adequate capacity
to lift the lift truck or component to avoid personal 2. Move the MDU into approximate alignment under
injury. the frame.
10
0630 YRM 1609 Master Drive Unit
3. Align both the MDU with the screw holes and the • Periodic Maintenance 8000YRM1705 for lift
steer gear with the axle pilot hole. Carefully raise truck models MPR080VG, MPR100VG (A284)
the frame and remove the blocks. Lower the Add oil slowly. The oil passes through the
frame and align the capscrew holes in the large bearings to the lower part of the MDU.
ball bearing steering gear and the frame.
4. Install the capscrews and lockwashers that fasten WARNING
the steering gear and MDU to the frame. Use
The motor is heavy. Use appropriate lifting
cross pattern to tighten the capscrews to the
equipment to avoid personal injury.
appropriate torque. Make sure the steering
bearing is in the correct position around the 6. Install the traction motor onto the MDU.
complete circumference. See Figure 3.
See A/C Motor Repair S/N A474N03000L=> S/N
5. Fill the MDU to the level/fill plug using the proper A497N030000L=> S/N D801N02161L=> S/N
oil. The proper lubricants are listed in the E826N01917L=> 0620YRM1621 for lift truck
Operating Manual or see: models NDR035EB, NR045EB (D861),
NDR030EB, NR035-040EB (E815), NDR030DB,
• Periodic Maintenance 8000YRM1617 for lift
truck models NDR035EB, NR045EB (D861), NR035-040DB (B295), MPC060-VG (A372),
NDR030EB, NR035-040EB (E815) and MPC080-VG (A283), MPE060-VG (B292) and
NDR030DB, NR035-040DB (B295) MPE080-VG (B287), MPE060VH (C292) and
MPE080VH (C287) .
• Periodic Maintenance 8000YRM1472 for lift
truck models SS030BF (A474), FS030BF See AC Motor Repair 0620YRM1461 for lift truck
(A497), OS030EF (D801) and OS030BF (E826) models SS030BF (A474), FS030BF (A497),
• Periodic Maintenance 8000YRM1635 for lift OS030EF (D801) and OS030BF (E826) .
ruck models MPC060-VG (A372) and MPC080-
See AC Motor Repair 0620YRM1695 for lift truck
VG (A283)
models MPR080VG, MPR100VG (A284) .
• Periodic Maintenance 8000YRM1644 for lift
truck models MPE060-VG (B292) and MPE080-
VG (B287)
• Periodic Maintenance 8000YRM2105 for lift
truck models MPE060VH (C292) and
MPE080VH (C287)
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.
Replace master drive unit.
Damaged race on input- and/or
wheel shaft.
Oil leaks at the filler plug or drain Dirt between sealing ring and Clean sealing ring and housing.
plug. housing.
Tighten to appropriate torque.
Plugs not tightened to specified
Install new sealing ring.
torque.
Sealing ring worn.
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 correct
sequence of tightening and the sequence of tightening and with the
tightening torque. tightening torque specified.
No uniform adhesive application of Apply LOCTITE 5910™ evenly and
LOCTITE 5910™. continuously.
Steering bearing difficult to turn, Cover disc has loosened and dirt Replace pivoted steering bearing.
binds, or exceeds maximum got into bearing.
Replace Trunnion bearing.
clearance.
Cage segments are damaged.
Replace Trunnion bearing.
Deformation of the balls or ball
Replace Trunnion bearing.
races.
Bearing not properly lubricated.
12
0630 YRM 1609 12/18 (10/18)(6/14)(2/14)(10/13)(7/13)
