YALE (A295) NDR30DA LIFT TRUCK Service Repair Manual by 1637912

NR35-40DA, NDR30DA (A295) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ AC MOTOR REPAIR...................................................................................................... MASTER DRIVE UNIT.................................................................................................... STEERING SYSTEM...................................................................................................... BRAKE SYSTEM............................................................................................................ HYDRAULIC SYSTEM.................................................................................................... TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS PROGRAM................................................................................................................. ELECTRICAL SYSTEM.................................................................................................. SUPERVISOR INTERFACE - STANDARD.................................................................... TECHNICIAN INTERFACE - STANDARD...................................................................... SUPERVISOR INTERFACE - PREMIUM....................................................................... TECHNICIAN INTERFACE - PREMIUM......................................................................... AC MOTOR CONTROLLERS/DISPLAY PANEL........................................................... INDUSTRIAL BATTERY................................................................................................. LIFT CYLINDERS........................................................................................................... MAST DESCRIPTION..................................................................................................... MAST REPAIRS............................................................................................................. REACH CARRIAGES..................................................................................................... METRIC AND INCH (SAE) FASTENERS....................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS.....................................................................................................................

PART NUMBER

YRM NUMBER

REV DATE

524233333 524233334 524166250 524233332 524233335 524287793

0100 YRM 1185 0620 YRM 1186 0630 YRM 1022 1600 YRM 1187 1800 YRM 1188 1900 YRM 1307

03/11 08/09 08/09 09/09 07/13 09/09

524183085 524233338 524233339 524233340 524260263 524260264 524287794 524158040 524164473 524233341 524233342 524233343 524150797 524233344 524233345 524233346

2200 YRM 1058 2200 YRM 1191 2200 YRM 1192 2200 YRM 1193 2200 YRM 1240 2200 YRM 1241 2200 YRM 1308 2240 YRM 0001 4000 YRM 0481 4000 YRM 1194 4000 YRM 1195 4500 YRM 1196 8000 YRM 0231 8000 YRM 1197 8000 YRM 1198 8000 YRM 1199

04/11 11/08 11/12 11/12 11/08 11/08 10/10 09/14 07/13 07/13 07/13 07/13 10/13 08/09 05/08 12/13

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 524287792 (09/14)

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 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 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 background. The CAUTION symbol and word are on yellow background.

Frame

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Description .......................................................................................................................................................... Repairs - General ................................................................................................................................................ Covers, Panels, and Plates ................................................................................................................................. Front Frame Panel (Left and Right) ................................................................................................................. Operator Compartment Cover......................................................................................................................... Drive Unit Compartment Door......................................................................................................................... Door Pad ......................................................................................................................................................... Operator Back Pad.......................................................................................................................................... Side-Stance Models.................................................................................................................................... Forward-Stance Models .............................................................................................................................. Operator Front Pad.......................................................................................................................................... Caster Wheel Cover ........................................................................................................................................ Load Wheels........................................................................................................................................................ Remove ........................................................................................................................................................... Install............................................................................................................................................................... Overhead Guard Replacement............................................................................................................................ Remove ........................................................................................................................................................... Install............................................................................................................................................................... Front Lights ..................................................................................................................................................... Bulb Replacement ...................................................................................................................................... Assembly Replacement .............................................................................................................................. Rear Work and Caution Light...................................................................................................................... Caution Light............................................................................................................................................... Painting Instructions ............................................................................................................................................ Safety Labels Replacement.................................................................................................................................

1 1 2 2 2 3 3 3 3 3 3 4 4 4 4 4 5 9 9 9 9 10 11 11 12 13

This section is for the following models: NDR035EA, NR045EA [C861]; NDR030EA, NR035/040EA [D815]; NDR030DA, NR035/040DA [A295]

ÂŠ2011 Yale Materials Handling Corp.

100 YRM 1185

Description

General WARNING DO NOT make repairs or adjustments unless you have been properly trained and specifically authorized to do so. Repairs and adjustments that are incorrect can create dangerous operating conditions. DO NOT operate a lift truck that needs repairs. Report the need for repairs to your supervisor immediately. If repair is necessary, disconnect the battery and attach a DO NOT OPERATE tag to the control handle. This section contains descriptions of the frame components, repair procedures, and assembly information. These components include the frame weldment, door, floor plate, and covers. The overhead guard and base arms are also covered in this section.

A. LEFT B. RIGHT

C. FORWARD

Figure 1. Travel Orientation

Throughout this section, forward will refer to travel in the direction of the forks, and left and right will be from the perspective of an operator in the operator compartment facing the forks. See Figure 1.

Description The frame is available in two sizes: small chassis and large chassis. The small chassis is used for the NDR030DA, NR035/040DA, NDR030EA, and NR035/040EA unit and uses a smaller drive unit. The small chassis frame is available with a 368.3 mm (14.5 in.) or 419.1 mm (16.5 in.) battery compartment width. The large chassis is used for the NDR035EA and NR045EA unit and uses a larger drive unit. The large chassis frame is available with a 419.1 mm (16.5 in.), 469.9 mm (18.5 in.), or 546.1 mm (21.5 in.) battery compartment width.

• Electrical System Parts • Hydraulic System Parts • Door, Floor Plate, Access Panels, and Covers The overhead guard fastens to the mast. A rear operator guard leg provides protection for the operator and unobstructed operation of the lift truck. The operator guard leg fastens between the overhead guard and the frame. Repair procedures for major components that fasten to the frame are in separate sections. See each section for the system that has the part to be repaired.

The frame has mounts for the following parts: • Mast Assembly • Steering System Parts

Covers, Panels, and Plates

100 YRM 1185

Repairs - General Repair is seldom required on the frame unless the truck has been structurally damaged. Most truck repairs involve removing the system parts that attach to the frame. Refer to the appropriate section for the system that needs repair. To separate the mast from the frame, refer to the sections Mast, Repair 4000 YRM 1195 and Reach Carriages 4500 YRM 1196. To replace the load wheels in the base arms, see the section Periodic Maintenance 8000 YRM 1197 or Load Wheels in this section.

The caster wheel assembly is part of the steering assembly. See the section Steering System 1600 YRM 1187 to replace the caster wheel assembly or the caster wheels. To replace the drive wheels or tires, see the section Periodic Maintenance 8000 YRM 1197.

Covers, Panels, and Plates FRONT FRAME PANEL (LEFT AND RIGHT) Remove the screws from the upper and lower ends of the front frame panel. Pull the lower end of the panel away from the frame of the lift truck and gently work up the side of the panel to pull it from the retainer clips securing the panel to the frame. Pull the top end tabs out of the operator compartment cover. Repeat for opposite side as necessary. See Figure 2. NOTE: On right-side, front frame panels, ensure the diagnostic connector cap is positioned correctly to allow the cover to seat properly. To install the panel, position the upper end of the panel partially into the retaining clip on the frame. Insert the tabs on the upper end of the panel into the slots in the operator compartment cover. Work the sides of the panel into the retaining clips until all areas of the panel are aligned with the frame. Align the holes in the panel with the mounting brackets on the frame and loosely install the screws into the upper end and lower end of the panel. Make certain the panel is seated correctly against the frame and tighten the screws to secure in place. See Figure 2. 1. 2. 3. 4. 5. 6. 7. 8.

OPERATOR COMPARTMENT COVER FRAME LOWER BRACKET LOWER SCREW FRONT COVER PANEL (LEFT) TABS UPPER BRACKET UPPER SCREW

Figure 2. Front Frame Panel (Left Side)

100 YRM 1185

Covers, Panels, and Plates

OPERATOR COMPARTMENT COVER

DRIVE UNIT COMPARTMENT DOOR

Remove the front frame panels from the lift truck. See Front Frame Panel (Left and Right). Remove the two screws securing the operator cover to the frame brackets. One is located on the lower right side of the operator compartment above the operator presence switch. The other is located beside the overhead guard post mount, at the bottom of the cup holder. Pull the operator compartment cover up from the front right corner. Continue pulling the cover up along the edge of the frame in both directions until the cover is free from the retaining clips. See Figure 3. To install, position the cover over the electrical compartment. Align the lip of the cover to the retaining clips. Press the lip of the cover into the retaining clips starting at the overhead guard post and continue around until completely seated. Align the holes in cover with the mounting brackets and install retaining screws as removed. Install the front frame panels to complete assembly. Refer to Front Frame Panel (Left and Right).

Completely loosen the two socket head capscrews securing the drive unit compartment door closed. The screws are spring-loaded and are retained to the door by clips. Pull the door open on its hinges. To close, push the door closed and start both socket head capscrews loosely into the mounting holes. When both screws are started, verify that the door seats properly against the frame and tighten the screws.

DOOR PAD Open compartment door and remove the seven capscrews holding the pad to the door. Lift the pad over the steering mechanism and remove. To instal the pad, lower it over the steering mechanism and position it onto the door. Install the seven socket head capscrews as removed.

OPERATOR BACK PAD Side-Stance Models Remove the five socket head capscrews retaining pad to the adjuster mechanism and remove the pad. To install, position the back pad onto the adjuster mechanism and loosely install the five socket head capscrews as removed. Verify that the back pad seats properly to the adjuster mechanism and tighten to secure as removed.

Forward-Stance Models NOTE: On models with Aft Travel controls, guide the aft travel control handle wiring harness into/out of the frame when installing/removing the operator back pad. Remove the operator compartment cover to access the screw securing the front of the operator back pad to the frame. Remove the two screws securing the operator back pad to the frame and remove the pad from the frame.

1. 2. 3. 4.

OPERATOR COMPARTMENT COVER RETAINING SCREW FRAME FRONT COVER PANEL (LEFT)

To install, position the back pad against the frame as removed. Install the two screws securing pad to frame as removed, and reinstall the operator compartment cover.

Figure 3. Operator Compartment Cover

Load Wheels

100 YRM 1185

OPERATOR FRONT PAD

CASTER WHEEL COVER

Remove the operator compartment cover from the lift truck. See Operator Compartment Cover. Remove the screws securing the pad brackets to the frame. Pull the top of the pad away from the frame and then lift the pad from the lower retaining clips.

Remove the two socket head capscrews on top of the caster wheel cover and lift cover from the clips securing it to the frame.

To install, position the lower pad brackets into the retaining clips. Position the upper end of the pad to the frame. Align the pad bracket holes and install the screws to secure the pad in place. Install the operator compartment cover in place.

To replace, fit the bottom of the cover into the clips inside the opening and slide the cover into place. Install two socket head capscrews to secure the top of the cover in place.

Load Wheels REMOVE Slightly raise the base arms and support on blocks as described in the Periodic Maintenance 8000 YRM 1197. Make sure the base arms and load wheels do not support any weight. 1. Remove the nut, washers, and axle bolt. See Figure 4. 2. Remove the load wheels from the hanger brackets.

3. Remove the axle sleeves and bearings from the load wheels. Check for wear or roughness as the bearings are rotated. Replace both bearings if wear or roughness is noted. Inspect the load wheels for damage or wear. Replace as necessary.

CAUTION Use a hammer and a soft punch when removing bearings to avoid damage to bearings and/or load wheel. 4. Remove the hanger bracket from the base arms and inspect thoroughly. Inspect the base arms thoroughly for damage.

INSTALL WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. Wear protection when handling solvents and always follow the recommendations of the manufacturer.

CAUTION 1. Clean all parts with solvent and inspect thoroughly. Replace damaged parts as necessary. 1. AXLE BOLT 2. WASHER 3. HANGER BRACKETS

4. 5. 6. 7.

AXLE SLEEVE BEARING LOAD WHEEL NUT

Figure 4. Load Wheels

2. Apply lithium grease to the pivot contact on the hanger brackets. Position the hanger brackets into the base arms and install the load wheels and axle sleeves into the hanger brackets. See Figure 5.

100 YRM 1185

Overhead Guard Replacement equipped with lube fittings use sealed bearings and cannot be greased. 3. Install the bearings into the load wheels. a. Sealed Bearings - Install the bearings into the load wheel assemblies. Position the axle sleeve into the assembly. Apply antiseize lubricant to the axle bolt.

1. 2. 3. 4.

b. Side-Shielded Bearings - Install one bearing into the load wheel with the shielded side facing out. Fill the cavity inside of the load wheel with grease. Install the other bearing into the load wheel with the shielded side facing out. Position the axle sleeve into the assembly.

PIVOT CONTACT HANGER BRACKET LOAD WHEELS BASE ARM

Figure 5. Hanger Bracket Pivots

CAUTION The bearings are replaced by pressing on the outer race of the bearing only. Pressing or tapping on the inner race will damage the bearing. Use a suitable driver when installing bearings to avoid damage to bearings and/or load wheel. Replace bearings in sets to maintain proper wheel loading and operation. NOTE: Load wheel assemblies that have axle bolts equipped with lube fittings use side-shielded bearings and must be greased. Assemblies with axle bolts not

4. Apply grease to the pivot contact on the hanger brackets. Position the hanger brackets into the base arms and install the load wheels and axle sleeves into the hanger brackets. 5. Install a washer onto the axle bolt. Install the axle bolt through the hanger brackets, bearings, and axle sleeve with the threads to the inside of the base arms. 6. Install washers and nuts to the axle bolts. Torque to 68 Nâ&#x20AC;˘m (50 lbf ft). NOTE: If axle shafts are equipped with lube fittings, grease to fill load wheel cavity. Refer to Periodic Maintenance 8000 YRM 1197 for regularly scheduled maintenance procedures.

Overhead Guard Replacement WARNING DO NOT weld mounts for lights or accessories to the overhead guard. The strength of the overhead guard can be reduced by welding or heating. Install lights and accessories or their mounts with clamps. The strength of the overhead guard can be reduced if holes are drilled in the wrong location or are too large. Contact your lift truck dealer before welding or drilling holes in any part of the overhead guard.

The overhead guard assembly is heavy. Be sure that all lifting devices (hoists, cables, chains, slings, etc.) are suitable and of adequate capacity to lift the overhead guard. The overhead guard assembly consists of the overhead guard and a support post. See Figure 6 and Figure 7. The overhead guard is attached to the mast with six capscrews (2) and lockwashers (3). The top of the support post is bolted to the overhead guard. The bottom of the post fits into a retainer in the drive unit compartment.

Overhead Guard Replacement

Figure 6. Overhead Guard (NDR035EA, NR045EA, NDR030EA, NR035/040EA)

100 YRM 1185

Overhead Guard Replacement

Legend for Figure 6 1. 2. 3. 4. 5.

OVERHEAD GUARD CAPSCREW LOCKWASHER PLUG (W/O HEAD LAMPS) CAPSCREW

6. 7. 8. 9.

CAPSCREW PLUG SUPPORT POST BUSHING

Overhead Guard Replacement

Figure 7. Overhead Guard (NDR030DA, NR035/040DA)

100 YRM 1185

Overhead Guard Replacement

Legend for Figure 7 1. 2. 3. 4.

OVERHEAD GUARD CAPSCREW LOCKWASHER PLUG (W/O HEAD LAMPS)

5. 6. 7. 8.

The size of the overhead guard varies depending upon the battery compartment size.

REMOVE Refer to WARNING (above) before performing service to any overhead guard components. 1. Attach a suitable lifting device to the overhead guard. 2. Remove the two capscrews (6) retaining the support post to the overhead guard. See Figure 6. Pull the support post out of the retainer in the lift truck frame. Remove the support post.

CAPSCREW CAPSCREW SUPPORT POST BUSHING until all screws have been removed then remove the lens and retainer. Replace as required. See Figure 8.

2. Remove the bulb from the fixture and replace with new.

CAUTION Overtightening the screws can break the lens. 3. Position the lens and the retainer to the fixture and install the four screws.

3. Remove the six capscrews (2) and lockwashers (3) retaining the overhead guard to the mast. Lower the overhead guard to the floor.

INSTALL Refer to WARNING (above) before performing service to any overhead guard components. 1. Attach a suitable lifting device to the overhead guard. 2. Align the overhead guard with the top of the mast and install the six capscrews (2) and lockwashers (3). See Figure 6. Torque the capscrews to 149 Nâ&#x20AC;˘m (110 lbf ft). 3. Slide the support post into the retainer in the lift truck frame. Install the two capscrews (6) retaining the support post to the overhead guard.

FRONT LIGHTS Two front (head) lights are mounted by their brackets to the front of the overhead guard.

Bulb Replacement 1. Remove the four screws securing the lens retainer and lens to the assembly. Hold the lens in place

1. 2. 3. 4. 5.

BRACKET RETAINING CAPSCREW AND NUT SCREW LENS RETAINER LENS

Figure 8. Lens Removal

Overhead Guard Replacement

100 YRM 1185

Assembly Replacement 1. Disconnect the wiring harness from the light assembly connector.

3. Remove the bracket from the overhead guard and replace, if necessary. 4. Install bracket to overhead guard, if removed.

2. Remove the nut and washers from the capscrew securing the headlight assembly to the bracket. Slide the capscrew from the bracket and remove the headlight. See Figure 9.

5. Position the light assembly to the bracket and install capscrew and attaching hardware. Tighten slightly to allow for adjustment.

1. 2. 3. 4.

5. 6. 7. 8.

ADJUSTMENT SLOT ADJUSTMENT BOLT OVERHEAD GUARD WIRING HARNESS

HEADLIGHT CONNECTOR WIRE CLAMP ATTACHING HARDWARE

Figure 9. Head Light Mounting

100 YRM 1185

Rear Work and Caution Light The rear work and caution lights are options that mount to the overhead guard near the rear of the truck. Several configurations of these assemblies are available and connect to the options harness. To repair the light assemblies, perform the following procedures. Some repairs may not require total disassembly. Perform only the steps necessary to safely complete the required service. See Figure 10.

Overhead Guard Replacement 9. Remove blocks from the wheel and return to service.

The work light is very similar to the front light, except for its mounting platform and location. To repair or replace the work light, refer to the instructions for repairing or replacing the front lights. See Front Lights.

Caution Light 1. Move the lift truck to a safe, level area and completely lower the mast. Turn the key switch to the OFF position and attach a DO NOT OPERATE tag to the control handle. Block the drive wheel to prevent unexpected movement. 2. Disconnect the battery power cable connector from the truck connector located on the right side of the frame. Pull the battery cable connector handle to separate the battery connector from the truck connector. 3. Remove the nuts securing the cage to the light assembly. Remove the cage. 4. Remove the screws and washers securing the lens globe to the light assembly. Remove the lens globe. 5. Remove the bulb from the fixture and replace if necessary. 6. Connect the battery and turn the key switch to the ON position. Test for proper operation.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

CAGE GLOBE STUDS AND NUTS UPPER MOUNTING FLANGE LOWER MOUNTING FLANGE SCREW MOUNTING BRACKET WORK LIGHT WITH ADJUSTABLE BRACKET WORK LIGHT WIRING HARNESS STROBE WIRING HARNESS

Figure 10. Rear and Caution Light

7. Position the lens globe to the light assembly. Install screws to secure. 8. Position the cage onto the studs of the light assembly. Install nuts and washers onto studs.

Painting Instructions

100 YRM 1185

Painting Instructions WARNING Some frames and components are painted with polyurethane paint. Welding, burning, or other heat sufficient to cause thermal decomposition These of the paint may release isocyanates. chemicals are allergic sensitizers to the skin and respiratory tract irritants. Overexposure may occur without odor warning. When heat must be applied, use good industrial hygiene practices, including removal of all paint (prime and finish coats) to the metal around the area to be heated. Use local ventilation, and/or supplied, air-respiratory protection. Cleaning solvents may be flammable and/or toxic and may cause skin irritation. Always wear proper eye and skin protection. Always use solvents and paints in an area with adequate ventilation. DO NOT use solvents or paints near heat, fire, or electrical equipment that can make sparks. Follow the paint manufacturerâ&#x20AC;&#x2122;s instructions and precautions.

2. Use sandpaper to remove the top surface of paint and rust from the metal. All metal surfaces where the paint has been removed to the bare metal must be primed. Apply primer BEFORE applying the paint. 3. Protect all surfaces that will not be painted. DO NOT paint: All Plastic Covers Steering Handle Dash Display Control Handles Labels and Information Plates Operator Pads Tires and Load Wheels Chains and Hoses Battery Connectors All Switches Cylinder Rods Pumps and Motors Wiring Harnesses or Connectors

CAUTION CAUTION DO NOT put tape on cylinder rods to protect from paint. Use a thick layer of multipurpose grease to protect cylinder rods. Cylinders can be damaged if operated with tape on the cylinder rod. 1. Clean the surface to be painted. Use a solvent on surfaces to be painted to remove grease and oil before sanding. DO NOT use solvent to clean new paint. Make sure all oil and grease is removed.

Protect electrical components, wiring, and electrical contacts from overspray. 4. Paint the surfaces using Yale approved paints. Follow the proper paint scheme for your lift truck model (refer to the Parts Manual for specific information on paint for your lift truck). 5. Install new safety labels. See Safety Labels Replacement.

100 YRM 1185

Safety Labels Replacement

Safety Labels Replacement all air is removed from under the label or plate and the corners and edges are tight. DO NOT attempt to move the label or plate once it has been stuck down.

WARNING Safety labels are installed on the lift truck to give information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read. DO NOT add to or modify the lift truck. Any change to the lift truck, the tires, or its equipment can change the lifting capacity. The lift truck must be rated as equipped and the nameplate must show the new capacity rating. Contact your lift truck dealer for a replacement nameplate. Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. If an adhesive plate or label must be replaced, use the following procedure to install a new label or plate. See Figure 11 and Figure 12. 1. Clean area with an oil-free cleaner to remove all oil, grease, and foreign matter. Wipe until completely dry. 2. Carefully remove only the paper backing from adhesive. DO NOT touch adhesive surface with hands or remove front mask from label or plate face. 3. Exposed adhesive face must be free from all foreign matter before positioning label or plate on surface.

1. 2. 3. 4. 5.

MULTIFUNCTION CONTROL LABEL NAMEPLATE NAMEPLATE COVER RIVET HYDRAULIC FUNCTION DECAL

Figure 11. Operator Compartment Label Placement

4. Press label or plate down firmly making sure that all corners are stuck down tight. Make sure that

Safety Labels Replacement

100 YRM 1185

Figure 12. Label Placement

100 YRM 1185

Safety Labels Replacement

Legend for Figure 12 A. LEFT SIDE B. RIGHT SIDE

C. FRONT D. REAR

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

YALE DECAL FORK WARNING LABEL PINCH WARNING LABEL AC LABEL ACCENT STRIPE YALE DECAL EE LABEL BATTERY NOTICE LABEL RIVET MOUNTING STRIP OVERHEAD GUARD WARNING DECAL

INFO CASE COVER INFO CASE BASE OPERATOR WARNING LABEL CRUSH WARNING LABEL YALE DECAL FREEZER LABEL PATENTS AND TRADEMARKS LABEL RIVET UL LABEL NON-POWERED LOWERING LABEL (LOCATED INSIDE DOOR)

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Master Drive Unit

Table of Contents

TABLE OF CONTENTS HFK400 Master Drive Unit................................................................................................................................... General ........................................................................................................................................................... Description ...................................................................................................................................................... Drive Unit Maintenance and Repair ................................................................................................................ Remove....................................................................................................................................................... Install .......................................................................................................................................................... Disassemble ............................................................................................................................................... Assemble .................................................................................................................................................... Troubleshooting ............................................................................................................................................... GK Master Drive Unit........................................................................................................................................... General ........................................................................................................................................................... Description ...................................................................................................................................................... Maintenance.................................................................................................................................................... Changing the Oil ......................................................................................................................................... Traction Motor and Drive Unit Splines......................................................................................................... Remove ........................................................................................................................................................... Assemble ........................................................................................................................................................ Mounting Electric Motor .............................................................................................................................. Pivoted Connection - Geared Steering ....................................................................................................... Disassemble.................................................................................................................................................... Install............................................................................................................................................................... Troubleshooting ...............................................................................................................................................

1 1 1 2 2 3 3 7 15 17 17 17 18 18 18 18 19 20 20 21 21 22

This section is for the following models: NDR030GB, NR045GB [B861]; NDR030AE, NR035/040/045AE [C815]; NDR035EA, NR045EA [C861]; NDR030EA, NR035/040EA [D815]; NDR030DA, NR035/040DA [A295]; NS040/050AF [C816]; NDR030CB, NR045CB [D829]

630 YRM 1022

HFK400 Master Drive Unit

HFK400 Master Drive Unit GENERAL CAUTION Some of the hardware used on the MDU and traction motor is metric. Use the correct tool to avoid damage. This section contains a description, repair, and adjustment procedures for the parts of the HFK400 master drive unit (MDU) used on the narrow aisle and grocery reach lift trucks. The traction motor, steering, and brake repair information 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

HFK400 Master Drive Unit

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.

630 YRM 1022 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 prevent the motor from falling. See Figure 2.

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

WARNING Disconnect the battery and separate the connector before opening the drive unit compartment door and before inspecting or repairing the electrical system. If a tool causes a short circuit, the high-current flow from the battery can cause injury or parts damage. 2. Disconnect and remove the battery. Use the battery removal procedure described in either the Operating Manual or the section Periodic Maintenance 8000 YRM 970. 3. Remove the electrical compartment cover for access 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 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. Discharge the capacitors in the controller by connecting a load (such as a contactor coil or horn) across the controllerâ&#x20AC;&#x2122;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 connecting 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 Nâ&#x20AC;˘m (16 lbf ft).

1. 2. 3. 4. 5. 6. 7.

TRACTION MOTOR CAPSCREW LOCKWASHER CAPSCREW LOCKWASHER O-RING PINION GEAR

8. 9. 10. 11. 12. 13.

LOCKWASHER NUT WHEEL NUT WHEEL DRIVE UNIT ARTICULATING AXLE

Figure 2. Separating Traction Motor 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 the section Steering System 1600 YRM 974.

630 YRM 1022

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 the parts have blocks to prevent movement. If the MDU falls, it can cause an injury. Support the MDU vertically to prevent it from falling. 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.

Install

HFK400 Master Drive Unit to 25 N•m (18 lbf ft). 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 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 lubricant. Carefully install and align the motor on the adapter ring and MDU. DO NOT damage the pinion 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 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 potentiometer, and limit switches using the procedures in the section Steering System 1600 YRM 974.

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 rating 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 under 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 fasten the adapter ring and MDU to the frame or axle plate. Use a cross pattern to tighten the capscrews

CAUTION The steering system MUST be adjusted before operating 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 the section Periodic Maintenance 8000 YRM 970. 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 compartment 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 opposite side of the upper housing. Make certain to remove the capscrews, lockwashers, and nuts before

HFK400 Master Drive Unit attempting to separate the upper housing from the lower housing.

630 YRM 1022 4. Remove the capscrews retaining the drive unit cover. Remove the drive unit cover. 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 retaining the bevel gear to the axle shaft. Remove the special capscrew (24 mm) and the special washer.

WARNING Toxic vapors may be generated by heating the axle shaft to remove the LoctiteÂŽ adhesive. 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 LoctiteÂŽ 270. It may be necessary to use a welding 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. Remove 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.

1. 2. 3. 4. 5. 6. 7.

TOP CASE CAPSCREWS INSIDE TOP CASE BOTTOM CASE CAPSCREWS (3 EACH SIDE) CAPSCREW (CENTER) CAPSCREW IN PIN SPACER Figure 3. Separating Cases

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. Carefully 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.

7. Use a copper mandrel and a plastic hammer to drive the axle shaft out of the lower housing. Remove 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 replaced, the same shim sets can be used during assembly. 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 open the cage and remove the rollers. Use a puller to remove the cage from the axle shaft. 9. Remove the bearing shield from the lower housing using a plastic hammer. See Figure 4.

630 YRM 1022

Figure 4. Removing Bearing Shield 10. If necessary, remove the motor nut, lockwasher, bevel pinion, and key from the motor shaft. Remove the O-ring from the motor.

HFK400 Master Drive Unit 12. If necessary, remove the bearing cups. See Figure 6. Use a puller or copper mandrel and a plastic hammer. DO NOT damage or lose the shims between the cups and the bore in the case. Keep each set of shims together and separate from the other sets of shims. Put a label on each set so that the sets can be installed in the correct position during 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.

11. Remove the wheel bolts from the axle shaft, using a hydraulic press, if necessary. See Figure 5.

HFK400 Master Drive Unit

630 YRM 1022

Figure 5. Master Drive Unit Parts

630 YRM 1022

HFK400 Master Drive Unit Legend for Figure 5

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

SCREW CENTERING RING SOCKET HEAD SCREW WASHER NUT SOCKET HEAD SCREW SOCKET HEAD SCREW SOCKET HEAD SCREW DOWEL PIN UPPER HOUSING BREATHER VALVE PLUG/OIL FILL

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

SEAL RING LUBE FITTING PINION GEAR LOCK NUT GEAR BEARING SHIM PLUG/OIL DRAIN SEAL RING CAPSCREW COVER WHEEL SHAFT

25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

WHEEL STUD SEALING RING BEARING SHIM OIL RING SEALING RING CAPSCREW DISK RING AND PINION BEARING SHIM LOWER HOUSING

Assemble WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, 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. The top case and the ball bearing are replaced as a unit.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

UPPER PINION BEARING CUP LOWER PINION BEARING CUP INNER AXLE SHAFT BEARING CUP OUTER AXLE SHAFT BEARING CUP UPPER PINION BEARING SHIMS LOWER PINION BEARING SHIMS INNER AXLE SHAFT SHIMS OUTER AXLE SHAFT SHIMS INNER SEAL RING BEARING SHIELD Figure 6. Bearing and Shim Location

1. Clean all components thoroughly. Use LoctiteÂ® Fast Cleaner No. 706 to remove all traces of adhesive from the lower housing in the area where the thread-protecting shield had been located. Spray the cleaner from a distance of approximately 30 cm (12 in.) while holding the can upright. Allow the cleaner to work; then thoroughly remove the dissolved dirt from the lower housing using a clean cloth. Spray the surface with the cleaner again and allow to air-dry. 2. Check all parts for damage or cracks. Replace any damaged parts.

HFK400 Master Drive Unit

630 YRM 1022

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 pinion shaft and bevel gear are matched sets and MUST be replaced as sets. When replacing the gear sets, always replace the tapered roller bearings. The bearing cup and bearing cone MUST be from the same manufacturer. Lubricate the bearings with clean transmission oil prior to assembly.

NOTE: Assembly of the drive unit requires the use of a standard micrometer, torque wrench, and dial indicator. The procedure below specifies the use of a special measuring tool (Yale P/N 518096888) and a special clamping tool (Yale P/N 518096890). The measuring 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 special clamping tool can be used to facilitate easy assembly. 3. Insert the special measuring tool in the pinion shaft lower bearing bore. Determine the correct thickness 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. 2. 3. 4. 5.

BEVEL PINION SHAFT SPACER SPECIAL MEASURING TOOL LOWER CASE LOWER BEARING

6. 7. 8. 9.

LOWER BEARING SHIM SET UPPER BEARING SHIM SET UPPER BEARING DIMENSION B (MM) STAMPED ON END OF BEVEL PINION SHAFT

Figure 7. Bevel Pinion Shaft Installation

630 YRM 1022

HFK400 Master Drive Unit

a. Measure dimension F (the difference between the axle bearing bore and the end of the bushing). 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 [Âą0.05 mm (0.002 in.)]. Install the lower bearing shim set into the lower bearing bore. Press the lower bearing cup into the bore.

CAUTION

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 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.

DO NOT use damaged or distorted shims in the following steps.

7. Press the taper roller bearing cone up to the stop on the pinion shaft.

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.

8. Lubricate the bearing cup with transmission oil. Install 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 shoulder of the pinion shaft and the bottom of the bore for the upper bearing. See Figure 9.

HFK400 Master Drive Unit

630 YRM 1022

Figure 9. Shim Measurement

Figure 10. Pinion Shaft Bearing Clearance Check

10. Add 0.02 mm (0.00079 in.) to the value of dimension A and install a shim set equal to that sum into the bearing bore. Shim set (mm) = A + 0.02 mm

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 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

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 install 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.

If no clearance was measured, add a total of 0.02 mm (0.00079 in.) to the shims installed earlier.

13. Remove the special clamping tool or piece of wood holding the pinion shaft in place.

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.

14. Press the pinion shaft downward by hand while turning the shaft several times to align the taper rollers within the bearing.

18. Cover the splines of the helical gear with a thin coat of Loctite® 270. Wipe off any excess with a rag.

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 indicator. This value is the bearing clearance. Repeat the procedure to be sure to obtain the correct value.

19. Place the helical gear onto the pinion shaft and install 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.

630 YRM 1022

HFK400 Master Drive Unit

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 capscrew to 245 Nâ&#x20AC;˘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 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.

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 adjusted 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 procedure and will necessitate repeating the assembly procedure. See Table 1.

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