Description
SixcapscrewsfastenthelargeballbearingandMDU totheframeoraxleplate.ThebearingletstheMDU turnforsteering.Thereisasmallhelicalpiniongear onthemotorarmatureshaft.Thisgearturnsalarge helicalgearontheshaftofthespiralbevelpinionin
theMDU.Thespiralbevelpinionturnsaspiralbevel gearontheaxletoturnthedrivewheel.Thebrake isfastenedtothetopendofthemotorshafttostop rotationoftheshaft.Thebrakeactionworksthrough thegearstostoptheunit.
HFK300and400MasterDriveUnit
GENERAL
Thismanualhasadescriptionandtherepairand adjustmentproceduresforthepartsofthemaster driveunit(MDU)manufacturedbyHurth.See Figure1.ThissectionisfortheHurthModelsHFK 200through500.Thetractionmotor,steering,and brakerepairproceduresareinseparatesections. ThemainpartsoftheMDUarethecase,pinion (motor)andlargegearset,thepinionandspiral bevelgearset,bearings,andtheaxleandwheel. Thelargeballbearingforsteeringispartofthe topcaseoftheMDU.Thetractionmotorfastensto theMDU(TypeA)onthefollowingunits:W40XL; W60XL;B40XL;B60XL;C60XL;T5XL;TWR;R30F, FA,FF,XM,XMA,XMF,XM2,XMA2,XMF2,and XMS2.ThetractionmotorandMDUturnasa unitforsteering.Thetractionmotorfastenstoan adapterringattheMDU(TypeB)onthefollowing units:A1.00XL,A1.25XL,A1.50XL(A20XL,A25XL, A30XL),N40EA,N50EA,N40ER,N45ER,N50FA, N30FR,N40FR,N45FR,R30DH,R30E,R30EA, R30EF,andR30ES.Theadapterringfastenstothe lifttruckframeorsteeringaxle.TheMDUturnsfor steeringandthetractionmotordoesnotturn.
NOTE: EarlyA1.00-1.50XL(A20-30XL)unitshavea SpethMDU.Seethesection SpethMasterDrive Unit 630SRM363.
TherearethreedifferenttypesofMDUsusedonthe lifttruckmodelslisted.Themajordifferenceisthe physicalsizeandthetopcase.Therearealsotwo methodsofmountingtheMDUandtractionmotor inthelifttruck.SeeFigure2andFigure4.Intype A,thetractionmotorfastenstotheMDUandturns withtheMDU.IntypeB,thetractionmotorfastens toanadapterringthatisfastenedtothelifttruckor steeringaxleframe.Thisadapterringispartofthe largeballbearingandallowstheMDUtoturnonthe axisofthetractionmotor.Thetractionmotordoes notturnwiththeMDU.Thelowercaseandinternal partsoftheseMDUsareverysimilar.
NOTE: MDUSHOWNWITHMOTORANDWHEEL.
Figure1.MasterDriveUnit
NOTE: Themanufacturerrecommendsdrainingand refillingthedriveunitoilafterthefirst350hoursof useonallnewtrucks.
TherearealsothreedifferentHysterpartnumbers forthemain(lower)partoftheMDUdependingon thetruckseries.MDUPartNo.2007081isareplacementforMDUPartNo.338600.PartNo.1335340
isusedontheA1.00-1.50XL(A20-30XL).Theaxle andaxlesealsaredifferentfortheMDUs,sointernal partsfromonecannotbeusedintheother.Theoperationisthesame.MDUremoval,disassembly,assembly,adjustment,andinstallationproceduresare writtenforallthelifttruckmodelslistedandthe MDUsdescribed.
LegendforFigure2
NOTE: MDUPARTNO.338600SHOWN.MDUPARTNO.2007081AND1335340SIMILAR.
A. MOUNTTYPEA(W/B40-60XL,C60XL,T5XL,ANDTWR)
B. MOUNTTYPEB(A1.00-1.50XL,N40/50EA,N40/50ER,N50FA,N30-45FR,R30DH,ANDR30E/EA/EF/ES)
1.TRACTIONMOTOR
2.FRAMEORAXLEPLATE
3.CAPSCREWTOFASTENBEARINGANDMDU
4.SHIM(W/B40-60XL)ORADAPTERRING (R30DH)
5.CAPSCREWTOFASTENMOTOR
REMOVE MountTypeA WARNING
IftheMasterDriveUnit(MDU)falls,itcan causeapersonalinjury.HoldtheMDUvertical topreventitfromfalling.
CAUTION
ThecapscrewsusedtofastentheMDUand tractionmotorareallmetric.Donotdamage themusingthewrongtools.
TheMDUcanberemovedfromthelifttruckwithoutremovingthemotor,steering,orbrakeassembliesfromthelifttruck.RemovetheMDUasfollows. SeeFigure2.
1. Removethehood.Disconnectandremovethe battery.Usethebatteryremovalprocedurein the PeriodicMaintenance manualforyourlift truck.
2. Putapanunderthedrainplugandremovethe drainplug.Aftertheoilhascompletelydrained, installthedrainplug.Tightenthedrainplugto 22N•m(16lbfft).
3. RemovethethreecapscrewsthatfastenthemotortothecaseoftheMDU.Carefullyliftthemotor,steering,andbrakeassemblies.Donotdamagethebrakeassemblyorthepiniongearonthe motorshaft.Useropetofastenthemotortopreventthemotorfromfalling.
4. Removethesixcapscrewsthatfastenthebearing andMDUtothemainframe.HoldtheMDUto keepitfromfalling.Useacraneandchainsthat haveacapacityof450kg(1000lb).Carefullylift
themainframeandmovetheMDUfromunder themainframe. DoNOTlosetheshims.Carefullyremovethebearingshield.
5. Lowerthemainframeontoblocks.
MountTypeB(A1.00-1.50XL, N40-50EA/ER,N50FA,N30-45FR, R30E/EA/EF/ESOnly)
WARNING
IftheMDUfalls,itcancauseapersonalinjury.HoldtheMDUverticaltopreventitfrom falling.
1. Alignthesteeringwheelsothatthedrivewheel isinapositionforstraighttravel.SeeFigure2.
2. Disconnectandremovethebattery.Usethebatteryremovalprocedureinthe PeriodicMaintenance manualforyourlifttruck.
3. Openthedriveunitcompartmentdoors.Fasten thedoorssothattheyarefullyopen.Putapan undertheMDUdrainplugandremovethedrain plug.Aftertheoilhascompletelydrained,install thedrainplug.Tightenthedrainplugto22N•m (16lbfft).
4. Identifyandtagthewirestothebrakeassembly andthepowercablesofthetractionmotorfor laterinstallation.
5. Disconnectthepowercablesandwires.
6. Removethesixcapscrewsandlockwashersthat fastenthetractionmotortotheadapterringon theMDU.Carefullyliftthemotorandsetthe motoroutoftheway.Donotdamagethepinion gearonthemotorshaft.Useropetofastenthe motortopreventthemotorfromfalling.
7. Loosenthelocknutatthechainanchorforthe steeringchain.Removethecapscrewatthe chainanchor.PutamarkontheMDUforthelocationofthepinthatfastensthechainanchorto thesprocket.Removethepin.Carefullyremove thechainanchorandchainfromthesprocket.
8. Carefullyputaslingunderthelifttruckframe onthemastsideoftheMDU. Donotdamage theguidancesensorifthelifttruckhas wireguidance. Makesuretheliftingdevice andslinghavetheabilitytoliftapproximately 450kg(1000lb).
9. Removethesixcapscrewsandlockwashersthat fastentheadapterringandMDUtotheframeor axleplate.
10. HoldtheMDUandraisethelifttruckframeso thattheMDUisfree.OntheN40/50EAand N40/45ERunits,thesteeraxlewillpivotonthe articulationshaft.CarefullylowertheMDUto thefloorandmovetheMDUfromunderthelift truck.Lowerthelifttruckframeonblocks.
MountTypeB(R30DHOnly)
WARNING
IftheMDUfalls,itcancauseapersonalinjury.HoldtheMDUverticaltopreventitfrom falling.
WARNING
TherearecloseclearancesbetweentheMDU, drivechassis,andbasearmassemblythatcan causeseriousinjury.NEVERputhands,arms, head,orlegsbetweenthesepartsunlessthe partshaveblockstopreventmovement.
1. Movethesteeringwheelsothatthedrivewheel isinapositionforstraighttravel.
2. Disconnectandremovethebattery.Usethebatteryremovalprocedureinthesection Periodic Maintenance 8000SRM295.
3. Opentheelectricalcompartmentdoors.Fasten thedoorssothattheyarefullyopen.Putapan undertheMDUdrainplugandremovethedrain plug.Aftertheoilhascompletelydrained,install thedrainplug.Tightenthedrainplugto22N•m (16lbfft).
WARNING
Thetractionmotorisheavy.Besurethatall liftingdevices(hoists,cables,chains,slings, etc.)aresuit ableandofadequatecapacityto liftthetract ionmotor.Thetractionmotorcan weigharound40kg(85lb).
4. Removethesixcapscrewsandlockwashersthat fastenthetractionmotortotheadapterringon theMDU.Carefullyliftthemotorandsetthe motoroutoft heway.Donotdamagethepinion gearonthemotorshaft.Useropetofastenthe motortopreventthemotorfromfalling.
5. Loosenthelocknutatthechainanchorforthe steeringchain.Removethecapscrewatthe chainanchor.PutamarkontheMDUforthe locationof thepinthatfastensthechainanchor tothesprocket.Removethepin.Carefully removethe chainanchorandchainfromthe sprocket. Donotdamagethesprocketandsteeringpotentiometerassembly.Donotdamagethe limitswit ches.Removethetwocapscrewsthat fastenthebracketfortheswitches.Movethe switches andbracketsothattheywillnotbe damaged. Usestringorwiretokeepthebracket inthislocation.
6. Carefull yputaslingaroundthedrivechassis. Puttheslingunderthedrivechassisandbetweenthe drivechassisandthebasearms.The slingmustalsobebetweentheMDUandthe pivotforthedrivechassis.Makesurethelifting deviceandslinghavetheabilitytoliftapproximately4 5kg(100lb).
7. Removethesixcapscrewsandlockwashersthat fasten theadapterringandMDUtothedrive chassis.PutmarksontheMDUforthelocation oftherollerguideforthelimitswitchesandfor thestoppins.
8. HoldtheMDUandliftthedrivechassissothat theMDU isfree.CarefullylaytheMDUonthe floor. Donotdamagethesprocketandsteeringpotentiometerassemblyorthelimitswitches. MakesurethereisclearancebetweentheMDU andallpartsondrivechassis.Carefullylower thedrivechassisonthestops.
9. Carefullyputaslingunderthebasearmassemblyon themastsidenearthecasters.Makesure theslingisNOTundertheMDU.Slowlyraise thebasearmassemblyforclearancetoslidethe
MDUundertheplatebetweenthecasterassemblies. Donotdamagetheguidancesensorif thelifttruckhaswireguidance. Slidethe MDUoutfromunderthelifttruckandlowerthe basearmassemblyonthecasters.Ifnecessary, removetherollerguideandstoppins.
DISASSEMBLE CAUTION
Failuretocompletelystraightenthestaked portionofthenutpriortoremovalcancause damagetotheshaftthreads.
CAUTION
ThecapscrewsandnutsusedontheMDU areallmetric.Donotdamagethemusingthe wrongtool.
NOTE: Beforedisassemblingthedriveunitmakecertaintheworkareaiscleanandallnecessarytoolsare available.Thenutsretainingthedriveaxleanduppergearonthepinionshaftarestakedinplaceand thestakedportionmustbecompletelyremovedbeforeattemptinganydisassembly.
1. Removethelugnutsandthewheel.
2. Removethefourcapscrewsinsidethetopcase. SeeFigure3.Removethesevencapscrewsthat fastenthebottomcasetothetopcase.Thereare threeoneachsideandoneatthecenter.
CAUTION
DoNOTtrytoseparatethetopandbottom cases.Twopinsmustberemovedtoseparate thecases.
3. Removethetwopinstoseparatethecases.The pinshaveinternalthreads.Useametriccapscrewandflatwashertogetherwithspacersof differentlengthstopullthepinsoutofthetop case.SeeFigure3.
4. Carefullyseparatethetopcasefromthebottom case.Slidethetopcaseforclearancebetweenthe topcaseandlargegear.SeeFigure4.Remove thetopcase.
1.TOPCASE
2.CAPSCREWSINSIDETOPCASE
3.BOTTOMCASE
4.CAPSCREWS(3EACHSIDE)
5.CAPSCREW(CENTER)
6.CAPSCREWINPIN
7.SPACER
Figure3.SeparatingCases
5. Useapieceofwoodtopreventtheaxlefromturning.Putthewoodbetweenthewheelstudson theaxle.Removethespecialnutatthelarge gear.SeeFigure4.Removethelargegear,bearingcone,andspacerfromthespiralbevelpinion.
CAUTION
Keepallshimsetstogetherandlabeledforcorrectlocationandinstallationduringassembly.
6. Preventtheaxlefromturning.Removethespecialcapscrewfortheaxle.Removethecapscrew, specialwasher,andshims.Holdthespiralbevel pinionandremovethespiralbevelgearandbearingcone.Do NOT letthespiralbevelpinionfall. Removethespiralbevelpinionandbearingcone.
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LegendforFigure4
A. A1.00-1.50XL, N40-50EA/ER,N50FA,N30-45FR,R30D/DH,R30E/EA/EF/ES
B. W/B40-60XL,C60XL,T5XL,TWR
NOTE: Ifthespiralbevelpinionandgearsetwill NOT bereplaced,t hesameshimsetscanbeused duringassembly. Adjustmentwillnotbenecessary.
7. Carefullyremov etheaxle,bearingseal,and bearingcone.If necessary,removethebearing shield(MDUPart No.383600only).
8. Ifnecessary,removeeachofthebearingcups. Useapuller.Do NOT losetheshimsbetween thecupsandthe boreinthecase.Keepeachset ofshimstogetherandseparatefromtheother setsofshims.Putalabeloneachsetsothat thesetscanbeinstalledinthecorrectposition duringassembly.
9. OnMDUPartNo. 383600,measurethedistance betweentheedgeofthecaseandthesealatthe axlebore.The replacementseal MUST beinstalledinthe samepositionastheoldseal.Removetheseal.
10. Ifnecessary,removethebearingconesfromthe axle,fromthespiralbevelgear,andfromthespiralbevelpinion.
11. Ifnecessary,removethemotornut,lockwasher, piniongear, andkeyfromthemotorshaft.RemovetheO-ringfromthemotor.
ASSEMBLE General WARNING
Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing
cleaningsolvent s,alwaysfollowtherecommendationsofthe manufacturer.Alwayswear eyeprotection.
1. Cleanallcomponentsthoroughly.Removeall tracesofLoctite™.UseLoctite™ FastCleaner number706toremoveLoctite™ fromthelower housingintheareawherethethreadprotecting shieldwaslocated.Spraythecleanerfromadistanceofapprox imately30cm(12in.),whileholdingthecanupright.Allowthecleanertimeto work,thenthoroughlyremovethedissolveddirt fromthelower housingusingacleancloth.Spray thesurfacewiththecleaneragainandallowto airdry.
CAUTION
Theaxleandgearassembliesareinstalledand removedseveraltimesduringthisprocedure. Becarefulduringinstallation,DoNotDamage thebearingseal.
2. Checkallpartsfordamageorcracks.Replaceall wornordamagedparts.Whenassemblingthe driveunit,useallnewstakenuts,O-rings,and seals.
NOTE: Thepiniongearandthelargegear MUST be replacedasaset.Thespiralbevelpinionandgear set MUST bereplacedasaset.Whenreplacingthe gearsets,alwaysreplacethetaperedrollerbearings. Theinnerbearingsandouterraces MUST befrom thesamemanufacturer.Lubricatethebearingswith cleantransmissionoilpriortoassembly.
NOTE: Assemblyofthedriveunitrequirestheuse ofastandardmicrometer,torquewrenchandadial indicator.Theuseofotherspecialtoolsisrecommendedbythemanufacturerofthedriveunit.
NOTE: Thelargeballbearingispartofthetopcase. Thetopcaseandtheballbearingarereplacedasa unit.
SpiralBevelPinion,Install
Thisprocedurehasthenecessarystepsneededtoinstallthespiralbevelpinionshaft.Allofthestepsare necessaryifareplacementspiralbevelpinionshaft andgearsetorareplacementlowercaseisneeded. Normally,itisnotnecessarytoreplacethelowercase orspiralgearset.SeeFigure5.
Iftheoriginalspiralgearsetwillbeinstalledinthe samelowercase,usetheoriginalshimsets(xandy). SeeFigure5.Installtheshimsets,bearing,spiral bevelpinion,largegear,andspecialnut.Checkthe bearingclearanceasdescribedinStep7.
Ifonlythespiralgearsetisreplaced,usethenumber (*)tofindthecorrectshimset(x).Ifthenewnumber issmallerthantheoldnumber,removeshims.Ifthe oldnumberislarger,addtheshims.Addorremove shimsequaltothedifferencebetweenthenumbers. Do NOT usedamagedordistortedshims.
EXAMPLE:
Theoldnumber74.25minusthenewnumber74.15,willmakeremovingshims0.1mm (0.004in.)inthicknessnecessary.
Ifthismethodoffindingthecorrectsetisused,it is NOT necessarytodoStep2throughStep4.Do Step1andStep5throughStep7.
Useallofthefollowingstepstoassemble,adjust,and installa NEW spiralbevelpinion(ifyoudonothave oneoftheabovenumbers)ortheoriginalspiralbevel pinionina NEW case.
NOTE: Therearetwonumbersoneachofthetwo partsofthespiralgearset.Onenumberoneachpart isthesetnumber.Thenumbers MUST bethesame. Theothernumberonthespiralbevelgearisthegear clearancenumber.Theothernumberonthespiral bevelpinionisthedimensionBvalue.Checkthat thenumbersarecorrect.
Installthespiralbevelpinionshaftasfollows:
1. Makeabushingtofittheboreforthelowerpinionshaftbearing.Differentmodelsneeddifferentsizebushings.Thebushingoutsidediminshed(O.D.)willbeeither(1)46.5mm(1.83in.), (2)51.5mm(2.03in.),or(3)63.5mm(2.50in.). Bushing(1)mustbe55mm(2.17in.)long.Bushing(2)mustbe67.5mm(2.66in.)long.Bushing (3)mustbe77.5mm(3.05in.)long.
2. Installthebushinginthebore.Tofindthecorrectthicknessforshimsetx,itisnecessaryto knowcasedimensionE.Tofindcasedimension
E,usetheformula:
E=L F+d/2
L=bushinglength
F=thedifferencebetweenthebearingbore fortheaxleandtheendofthebushing.See Figure5.
d/2=37.50mm(1.48in.)withbushing(1) d/2=44.45mm(1.75in.)withbushing(2) d/2=45.00mm(1.77in.)withbushing(3)
3. MeasuredimensionF.SeeFigure6.Subtract valueFfromthelength(L)ofthebushingand addthevalued/2.TheresultisdimensionE.
4. TheshimsetthicknessXforshimsetxforthe lowerbearingisfoundasshowninFigure5.
X=E B T
E=thevaluefoundinStep3.
B=thenumberontheendofthepinionshaft
T=thetotalthicknessofthebearing
5. Installtheshimsetxandpressthebearingcup intothebore.Installthebearingconeandspacer onthepinionshaft.Installthepinionshaftinthe case.
6. Installapieceofwoodbetweentheendofthepinionandthecasetoholdthepiniontightlyinthe bore.DoNOTinstallshimsorbearing.Measure thedistancebetweenthetopendofthespacer andthebottomoftheboreforthebearing.This isdistanceCinFigure5.
7. MeasuredistanceSbetweentheedgesofthe bearingcupandcone.SeeFigure5.Ifthecup extendsbelowthecone,dimensionSisnegative (subtract).Iftheconeextendsbelowthecup, dimensionSispositive(add).
8. Addorsubtract(Step7)dimensionSfromdimensionC.Theresultminus0.02mm(0.001in.)is dimensionXorthethicknessofshimsetyforthe topbearing.
X(inmm)=C+or S 0.02mm
9. Installtheshimsety,thebearingcup,bearing cone,largegear,andspecialnut.Useapressto installthebearingcup.
10. Useastrapwrenchorapieceofwoodtokeepthe largegearfromturningandtightenthenutto 60N•m(44lbfft).DoNOTuseapunchtolock thenutatthistime.
A. MDUPARTNO.2007081ANDPARTNO.1335340
B. MDUPARTNO.338600
SpiralBevelGear,Install
1. Useapresstoinstallthebearingconeonthe spiralbevelgear.Also,useapresstoinstallthe bearingcupinthecaseneartheaxleflange.
2. OnMDUswithPartNo.383600,installtheseal intheaxleboreofthecaseusingLoctite.Use thedimensionsmeasuredduringdisassemblyto makesurethesealisinstalledinthecorrectposition.Makesurethelipofthesealistoward thegearasshowninFigure6.Usesomeofthe greasetolubricatethelipofthebearingsealand thesealsurfaceoftheaxle.FilltheouterbearingconeusingShellAlvaniaR3grease.Install
thenylonringontheaxle,theninstalltheouter bearingcone.
3. Installthebearingshieldonthecaseusing Loctite242(Hyster318702).OnMDUPartNo. 2007081or1335340,filltheouterbearingcone usingShellAlvaniaR3grease.Installthecone ontheaxle.DoNOTinstallthebearingsealin thecaseuntilalladjustmentsarecomplete.
4. Installtheoriginalshimsundertheinnerbearingcup.Useapresstoinstallthebearingcupin thecase.
5. Carefullyinstalltheaxleassemblyinthecase andspiralbevelgear.Donotdamagetheseal onMDUswithPartNo.383600.
6. Preventtheaxlefromturning.TightentheM12 capscrewto110N•m(81lbfft).Tightenthespecialnutatthelargegearto60N• m(44lbfft). SeeFigure4.Useapunchatthedetenttolock thenut.
7. UseLoctite574onthecover.UseLoctite242 (Hyster318702)onthethreadsofthecovercapscrews.Installthecoverandtightenthecapscrewsto9.5N• m(7lbfft).
8. UseLoctite574andinstallthetopcaseonthe bottomcase.Makesurethetopcaseisaligned correctlyanduseapunchtoinstallthetwopins. SeeFigure3.SeeStep3oftheDisassembleprocedure.Installthecasecapscrews.Tightenthe8 mmcapscrewsto23N• m(17lbfft).Tightenthe 10mmcapscrewsto46N•m(34lbfft).
9. OnR30DHunits,installtherollerguideforthe limitswitches.Installtherollerguideinthe holesofthetopcaseatthemarksmadeduring removal.Ifnecessary,installthestoppins.
10. UseastandardM12capscrewwiththesame lengthasthespecialcapscrew.Installthespecialwasherandusethecapscrewtofastenthe axleandgearassembly.Tightenthecapscrew untilthereiszeroclearance.
11. SeeBacklashAdjustmentandToothContact PatternandBearingClearanceAdjustmentof thissectiontocheckandadjustthebacklash andgearclearanceBEFOREcontinuing.
NOTE: Toreplacethedrivetireonthewheel,the wheelmustbepressedoutofthetirerim.Useapress withacapacityofapproximately36,000kg(40ton) topressthetireoffthewheel.Pressthenewtireand rimontothewheelusingthesamepress.Theedge ofthewheelnearthewheelnutsmustbeevenwith thetirerim.
NOTE: UseLoctitetoinstallanynewwheelstuds.
12. Installthewheelandthewheelnutsorbolts. Tightenthenutsorboltsinacrosspatterntothe valuespecifiedinthe PeriodicMaintenance sectionforyourlifttruck.Tightenthenutsor boltsagainusingthecrosspattern.
INSTALL MountTypeA
1. Ifnotalreadyinposition,installthebearing shieldonthelargeballbearing.Aligntheholes. Useacraneandchainorslingwithacapacity ratingof450kg(1000lb)toliftthemainframe. Carefullyliftthemainframe.Temporarily installblocksunderthemainframetoprevent itfromlowering.MovetheMDUintoposition underthemainframe.
2. Liftthemainframe,removetheblocks,andcarefullylowerthemainframetoalignthecapscrew holes.Installandalignthethreeshimsonthe bearingshield.Installthesixcapscrewsand lockwashers.Slowlytightenthecapscrewsto approximately60N•m(44lbfft)usingacross pattern.Makesurethelargeballbearingisin thecorrectpositionaroundthecompletecircumference.Usethecrosspatterntotightenthe W/B40/60XLcapscrewsto120N•m(89lbfft). UsethecrosspatterntotightentheTWRcapscrewsto82N• m(60lbfft)andalltherestof theunits.
3. Ifthepiniongearonthemotorshaftwasremoved,installthekey,gear,lockwasher,andnut. Tightenthenutto55to65N•m(41to48lbfft).If animpactwrenchisused,makesureitdoesnot tightenthenuttomorethanthecorrecttorque.
4. InstallanewO-ringonthemotorusingO-ring lubricant.Carefullyinstallandalignthemotor ontheMDU.MakesuretheMDUisinthepositionforstraighttravelwiththetiretotheright ofthecase.Installandtightenthethreemotor capscrewsandlockwashersto23N•m(17lbfft).
5. Lubricatethelargeballbearingusingthegrease showninthesection PeriodicMaintenance 8000SRM281or8000SRM921.FilltheMDU tothelevel/fillplugusingtheoilshowninthe PeriodicMaintenance section.Addtheoil slowly.Theoilmustgothroughthebearingsto thelowerpartoftheMDU.
6. Installthebatteryandthehood.
MountTypeB(A1.00-1.50XL, N40/50EA,N40/45ER,N50FA,N30-45FR, R30E/EA/EF/ESOnly)
1. Useacraneandchainorslingwithacapacity ratingof450kg(1000lb)tolifttheframe. Do notdamagetheguidancesensorifthelift truckhaswireguidance. Lifttheframefor clearancetoslidetheMDUundertheframeor steeraxle.Temporarilyinstallblocksunderthe frametopreventlowering.LaytheMDUonthe floor.SlidetheMDUunderthedrivechassis.
2. MovetheMDUintoapproximatealignmentundertheframeoraxleplate.
3. HoldtheMDUintheverticalpositionthrough theholeintheplate.Do NOT putanypartof yourbodybetweentheMDUandtheframeor axleplate.Carefullyraisetheframeandremovetheblocks.Carefullylowertheframeand alignthecapscrewholesinthelargeballbearing,adapterring,andtheframeoraxleplate.
4. Installthesixcapscrewsandlockwashersthat fastentheadapterringandMDUtotheframe oraxleplate.Useacrosspatterntoslowly tightenthecapscrewstoapproximately25N•m (18lbfft).Makesurethelargeballbearingand adapterringareinthecorrectpositionaround thecompletecircumference.Usethecross patterntotightenthecapscrewsto68N•m (50lbfft).
5. Ifthepiniongearonthemotorshaftwasremoved,installthekey,gear,lockwasher,andnut. Tightenthenutto54N•m(40lbfft).Ifanimpact wrenchisused,makesureitdoesnottightenthe nuttomorethanthecorrecttorque.
6. InstallanewO-ringonthemotorusingO-ring lubricant.Carefullyinstallandalignthemotor ontheadapterringandMDU.Do NOT damage thepiniongearonthemotorshaftorthelarge gearoftheMDU.Installthesixcapscrewsand lockwashers.Tightenthecapscrewsto20N•m (15lbfft).
7. MakesuretheMDUisinthepositionforstraight travelwiththetiretotheleftofthecase(facingMDU).Carefullyinstallthesteeringchain. Usethepintoinstallthechainanchoronthe adapterring.Usethecapscrewtofastenthe twochainanchorstogether.Adjustthesteering
chain,steeringpotentiometer,andlimitswitches usingtheproceduresinthefollowingsections:
• N40/50EA,N40/45ER,N50FA,N30-45FRSteeringSystem 1600SRM378
• R30E/EA/EF/ES(NoWireGuidance)- ElectricPowerSteering 1600SRM418
• R30E/EA/EF/ES(WireGuidance)- WireGuidance 2200SRM422
MountTypeB(R30DHOnly)
WARNING
TherearecloseclearancesbetweentheMDU, drivechassis,andbasearmassemblythatcan causeseriousinjury.NEVERputhands,arms, head,orlegsbetweenthesepartsunlessthe partshaveblockstopreventmovement.
1. InstalltheadapterringontheMDUandalign theholes.Useacraneandchainorslingwith acapacityratingof450kg(1000lb)toliftthe basearmassemblyatthedrivechassis. Donot damagetheguidancesensorifthelifttruck haswireguidance. Installthechainorsling underthebasearmsonthemastsidenearthe casters.Carefullyliftthebasearmassembly. Temporarilyinstallblocksunderthebasearms topreventlowering.LaytheMDUonthefloor. SlidetheMDUunderthedrivechassis.Liftthe basearmassembly,removetheblocks,andcarefullylowerthebasearmassemblyonthecasters. MakesurethereisclearancebetweentheMDU andallpartsofthedrivechassisandbasearmassemblies.Donotdamagethesprocketandsteeringpotentiometerassemblyorthelimitswitches.
2. Putaslingaroundthedrivechassis.Putthe slingunderthedrivechassisandbetweenthe drivechassisandthebasearms.Liftthedrive chassis.Temporarilyinstallblocksbetweenthe drivechassisandbasearmstopreventlowering. TheslingmustalsobeinapositionthatwillallowinstallationoftheMDUontheframeplate. MovetheMDUintoapproximatealignment.
3. HoldtheMDUintheverticalpositionthrough theholeintheframeplate.Do NOT putany partofyourbodybetweentheMDU,basearm assembly,ordrivechassis.Carefullyraisethe drivechassisandremovetheblocks.Carefully lowerthedrivechassisandalignthecapscrew holesinthelargeballbearing,adapterring,and theframeplate.