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• 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.
• Always use HYSTER 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.
• 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 back-
ground. The CAUTION symbol and word are on yellow background.
Master Drive Unit Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Check Oil Level.............................................................................................................................................. 2
Change Gear Oil (T5-7Z AC, B60-80Z AC, C60-80Z AC, and B60-80Z HD) ........................................................ 2
Safety Precautions ............................................................................................................................................. 3
Drive Tire ........................................................................................................................................................... 5
Remove ........................................................................................................................................................... 5
Install ............................................................................................................................................................. 5
Master Drive Unit.............................................................................................................................................. 5
Remove ........................................................................................................................................................... 5
Install ............................................................................................................................................................. 11
Troubleshooting ................................................................................................................................................. 12
B60Z [A230];
W60Z [A231];
W65Z [A229];
B80Z [A233];
W80Z [A234];
T5Z [A476];
T7Z [A477];
C60Z [A478];
C80Z [A479];
T5Z AC [B476];
T7Z AC [B477];
C60Z AC [B478];
C80Z AC [B479];
W30-40ZA [B453];
W20-30ZR [B455];
W25-30-40ZC [B454];
B60Z AC [B230];
B80Z AC [B233];
B60Z HD [A262];
B80Z HD [A257]
HYSTER
APPROVED
PARTS
630 SRM 961 General
General
The master drive unit (MDU) includes the drive mo- • Steering Mechanism 1600 SRM 1031 for unit
tor, brake assembly, drive unit, and drive tire and codes A476, A477, A478, A479, B476, B477, B478,
wheel assembly. and B479
• Steering Mechanism 1600 SRM 1284 for unit
The drive motor is vertically mounted on top of the codes B230 and B233
MDU. In some instances, it may be necessary to re- • Steering Mechanism 1600 SRM 1449 for unit
move the drive motor to work on the MDU. In other codes A257 and A262
cases, the drive motor may remain attached to the • Brakes 1800 SRM 963 for unit codes A229, A230,
MDU while repairs are made. The complete MDU, A231, A233, A234, A476, A477, A478, A479, B453,
including the motor, may also be removed if neces- B454, and B455
sary. Determine the extent of disassembly required • Brakes 1800 SRM 1285 for unit codes A257, A262,
before proceeding with any repairs. B230, B233, B476, B477, B478, and B479
NOTE: Unit codes can be found on the truck name- NOTE: The drive unit bearings used on these models
plate. are lubricated by the drive unit gear oil and do not
require packing with grease.
Additional information concerning the MDU may be
included in other sections when the information is The upper housing of the MDU supports the traction
more closely related to other systems. Sections that motor. A bevel pinion gear is attached to the traction
may contain related information include: motor shaft. The bevel pinion gear drives the bevel
• AC Motor Repair 620 SRM 1283 for all models gear, which is mounted on the wheel shaft. The wheel
utilizing an AC traction motor shaft is machined with spur gear teeth that drive the
• DC Motor Maintenance 620 SRM 294 for all idler gear located in the lower housing.
models utilizing a DC traction motor
• Electrical System 2200 SRM 1357 for unit codes Two different MDU designs are used:
B476, B477, B478, and B479 Top Mount Handle
• Electrical System 2200 SRM 1052 for unit codes Bottom Mount Handle
A476, A477, A478, and A479
• Electrical System 2200 SRM 929 for unit codes The MDUs for these trucks are the Carraro™
A229, A230, A231, A233, and A234 MDU115 and MDU150. These assemblies are
• Electrical System 2200 SRM 1287 for unit codes available with three different gear ratios. Refer to
B230 and B233 Table 1. The highest ratio is 16:1 which will produce
• Electrical System 2200 SRM 1026 for unit codes higher output speed with lower torque. The lowest
B453, B454, and B455 ratio (25:1) produces lower output speed with higher
• Electrical System 2200 SRM 1451 for unit codes torque.
A257 and A262
• Periodic Maintenance 8000 SRM 919 for unit Table 1. Drive Unit Specifications
codes A229, A230, A231, A233, and A234
• Periodic Maintenance 8000 SRM 1027 for unit Gear
Model MDU
codes B453, B454, and B455 Ratio
• Periodic Maintenance 8000 SRM 1368 for unit W60/65/80Z,
codes B476, B477, B478, and B479 Carraro™
W30/40ZA, W20/30ZR, 25:1
• Periodic Maintenance 8000 SRM 1032 for unit MDU115
W25/30/40ZC
codes A476, A477, A478, and A479
• Periodic Maintenance 8000 SRM 1453 for unit B80Z, T7Z, C80Z,
Carraro™
codes A257 and A262 T7Z AC, C80Z AC, 17.8:1
MDU150
• Periodic Maintenance 8000 SRM 1298 for unit B80Z AC, B80Z HD
codes B230 and B233 B60Z, T5Z, C60Z,
• Steering Mechanism 1600 SRM 962 for unit Carraro™
T5Z AC, C60Z AC, 16:1
codes A229, A230, A231, A233, A234, B453, B454, MDU115
B60Z AC, B60Z HD
and B455
1
General 630 SRM 961
CHECK OIL LEVEL Operate the lift truck MDU for several minutes to
warm the gear oil. Elevate truck to access drive unit.
1. Rotate the steering control handle until the oil Keep truck level. Remove drive unit cover. Remove
fill plug is exposed. both drain and oil fill plugs and drain gear oil into a
suitable container. Replace drain plug. Add gear oil
2. Remove the oil fill plug.
through oil fill plug until oil is level with top of gear
3. Move the directional control knobs, turning the without covering gear. Replace oil fill plug. DO NOT
drive wheel slightly forward or backward until OVERFILL.
one of the gear holes lines up with the fill hole.
Check the level of lubricant. There is enough
lubricant in the MDU when the lubricant level
is up to the bottom of the gear or halfway to the
top of the gear. See Figure 1.
CHANGE GEAR OIL (T5-7Z AC, B60-80Z AC, 1. MASTER DRIVE UNIT FRAME
C60-80Z AC, AND B60-80Z HD) 2. OIL FILL HOLE
3. OIL LEVEL SHOULD BE AT THE BOTTOM EDGE
NOTE: The oil used in the master drive unit should OF GEAR OR HALFWAY UP.
be drained and replaced after the initial 500 hours
Figure 1. Check Oil Level
break-in period. After the initial oil change, the
MDU gear oil should be changed every 2000 hours.
2
630 SRM 961 Safety Precautions
Safety Precautions
2. Turn the key switch to the OFF position and dis-
WARNING connect the battery.
Put blocks under each side of the truck under
the drive unit frame. Position blocks on both 3. Discharge the capacitors in the controllers by
sides of the load wheels. The blocks must pre- connecting a 200-ohm, 2-watt resistor across the
vent the motorized hand truck from falling and controller’s B+ and B terminals using insu-
causing injury or damage. lated jumper wires. See Figure 2, Figure 3, or
Figure 4. DO NOT short across the motor con-
troller terminals with a screwdriver or a jumper
WARNING
wire. Remove the 200-ohm, 2-watt resistor be-
The capacitor in the transistor controller can fore reconnecting the battery.
hold an electrical charge after the battery is
disconnected. To prevent electrical shock and
personal injury, discharge the capacitor before
inspecting or repairing any component in the
MDU compartment. Wear safety glasses. Make
certain the battery has been disconnected. DO
NOT use a screwdriver to make a short circuit
across the B+ and B terminals of the transis-
tor controller.
WARNING
To avoid personal injury and prevent electri-
cal shock, perform the following steps before
performing any troubleshooting or adjust-
ments, and before connecting or disconnecting
a handset or Personal Computer.
WARNING
To avoid controller damage, always disconnect
the battery. Discharge the capacitor and never
put power to the controller with any power
wire disconnected. Never short any controller
terminal or motor terminal to battery. Make
1. POSITIVE CONNECTION
sure to use proper procedure when servicing 2. NEGATIVE CONNECTION
the controller. 3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
1. Block the lift truck so that the drive wheel is off
the floor. Refer to the section Periodic Main- Figure 2. Discharging Controller - B60-80Z,
tenance, How to Put Lift Truck on Blocks. (See C60-80Z, T5-7Z, and W60-65-80Z
General in this section for a list of specific section
numbers.)
3
Safety Precautions 630 SRM 961
1. NEGATIVE CONNECTION
2. POSITIVE CONNECTION
3. 200-OHM, 2-WATT RESISTOR
4. INSULATED JUMPER WIRES
1. CONTROLLER
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION
4
630 SRM 961 Master Drive Unit
Drive Tire
REMOVE T7Z, and T7Z AC drive tire is secured with lug
nuts) securing drive tire and wheel assembly to
WARNING axle shaft.
Block each side of the truck under the drive 4. Remove the drive tire and wheel assembly.
unit frame. Position blocks on both sides of the
load wheels to prevent the truck from falling. INSTALL
1. Block the lift truck so the drive tire is off the floor. 1. Mount the drive tire and wheel assembly on drive
Refer to the section Periodic Maintenance, axle shaft.
How to Put Lift Truck on Blocks. (See General in
this section for a list of specific section numbers.) 2. Install washers and wheel bolts or lug nuts.
Tighten wheel bolts or lug nuts to 200 ±9 N•m
2. Turn the key switch to the OFF position and dis- (148 ±7 lbf ft).
connect battery.
3. Remove blocks and lower the lift truck to floor.
3. Loosen and remove the five wheel bolts and Reconnect the battery.
washers (B80Z, B80Z AC, B80Z HD, C80Z, C80Z AC,
5
Master Drive Unit 630 SRM 961
6
630 SRM 961 Master Drive Unit
7
Master Drive Unit 630 SRM 961
Figure 7. Drive Unit Assembly B80Z AC, B80Z HD, C80Z AC, and T7Z AC (Power Assist Shown)
8
630 SRM 961 Master Drive Unit
8. Disconnect all wires and cables connected to a. Remove four nuts, lockwashers, washers,
MDU and the harness clamps on the drive mo- and wire clamp from the studs retaining the
tor. drive motor.
9. Remove the steering components as necessary for b. Attach a sling and an overhead hoist to the
repair. Refer to the section Steering Mecha- drive motor.
nism. (See General in this section for a list of
specific section numbers.) c. Lift the drive motor from the drive unit.
10. Assisted steering models have a steering motor d. Remove the brake assembly from the trac-
and a lower bearing assembly for the articulat- tion motor if necessary. Refer to the section
ing shaft that mounts to the MDU housing. If Brakes for your lift truck model. (See Gen-
removed, the lower bearing pin and gear must eral in this section for a list of specific section
be aligned with the notch in the pinion shaft fac- numbers.)
ing straight ahead and with the drive tire in the
e. Remove wire guard from lower end of studs.
same position during installation. Refer to the
section Steering Mechanism for steer motor f. Remove studs, nuts, and two alignment pins
and lower bearing assembly removal. (See Gen- from drive unit.
eral in this section for a list of specific section
numbers.)
WARNING
NOTE: The traction motor is most commonly re- To avoid personal injury, keep the MDU sup-
moved BEFORE the drive unit is removed from the ported at all times using a sling and an over-
truck. However, it can also be removed after the head hoist when removing the MDU from the
MDU has been removed from the truck. lift truck.
11. Remove the traction motor and brake as a single 12. Attach a sling and an overhead hoist to the drive
assembly: unit. Remove the four capscrews and nuts at-
taching the drive unit to the frame.
NOTE: Wire clamp(s) placement may vary with mod-
els. Note where each wire clamp is located prior to 13. Lift the drive unit out of the truck and place on a
removal. clean work bench. Remove the sling.
9
Master Drive Unit 630 SRM 961
Figure 8. Drive Unit Assembly B60Z AC, B60Z HD,C60Z AC , and T5Z AC
10
630 SRM 961 Master Drive Unit
11
Troubleshooting 630 SRM 961
10. Fill the gear oil in the MDU to the correct level.
See General, Figure 1 in this section.
Troubleshooting
Lift truck will not move. Motor not operating. Check wiring or repair motor. Check
battery, battery connection, and
truck fuses.
MDU makes noise. The wrong lubricant is used. Drain incorrect lubricant and refill
with correct gear oil. Refer to the
section Periodic Maintenance for
your lift truck model. (See General
in this section for a list of specific
section numbers).
12
630 SRM 961 Troubleshooting
Oil leakage at fill plug or Dirt between sealing ring and hous- Clean sealing ring and housing.
drain plug. ing.
Oil leakage at upper part in Too much oil in drive unit. Check oil level and correct to proper
motor compartment. level.
Oil leakage at housing cover. Housing cover not sealed to housing. Clean, seal, and tighten housing
cover capscrews to correct torque.
13
NOTES
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