MASTER DRIVE UNIT

P2.0 [A290];W45ZHD [A419];P1.6, P1.8, P2.0,

P2.2 (W45ZHD2) [B419]

PART NO. 4035860 0630 SRM 1503

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow
instructions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use 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.
• 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 back-
ground. The CAUTION symbol and word are on yellow background.
 WARNING

California Proposition 65 - Operating, servicing and maintaining a powered industrial truck can
expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are
known to the State of California to cause cancer and birth defects or other reproductive harm. For
more information, go to www.P65Warnings.ca.gov.
 Table of Contents

TABLE OF CONTENTS
General................................................................................................................................................................... 1
Safety Precautions.................................................................................................................................................1
Drive Tire............................................................................................................................................................... 3
Remove.................................................................................................................................................................3
Install...................................................................................................................................................................3
Master Drive Unit..................................................................................................................................................3
Remove.................................................................................................................................................................3
Steering Bearing...............................................................................................................................................5
Install...................................................................................................................................................................5
Troubleshooting..................................................................................................................................................... 6

©2022 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
0630 SRM 1503 General

General
The master drive unit (MDU) includes the drive
The MDU is vertically installed in the truck and
motor, brake assembly, drive unit, and drive tire
allows an effective utilization of space. The compact,
and wheel assembly.
one-piece housing is made of high-duty nodular iron;
The drive motor is vertically mounted on top of the thus having a high rigidity and optimum guiding
MDU. In some instances, it may be necessary to precision. This allows a fully integrated bearing of
remove the drive motor to work on the MDU. In the helical spur gear stage with a very high running
other cases, the drive motor may remain attached to smoothness; i.e., no drive pinion on the motor shaft
the MDU while repairs are made. The complete of the electric motor.
MDU, including the motor, may also be removed if
The MDU consists of two ratio steps. Gear ratio 1 is
necessary. Determine the extent of disassembly
designed as helical spur gear stage and
required before proceeding with any repairs.
permanently integrated in the housing. Gear ratio 2
NOTE: The drive unit bearings are lubricated by is designed as Gleason bevel gearing of the hypoid
the drive unit gear oil and do not require packing type with offset bevel pinion shaft.
with grease.
NOTE: There are no serviceable parts within the
drive unit. If repair of the master drive unit is
required, the entire assembly must be replaced.
CAUTION
Some of the hardware used on the MDU and
traction motor is metric. Use the correct tools to
avoid damage.

Safety Precautions

WARNING WARNING
Put blocks under each side of the truck under the To avoid personal injury and prevent electrical
drive unit frame. Position blocks on both sides of shock, perform the following steps before
the load wheels. The blocks must prevent the performing any troubleshooting or adjustments,
motorized hand truck from falling and causing and before connecting or disconnecting a handset
injury or damage. or Personal Computer.

WARNING WARNING
The capacitor in the transistor controller can hold To avoid controller damage, always disconnect the
an electrical charge after the battery is battery. Discharge the capacitor and never put
disconnected. To prevent electrical shock and power to the controller with any power wire
personal injury, discharge the capacitor before disconnected. Never short any controller terminal
inspecting or repairing any component in the MDU or motor terminal to battery. Make sure to use
compartment. Wear safety glasses. Make certain proper procedure when servicing the controller.
the battery has been disconnected. DO NOT use a
screwdriver to make a short circuit across the B+ 1. Block the lift truck so that the drive wheel is off
and B- terminals of the transistor controller. the floor. See:
• Periodic Maintenance 8000SRM1510
for lift truck model A290
• Periodic Maintenance 8000SRM1666
for lift truck model A419
• Periodic Maintenance 8000SRM2077
for lift truck B419

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Safety Precautions 0630 SRM 1503

2. Turn the key switch to the OFF position and

disconnect the battery.

3. Discharge the capacitors in the controllers by

connecting a 200-ohm, 2-watt resistor across
the controller's B+ and B- terminals using
insulated jumper wires. See Figure 1 for lift
trucks A290 and A419 and Figure 2 for lift
trucks B419. DO NOT short across the motor
controller terminals with a screwdriver or a
jumper wire. Remove the 200-ohm, 2-watt
resistor before reconnecting the battery.

1. TRACTION CONTROLLER
2. INSULATED JUMPER WIRES
3. 200-OHM, 2-WATT RESISTOR
4. POSITIVE CONNECTION
5. NEGATIVE CONNECTION

Figure 2. Discharging Controller, Lift Trucks B419

1. CONTROLLER
2. POSITIVE CONNECTION
3. INSULATED JUMPER WIRES
4. 200-OHM, 2-WATT RESISTOR
5. NEGATIVE CONNECTION

Figure 1. Discharging Controller, Lift Trucks A290

and A419

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0630 SRM 1503 Drive Tire

Drive Tire
REMOVE 2. Turn the key switch to the OFF position and
disconnect battery.

WARNING 3. Loosen and remove the five lug nuts securing

Block each side of the truck under the drive unit the drive tire and wheel assembly to the axle
frame. Position blocks on both sides of the load shaft.
wheels to prevent the truck from falling.
4. Remove the drive tire and wheel assembly.
1. Block the lift truck so the drive tire is off the
floor. Refer to the section; INSTALL
• Periodic Maintenance 8000SRM1510 1. Mount the drive tire and wheel assembly on the
for lift truck model A290 axle shaft.
• Periodic Maintenance 8000SRM1666
2. Install lug nuts. Tighten lug nuts to
for lift truck model A419 120 N•m (88 lbf ft).
• Periodic Maintenance 8000SRM2077
for lift truck B419 3. Remove blocks and lower the lift truck to the
floor. Reconnect the battery.

Master Drive Unit

REMOVE NOTE: Insure the truck is blocked high enough to
remove the drive unit from below the truck frame.
The master drive unit (MDU) has five main
components: the traction motor, brake, steering 1. Raise the drive tire off the floor. Block the lift
control handle, drive unit, and drive tire and wheel truck. Refer to the section:
assembly. • Periodic Maintenance 8000SRM1510
Separate parts of the MDU can be removed without for lift truck model A290
removing the complete MDU. It is not necessary to • Periodic Maintenance 8000SRM1666
perform each step of the entire procedure to remove
for lift truck model A419
some parts of the MDU. The procedure has steps to
remove and disassemble the complete MDU. Read • Periodic Maintenance 8000SRM2077
the entire procedure first and perform only the steps for lift truck B419
necessary to make the required repairs.

WARNING
WARNING Always disconnect the battery connector so that
Cleaning solvents can be flammable, toxic, and the connector is completely free before repairing
can cause skin irritation. Wear protective gear the brake system. If the connector is not
when handling solvents and always follow the completely free, it can reconnect the battery. Tag
recommendations of the manufacturer. the connector - DO NOT CONNECT.

2. Turn the key switch to the OFF position and

WARNING disconnect the battery connector.
Put blocks under each side of the truck under the Remove the drive unit compartment cover to
3.
MDU frame. Position blocks on both sides of the access the MDU. Refer to AC Motor Repair
load wheels. The blocks must prevent the lift truck 0620SRM1513.
from falling and causing personal injury or
property damage. 4. Discharge the capacitors. Refer to Safety
Precautions in this section.

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Master Drive Unit 0630 SRM 1503

5. Remove the lug nuts and remove the drive tire 8. Tag and disconnect the wiring from the
and wheel. See Figure 3. steering tiller to the lift truck.

9. Support the steering tiller and remove the four

capscrews and washers securing the tiller to
the master drive unit. See Figure 4.

1. TILLER MOUNTING BOLTS

2. TILLER MOUNT
3. TILLER ASSEMBLY

Figure 4. Tiller Mounting

10. Remove the tiller from the lift truck.

11. Remove the traction motor and brake as a

single assembly.

a. Remove the four screws and lockwashers

retaining the drive motor. See Figure 5.
1. BRAKE 4. DRIVE TIRE
2. MOTOR 5. LUG NUTS
3. DRIVE UNIT 6. MDU UNIT

Figure 3. MDU Assembly

6. Identify and tag all wires and cables connected

to MDU for later installation.

7. Disconnect all wires and cables connected to

MDU and the harness clamps on the drive
motor.

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0630 SRM 1503 Master Drive Unit

1. CAPSCREWS

Figure 6. Steering Bearing

1. MOUNTING SCREWS

Figure 5. Motor Mounting 2. Carefully use a pry bar or other device to

remove the steering bearing from the casting.
b. Attach a sling and an over head hoist to the
drive motor. INSTALL

c. Lift the drive motor and brake assembly

WARNING
from the drive unit.
To avoid personal injury when installing the drive
d. Remove the brake assembly from the unit in the lift truck, keep the drive unit supported
traction motor if necessary. Refer to the at all times.
section Brakes 1800SRM1505.
1. Install the steering bearing on the mounting
casting.
WARNING 2. Align the eight mounting holes in the bearing
To avoid personal injury, keep the MDU supported with the holes in the casting.
at all times.
3. Install the eight capscrews to retain the
12. Use a jack to support the drive unit. Remove bearing to the casting. Torque the mounting
the capscrews attaching the drive unit to the capscrews to 23 N•m (17 lbf ft).
steer bearing.
4. Use a jack to position the drive unit.
13. Remove the drive unit from the truck and place
on a clean work bench. 5. Align the drive unit with the screw holes in the
steering bearing and install the capscrews
Steering Bearing attaching the drive unit to the bearing. Tighten
NOTE: It is necessary to remove the master drive all of the capscrews to 23 N•m (17 lbf ft).
unit, before the steering bearing can be removed.
NOTE: The traction motor is easily installed
1. From underneath the master drive unit AFTER the MDU has been mounted to the frame of
mounting casting, remove the eight capscrews the lift truck.
retaining the steering bearing to the mounting
casting. See Figure 6. 6. Install the traction motor:

a. Apply a light coat of moly paste lubricant

Hyster® part no. 339068 to the traction
motor splines.

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Troubleshooting 0630 SRM 1503

b. Position traction motor over drive unit using 8. Mount the drive wheel on the axle shaft and
an overhead lifting device and sling. Lower install lug nuts. Tighten lug nuts to
motor slowly to check for proper entry into 120 N•m (88 lbf ft).
the seal and to align pins.
9. Connect the motor wires and cables. Attach the
c. Secure motor to drive unit. harness clamps.

(1) Install the four capscrews to secure motor 10. Install the steer components as removed. See
as removed. the section Steering Mechanism
1600SRM1504 for lift trucks A290 and A419, or
(2) Torque capscrews to Steering Mechanism 1600SRM2064 for lift
17 ±1 N•m (150 ±9 lbf in). trucks B419 .

11. Lower the truck to the floor.

CAUTION
To prevent damage to the brake assembly always 12. Connect the battery and turn the key switch to
follow the special procedure for brake adjustment the ON position.
when adjusting the brake.
13. Test the operation of the truck.
7. Install and adjust the brake if removed. Refer
to the section Brakes 1800SRM1505. 14. Install the drive unit compartment cover and
return truck to service.

Troubleshooting

Table 1. Troubleshooting
Problem Possible Cause Procedure or Action
Lift truck will not move. Motor not operating. Check wiring or repair motor.
Check battery, battery connection,
and truck fuses.
Damaged gears or bearings. Replace drive unit.
MDU makes noise. Dry or damaged bearings. Replace drive unit.
Worn or damaged gears. Replace drive unit.
Oil leakage at upper part in motor Motor seal defective Replace motor seal
compartment.
Oil leakage at housing cover. Housing cover not sealed to Clean, seal, and tighten housing
housing. cover capscrews to correct torque.
Capscrews not sealed or not Tighten housing cover capscrews
tightened to correct torque. to 32 N•m (24 lbf ft)

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 TECHNICAL PUBLICATIONS

0630 SRM 1503 9/22 (3/15)(12/13)(6/11)