Hyster Forklift R30XMA3

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.

Clean all components thoroughly. Use Loctite® 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.

Check all parts for damage or cracks. Replace any damaged parts.

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.

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 (Hyster P/N 2036120) and a special clamping tool (Hyster P/N 2036121).

Upload a photo of the MDU sealing surface with Loctite 243® and Loctite 5910®

Side cover installed onto MDU assembly

Enter the torque applied to the side cover

Breather valve installed into sealing cap

Steering gear installed onto MDU assembly

Upload a photo of the steering gear and MDU assembly

Enter the torque applied to the hexagon screws

Oil drain plug installed into MDU assembly

Enter the torque applied to the oil drain plug

CAUTION: The traction motor is only allowed to be lifted with soft ropes or belts, never with steel cables or chains. Care must be taken during transport to avoid shocks.

NOTE: The traction motor shaft and MDU input pinion splines should be lubricated every 2000 hours.

Traction motor removed from the drive unit?

Motor shaft splines and the drive unit input pinion wiped clean?

Upload a photo of the cleaned motor shaft splines and the drive unit input pinion

Dow Corning® Molykote G-N paste (or equivalent) (Hyster P/N 0339068) applied with a small brush to moderately coat internal MDU splines and external drive motor splines?

Upload a photo of the coated internal MDU splines and external drive motor splines

Traction motor reinstalled to the drive unit?

Sign off on the 2000 Hourly Traction Motor And Drive Unit Splines Maintenance

Remove the wheel nuts and the drive/steer wheel

Remove the nine capscrews that fasten the lower housing to the upper housing

Remove the four capscrews inside the upper housing

Remove the two capscrews inside the case that are secured with washers and nuts on the opposite side of the upper housing

Separate the upper housing from the lower housing using a plastic hammer

Slide the upper housing for clearance between the upper housing and helical gear

Remove the capscrews retaining the drive unit cover

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.

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.

Disconnect and remove the battery.

Remove the electrical compartment cover for access to the traction motor controller.

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.

Discharge the traction motor controller by connecting a load across terminals B+ and B-.

Open the drive unit compartment door and drain the oil.

Remove the six capscrews and lockwashers that fasten the traction motor to the adapter ring on the MDU.