Hyster Forklift N35ZDR2

Warning: The oil used in the master drive unit should be drained and replaced after 350 hours of initial operation in accordance with the maintenance schedule. After the initial oil change, the master drive unit requires only the addition of the recommended oil to maintain the oil at the proper level.

Drain the oil when it is warm by removing the drain and fill plugs.

Upload a photo of the drain pan under the drain to keep oil off the floor.

Install the drain plug and fill the unit by adding oil slowly.

Allow enough time for the oil to flow through the bearings to fill the reservoir.

The correct level is at the bottom of the fill plug hole.

Sign off on the oil change procedure

CAUTION: The MDU 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. This is especially important pertaining to wheel bolts, the electric motor, and accessories.

The corrosion protection can only be removed from the connecting points using a suitable cleaner. Never use benzene, solvents, or other combustible substances for cleaning. Use only nontoxic, noncombustible, and commercially permissible cleaning agents. Wear safety gloves and goggles!

CAUTION: After removal of the drive motor, cover the MDU bearing input opening with a cap to prevent dirt or contamination from entering the MDU.

DO NOT drain cleaners into the soil. DO NOT allow cleaners to contact rubber parts, electrical connections of accessories, or the motor ventilation.

NOTE: Only disassemble the MDU to the extent required to replace the damaged component. Some parts may be removed without complete disassembly. Disassembly and repair of the MDU requires special tools, equipment and training to perform properly. Only properly trained and equipped repair personnel should attempt disassembly of the internal gears, bearings and seals.

CAUTION: Disposal of lubricants and fluids must meet local environmental regulations.

NOTE: Position a drain underneath MDU with enough capacity for your lift truck model.

Remove oil drain plug and oil fill plug from MDU assembly.

NOTE: For STEP 2 and STEP 3, support the MDU in a vertical position.

WARNING: The lift truck and components are heavy. All lifting devices (hoists, cables, chains, slings, etc.) must be 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. Use the battery removal procedure described in either the Operating Manual or the section Periodic Maintenance 8000SRM1472.

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. Make certain the battery has been disconnected.

Discharge the capacitor in the controller by connecting a 200-ohm, 2-watt resistor across the controller's a load across the B+ and B- terminals of the motor controller for 10 seconds. Remove the resistor after discharging the capacitor See Figure 18.

Open the drive unit compartment doors and fasten them so that they are fully open. Put a pan under the MDU drain plug and remove the plug. After the oil has completely drained, reinstall the drain plug. Tighten to 22 N•m (16 lbf ft).

WARNING: The motor is heavy. Use appropriate lifting equipment to avoid personal injury.

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.

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):

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