Hyster Forklift N35ZR2

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 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 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 cleaned?

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 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

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. Fasten the door so that it is fully open.

Put a pan under the MDU drain plug and remove the drain plug. After the oil has completely drained, install the drain plug.

Warning: This procedure requires trained personnel with PPE!

Upload a photo of the MDU before assembly

Loctite 243® applied to each capscrew through hole?

Loctite 5910® applied to the MDU sealing surface for side cover?

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?

Steering bearing installed onto steering gear and MDU assembly?