Hyster Forklift N40ZRS2

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?

Type of paste used for lubrication

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

Traction motor reinstalled to the drive unit?

Sign off on the maintenance 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.

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

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.

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

Remove the capscrews retaining the drive unit cover

Install two wheel nuts on to the wheel bolts