Hyster Forklift N45ZR2

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. Use the battery removal procedure described in either the Operating Manual or the section.

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

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. Tighten the drain plug to 22 N•m (16 lbf ft).

Remove the six capscrews and lockwashers that fasten the traction motor to the adapter ring on the MDU. Carefully lift the motor and set the motor out of the way. DO NOT damage the pinion gear on the motor shaft. Use a rope to fasten the motor to prevent the motor from falling.

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.

Enter the current operation hours of the master drive unit

If not, run the unit until the oil is warm.

Drain plug and fill plugs removed?

Upload a photo of the drain pan under the drain

Oil level at the bottom of the fill plug hole?

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

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.