1

INTRODUCTION

GENERAL

This section has a description and the repair procedures
for the speed reducer.

DESCRIPTION (See FIGURE 1.)

The speed reducer transfers power between the trans-
mission and the differential and increases the torque
from the engine to the drive wheels. The speed reducer

also has the gears and linkage to permit forward and re-
verse travel of the lift truck.

The speed reducer is installed on the differential hous-
ing. The output shaft of the transmission is connected to
the input shaft of the speed reducer. The forward and re-
verse gears and the sliding sleeve are installed on the in-
put shaft. A pair of idler gears are used to connect the re-
verse gear to the output gear. The output gear is installed
on the pinion shaft of the differential.

FIGURE 1. SPEED REDUCER

11608

26.9 mm
(1.059 in)

1. DIFFERENTIAL HOUSING
2. SPEED REDUCER HOUSING
3. INPUT SHAFT
4. REVERSE GEAR
5. SLIDING SLEEVE
6. FORWARD GEAR
7. BEARING COVER
8. IDLER GEAR
9. IDLER SHAFT

10. OUTPUT GEAR

11. PINION SHAFT

12. BEARING COVER

2

OPERATION (See FIGURE 2.)

When the engine is running and the direction control le-
ver is in the Neutral position, the input shaft in the speed
reducer rotates freely. When the lever is moved to the
Forward position, the sliding sleeve moves and engages
the forward gear to the input shaft. The forward gear en-
gages directly with the output gear and rotates the differ-
ential for Forward travel. For Reverse travel, the sliding
sleeve engages the reverse gear to the input shaft. The
reverse gear is in contact with the idler gear and the idler
gear is in contact with the output gear. The transfer of
power through the idler gears causes the output gear to
rotate in the opposite direction for Reverse travel.

FIGURE 2. OPERATION OF THE

SPEED REDUCER

11577

1. INPUT SHAFT
2. IDLER GEARS
3. FORWARD GEAR
4. REVERSE GEAR

5. OUTPUT GEAR
6. SLIDING SLEEVE
7. SELECTOR RAIL

FORWARD

REVERSE

REPAIRS

REMOVAL (See FIGURE 3.)

1. Disconnect the linkage at the lever that is on the speed
reducer housing. Disconnect the wires at the neutral
start switch. Disconnect the cable clamps at the housing.

FIGURE 3. REMOVE THE

SPEED REDUCER

3443

1. OUTPUT GEAR
2. TAPERED SLEEVE
3. PINION SHAFT

3

2

1

2. Disconnect and remove the drive shaft between the
speed reducer and the transmission.

3. Drain the oil from the speed reducer housing. Remove
the cover from the speed reducer.

4. Remove the nut from the pinion shaft and remove the
output gear. Remove the nuts and tapered sleeves that
hold the speed reducer to the differential housing. Re-
move the speed reducer from the bottom of the lift truck.

DISASSEMBLY (See FIGURE 4.)

1. Remove the detent ball and spring and the neutral start
switch assembly. Loosen the nut on the selector rail,
then remove the rail from the fork. Pull the selector rail
from the housing. Remove the fork from the sliding
sleeve.

2. Remove the bearing covers for the input shaft and the
idler shaft.

3. Use a press to push the input shaft from the housing as
shown in FIGURE 4. Make sure to use a block as a sup-
port under the sliding sleeve. Also make sure the sliding
sleeve is aligned with the teeth of the drive gear. The
drive gear must be pushed through the sliding sleeve.

3

FIGURE 4. DISASSEMBLE THE SPEED REDUCER

2566

1. PRESS
2. INPUT SHAFT
3. SLIDING SLEEVE

3

2

1

4. Disassemble the bearings and gears from the input
shaft.

5. Remove the plug in the housing for the idler shaft. Use
a press at this hole to push the idler shaft from the gears.

CLEANING AND INSPECTION

Clean the parts of the speed reducer in solvent. Check
the gear teeth and splines for wear or damage. Check the
bearings and the bores for the shafts for wear or damage.

ASSEMBLY (See FIGURE 1., FIGURE 5.
and FIGURE 6.)

1. Install the bearing cups for the input shaft and the idler
shaft in the speed reducer housing.

2. Install the bearing cone for the idler shaft in the bear-
ing cup that is in the housing. Install the idler gears in the
housing. The large gear fits toward the input side of the

housing. Use a press to push the idler shaft through the
gears and into the bearing cone. Use a press to install the
bearing cone on the other end of the idler shaft.

3. Install the bearing cup in the bearing cover for the
idler shaft. Install the bearing cover without shims.
Tighten the capscrews to 27 N.m (20 lbf ft). Measure the
clearance between the housing and the bearing cover.
Add shims under the bearing cover that are 0.03 to 0.08
mm (0.001 to 0.003 in) greater than the measured clear-
ance. Install the bearing cover and the bracket for the di-
rection control linkage. Tighten the capscrews to 27
N.m (20 lbf ft). (See FIGURE 5.)

4. Install the bearings in the forward and reverse gears.
Install the reverse gear (small) on the input shaft. Install
the bearing cone in the bearing cup that is in the housing.
Put the forward gear (large) in the housing against the
bearing cone. Put the sliding sleeve in the housing. Use a
press to install the input shaft through the bearings.
Make sure the drive gear on the input shaft is aligned

4

with the sliding sleeve. Install the bearing cone on the

input shaft.

FIGURE 5. INSTALL THE BEARING

COVERS

3461

1. BEARING COVER

1

1

5. Install the bearing cup in the bearing cover for the in-

put shaft. Install the bearing cover without shims. Tight-

en the capscrews to 27 N.m (20 lbf ft). Loosen the cap-

screws then tighten them by hand. Measure the clear-

ance between the bearing cover and the housing. Add

shims under the bearing cover that are 0.03 to 0.08 mm

(0.001 to 0.003 in) greater than the measured clearance.

Install the bearing cover and tighten the capscrews to 27

N.m (20 lbf ft). (See FIGURE 5.) Use a sealant on the

flange and install the oil seal carrier for the input shaft.

Tighten the capscrews to 27 Nm (20 lbf ft).

6. Install the fork on the sliding sleeve. Install the selec-

tor rail, washer and nut. Install the detent ball, spring and

capscrew. Install the neutral start switch assembly. Ad-

just the fork on the selector rail so that the sliding sleeve

engages the forward and reverse gears when in those

detent positions. Make sure the sliding sleeve is in the

Neutral position when the rail is in the neutral detent po-

sition. Tighten the nut when the adjustment is complete.

(See FIGURE 6.).

FIGURE 6. INSTALL THE SELECTOR RAIL

AND FORK

11577

1. FORK
2. SELECTOR RAIL
3. SLIDING SLEEVE
4. NEUTRAL START SWITCH
5. DETENT BALL

1

2

3

7. Apply a sealant (Hyster Part No. 264159) to the flange
of the plug for the idler shaft. Install the plug in the speed
reducer housing.

5

INSTALLATION (See FIGURE 1.)

NOTE: Check the length of the studs on the differential.
The length must be the dimension shown in Figure 1 to
make sure there is adequate threads for installation of
the tapered sleeves and nuts.

1. Apply a sealant (Hyster Part No. 264159) to the flange
of the bearing carrier on the differential. Put the output
gear on the pinion shaft. Put the speed reducer in posi-
tion on the differential. Install the tapered sleeves and
nuts. Tighten the nuts to 100 N.m (74 lbf ft).

2. Install the nut on the pinion shaft. Tighten the nut to
855 to 1100 N.m (630 to 812 lbf ft).

3. Install the gasket and cover on the speed reducer.

4. Lubricate the splines with grease and install the yoke
for the drive shaft. Install the drive shaft. Use a thread
locking compound on the capscrews for the universal
joints. Tighten the capscrews to 28 N.m (21 lbf ft).

5. Fill the speed reducer with 85W–140 lubricant. The
oil level is correct when it is even with the fill plug on the
speed reducer cover.

6. Install the bracket for the shift lever. Connect the link-
age to the selector rail. Adjust the linkage as described in
Checks and Adjustments. Check the operation of the
neutral start switch. The engine must start only when the
direction control lever is in the Neutral position.

CHECKS AND ADJUSTMENTS

ADJUST THE DIRECTION CONTROL
LINKAGE (See FIGURE 7.)

1. Adjust the ball joint (2) so that the shaft is 52 to 56 mm
(2.05 to 2.21 in) from the crank.

2. Put the selector rail in the speed reducer in the Neutral
position. Install the link (4). Adjust the length of the link
so that the control lever is 90

°

to the center line of the lift

truck.

3. Move the control lever to the Forward position. Ad-
just the stop (7) so that there is 0.025 to 0.050 mm (0.001
to 0.002 in) clearance between the stop and the crank on
the shaft. Shift the control lever to the Reverse position
and adjust the stop as described for the Forward posi-
tion.

FIGURE 7. ADJUST THE DIRECTION

CONTROL LINKAGE

11601

5. FORWARD–REVERSE

SPOOL

6. SPEED REDUCER
7. STOP
8. BEARING BLOCK

1. SHIFT LEVER

SHAFT

2. BALL JOINT
3. CRANK
4. LINK

52 to 56 mm
(2.05 to 2.21 in)