GENERAL also has the gears and linkage to permit forward and re-
verse travel of the lift truck.
This section has a description and the repair procedures
for the speed reducer. The speed reducer is installed on the differential hous-
ing. The output shaft of the transmission is connected to
DESCRIPTION (See FIGURE 1.) the input shaft of the speed reducer. The forward and re-
verse gears and the sliding sleeve are installed on the in-
The speed reducer transfers power between the trans- put shaft. A pair of idler gears are used to connect the re-
mission and the differential and increases the torque verse gear to the output gear. The output gear is installed
from the engine to the drive wheels. The speed reducer on the pinion shaft of the differential.
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
26.9 mm 10. OUTPUT GEAR
(1.059 in) 11. PINION SHAFT
12. BEARING COVER
11608
1
OPERATION (See FIGURE 2.)
REPAIRS
REMOVAL (See FIGURE 3.) 2. Disconnect and remove the drive shaft between the
speed reducer and the transmission.
1. Disconnect the linkage at the lever that is on the speed 3. Drain the oil from the speed reducer housing. Remove
reducer housing. Disconnect the wires at the neutral the cover from the speed reducer.
start switch. Disconnect the cable clamps at the housing.
4. Remove the nut from the pinion shaft and remove the
output gear. Remove the nuts and tapered sleeves that
3 hold the speed reducer to the differential housing. Re-
move the speed reducer from the bottom of the lift truck.
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.
1 3443 2. Remove the bearing covers for the input shaft and the
2
idler shaft.
1. OUTPUT GEAR
2. TAPERED SLEEVE 3. Use a press to push the input shaft from the housing as
3. PINION SHAFT shown in FIGURE 4. Make sure to use a block as a sup-
FIGURE 3. REMOVE THE port under the sliding sleeve. Also make sure the sliding
SPEED REDUCER sleeve is aligned with the teeth of the drive gear. The
drive gear must be pushed through the sliding sleeve.
2
2
2566
1. PRESS
2. INPUT SHAFT
3. SLIDING SLEEVE
3
with the sliding sleeve. Install the bearing cone on the
input shaft.
2
1
3461
1
1. BEARING COVER
FIGURE 5. INSTALL THE BEARING
COVERS
3
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
11577
(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). 1. FORK
2. SELECTOR RAIL
3. SLIDING SLEEVE
4. NEUTRAL START SWITCH
6. Install the fork on the sliding sleeve. Install the selec- 5. DETENT BALL
tor rail, washer and nut. Install the detent ball, spring and
FIGURE 6. INSTALL THE SELECTOR RAIL
capscrew. Install the neutral start switch assembly. Ad- AND FORK
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- 7. Apply a sealant (Hyster Part No. 264159) to the flange
sition. Tighten the nut when the adjustment is complete. of the plug for the idler shaft. Install the plug in the speed
(See FIGURE 6.). reducer housing.
4
INSTALLATION (See FIGURE 1.) 3. Install the gasket and cover on the speed reducer.
4. Lubricate the splines with grease and install the yoke
NOTE: Check the length of the studs on the differential.
for the drive shaft. Install the drive shaft. Use a thread
The length must be the dimension shown in Figure 1 to
locking compound on the capscrews for the universal
make sure there is adequate threads for installation of
joints. Tighten the capscrews to 28 N.m (21 lbf ft).
the tapered sleeves and nuts.
5. Fill the speed reducer with 85W140 lubricant. The
1. Apply a sealant (Hyster Part No. 264159) to the flange oil level is correct when it is even with the fill plug on the
of the bearing carrier on the differential. Put the output speed reducer cover.
gear on the pinion shaft. Put the speed reducer in posi-
tion on the differential. Install the tapered sleeves and 6. Install the bracket for the shift lever. Connect the link-
nuts. Tighten the nuts to 100 N.m (74 lbf ft). age to the selector rail. Adjust the linkage as described in
Checks and Adjustments. Check the operation of the
2. Install the nut on the pinion shaft. Tighten the nut to neutral start switch. The engine must start only when the
855 to 1100 N.m (630 to 812 lbf ft). direction control lever is in the Neutral position.
5. FORWARDREVERSE
SPOOL
6. SPEED REDUCER
7. STOP
8. BEARING BLOCK
FIGURE 7. ADJUST THE DIRECTION
CONTROL LINKAGE