SERVICE Section: REDUCTION GEAR

REDUCTION
GEAR
a REDUCTION GEAR COMPONENTS ..................................... 2

a REDUCTION GEAR REMOVAL PROCEDURE .....................3

a REPLACING THE MOTOR SHAFT OIL SEAL ..................... 5

a REPLACING THE DRIVE WHEEL AXLE SHAFT OIL SEAL ..6

REDUCTION GEAR

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 Section: REDUCTION GEAR SERVICE

1.00 REDUCTION GEAR COMPONENTS

MODEL ALL MODELS

4 2
2

8
5

6
4
5
8
7 1

Fig. 1

1.01 TABLE OF REDUCTION GEAR COMPONENTS

REDUCTION GEAR

Ref. Component description

1 Complete reduction gear
2 Upper flange
3 Drive wheel
4 Drive motor shaft oil seal
5 Drive wheel axle shaft oil seal
6 Wheel stud
7 Motor shaft
8 Steering gear wheel
9 Oil filler plug
MDU 150 Oil Kg 2,00 (Std Const. Spirax a 80W-90 = Cold Store Transaxle oil 75W-90) Sheel
MDU 170 Oil Kg 2,50 (Std Const. Spirax a 80W-90 = Cold Store Transaxle oil 75W-90) Sheel

NOTE: All Hyster Part Numbers are given in the parts catalogue.

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SERVICE Section: REDUCTION GEAR

2.00 REDUCTION GEAR REMOVAL PROCEDURE

MODEL ALL MODELS

There are two different models of reduction gear utilized, identifiable by means of a code:

- MDU 150 installed on models R1.4 - R1.4H - R1.6 - R1.6N

- MDU 170 installed on models R1.6H - R2.0 - R2.0H - R2.0W - R2.5

The technical specifications of the two units are similar and the units are interchangeable.
The removal and installation procedure is therefore identical for both units.

SPECIAL EQUIPMENT REQUIRED

500 mm lever with flat bladed end

2 Wooden blocks 150x150x200
Sling with two hooks

STANDARD TOOLS REQUIRED

12
12
12
12
12

HEX WRENCH EYEBOLT ALLEN WRENCH OVERHEAD HYDRAULIC

10-13-17-24 mm 5-6 mm CRANE JACK

PROCEDURE

Before starting work, make sure you are wearing suitable safety clothing.

Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach
carriage to its forward position, lower the forks to the ground, set the keyswitch to OFF and
disconnect the battery.

REDUCTION GEAR
1) 5-6 mm ALLEN WRENCH - Use the 6 mm Allen wrench to
open the motor compartment hood, and use the 5 mm Allen
wrench to remove the floor panel.

2) HYDRAULIC JACK - Place the jack alongside the drive

wheel and lift the truck until the blocks can be inserted
under it.
Place the blocks at the sides (Fig. 2) and lower the jack
so that the truck is supported on the blocks. Remove the
jack.

3) Remove the steering motor (see mechanical section

Fig. 2
heading 5.00, page 20).

4) Remove the drive motor (see mechanical section

heading 3.00 page 12).

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 Section: REDUCTION GEAR SERVICE

5) Remove the drive wheel (see mechanical section heading

1.01 page 3).

6) LIFTING SLING - EYEBOLTS - Screw the eyebolts into two

opposite side drive motor fixing holes, (Fig. 4).
Attach the lifting sling hooks to the two eyebolts (Fig. 4) and the
other end of the sling to the overhead crane hook. A
Take the strain with the sling.

7) TWO 24 mm HEX WRENCHES - LEVER - Unscrew the nuts of

the bolts responsible for fixing the reduction gear to the truck body
(Ref. A Fig. 3) and withdraw the bolts.
The reduction gear fixing holes are equipped with precision steel Fig. 3
bushings that protrude 20 mm above the seat.
When the reduction gear unit is installed the protruding part of the
bushings is inserted in the holes in the truck body with the maximum
precision.
In order to extract the bushings in order to remove the reduction
gear, insert the lever or screwdriver between the reduction gear
unit and the truck body (Ref. B Fig. 4) and pry the reduction gear
until the bushings are disengaged. Remove the reduction gear and
replace it or strip it down in order to replace the necessary
components. B

To reassemble, perform the disassembly steps in reverse order.

NOTES: Fig. 4
REDUCTION GEAR

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SERVICE Section: REDUCTION GEAR

2.01 REPLACING THE MOTOR SHAFT OIL SEAL

MODEL ALL MODELS

The motor shaft oil seal is located in the reduction gear upper flange and cannot be removed without first
removing the drive motor.

STANDARD TOOLS REQUIRED

HEX WRENCH ALLEN WRENCH MEDIUM SLOTTED

13-17 mm 5 mm SCREWDRIVER

PROCEDURE

Before starting work, make sure you are wearing suitable safety clothing.

Park the truck in a safe place away from moving vehicles and pedestrians. Bring the reach
carriage to its forward position, lower the forks to the ground, set the keyswitch to OFF and
disconnect the battery.

1) Remove the drive motor (see heading mechanical section heading 3.00 page 12).

2) SLOTTED SCREWDRIVER - Use the screwdriver to prise the oil seal (Ref. C Fig. 5), remove the oil
seal and fit a replacement.

To reassemble, perform the disassembly steps in reverse order.

C REDUCTION GEAR

Fig. 6
Fig. 5

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2.02 REPLACING THE DRIVE WHEEL AXLE SHAFT OIL SEAL

MODEL ALL MODELS

The oil seal can be removed without having to remove the reduction gear from the truck.

SPECIAL EQUIPMENT REQUIRED

Lever or tube 30x300

Loctite sealing compound for gaskets
2 wooden blocks 150x150x200
Oil collection container

STANDARD TOOLS REQUIRED

ALLEN WRENCH HEX WRENCH SOCKET WRENCH HYDRAULIC MEDIUM SLOTTED

5-10 mm 13 mm 13-19 mm WITH JACK SCREWDRIVER
RATCHET

C-SPANNER FOR DRIFT 30x200 MEDIUM-WEIGHT RUBBER SMALL CHISEL

60 RINGNUTS STEEL HAMMER MALLET
REDUCTION GEAR

F
Fig. 7

G
E

Fig. 10 Fig. 8
D Fig. 9

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SERVICE Section: REDUCTION GEAR

PROCEDURE

Before starting work, make sure you are wearing suitable safety
clothing. H

Park the truck in a safe place away from moving vehicles and
pedestrians. Bring the reach carriage to its forward position, lower
the forks to the ground, set the keyswitch to OFF and disconnect
the battery.

1) HYDRAULIC JACK - WOODEN BLOCKS - Place the jack in the centre of

the carriage alongside the drive wheel, and lift the truck until the wooden
blocks can be inserted. Place the blocks alongside the jack and then lower
the jack until the truck body is resting on the blocks. Now remove the jack.

2) ALLEN WRENCH 5-10 mm - Use the 5 mm wrench to open the motor Fig. 11
compartment hood. With the 10 mm Allen wrench remove the guard in
correspondence with the drive wheel.

3) Remove the drive wheel (see mechanical section heading 1.01

page 2).

4) 10 mm ALLEN WRENCH - OIL COLLECTION CONTAINER - Position the

container under the reduction gear drain plug (Ref. D Fig. 9), using the Allen
wrench unscrew and remove the plug and allow the oil to drain out of the
reduction gear.
Fig. 12
5) 13 mm SOCKET WRENCH WITH RATCHET - Unscrew and remove the
reduction gear cover fixing screws (Ref. E Fig. 9). Remove the cover to
gain access to the gears.

6) CHISEL - MEDIUM-WEIGHT STEEL HAMMER - Using the hammer and

chisel raise the clenched lip of the locking ring in the axle shaft seat (Ref. F
Fig. 7) so that the locking ring can be unscrewed.

7) C-SPANNER - LEVER OR TUBE - Fit two screws into the axle shaft flange
and between them insert the tube or lever; use the C-spanner to unscrew
the locking ring completely (Fig. 14).

REDUCTION GEAR
8) RUBBER MALLET - DRIFT - Place the drift on the shaft (Ref. G Fig. 8) and
using the hammer to drive out the shaft from the opposite side. Fig. 13
Attention is required because inside the reduction gear there are a distance
ring and several shims located beyond the bevel gear; these components
must be recovered and then re-fitted when the unit is reassembled
(Fig. 12).

9) SLOTTED SCREWDRIVER - Use the screwdriver to prise between the oil

seal and bearing (Ref. H Fig. 11). Extract the oil seal from its seat and fit
a replacement part.

To reassemble, perform the disassembly steps in reverse order.

Fig. 14

MDU 150 Oil Kg 2,00 (Std Const. Spirax a 80W-90 = Cold Store Transaxle oil 75W-90) Sheel
MDU 170 Oil Kg 2,50 (Std Const. Spirax a 80W-90 = Cold Store Transaxle oil 75W-90) Sheel

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 Section: REDUCTION GEAR SERVICE
NOTES:
REDUCTION GEAR

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