Hyster D222 (RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L-CH, RS46-41S-CH, RS46-41LS-CH) Internal Combu

Hyster D222 (RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L-CH, RS46-41S-CH, RS46-41LS-CH) Internal Combustion Engine Trucks Service Repair Manual

TRANSMISSION REPAIR

(TE27 AND TE32) H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]; H36XMS-12, H40XM-12, H44XM-12, H48XM-12 (H800HD, H1050HD) [B917]; RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH, RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222]; RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS CH, RS45-24 IH, RS45-28IH, RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS IH (RS45-27, RS45-31, RS46-36, RS46-41L, RS46-41S, RS46-41LS) [C222]; HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS, HR45-45LSX [C227]; H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [F117]; H40XM-16CH, H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH (H1050HD, H1150HD) [G117]; H40.00-52.00XM-16CH (H1050HD-16CH, H1150HD-16CH) [H117]; RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS CH, RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS IH (RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS CH) [D222]; H40XM-12, H44XM-12, H48XM-12, H36XMS-12, H40XMS-12, H44XMS-12, H48XMS-12 (H800HDS, H900HDS, H970HDS, H1050HDS) [C917]

PART NO. 4025121

1300 SRM 1445

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Hyster® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

Do not lift heavy parts by hand, use a lifting mechanism.

Wear safety glasses.

DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

Keep the unit clean and the working area clean and orderly.

Use the correct tools for the job.

Keep the tools clean and in good condition.

Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

Be sure to follow the WARNING and CAUTION notes in the instructions.

Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

Table of Contents

TABLE OF CONTENTS General .....................................................................................................................................................................1 Transmission Repair ............................................................................................................................................... 1 Remove ................................................................................................................................................................ 1 Disassemble .........................................................................................................................................................4 Transmission Case, Disassemble ...................................................................................................................5 Converter Housing, Disassemble .................................................................................................................28 Reverse and Second-Speed Clutch ...............................................................................................................30 Reverse, Disassemble ...............................................................................................................................30 Second-Speed Clutch, Disassemble ......................................................................................................... 35 Forward Clutch, Disassemble ...................................................................................................................... 37 Third-Speed Clutch, Disassemble ................................................................................................................43 Fourth-Speed Clutch, Disassemble ............................................................................................................. 47 First-Speed Clutch, Disassemble .................................................................................................................50 Output Shaft, Disassemble .......................................................................................................................... 56 Turbine Shaft, Disassemble ......................................................................................................................... 57 Impeller and Baffle, Disassemble ................................................................................................................ 59 Impeller Cover and Turbine Assembly, Disassemble .................................................................................62 Pump Drive Gear, Disassemble ................................................................................................................... 63 Clean and Inspect ............................................................................................................................................. 64 Housings ........................................................................................................................................................64 Oil Seals and Gaskets ...................................................................................................................................65 Bearings ........................................................................................................................................................ 65 Gears and Shafts .......................................................................................................................................... 65 Assemble ............................................................................................................................................................65 Pump Drive Gear, Assemble ........................................................................................................................ 65 Impeller Cover and Turbine, Assemble .......................................................................................................66 Impeller and Baffle, Assemble ..................................................................................................................... 67 Turbine Shaft, Assemble .............................................................................................................................. 70 Output Shaft, Assemble ............................................................................................................................... 72 First-Speed Clutch, Assemble ......................................................................................................................73 Fourth-Speed Clutch, Assemble .................................................................................................................. 80 Third-Speed Clutch, Assemble .....................................................................................................................85 Forward Clutch, Assemble ........................................................................................................................... 90 Reverse and Second-Speed Clutch ...............................................................................................................97 Second-Speed Clutch, Assemble .............................................................................................................. 97 Reverse Clutch, Assemble ......................................................................................................................100 Converter Housing, Assemble ....................................................................................................................106 Transmission Case, Assemble ....................................................................................................................110 Install ...............................................................................................................................................................131 Control Valve With Solenoid Cover ....................................................................................................................134 Remove ............................................................................................................................................................ 134 Install ...............................................................................................................................................................134 Control Valve Disassemble and Assemble .....................................................................................................136 Control Valve Cover Removal ........................................................................................................................ 136 Control Valve Components .............................................................................................................................136 Disassemble ................................................................................................................................................ 136 Install .......................................................................................................................................................... 136 Control Valve Cover Installation ................................................................................................................... 137 Full Flow Control Valve Repair ..........................................................................................................................138 Remove ............................................................................................................................................................ 138

©2014 HYSTER COMPANY

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Table of Contents

TABLE OF CONTENTS (Continued) Install ...............................................................................................................................................................138 Control Valve Components .............................................................................................................................140 This section is for the following models: H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]; H36XMS-12, H40XM-12, H44XM-12, H48XM-12 (H800HD, H1050HD) [B917]; RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH, RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222]; RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS CH, RS45-24 IH, RS45-28IH, RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS IH (RS45-27, RS45-31, RS46-36, RS46-41L, RS46-41S, RS46-41LS) [C222]; (HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS, HR45-45LSX) [C227]; H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [F117]; H40XM-16CH, H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH (H1050HD, H1150HD) [G117]; H40.00-52.00XM-16CH (H1050HD-16CH, H1150HD-16CH) [H117]; RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS CH, RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS IH (RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS CH) [D222]; H40XM-12, H44XM-12, H48XM-12, H36XMS-12, H40XMS-12, H44XMS-12, H48XMS-12 (H800HDS, H900HDS, H970HDS, H1050HDS) [C917]

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1300 SRM 1445

General

General This manual provides information on the repair and diagnostics of the TE-27 and TE-32 transmission. The difference between models TE-27 and TE-32 is in the number of discs in the clutches.

Model TE-32 is fitted on trucks with the 250 kW QSM-11 engine, or as an option for trucks with QSL-9 engines.

Two different types of control valve are used: •

Control valves that have a cover to protect the solenoids are used on truck series B222, F117, and A917.

•

Full flow control valves (with exposed solenoids) are used on truck series C222, G117, and B917.

Electrical system diagrams are shown in Diagrams 8000SRM1153 for A917 and F117 and in Diagrams 8000SRM1261 for B222.

Electrical system diagrams are shown in Diagrams 8000SRM1491 for C222 and in Diagrams 8000SRM1563 for B917 and G117.

Transmission Repair REMOVE

4. Disconnect the cables at the battery.

NOTE: The transmission can be removed by lifting it out of the lift truck.

5. Remove floor plates and covers to provide access to the hydraulic pumps and transmission.

1. Place the lift truck on a solid, level surface.

6. Close shutoff valves on the bottom of the hydraulic tank.

2. Turn the key to OFF position to shut down the engine.

3. Apply the parking brake.

7. Disconnect the drive shaft at the differential.

Remove the drive shaft between the transmission and the differential. See Figure 1.

NOTE: When removing battery cables, always disconnect the ground cable first and then the positive cable.

1

Transmission Repair

1300 SRM 1445

Figure 1. Transmission Arrangement

2

1300 SRM 1445

Transmission Repair Legend for Figure 1

1.

2.

3.

4.

FRAME (REFERENCE) DIPSTICK ASSEMBLY TRANSMISSION MOUNT ASSEMBLY TORQUE CONVERTER HOUSING

5.

6.

7.

8.

FLYWHEEL HOUSING CAPSCREW OUTPUT YOKE DRIVE SHAFT

3

Transmission Repair 8. Disconnect the wiring harnesses on top of the transmission.

9. Disconnect the wires at the pressure and temperature sending unit on the transmission. Put identification tags on the wires so they can be correctly connected again.

10. Place a suitable container under the transmission sump and remove the transmission sump drain plug and drain the transmission oil.

11. Disconnect the oil lines to the oil cooler at the transmission. Drain the oil into a drain pan.

Put plugs and caps on open lines/fittings.

12. Disconnect the oil hoses at the hydraulic pumps. Put plugs and caps on open lines/ fittings.

NOTE: The hydraulic pumps are connected to the transmission cover with four capscrews each. The drive shaft of the hydraulic pump is engaged in the splines of the drive gear. The drive shaft of the hydraulic pump will slide out of the drive gear when the hydraulic pump is removed.

1300 SRM 1445 17. Connect a lifting device to the transmission.

18. Remove the transmission mounts to the frame.

CAUTION Do not drop the capscrews into the converter housing. They will be difficult to retrieve.

NOTE: You must turn the flywheel to gain access to each capscrew.

19. Remove the eight capscrews retaining the drive plate to the flywheel.

20. Raise the lifting device to hold the weight of the transmission only. Remove all fasteners between the torque converter housing to the flywheel housing.

21. Make sure that all connections have been removed.

WARNING The transmission is heavy. Verify that the lifting devices are properly positioned.

13. Remove the hydraulic pumps.

14. Disconnect and remove the dipstick assembly from the transmission.

15. Install blocks and a jack under the flywheel end of the engine as a support. If the support is under the engine oil sump, make sure that the support is across the width of the oil sump so the weight of the engine does not damage the oil sump.

16. Disconnect the exhaust system to avoid possible damage.

WARNING Verify that the lifting device has a minimum capacity of 1730 kg (3814 lb).

4

CAUTION Keep the transmission level when the transmission is separated from the engine so the drive plate is not damaged.

22. To avoid damage to the drive plate, carefully lift the transmission assembly past the crossmember support.

23. Carefully ground.

lower

the

transmission

on

the

DISASSEMBLE Figure 2 shows the front view of the TE27 and TE32 transmission.

1300 SRM 1445

Transmission Repair

Figure 2. TE27 and TE32 Transmission

Transmission Case, Disassemble

CAUTION Be sure to support the impeller cover bearing cap while removing the drive plate mounting bolts or the bearing cap may drop.

STEP 1.

Remove the drive plate mounting bolts and washers.

STEP 2.

Remove the drive plate and backing ring.

5

Transmission Repair STEP 3.

Remove impeller cover bearing cap and O-ring.

STEP 4.

Remove turbine shaft outer retaining snap ring.

STEP 5.

Remove converter assembly bolts.

6

1300 SRM 1445

1300 SRM 1445

Transmission Repair

STEP 6.

Using a special tool, lift and remove the impeller and cover assembly.

STEP 7.

Remove turbine locating ring from turbine shaft.

STEP 8.

Remove reaction member retaining snap ring.

STEP 9.

Remove reaction member.

7

Transmission Repair STEP 10.

Remove reaction member spacer.

STEP 11.

Remove oil baffle retaining ring.

STEP 12.

An impeller removal tool, like the one shown, can be fabricated to aid in the removal of the impeller and oil baffle. Remove the impeller and oil baffle.

8

1300 SRM 1445

1300 SRM 1445

Transmission Repair

STEP 13.

Remove pump manifold capscrews and hose clamps.

STEP 14.

Remove pump manifold and hose.

STEP 15.

Remove pump mounting capscrews.

STEP 16.

Remove the pump.

9

Transmission Repair STEP 17.

Remove pump drive sleeve.

STEP 18.

Remove regulator valve capscrews.

STEP 19.

Remove the regulator valve and gasket.

10

1300 SRM 1445

1300 SRM 1445

Transmission Repair

STEP 20.

If fitted, remove pump drive blanking cover bolts.

STEP 21.

If fitted, remove pump drive blanking cover and gasket.

STEP 22.

Remove stator support bolts and lockwashers.

11

Transmission Repair STEP 23.

Remove stator support.

STEP 24.

Remove pump drive idler gear bolts.

STEP 25.

Remove pump drive idler gear, bearing, and support assembly.

12

1300 SRM 1445

1300 SRM 1445

Transmission Repair

STEP 26.

Remove pump drive gear bolts (position A).

STEP 27.

Remove pump drive gear (position A).

STEP 28.

Remove pump drive gear bolts (position B).

13

Transmission Repair STEP 29.

Remove pump drive gear (position B).

STEP 30.

Remove the control valve. See Control Valve With Solenoid CoverRemove for removal procedures.

STEP 31.

Remove all sensors from converter housing.

14

1300 SRM 1445

1300 SRM 1445

Transmission Repair

STEP 32.

Remove temperature sensor.

STEP 33.

Remove converter housing to transmission case bolts and washers.

NOTE: Reverse and 2nd clutch drum and 4th clutch drum will stay in the converter housing.

STEP 34.

Support converter housing with chain hoist and strap. Use a soft hammer to separate converter housing from transmission case.

15

Transmission Repair STEP 35.

Converter assembly removed.

STEP 36.

Remove snap ring from 2nd clutch hub (driven gear).

STEP 37.

Remove washer from 2nd clutch hub.

16

1300 SRM 1445

1300 SRM 1445

Transmission Repair

STEP 38.

Remove inner retaining ring from 2nd clutch hub.

STEP 39.

Remove 2nd clutch hub.

STEP 40.

Remove snap ring from 4th clutch hub and remove hub.

17

Transmission Repair STEP 41.

Install special tool to prevent 1st shaft from damaging bearing.

STEP 42.

Using an impact gun, remove output flange nut.

STEP 43.

Output flange nut, washer, and O-ring removed.

STEP 44.

Remove output flange.

18

1300 SRM 1445

1300 SRM 1445

Transmission Repair

STEP 45.

Remove bolts from 3rd clutch shaft rear bearing cap.

STEP 46.

Remove 3rd clutch shaft rear bearing cap and Oring.

STEP 47.

Remove 3rd clutch shaft rear bearing cap locating ring.

STEP 48.

Remove 1st clutch shaft rear bearing cap bolts.

19