Hyster B917 Operating instructions

Hyster B917 (H800HDS, H900HDHDS, H970HDHDS,
H1050HDHDS) 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 in-
structions 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 ex-
ceed 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 flamma-
ble. 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 back-
ground. The CAUTION symbol and word are on yellow background.

©2014 HYSTER COMPANY
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
Table of Contents
i

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]
Table of Contents
ii

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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
NOTE: The transmission can be removed by lifting
it out of the lift truck.
1. Place the lift truck on a solid, level surface.
2. Turn the key to OFF position to shut down the
engine.
3. Apply the parking brake.
NOTE: When removing battery cables, always dis-
connect the ground cable first and then the positive
cable.
4. Disconnect the cables at the battery.
5. Remove floor plates and covers to provide ac-
cess to the hydraulic pumps and transmission.
6. Close shutoff valves on the bottom of the hy-
draulic tank.
7. Disconnect the drive shaft at the differential.
Remove the drive shaft between the transmis-
sion and the differential. See Figure 1.
1300 SRM 1445 General
1

Figure 1. Transmission Arrangement
Transmission Repair 1300 SRM 1445
2

Legend for Figure 1
1. FRAME (REFERENCE)
2. DIPSTICK ASSEMBLY
3. TRANSMISSION MOUNT ASSEMBLY
4. TORQUE CONVERTER HOUSING
5. FLYWHEEL HOUSING
6. CAPSCREW
7. OUTPUT YOKE
8. DRIVE SHAFT
1300 SRM 1445 Transmission Repair
3

8. Disconnect the wiring harnesses on top of the
transmission.
9. Disconnect the wires at the pressure and tem-
perature 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 transmis-
sion 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 hy-
draulic pump will slide out of the drive gear when
the hydraulic pump is removed.
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 un-
der 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 ca-
pacity of 1730 kg (3814 lb).
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 be-
tween the torque converter housing to the fly-
wheel housing.
21. Make sure that all connections have been re-
moved.
WARNING
The transmission is heavy. Verify that the lifting
devices are properly positioned.
CAUTION
Keep the transmission level when the transmis-
sion 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 cross-
member support.
23. Carefully lower the transmission on the
ground.
DISASSEMBLE
Figure 2 shows the front view of the TE27 and
TE32 transmission.
Transmission Repair 1300 SRM 1445
4