Hyster D117 Operating instructions

Hyster D117 (H1050EH, H800E, H880E, H970E) Forklift

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SERVICE BRAKE
RS45-30CH, RS46-33CH, RS45-27IH,
RS46-60IH (RS45-30CH, RS46-33CH, RS45-27IH,
RS46-60IH) [A222];
HR45-25, HR45-27, HR45-31, HR45-40S,
HR45-36L, HR45-40LS, HR45-45LSX,
HR45H [A227, B227];
H36.00-48.00E (H800-1050E) [D117];
H36.00-48.00E-16CH (H800-1050E-16CH) [D117];
H20.00-32.00F (H440-700F/FS) [E008]
PART NO. 1531822 1800 SRM 1038

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•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 Mainte-
nance 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 condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!

Service Brake Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
Repair ................................................................................................................................................................. 2
Remove ........................................................................................................................................................... 2
Brake Assembly......................................................................................................................................... 2
Spindle and Brake Cover .......................................................................................................................... 5
Disassemble ................................................................................................................................................... 6
Clean .............................................................................................................................................................. 8
Ground and Polished Parts....................................................................................................................... 8
Parts With Rough Finish .......................................................................................................................... 8
Wet Disc Brake and Axle Assembly ......................................................................................................... 8
Inspect ............................................................................................................................................................ 8
Face Seals .................................................................................................................................................. 8
Disc............................................................................................................................................................. 9
Wear Limits........................................................................................................................................... 9
Replace ........................................................................................................................................................... 9
Parts........................................................................................................................................................... 9
Assemble ........................................................................................................................................................ 9
Brake Housings ......................................................................................................................................... 9
Install ............................................................................................................................................................. 12
Hub Oil Seals............................................................................................................................................. 12
Double Seals.......................................................................................................................................... 12
Single Seal............................................................................................................................................. 12
Spindle and Brake Cover .......................................................................................................................... 13
Brake Housing........................................................................................................................................... 15
Specifications...................................................................................................................................................... 18
Brake Coolant ................................................................................................................................................ 21
Coolant Change Intervals ......................................................................................................................... 21
Break-In................................................................................................................................................. 21
Normal Maintenance ............................................................................................................................ 21
Hydraulic Fluid.............................................................................................................................................. 21
Troubleshooting.................................................................................................................................................. 21
This section is for the following models:
RS45-30CH, RS46-33CH, RS45-27IH, RS46-60IH (RS45-30CH,
RS46-33CH, RS45-27IH, RS46-60IH) [A222];
HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS,
HR45-45LSX, HR45H [A227, B227];
H36.00-48.00E (H800-1050E) [D117];
H36.00-48.00E-16CH (H800-1050E-16CH) [D117];
H20.00-32.00F (H440-700F/FS) [E008]
©2003 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

1800 SRM 1038 Description and Operation
General
For the service brake system, there are oil-cooled
brakes at the drive wheels. This service manual has
information on how to drain, fill, remove, disassem-
ble, clean, check, assemble, and install the service
brake system. This service manual also includes
troubleshooting and specifications.
Description and Operation
The service brake pedal (treadle valve) or the de-
clutch/brake pedal, when operated by the driver, con-
trols the flow of oil to the service brake piston at each
drive wheel.
Two to ten friction discs are used in the housing de-
pending on the requirements of the brake system.
Friction discs, each between stationary discs, rotate
with the wheel hub. The stationary discs are locked
to the brake housing. The disc brakes are installed
on the drive wheels and are oil-cooled. See Figure 1
and the section Planetary Gear Axle.
Figure 1. Wet Disc Brake Housing
1

Repair 1800 SRM 1038
Legend for Figure 1
1. BRAKE HOUSING COVER CAPSCREW
2. BRAKE HOUSING COVER WASHER
3. BLEEDER SCREW
4. FORCED COOLING INLET PLUG
5. BRAKE HOUSING COVER PLUG
6. INLET FITTING PLUG
7. BRAKE HOUSING COVER
8. AXLE COVER HOUSING WASHER
9. AXLE COVER HOUSING CAPSCREW
10. PISTON SEAL
11. PISTON SEAL SPACER
12. PISTON
13. STATIONARY DISC
14. FRICTION DISC
15. STATIONARY BRAKE HOUSING DISC SPACER
16. BRAKE HOUSING
17. PISTON RETURN SPRING GUIDE
18. PISTON RETURN SPRING
19. PISTON RETURN SPRING PLUG
20. BRAKE HOUSING PLUG
21. FACE SEAL ASSEMBLY
22. TEMPERATURE SENSOR BRACKET
CAPSCREW
23. TEMPERATURE SENSOR BRACKET WASHER
24. TEMPERATURE SENSOR BRACKET
25. TEMPERATURE SENSOR PLUG
26.FILLANDLEVELPLUG
27. MAGNETIC DRAIN PLUG
28. INLET FITTING PLUG
29. BRAKE INLET FITTING
30. FORCED COOLING OUTLET PLUG
Repair
REMOVE
Brake Assembly
WARNING
Support the truck with safety stands. Do not
workunderatrucksupportedonlybyjacks.
Completely remove the air pressure from the
tires before removing the wheels from the lift
truck. Air pressure in the tires can cause the
tire and rim parts to explode, causing serious
injury or death.
Always wear safety glasses.
1. Place truck on level surfaces.
2. Lower the mast completely.
3. Shut down the engine.
4. Place blocks at front and rear of steer tires. See
Figure 2.
5. Raise the drive wheels.
6. Put blocks under frame.
1. DRIVE TIRES 2. STEER TIRES
Figure2. PutLiftTruckonBlocks
2

1800 SRM 1038 Repair
7. Apply brakes ten to twenty times until accumu-
lated hydraulic brake pressure is removed.
8. Remove tire and rim assembly.
9. Remove end drive. See 1400 SRM 47.
10. Remove inner face seal from inside the brake
housing. See Figure 3.
1. BRAKE HOUSING 2. FACE SEAL
Figure 3. Brake Housing
11. Remove the outer face seal from the wheel hub.
SeeFigure4.
1. WHEEL HUB
Figure 4. Wheel Hub
12. Place a container on inner side of the brake hous-
ing.
13. Disconnect the coolant input line.
14. Place cap on line.
15. Drain coolant until no oil flows from the input
port. See Figure 5.
1. LH HOUSING COOLANT INPUT PORT
2. RH HOUSING COOLANT INPUT PORT
3. RH HOUSING COOLANT OUTPUT PORT
4. MAGNETIC DRAIN PLUGS
5. LH HOUSING COOLANT OUTPUT PORT
Figure 5. Coolant Input Port
16. Disconnect coolant output line.
17. Put cap on line.
18. Drain the coolant until no oil flows from the out-
put port.
19. Remove the two magnetic drain plugs.
20. Drain all the oil that remains in the brake hous-
ing.
21. Record the amount of oil that is being drained
from the brake housing.
22. Remove the brake lines from the brake housing.
23. Put caps on lines.
24. Clean the magnetic drain plugs.
25. Install and tighten the drain plugs to 27 N•m
(20 lbf ft).
3

Repair 1800 SRM 1038
26. Remove temperature sensor, if fitted.
27. Remove bleeder screw and inlet fittings for the
hydraulic lines. See Figure 6.
1. BLEEDER SCREW
2. HYDRAULIC INLET FITTING, O-RING TYPE
3. HYDRAULIC INLET FITTING, TAPERED SEAT
TYPE
Figure 6. Bleeder Screw and Inlet Fittings
WARNING
Verify the lifting device has the rated capacity
to lift the brake assembly.
28. Support the brake assembly using a lifting de-
vice.
29. Remove the capscrews that fasten the cover to
thebrakehousing.SeeFigure7.
CAUTION
Do not damage spindle when removing the
brake assembly.
30. Carefully slide the brake assembly away from
the spindle using the lifting device. See Figure 8.
31. Remove all gasket material from surfaces.
1. CAPSCREW
Figure 7. Brake Housing Capscrews
1. LIFTING DEVICE 2. BRAKE HOUSING
Figure 8. Brake Housing
4

1800 SRM 1038 Repair
Spindle and Brake Cover
NOTE: On some axle assemblies, the brake cover
is mounted between the spindle and axle housing
flanges. To remove the spindle and brake cover, use
the following procedure.
Remove the spindle first followed by the brake cover.
1. Support the cover of the brake housing with a
lifting device.
2. Remove two of the capscrews that fasten the
brake cover and spindle to the axle housing.
Replace them with two studs. See Figure 9.
1. STUD
Figure 9. Brake Housing Studs
3. Remove the remaining capscrews.
4. Hold the spindle against the axle housing.
NOTE: If necessary, tap the brake cover with a rubber
or plastic hammer to separate it from the spindle.
5. Usealiftingdevicetoremovethebrakecover.
See Figure 10.
NOTE: If necessary, tap the brake cover with a rub-
berorplastichammertoseparateitfromtheaxle
housing.
6. Usealiftingdevicetoremovethespindle. See
Figure 11.
7. Remove all gasket material from the mounting
surfaces of the cover, spindle, and axle housing.
1. LIFTING DEVICE 2. BRAKE COVER
Figure 10. Brake Cover
1. LIFTING DEVICE 2. SPINDLE
Figure 11. Spindle
5

Repair 1800 SRM 1038
DISASSEMBLE
WARNING
To prevent serious eye injury, always wear safe
eye protection when doing maintenance or ser-
vice.
1. Put the appropriate pry bars under the inner di-
ameter of the piston to lift the piston out of the
housing. The two piston seals and the seal spacer
are removed when the piston is removed from the
housing. See Figure 12.
Figure 12. Piston, Piston Seals, and Seal
Spacer
2. Remove the stationary discs and the friction
discs from the brake housing. See Figure 13.
1. STATIONARY DISC 2. FRICTION DISC
Figure 13. Stationary and Friction Disc
NOTE: Some brake assemblies use a spacer and stan-
dard stationary disc. Some use a single thick-splined
stationary disc as the first disc against the housing
instead of a spacer and standard stationary disc com-
bination. Brake housings are designed to use only
onetypeofdiscconfiguration. Donotinterchange
parts.
3. Removethediscspacerfromthebottomofthe
brake housing. See Figure 14.
1. DISC SPACER
Figure 14. Disc Spacer
WARNING
The piston return spring applies pressure to
the plug. Use the following procedure or the
spring can push the plug out of the housing
with enough force to cause serious personal in-
jury.
NOTE: If necessary, remove the four piston return
spring assemblies with the following procedure.
4. Put the brake housing on a bench so that the
outboard side is toward you. See Figure 15.
6

1800 SRM 1038 Repair
1. PISTON RETURN SPRING ASSEMBLY
Figure 15. Piston Return Spring
WARNING
Observe all WARNINGS and CAUTIONS pro-
vided by the press manufacturer concerning
press operation to avoid serious personal in-
jury and possible damage to components.
5. Use a press to apply and keep pressure on the
plug. See Figure 16.
1. PRESS
Figure 16. Plug
6. Slowly release pressure while loosening the plug
until the threads are completely disengaged and
the spring is fully expanded. See Figure 17.
1. HOUSING
2. SPRING, FULLY EXPANDED
3. SHOULDER
4. SPRING GUIDE
Figure 17. Piston Return Spring
7. Remove the plug and pin assembly, the spring,
and the spring guide from the housing.
NOTE: Two types of spring guides are used. One type
of guide has a pin on the bottom that is installed in-
side the spring. The other type of guide has a hole
in the bottom so that the end of the pin is installed
inside the guide. See Figure 18.
8. Inspect the O-ring on the plug. If necessary, re-
move and replace the O-ring.
1. SPRING GUIDE, HOLE TYPE
2. SPRING GUIDE, PIN TYPE
3. SPRING
4. O-RING
5. PIN AND PLUG ASSEMBLY
Figure 18. Piston Return Spring Assembly
7

Repair 1800 SRM 1038
CLEAN
CAUTION
The bearing cones can be damaged if the cones
are dried by rotating with compressed air.
The parts, except the bearing cones, can be dried with
compressed air.
NOTE: Dry the parts immediately after the parts are
cleaned and washed.
Dry the parts with soft, clean paper or rags.
NOTE: Apply the fluid used in the brake housing to
the cleaned and the dried parts that are not damaged
and are to be assembled.
Apply a special material that prevents corrosion and
rust to all surfaces. If parts are to be stored, put the
parts in a special paper that prevents corrosion and
rust.
Ground and Polished Parts
WARNING
To prevent serious eye injury, always wear safe
eye protection when doing maintenance or ser-
vice.
If you use cleaning solvents, hot solution tanks,
or alkaline solutions incorrectly, serious per-
sonal injury can occur. To prevent serious
personal injury, follow the instructions sup-
plied by the manufacturer of these products.
Do NOT use gasoline to clean parts. Gasoline
can explode and cause serious personal injury.
CAUTION
Use only solvent cleaners to clean ground or
polished metal parts. Hot solution tanks or wa-
ter and alkaline solutions will damage these
parts. Isopropyl alcohol, kerosene, or diesel
fuel can be used for this purpose.
1. Use solvent cleaner to clean surfaces.
2. If necessary, remove gasket material from parts.
Parts With Rough Finish
NOTE: Do not clean friction discs. Wipe off each disc
with a clean rag before applying brake cooling fluid
to their surfaces during assembly.
Parts must remain in hot solution tanks until com-
pletely cleaned and heated.
1. Clean with cleaning solvent or in a hot solution
tank with a weak alkaline solution.
2. Remove parts from the hot solution and wash
them with water until the hot solution is re-
moved.
Wet Disc Brake and Axle Assembly
NOTE: Before the assembly is cleaned, close or put
a cover over all openings. Breathers or vents in the
axle assembly are some examples of openings.
1. Use steam to clean the outside of the wet disc
brake and axle assembly.
INSPECT
NOTE: Inspect all the parts before assembling the
wetdiscbrake. Checkallpartsforwearandre-
place the damaged parts. Replacing worn or dam-
aged parts prevents the failure of the assembly later.
Face Seals
Inspect the rubber elements and metal rings for
wear, damage, or distortion. If there is a problem
with either ring, always replace both rings with a
matchedpairofrings. Amatchedpairistwonew
rings or two used rings that have been run together.
Do not use one new and one used ring or two used
rings that were not run together or leaks may occur.
SeeFigure19.
1. METAL SEALING RINGS
2. RUBBER ELEMENTS
Figure 19. Face Seal Assembly
8

1800 SRM 1038 Repair
Disc
NOTE: If discs are reusable, maintain disc stack or-
der.
If any of the following conditions exist with a friction
or stationary disc, replace full disc stack:
•Thickness worn beyond limits
•Uneven wear
•Localized surface damage
•Warpage
•Scoring
•Damaged splines
Wear Limits
NOTE: If thickness of any friction or stationary disc
is less than or equal to overall thickness limits, re-
place full disc stack. See Table 1 and Table 2.
Remove the plug opposite the inlet fitting. The plug
is at 9 o’clock on the right hand side and at 3 o’clock
on the left hand side when viewed from the center-
line of the truck. When removed a measurement can
be made from the housing to the back of the piston.
With the brakes not activated, the value measured
from the edge of the housing to the piston should be
slightly less than 127 mm (5 in.). If the brake stroke
measurement is 13 mm (0.525 in.) or more, replace
thebrakes. Themeasurementofthenewbrakes
stroke will be between 3 to 7 mm (0.134 to 0.269 in.).
Table 1. FRICTION DISC
Disc Size Overall Thickness
Limit
330 mm (13 in.) 4.25 mm (0.167 in.)
432 mm (17 in.) 4.87 mm (0.192 in.)
560 mm (22 in.) 5.56 mm (0.219 in.)
Table 2. STATIONARY DISC
Disc Size Overall Thickness
Limit
330 mm (13 in.) 2.76 mm (0.109 in.)
432 mm (17 in.) 3.07 mm (0.121 in.)
432 mm (17 in.) 4.44 mm (0.175 in.)
560 mm (22 in.) 5.41 mm (0.213 in.)
REPLACE
Parts
Replace worn or damaged parts of the wet disc brake
assembly. The following are some examples to check:
•Replace any fasteners if the corners of the head are
worn.
•Replace the washers, if damaged.
•Replace the oil seals, face seals, and gaskets when
the components are separated from each other.
•Clean the parts before applying silicone gasket ma-
terial.
•Remove small damage from the parts that have
machined or ground surfaces. Use a fine-tooth file,
india stone, emery cloth, or crocus cloth for this
purpose.
•Clean and repair the threads of the fasteners and
the holes. Use a tap or a die of the correct size or a
fine-tooth file for this purpose.
•Tighten all fasteners to the correct torque value.
See Specifications.
ASSEMBLE
Brake Housings
WARNING
To prevent serious eye injury, always wear safe
eye protection when doing maintenance or ser-
vice.
The piston return spring applies pressure to
the plug. Use the following procedure or the
spring can push the plug out of the housing
with enough force to cause serious personal in-
jury.
NOTE: If the piston return spring assemblies were re-
moved, the assemblies must be installed in the hous-
ing.
Two types of spring guides are used. One type of
guide has a pin on the bottom that is installed in-
sidethespring.Theothertypeofguidehasaholein
the bottom so that the end of the pin is installed in
the guide. Use the correct parts for the piston return
spring assembly. Do not mix parts of the different as-
semblies. Use only one type of spring guide on each
brake housing assembly. See Figure 18.
1. Put the brake housing so that the wheel hub side
of the housing is toward you.
9

Repair 1800 SRM 1038
2. Install the O-ring on the plug.
3. Put the spring guide inside the brake housing
below the plug hole. Verify the flat area of the
guide is against the housing.
4. Install the spring on top of the guide.
5. Put the plug and pin assembly in the hole in the
brake housing and through the return spring.
6. Apply and hold pressure on the plug while the
plug is installed into the housing. Verify that the
pin is correctly installed in the spring guide and
that the flat areas on the spring guide are against
the housing. See Figure 15.
7. When the threads fully engage the housing, re-
leasethepressureontheplug.SeeFigure17.
8. Tighten the plug to 60 to 75 N•m (44 to 55 lbf ft).
9. Put the brake housing on a bench. The cover side
of the housing must be toward you.
10. Install the disc spacer in the bottom of the brake
housing. See Figure 14.
NOTE: If a thick-splined stationary disc is used in-
steadofthespacerandstandardstationarydisc,it
must be installed against the housing. Next, install
a friction disc followed by a standard stationary disc
and continue to complete the stack. Brake housings
aredesignedtouseonlyonetypeofdiscconfigura-
tion. Do not interchange parts.
11. Install the disc pack.
a. Apply the same fluid used in the brake cool-
ing system to the disc surfaces as the discs
are installed.
b. Install a stationary disc in the housing. The
first stationary disc must be against the disc
spacer. Make sure the splines on the outer
diameter of the stationary disc engage the
splines in the brake housing. Verify the wide
spaces on the outer diameter of the disc are
over the return spring assemblies. See Fig-
ure 13.
c. Install a friction disc in the housing. See
Figure 20.
1. FRICTION DISC
Figure 20. Friction Disc
d. Complete the installation of the disc pack.
Repeat steps Step b and Step c until the com-
plete disc pack is installed.
12. Align all of the teeth on the inner diameter of the
friction discs. When the discs are aligned, the
wheel hub can be installed without damaging the
discs.
13. Lubricate the outside diameter of the piston, the
housing bore, and the seals with the same fluid
used in the brake system.
14. Lower the piston into the housing until the piston
is installed on the guides of the return springs.
Verify the surfaces on the piston and the hous-
ing are not damaged when the piston is installed.
See Figure 21.
CAUTION
To prevent housing or piston damage, use fin-
gers or a non-metallic object to install the seals
and round spacer. Fluid can leak between the
housing and the piston if the surfaces are dam-
aged.
NOTE: The sealing arrangement between the piston
and the housing consists of one spacer and two piston
seals. See Figure 22.
15. Put the first seal in the space between the hous-
ing and the piston. The rubber part of the seal
must be toward you. Push on the seal until
the complete plastic bottom surface of the seal
touches the shoulder of the piston. See Fig-
ure 23.
10

1800 SRM 1038 Repair
1. PISTON
Figure 21. Piston Installation
1. PLASTIC SEAL BODY
2. ROUND SPAC ER
3. RUBBER ELEMENT SEAL ENERGIZERS
Figure 22. Piston Seal Arrangement
NOTE: An O-ring or garter spring seal spacer may
be used. If the O-ring is damaged, replace it with a
garter spring seal spacer.
16. Install the spacer around the outer diameter of
the piston. Push on the spacer until the entire
bottom surface of the spacer touches the top of
the first seal. See Figure 22 and Figure 24.
A. RUBBER PARTOUT
1. INNERPISTONSEAL
Figure 23. Inner Piston Seals
1. ROUND SPACER, O-RING, OR GARTER
SPRING TYPE
Figure 24. O-ring or Garter Spring Seal Spacer
11

Repair 1800 SRM 1038
17. Put the second seal in the space between the
housing and the piston on top of the first seal.
The rubber part of the seal must be away from
you. Install the second seal according to the fol-
lowing procedure:
a. Push on the seal until the seal touches the
spacer. Make sure the seal is correctly in-
stalled in the housing. The seals must be
parallel to each other. Install the complete
seal with this method. See Figure 22 and Fig-
ure 25.
A. RUBBER PART AWAY
1. OUTERPISTONSEAL
Figure 25. Outer Piston Seal
INSTALL
Hub Oil Seals
NOTE: Single- or double-hub oil seals are used on all
brake housings with forced cooling and most brake
housings with sump cooling. See Figure 26.
Double Seals
WARNING
To prevent serious eye injury, always wear safe
eye protection when doing maintenance or ser-
vice.
To avoid serious personal injury, be careful
when using Permatex. Follow the manufac-
turer’s instructions for safe use to prevent
irritation to eyes and skin. Wash after skin
contact. If the Permatex gets in the eyes, flush
your eyes with water for 15 minutes. Have
eyes checked by doctor.
1. Position the wheel hub so that the wheel hub is
flat on the floor.
2. Apply Permatex 51D or its equivalent to the
outerdiameterofthesealcasing.
3. Put the outer seal into the bore so the stamping
on the seal casing is toward you.
4. Use a suitable driver and a leather or plastic mal-
let to install the seal. Tap on the driver until the
seal casing is even with the top of the bore.
1. INNER BEARING CUP
2. INNER BEARING CONE
3. OUTER SEAL
4. INNER SEAL
Figure 26. Double Seal
NOTE: When installed, the inner seal pushes the first
or outer seal into the correct position.
5. Install the inner seal with the stamping on the
bottom, over the outer seal.
6. Use a suitable driver and a leather or plastic mal-
let to install the seal. Tap on the driver until the
seal casing is even with the top of the bore.
Single Seal
1. Position the wheel hub so that the wheel hub is
flat on the floor.
12

1800 SRM 1038 Repair
2. Apply Permatex 51D or its equivalent to the
outer diameter of the seal casing.
3. Position the seal over the bore so that the metal
part of the seal is up.
CAUTION
Do not apply pressure to the inner metal part of
the seal. Apply pressure only to the outer diam-
eter of the ring on the seal. The application of
pressure to the inner diameter of the ring dam-
ages the seal.
NOTE: On seals with flanges, tap on the sleeve until
the flange touches the outer surface of the hub. See
Figure 27.
NOTE: On seals without flanges, press the seal in the
hub until the top of the seal is even with the outer
surface of the hub. See Figure 28.
4. Use a sleeve that is installed on the outer metal
flange of the seal and a leather or plastic mallet
to install the seal.
A. APPLY PRESSURE HERE
1. INNER BEARING CONE
2. INNER BEARING CUP
3. SINGLE HUB
4. SEAL
Figure 27. Single-Hub Seal With Flanges
A. DO NOT STRIKE HERE
1. INNER BEARING CONE
2. INNER BEARING CUP
3. SINGLE HUB
4. SEAL
Figure 28. Single-Hub Seal Without Flanges
Spindle and Brake Cover
If necessary, install the spindle and the cover of the
brakehousingontheaxlehousingaccordingtothe
following procedure:
WARNING
Small amounts of acid vapor are present when
applying some silicone gasket materials. To
prevent possible serious personal injury, make
sure there is good ventilation in the work
area. If the silicone gasket material gets in
your eyes, flush your eyes with water for 15
minutes. Have your eyes checked by a doctor.
NOTE: On some axle assemblies, the brake cover
is mounted between the spindle and axle housing
flanges. Use the following procedure to install the
spindle and brake cover; but first, install the brake
cover followed by the spindle.
1. Install two studs opposite each other on the axle
housing flange. Verify the studs are long enough
to support the spindle and brake cover.
2. Apply a bead of silicone gasket material on the
mounting surface of the axle housing flange. The
bead must go around each capscrew hole. See
Figure 29.
13

Repair 1800 SRM 1038
1. AXLE FLANGE
2. SILICONE BEAD
Figure 29. Axle Flange
3. Use a lifting device to install the spindle on the
guide studs. Make sure the spindle cannot fall
before removing the lifting device. See Figure 29.
4. Apply a bead of silicone gasket material on the
spindle flange where the brake cover will mount.
Make sure to go around each capscrew hole. See
Figure 30.
1. SPINDLE FLANGE
2. SILICONE BEAD
Figure 30. Spindle Flange
5. Use a lifting device to install the brake cover over
the spindle and onto the housing. Make sure the
drain hole is located at the bottom of the cover
when installed. See Figure 31.
Figure 31. Spindle and Brake Cover
6. Install the capscrews and washers. See Fig-
ure 32. Remove the guide studs and install the
remaining two capscrews and washers. Tighten
the capscrews to the torque specified. See Spec-
ifications.
1. CAPSCREWS
Figure 32. Spindle and Brake Cover Capscrews
14