Hyster D117 Operating instructions

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

Thanks very much for your reading,
Want to get more information,
Please click here, Then get the complete
manual
NOTE:
If there is no response to click on the link above,
please download the PDF document first, and then
click on it.
Have any questions please write to me:
[e-mail]

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