HYDRAULIC GEAR

PUMP

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS

(H30FT, H35FT, H40FTS) [F001];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];

H2.0-3.5FT (H40-70FT) [L177]

PART NO. 1580514

1900 SRM 1136

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!

Hydraulic Gear Pump

Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

1

Gear Pump Assembly Repair ............................................................................................................................

1

Remove ...........................................................................................................................................................

1

Disassemble ...................................................................................................................................................

1

Inspect ............................................................................................................................................................

4

Clean ..............................................................................................................................................................

4

Assemble ........................................................................................................................................................

4

Install .............................................................................................................................................................

4

Gear Pump Specifications .................................................................................................................................

5

Torque Specifications .........................................................................................................................................

6

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];

S2.0-3.5FT (S40-70FT, S55FTS) [F187];

H2.0-3.5FT (H40-70FT) [L177]

©2005 HYSTER COMPANY

i

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

1900 SRM 1136

Gear Pump Assembly Repair

General

This section includes a description and the repair
procedures for the hydraulic gear pump assembly.
The lift trucks covered in this SRM can be equipped
with one of three different gear pumps: 24 cc/rev, 25.7
cc/rev, or 29.4 cc/rev. See the Gear Pump Specifica-
tions section in this manual. The repair procedures
are the same for each type of gear pump.

Repair information for other components of the hy-
draulic system are found in the following manuals:
Steering Axle 1600 SRM 1133, Main Control
Valve 2000 SRM 1137, and Mast Repairs, 2, 3,
and 4-Stage Masts 4000 SRM 1148.

Gear Pump Assembly Repair

REMOVE

WARNING

PUTTING THE LIFT TRUCK ON BLOCKS

The lift truck must be put on blocks for some
types of maintenance and repair. The removal
of the following assemblies will cause large
changes in the center of gravity: mast, drive
axle, engine, transmission, and counterweight.
When the lift truck is put on blocks, put ad-
ditional blocks in the following positions to
maintain stability:
• Before removing the mast and drive axle, put

blocks under the counterweight so the lift
truck cannot fall backward.

• Before removing the counterweight,

put

blocks under the mast assembly so the lift
truck cannot fall forward.

The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure any
blocks used to support the lift truck are solid,
one-piece units.

NOTE: Worn or damaged seals are the most common
cause of pump damage. The pump bushings, gears,
and shafts also wear. They must be checked during
disassembly. Do not make any repairs to the parts.
To prevent more failures, always replace parts that
are worn or damaged. If several main parts need
replacing, replace the complete group.

1.

Put the lift truck on blocks. See the Operating
Manual or the section Periodic Maintenance
8000 SRM 1150 for lift truck models S2.0-3.5FT
(S40-70FT, S55FTS) (F187) and H2.0-3.5FT
(H40-70FT) (L177) or the section Periodic
Maintenance 8000 SRM 1207 for lift truck

models S30FT, S35FT, S40FTS (E010) and
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001) for the procedures to put the lift
truck on blocks.

2.

If necessary, put a drain pan under the hydraulic
tank. Remove the drain plug at the bottom of
the hydraulic oil tank. Drain the oil from the
tank. The drain pan must have capacity of ap-
proximately 30 liter (8 gal).

3.

Put a drain pan under the pump assembly. Re-
move all hydraulic lines connected to the pump
assembly. Remove the inlet and outlet fittings
from the hydraulic pump. Put caps on all the
hose fittings and hydraulic pump ports. See Fig-
ure 1.

4.

Hold the pump assembly to keep it from falling.
Remove the two socket head screws and the lock-
washers that fasten the pump to the transmis-
sion housing. Remove the pump assembly.

DISASSEMBLE

1.

Put the pump body in a vise. Put an alignment
mark on each section of the pump body to aid in
reassembly.

2.

Remove the capscrews that hold the pump to-
gether. Remove the flange end housing. Remove
the rear valve housing. Do not let the seals and
gears fall. See Figure 2.

3.

Make a note of the position of the plate seals
and pressure plates. Carefully remove the plate
seals, pressure plates, and gears from the hous-
ings. Discard plate seals. Remove the snap ring
and shaft seal from the flange end housing.

1

Gear Pump Assembly Repair

1900 SRM 1136

1.

INLET HOSE ASSEMBLY

2.

OUTLET HOSE ASSEMBLY

3.

INLET FITTING

4.

SOCKET HEAD SCREW (2)

5.

HYDRAULIC PUMP

6.

TRANSMISSION

Figure 1. Hydraulic Pump Removal

2

1900 SRM 1136

Gear Pump Assembly Repair

1.

SNAP RING

2.

SHAFT SEAL

3.

FLANGE END HOUSING

4.

PLATE SEAL

5.

PRESSURE PLATE

6.

GEAR HOUSING

7.

DRIVEN GEAR

8.

DRIVE GEAR

9.

REAR VALVE HOUSING

10. CAPSCREW
11. BACKUP SEAL

Figure 2. Hydraulic Pump Assembly

3

Gear Pump Assembly Repair

1900 SRM 1136

INSPECT

Check parts for wear and damage. If any parts are
worn or damaged, replace the damaged parts. If the
pump housing is damaged, replace the pump.

CLEAN

WARNING

Cleaning solvents can be flammable and toxic
and can cause skin irritation.

When using

cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau-
tions.

WARNING

Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel.

Wear protective

goggles or a face shield to prevent injury to the
eyes.

Clean all parts in solvent. Dry parts with compressed
air. Do not dry the parts with a cloth. Make sure all
surfaces are free of scratches and sharp edges.

ASSEMBLE

1.

Coat all pump components with hydraulic oil.
Use hydraulic oil meeting specification ISO VG
46 hydraulic oil

15 C (5 F) and above.

2.

Use new plate and backup seals and install the
pressure plates and gears. Make sure to install
the pressure plates as removed during disas-
sembly. See the notes made during disassembly.
Make sure all seals are complete and in the
correct positions. See Figure 2.

3.

Install a new shaft seal in the flange end housing.
Carefully install the flange end housing. Do not
move the pressure plates. Make sure the seals do
not move out of the correct position. See Figure 2.

4.

Carefully install the valve end housing on the
pump body using the four capscrews and lock-
washers. Make sure the pressure plates do not
move and that the seals stay in the correct posi-
tion. Make sure the marks made during disas-
sembly are aligned. Tighten the capscrews to 46
to 49 N•m (34 to 36 lbf ft).

INSTALL

1.

Install inlet and outlet fittings and tighten inlet
fitting to 88 to 98 N•m (65 to 72 lbf ft).

2.

Clean the pump flange and transmission mount-
ing surfaces and put a 3-5 mm (0.118-0.197 in.)
bead of Loctite™ 515 (Hyster Part No. 264159)
on the pump flange or transmission mounting
surface. Hold the pump in the correct position
on the transmission.

Install the socket head

screws and lockwashers that fasten the pump to
the transmission housing. Tighten socket head
screws to 38 N•m (28 lbf ft). See Figure 1.

3.

Connect the hydraulic lines. Position the outlet
hydraulic line as shown in Figure 3.

A. Z = 60 ±5 FOR 1-SPEED TRANSMISSION,

LIFT TRUCK MODELS S30FT, S35FT, S40FTS
(E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001), AND S2.0-3.5FT (S40-70FT,
S55FTS) (F187)

B. Z = 75 ±5 FOR 2-SPEED TRANSMISSION,

LIFT TRUCK MODELS S2.0-3.5FT (S40-70FT,
S55FTS) (F187)

C. Z = 50 ±5 FOR LIFT TRUCK MODELS

H2.0-3.5FT (H40-70FT) (L177)

1.

OUTLET HOSE

2.

INLET HOSE

Figure 3. Inlet Hose Orientation

4

1900 SRM 1136

Gear Pump Specifications

4.

Remove the lift truck from the blocks.

Fill

the tank using the hydraulic oil shown in the
Maintenance Table of the section Periodic
Maintenance 8000 SRM 1150 for lift truck
models S2.0-3.5FT (S40-70FT, S55FTS) (F187)
and H2.0-3.5FT (H40-70FT) (L177) or the sec-
tion Periodic Maintenance 8000 SRM 1207

for lift truck models S30FT, S35FT, S40FTS
(E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001). When the oil level is
correct, operate the system and check for leaks.
Check the hydraulic oil level and add hydraulic
oil if necessary.

Gear Pump Specifications

Table 1. Standard Gear Pump

Model

Displacement

Relief

Pressure

Speed

Weight

GPM @

2000 RPM

S30FT, S35FT, S40FTS
(E010), H1.6FT, H1.8FT,
H2.0FTS (H30FT,
H35FT, H40FTS) (F001),
S2.0-3.5FT (S40-70FT,
S55FTS) (F187), and
H2.0-3.5FT (H40-70FT)
(L177)

24.0 cc/rev

21.4 MPa
(3104 psi)

3060 rpm

3.5 kg

(7.7 lb)

12 gal/min

S2.0-3.5FT (S40-70FT,
S55FTS) (F187) and
H2.0-3.5FT (H40-70FT)
(L177)

25.7 cc/rev

21.4 MPa
(3104 psi)

3060 rpm

3.7 kg

(8.2 lb)

13 gal/min

H1.6FT, H1.8FT,
H2.0FTS (H30FT,
H35FT, H40FTS)
(F001) and H2.0-3.5FT
(H40-70FT) (L177)

29.4 cc/rev

21.4 MPa
(3104 psi)

3060 rpm

3.9 kg

(8.6 lb)

15 gal/min

Table 2. High Pressure Gear Pump

Model

Displacement

Relief

Pressure

Speed

Weight

GPM @

2000 RPM

S2.0-3.5FT (S40-70FT,
S55FTS) (F187), and
H2.0-3.5FT (H40-70FT)
(L177)

24.0 cc/rev

23.4 MPa
(3393 psi)

3060 rpm

4.0 kg

(8.8 lb)

12 gal/min

H2.0-3.5FT (H40-70FT)
(L177)

25.7 cc/rev

23.4 MPa
(3393 psi)

3060 rpm

4.1 kg

(9.0 lb)

13 gal/min

H2.0-3.5FT (H40-70FT)
(L177)

29.4 cc/rev

23.4 MPa
(3393 psi)

3060 rpm

4.5 kg

(9.9 lb)

15 gal/min

5

Torque Specifications

1900 SRM 1136

Torque Specifications

Rear Valve End Housing to Gear Pump
Body Capscrews

46 to 49 N•m (34 to 36 lbf ft)

Inlet Fitting

88 to 98 N•m (65 to 72 lbf ft)

Gear Pump to Transmission Socket
Head Screws

38 N•m (28 lbf ft)

6

TECHNICAL PUBLICATIONS

1900 SRM 1136

5/05 (12/04) Printed in U.S.A.