HYDRAULIC VANE

PUMPS

S30-50C, S60-100B, S125-150A, H60-90C, H110-150F;

H6.00-7.00XL (H135-155XL) [F006]; KE, J25-35A,

J40-60A, J50-60AS, N30-50BA, N30-40BR, N30-50CA,

N30-40CR, R30B, R30BA, R30BR, R30C, R30CA,

R30CR, E20-100A, E20-100B, E30-60AC, E30-60BC

PART NO. 910092

1900 SRM 98

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 Vane Pumps

Table of Contents

TABLE OF CONTENTS

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

1

Description .........................................................................................................................................................

1

Operation............................................................................................................................................................

2

Pump ..............................................................................................................................................................

2

Relief Valve ....................................................................................................................................................

2

Hydraulic Vane Pumps Repair ..........................................................................................................................

3

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

3

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

3

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

4

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

7

Relief Valve Relief Pressure Check ...................................................................................................................

7

Lift Trucks With Internal Combustion Engines ..........................................................................................

7

Electric Lift Trucks........................................................................................................................................

7

Electric Lift Trucks With Adjustable Relief Valve .......................................................................................

8

Specifications......................................................................................................................................................

9

Pressure Relief Valve.....................................................................................................................................

9

Troubleshooting..................................................................................................................................................

9

This section is for the following models:

S30-50C, S60-100B, S125-150A, H60-90C, H110-150F H6.00-7.00XL

(H135-155XL) [F006];

KE, J25-35A, J40-60A, J50-60AS, N30-50BA, N30-40BR, N30-50CA,

N30-40CR, R30B, R30BA, R30BR, R30C, R30CA, R30CR, E20-100A,

E20-100B, E30-60AC, E30-60BC

©2003 HYSTER COMPANY

i

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

1900 SRM 98

Description

General

This section has a description and the repair procedures for several different types of hydraulic vane pumps.
While the number and type of parts can be different, the operation of the vane pumps is the same.

Description

The vane pump can have one or two pump sections. See Figure 1. The pump or pump sections have a housing,
a pressure plate, a cam ring, a rotor with vanes, and a shaft. Some of the pumps also have a relief valve. The
cam ring, pressure plate, rotor, and vanes fit between the housings. The rotor and vanes rotate within the cam
ring.

1.

HOUSING

2.

INLET

3.

OUTLET

4.

CAM RING

5.

VANE

6.

ROTOR

7.

PRESSURE PLATE

8.

RELIEF VALVE

9.

ORIFICE

10. BEARING
11. SHAFT
12. SEAL
13. FLEXIBLE PLATE
14. SUPPORT PLATE
15. VANE SUPPORT

Figure 1. Vane Pumps

1

Operation

1900 SRM 98

Operation

PUMP

The pump is driven by an engine or an electric motor.
See Figure 2. When the shaft rotates, the rotor turns
within the cam ring. Either the rotor or the surface of
the cam ring is not equally round. As the rotor turns,
there is a variation in volume between the rotor and
cam ring. Centrifugal force causes the vanes to fol-
low the inside surface of the cam ring. The pressure
from the oil behind the vanes make the vanes keep
a tight fit with the cam ring. The ports for the inlet
and the outlet are on opposite sides of the cam ring.
As the rotor turns past the inlet port, the volume is
increasing between the vanes.

This increase in volume causes a decrease in the
pressure or a vacuum at the inlet port. Because of
the difference in the pressures, the oil flows into
the inlet port. The oil between the rotating vanes
is moved to the outlet port. The volume between
the vanes decreases near the outlet port and the

pressure increases. Oil is discharged into the system
at a higher pressure.

RELIEF VALVE

The relief valve is installed in the housing for the
pump. See Figure 3. The valve controls the amount
and the pressure of the oil for the system. During
Slow Operation of the pump, all the oil flows through
the orifice to the system. During Normal Operation,
the flow of oil from the pump pushes the spool from
the seat. Oil for the system flows through the orifice.
The remainder of the oil flows past the spool and re-
turns to the tank. When the pressure of the oil is
more than the setting of the valve, the valve operates
as shown in Relief Operation. The increase in pres-
sure causes the pilot poppet to move from the seat
in the spool. The oil in the chamber for the spring
flows through the spool to the tank. This flow causes
a difference in the pressure on the spool. The spool
compresses the spring and lets all the oil from the
pump to go to the tank.

A. ROTATION

1.

INLET

2.

OUTLET

3.

CAM RING

4.

VANE

5.

ROTOR

6.

SHAFT

Figure 2. Pump Operation

2

1900 SRM 98

Hydraulic Vane Pumps Repair

A. SLOW OPERATION
B. NORMAL OPERATION

C. RELIEF OPERATION
D. TO TANK

E. TO SYSTEM
F.

FROM PUMP

1.

SPOOL SPRING

2.

RELIEF VALVE SPOOL

3.

RELIEF VALVE SPRING

4.

ORIFICE

5.

PILOT VALVE

Figure 3. Relief Valve Operation

Hydraulic Vane Pumps Repair

NOTE: Worn or damaged seals, bearings, and vanes
are the most common cause of failures of the pump.
Make sure to check all parts during disassembly. Do
not make any repairs to the parts. To prevent more
failures, always replace parts that are worn or have
damage. If several parts are worn or have damage,
replace the complete pump.

REMOVE

1.

If there is a shutoff valve on the hydraulic tank,
close the valve. Disconnect the lines at the pump.
Put caps on the lines. Put caps on the ports of the
pump.

2.

On electric lift trucks, disconnect the battery con-
nector. Remove the motor and pump as an as-
sembly. Remove the pump from the motor.

3.

On other lift trucks, remove the pump from the
engine or from the bracket for the pump.

DISASSEMBLE

1.

Make sure that the outside of the pump is clean.
Make marks on the housings so the parts will be
assembled correctly. Put the pump in a vise with
soft jaws. See Figure 4, Figure 5, or Figure 6.

2.

If equipped, remove the pulley or gear from the
shaft of the pump. See Figure 6.

3.

Remove the capscrews that hold the housings to-
gether. Separate the housings.

4.

For pumps with the rotor and cam ring as a unit,
remove the unit. Make marks for identification
on the covers. Separate the cam ring and covers.
Remove the support plates, flexible plates, and
the rotor and vanes.

5.

On other pumps, remove the pressure plate and
the spring. Remove the cam ring and the rotor
and vanes.

6.

Remove the O-rings, seals, and bearings.

7.

If equipped, remove the relief valve.

3

Hydraulic Vane Pumps Repair

1900 SRM 98

1.

HOUSING

2.

SPRING

3.

PRESSURE PLATE

4.

O-RING

5.

CAM RING

6.

ROTOR

7.

VANE

8.

PIN

9.

HOUSING

10. BEARING
11. SEAL*
12. SHAFT
13. SNAP RING

*NOT USED ON ALL TRUCKS

Figure 4. Vane Pumps (Set 1)

ASSEMBLE

NOTE:

Replace the O-rings, seals, and bearings dur-

ing the assembly procedures. Lubricate all the parts
with clean hydraulic oil.

1.

Replace the complete rotor and cam ring unit if
any parts of the unit are damaged. Assemble
the unit as follows (see Figure 4, Figure 5, or
Figure 6):

a. Install the vanes in the rotor. Install the ro-

tor in the cam ring.

b. Install the flexible plates and the support

plates. Install the covers.

c.

Install the seals and bearings in the covers.
Install the unit in the housing. Install the
shaft in the rotor.

4

1900 SRM 98

Hydraulic Vane Pumps Repair

1.

HOUSING

2.

SPOOL SPRING

3.

RELIEF VALVE

4.

O-RING

5.

PLUG

6.

PIN

7.

CAPSCREW

8.

GASKET

9.

SPRING

10. PRESSURE PLATE
11. PIN
12. CAM RING

13. ROTOR
14. VANE
15. O-RING
16. HOUSING
17. ROLLER BEARING
18. BALL BEARING

19. SHAFT
20. SNAP RING
21. KEY
22. WASHER
23. MANIFOLD

Figure 5. Vane Pumps (Set 2)

5

Hydraulic Vane Pumps Repair

1900 SRM 98

1.

PUMP COVER

2.

SPRING

3.

PLATE

4.

PIN

5.

RING

6.

ROTOR

7.

O-RING

8.

PUMP BODY

9.

NEEDLE BEARING

10. SEAL
11. SNAP RING
12. BALL BEARING
13. SHAFT
14. KEY
15. VANE
16. PLUG

17. RELIEF VALVE
18. CAPSCREW
19. WASHER
20. LOCKWASHER
21. INLET MANIFOLD
22. PULLEY
23. NUT

Figure 6. Vane Pumps (Set 3)

2.

Assemble the other pumps as follows:

a. Install the seals and bearings in the housing.

Install the bearing on the shaft.

b. Install the shaft in the housing. Install the

snap ring.

c.

Install the O-rings in the shaft housing. In-
stall the rotor on the shaft. Install the vanes
in the rotor.

d. Install the cam ring and pins. Install the

pressure plate and the spring.

e.

Install the housing on the end of the pump.

f.

If equipped, install the relief valve.

g. If equipped, install the manifold on the hous-

ing. Use Loctite

®

on the capscrews for the

manifold.

6

1900 SRM 98

Relief Valve Relief Pressure Check

INSTALL

1.

On electric lift trucks, install the pump as fol-
lows:

a. Install a new O-ring between the motor and

the pump. Install the pump on the motor.
Tighten the capscrews.

b. Install the motor and pump assembly. Con-

nect the oil lines and the electric cables.

c.

Make sure the hydraulic tank is full, then
remove the air from the system as specified
in Relief Valve Relief Pressure Check in this
section. Run the pump at a low speed and
check for leaks and correct operation. Check
the relief valve as specified in Relief Valve
Relief Pressure Check in this section.

2.

On lift trucks with internal combustion engines,
install the pump as follows:

a. If equipped, install the gear or pulley on the

shaft of the pump. Tighten the nut on pulley
to 72 N•m (53 lbf ft). See Figure 6.

b. If the pump is installed on an engine, install

a new gasket or O-ring between the engine
and pump. Tighten the capscrews.

c.

If the pump is installed in a bracket, install
the pump and tighten the capscrews. If the
pump is driven by a belt, adjust the belt so
that it has the correct tension.

d. Connect the hydraulic lines to the pump.

e.

Make sure the hydraulic tank is full, then
remove the air from the system as specified
in Relief Valve Relief Pressure Check in this
section. Run the pump at a low speed and
check for leaks and correct operation. Check
the relief valve as specified in Relief Valve
Relief Pressure Check in this section.

Relief Valve Relief Pressure Check

LIFT TRUCKS WITH INTERNAL
COMBUSTION ENGINES

1.

Install a fitting in the outlet line of the pump.
Connect a 0 to 20 MPa (0 to 3000 psi) gauge to
the fitting. Connect a tachometer to the engine.

NOTE:

If the pump is driven by a belt, make sure the

belt is correctly adjusted.

2.

Operate the hydraulic system until the tempera-
ture of the oil reaches 54 to 65 C (130 to 150 F).

3.

Start the engine and run it at 2500 rpm. Put a
block between the wheel and the frame or axle.
Make sure the wheel is not against the stop on
the axle. Turn the steering wheel and check the
reading on the gauge. The correct pressures are
shown in Specifications.

CAUTION

Do not keep the system at a pressure so that
the relief valve opens for more than 20 seconds.
This action will damage the pump.

4.

If the pressure for opening the relief valve is not
within the specifications, replace the valve. The
valve is not adjustable.

ELECTRIC LIFT TRUCKS

1.

Install a fitting in the outlet line of the pump.
Connect a 0 to 20 MPa (0 to 3000 psi) gauge to
the fitting.

2.

Operate the hydraulic system until the tempera-
ture of the oil reaches 54 to 65 C (130 to 150 F).

3.

Turn the steering wheel until it stops moving,
then check the reading on the gauge. The correct
pressures are shown in Specifications.

CAUTION

Do not keep the system at a pressure so that
the relief valve opens for more than 20 seconds.
This action will damage pump and the motor.

4.

If the pressure for opening the relief valve is not
within the specifications, replace the valve. The
valve is not adjustable.

7

Relief Valve Relief Pressure Check

1900 SRM 98

ELECTRIC LIFT TRUCKS WITH
ADJUSTABLE RELIEF VALVE

1.

Connect a 0 to 20 MPa (0 to 3000 psi) gauge to
the check port shown in Figure 7.

2.

Operate the motor for the steering pump until
the oil reaches 54 to 65 C (130 to 150 F).

3.

Turn the steering wheel until it stops moving,
then check the reading on the gauge. The correct
pressures are shown in Specifications.

CAUTION

Do not keep the system at a pressure so that
the relief valve opens for more than 20 seconds.
This action will damage the pump and the mo-
tor.

4.

To adjust the pressure, remove the relief valve
from the system. Use a 3/32 inch Allen wrench
and adjust the setscrew. One fourth of a turn
equals approximately 0.690 MPa (100 psi). Turn
the setscrew to the right to increase the pressure.

5.

Install the valve and check the pressure.

1.

O-RING

2.

METERING PIN

3.

PISTON

4.

METERING SPRING

5.

INNER VALVE

6.

O-RING

7.

SETSCREW

8.

CHECK BALL

9.

PISTON SPRING

10. ORIFICE PLUG
11. HOUSING
12. PRESSURE CHECK PORT
13. RELIEF VALVE

Figure 7. Relief Valve

8

1900 SRM 98

Troubleshooting

Specifications

PRESSURE RELIEF VALVE

S30-50C (All)

7.6 to 8.6 MPa (1100 to 1250 psi) @ 2500 rev/min

S60-100B (All)

6.6 to 7.6 MPa (950 to 1100 psi) @ 2500 rev/min

S125-150A (Oil Clutch)

9.7 to 10.7 MPa (1400 to 1550 psi) @ 2500 rev/min

H60-90C (All)

6.6 to 7.6 MPa (950 to 1100 psi) @ 2500 rev/min

H110-150F (All)

8.6 MPa (1250 psi) @ 2500 rev/min

H6.00-7.00XL (H135-155XL)

12.06 to 12.11 MPa (1736 to 1808 psi)
@ 2500 rev/min

KE (All)

7.4 to 8.5 MPa (1075 to 1225 psi) @ 2500 rev/min

J25-35A

8.6 to 9.3 MPa (1250 to 1350 psi)

J40-60A, J50-60AS

8.6 to 9.3 MPa (1250 to 1350 psi)

N30-50BA, N30-40BR

5.5 to 6.2 MPa (800 to 900 psi)

N30-50CA, N30-40CR

13.8 to 14.5 MPa (2000 to 2100 psi)

R30B/BA/BR, R30C/CA/CR

4.8 to 5.5 MPa (700 to 800 psi)

E20-100A, E20-120B

8.3 to 9.3 MPa (1200 to 1350 psi)

E30-60AC, E30-60BC

8.3 to 9.3 MPa (1200 to 1350 psi)

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

There is no output from the
pump.

There is no oil in the tank.

Fill tank to the correct level. Check
for leaks.

The shaft or drive belt is damaged.

Replace shaft or drive belt.

The drive belt does not rotate the
pump.

Adjust or replace drive belt.

There are leaks at the inlet of the
pump.

Tighten clamp, replace hose or pump.

The relief valve is open.

Repair or replace relief valve.

The vane(s) do not move freely in the
rotor.

Repair or replace pump.

There is not enough pressure
from the pump.

The internal parts (vanes and rotor)
are worn.

Repair or replace pump.

The relief valve is damaged.

Repair or replace relief valve.

9

Troubleshooting

1900 SRM 98

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

The pump makes noise.

There is a restriction in the inlet of
the pump.

Remove object restricting flow or re-
place damaged component.

There are air leaks at the inlet of the
seals of the pump.

Tighten clamp, replace hose or pump.

The drive speed of the pump is not
correct.

Replace incorrect pulleys.

The drive gear, pulley, or the coupler
is not aligned with the motor or en-
gine.

Replace

motor

mounts,

replace

mounting brackets.

10

TECHNICAL PUBLICATIONS

1900 SRM 98

7/03 (2/97)(11/81)(1/80)(9/79) Printed in United Kingdom