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 Repair information for other components of the hy-
procedures for the hydraulic gear pump assembly. draulic system are found in the following manuals:
The lift trucks covered in this SRM can be equipped Steering Axle 1600 SRM 1133, Main Control
with one of three different gear pumps: 24 cc/rev, 25.7 Valve 2000 SRM 1137, and Mast Repairs, 2, 3,
cc/rev, or 29.4 cc/rev. See the Gear Pump Specifica- and 4-Stage Masts 4000 SRM 1148.
tions section in this manual. The repair procedures
are the same for eachtype of gear pump.
Gear Pump Assembly Repair
REMOVE models S30FT, S35FT, S40FTS (E010) and
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001) for the procedures to put the lift
WARNING
truck on blocks.
PUTTING THE LIFT TRUCK ON BLOCKS
2. If necessary, put a drain pan under the hydraulic
The lift truck must be put on blocks for some
tank. Remove the drain plug at the bottom of
types of maintenance and repair. The removal
the hydraulic oil tank. Drain the oil from the
of the following assemblies will cause large
tank. The drain pan must have capacity of ap-
changes in the center of gravity: mast, drive
proximately 30 liter (8 gal).
axle, engine, transmission, and counterweight.
When the lift truck is put on blocks, put ad-
3. Put a drain pan under the pump assembly. Re-
ditional blocks in the following positions to
move all hydraulic lines connected to the pump
maintain stability:
assembly. Remove the inlet and outlet fittings
" Before removing the mast and drive axle, put
from the hydraulic pump. Put caps on all the
blocks under the counterweight so the lift
hose fittings and hydraulic pump ports. See Fig-
truck cannot fall backward.
ure 1.
" Before removing the counterweight, put
blocks under the mast assembly so the lift
4. Hold the pump assembly to keep it from falling.
truck cannot fall forward.
Remove the two socket head screws and the lock-
washers that fasten the pump to the transmis-
The surface must be solid, even, and level when
sion housing. Remove the pump assembly.
the lift truck is put on blocks. Make sure any
blocks used to support the lift truck are solid,
DISASSEMBLE
one-piece units.
1. Put the pump body in a vise. Put an alignment
NOTE: Worn or damaged seals are the most common
mark on each section of the pump body to aid in
cause of pump damage. The pump bushings, gears,
reassembly.
and shafts also wear. They must be checked during
disassembly. Do not make any repairs to the parts. 2. Remove the capscrews that hold the pump to-
To prevent more failures, always replace parts that gether. Remove the flange end housing. Remove
are worn or damaged. If several main parts need the rear valve housing. Do not let the seals and
replacing, replace the complete group. gears fall. See Figure 2.
1. Put the lift truck on blocks. See the Operating 3. Make a note of the position of the plate seals
Manual or the section Periodic Maintenance and pressure plates. Carefully remove the plate
8000 SRM 1150 for lift truck models S2.0-3.5FT seals, pressure plates, and gears from the hous-
(S40-70FT, S55FTS) (F187) and H2.0-3.5FT ings. Discard plate seals. Remove the snap ring
(H40-70FT) (L177) or the section Periodic and shaft seal from the flange end housing.
Maintenance 8000 SRM 1207 for lift truck
1
Gear Pump Assembly Repair 1900 SRM 1136
1. INLET HOSE ASSEMBLY 4. SOCKET HEAD SCREW (2)
2. OUTLET HOSE ASSEMBLY 5. HYDRAULIC PUMP
3. INLET FITTING 6. TRANSMISSION
Figure 1. Hydraulic Pump Removal
2
1900 SRM 1136 Gear Pump Assembly Repair
1. SNAP RING 7. DRIVEN GEAR
2. SHAFT SEAL 8. DRIVE GEAR
3. FLANGE END HOUSING 9. REAR VALVE HOUSING
4. PLATE SEAL 10. CAPSCREW
5. PRESSURE PLATE 11. BACKUP SEAL
6. GEAR HOUSING
Figure 2. Hydraulic Pump Assembly
3
Gear Pump Assembly Repair 1900 SRM 1136
INSPECT INSTALL
Check parts for wear and damage. If any parts are 1. Install inlet and outlet fittings and tighten inlet
worn or damaged, replace the damaged parts. If the fitting to 88 to 98 N" m(65 to 72 lbf ft).
pump housing is damaged, replace the pump.
2. Clean the pump flange and transmission mount-
ing surfaces and put a 3-5 mm (0.118-0.197 in.)
CLEAN
bead of Loctite"! 515 (Hyster Part No. 264159)
on the pump flange or transmission mounting
WARNING
surface. Hold the pump in the correct position
Cleaning solvents can be flammable and toxic
on the transmission. Install the socket head
and can cause skin irritation. When using
screws and lockwashers that fasten the pump to
cleaning solvents, always follow the solvent
the transmission housing. Tighten socket head
manufacturer s recommended safety precau-
screws to 38 N" m (28 lbf ft). See Figure 1.
tions.
3. Connect the hydraulic lines. Position the outlet
hydraulic line as shown in Figure 3.
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.
A. Z = 60 Ä…5 FOR 1-SPEED TRANSMISSION,
LIFT TRUCK MODELS S30FT, S35FT, S40FTS
3. Install a new shaft seal in the flange end housing. (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001), AND S2.0-3.5FT (S40-70FT,
Carefully install the flange end housing. Do not
S55FTS) (F187)
movethepressureplates. Makesurethesealsdo
B. Z = 75 Ä…5 FOR 2-SPEED TRANSMISSION,
not move out of the correct position. See Figure 2.
LIFT TRUCK MODELS S2.0-3.5FT (S40-70FT,
S55FTS) (F187)
4. Carefully install the valve end housing on the
C. Z = 50 Ä…5 FOR LIFT TRUCK MODELS
pump body using the four capscrews and lock-
H2.0-3.5FT (H40-70FT) (L177)
washers. Make sure the pressure plates do not
1. OUTLET HOSE
move and that the seals stay in the correct posi-
2. INLET HOSE
tion. Make sure the marks made during disas-
sembly are aligned. Tighten the capscrews to 46
Figure 3. Inlet Hose Orientation
to 49 N" m (34 to 36 lbf ft).
4
1900 SRM 1136 Gear Pump Specifications
4. Remove the lift truck from the blocks. Fill for lift truck models S30FT, S35FT, S40FTS
the tank using the hydraulic oil shown in the (E010) and H1.6FT, H1.8FT, H2.0FTS (H30FT,
Maintenance Table of the section Periodic H35FT, H40FTS) (F001). When the oil level is
Maintenance 8000 SRM 1150 for lift truck correct, operate the system and check for leaks.
models S2.0-3.5FT (S40-70FT, S55FTS) (F187) Check the hydraulic oil level and add hydraulic
and H2.0-3.5FT (H40-70FT) (L177) or the sec- oil if necessary.
tion Periodic Maintenance 8000 SRM 1207
Gear Pump Specifications
Table 1. Standard Gear Pump
Relief GPM @
Model Displacement Speed Weight
Pressure 2000 RPM
S30FT, S35FT, S40FTS 24.0 cc/rev 21.4 MPa 3060 rpm 3.5 kg 12 gal/min
(E010), H1.6FT, H1.8FT, (3104 psi) (7.7 lb)
H2.0FTS (H30FT,
H35FT, H40FTS) (F001),
S2.0-3.5FT (S40-70FT,
S55FTS) (F187), and
H2.0-3.5FT (H40-70FT)
(L177)
S2.0-3.5FT (S40-70FT, 25.7 cc/rev 21.4 MPa 3060 rpm 3.7 kg 13 gal/min
S55FTS) (F187) and (3104 psi) (8.2 lb)
H2.0-3.5FT (H40-70FT)
(L177)
H1.6FT, H1.8FT, 29.4 cc/rev 21.4 MPa 3060 rpm 3.9 kg 15 gal/min
H2.0FTS (H30FT, (3104 psi) (8.6 lb)
H35FT, H40FTS)
(F001) and H2.0-3.5FT
(H40-70FT) (L177)
Table 2. High Pressure Gear Pump
Relief GPM @
Model Displacement Speed Weight
Pressure 2000 RPM
S2.0-3.5FT (S40-70FT, 24.0 cc/rev 23.4 MPa 3060 rpm 4.0 kg 12 gal/min
S55FTS) (F187), and (3393 psi) (8.8 lb)
H2.0-3.5FT (H40-70FT)
(L177)
H2.0-3.5FT (H40-70FT) 25.7 cc/rev 23.4 MPa 3060 rpm 4.1 kg 13 gal/min
(L177) (3393 psi) (9.0 lb)
H2.0-3.5FT (H40-70FT) 29.4 cc/rev 23.4 MPa 3060 rpm 4.5 kg 15 gal/min
(L177) (3393 psi) (9.9 lb)
5
Torque Specifications 1900 SRM 1136
Torque Specifications
Rear Valve End Housing to Gear Pump Gear Pump to Transmission Socket
Body Capscrews Head Screws
46 to 49 N" m (34 to 36 lbf ft) 38 N" m (28 lbf ft)
Inlet Fitting
88 to 98 N" m (65 to 72 lbf ft)
6
TECHNICAL PUBLICATIONS
1900 SRM 1136 5/05 (12/04) Printed in U.S.A.