General
Thissectionincludesadescriptionandtherepair proceduresforthehydraulicgearpumpassembly.
Thefollowinglifttruckmodels,S30FT,S35FT, S40FTS(E010);H1.6FT,H1.8FT,2.0FTS(H30FT, H35FT,H40FTS)(F001);S2.0-3.5FT(S40-70FT, S55FTS)(F187);H2.0-3.5FT(H40-70FT)(L177)can beequippedwithoneofthreedifferentgearpumps: 24cc/rev,25.7cc/rev,or29.4cc/rev.
Thefollowinglifttruckmodels,S4.0,4.5,5.5FT, S5.5FTS,(S80,100,120FT;S80,100FTBCS; S120FTS;S120FTPRS)(G004)andH4.0FT5/FT6; H4.5FTS5,H4.5FT6;H5.0-5.5FT(H80,90,100,110, 120FT)(N005,P005)canbeequippedwithoneof twodifferentgearpumps:41.3cc/rev,or51.6cc/rev.
LifttruckmodelsH4.0FT5/FT6;H4.5FTS5, H4.5FT6;H5.0-5.5FT(H80,90,100,110,120FT) (N005,P005)canalsobeequippedwitha46.5cc/rev gearpump.
Thefollowinglifttruckmodels,S6.0FT,S7.0FT, (S135FT,S155FT)(D024,E024);H6.0FT,H7.0FT (H135FT,H155FT)(H006,J006)canbeequipped
withoneoftwodifferenttandemgearpumps:63.3 cc/revor68.5cc/rev.
Therepairproceduresaresimilarforeachtypeof gearpump.Whentherepairhasbeencompleted,see theGearPumpSpecificationssectioninthismanual.
Repairinformationforothercomponentsofthehydraulicsystemarefoundinthefollowingmanuals: SteeringAxle 1600SRM1133, MainControl Valve 2000SRM1137,and MastRepairs, 2,3, and4-StageMasts 4000SRM1148foralllift truckmodelsexceptS4.0,4.5,5.5FT,S5.5FTS,(S80, 100,120FT;S80,100FTBCS;S120FTS;S120FTPRS)(G004);H4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT)(N005,P005); S6.0FT,S7.0FT,(S135FT,S155FT)(D024,E024)and H6.0FT,H7.0FT(H135FT,H155FT)(H006,J006). ForlifttruckmodelsS4.0,4.5,5.5FT,S5.5FTS,(S80, 100,120FT;S80,100FTBCS;S120FTS;S120FTPRS)(G004);H4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT)(N005,P005); S6.0FT,S7.0FT,(S135FT,S155FT)(D024,E024)and H6.0FT,H7.0FT(H135FT,H155FT)(H006,J006), see MastRepairs, 2-and3-StageMasts 4000 SRM1250.
SingleGearPumpAssemblyRepair
REMOVE
WARNING
PUTTINGTHELIFTTRUCKONBLOCKS
Thelifttruckmustbeputonblocksforsome typesofmaintenanceandrepair.Theremoval ofthefollowingassemblieswillcauselarge changesinthecenterofgravity:mast,drive axle,engine,transmission,andcounterweight.
Whenthelifttruckisputonblocks,putadditionalblocksinthefollowingpositionsto maintainstability:
•Beforeremovingthemastanddriveaxle,put blocksunderthecounterweightsothelift truckcannotfallbackward.
•Beforeremovingthecounterweight,put blocksunderthemastassemblysothelift truckcannotfallforward.
Thesurfacemustbesolid,even,andlevelwhen thelifttruckisputonblocks.Makesureany
blocksusedtosupportthelifttruckaresolid, one-pieceunits.
NOTE: Wornordamagedsealsarethemostcommon causeofpumpdamage.Thepumpbushings,gears, andshaftsalsowear.Theymustbecheckedduring disassembly.Donotmakeanyrepairstotheparts. Topreventmorefailures,alwaysreplacepartsthat arewornordamaged.Ifseveralmainpartsneed replacing,replacethecompletegroup.
1. Putthelifttruckonblocks.Seethe Operating Manual orthe PeriodicMaintenanceManual foryourlifttruckfortheprocedurestoput thelifttruckonblocks.
2. Placeadrainpanunderthehydraulictank. Thedrainpanmusthavecapacityofapproximately30liter(8gal)forlifttruckmodelsS30FT,S35FT,S40FTS(E010),H1.6FT, H1.8FT,2.0FTS(H30FT,H35FT,H40FTS) (F001),S2.0-3.5FT(S40-70FT,S55FTS)(F187); H2.0-3.5FT(H40-70FT)(L177),40liter(11gal) forlifttruckmodelsS4.0,4.5,5.5FT,S5.5FTS,
(S80,100,120FT;S80,100FTBCS;S120FTS; S120FTPRS)(G004),and51liter(13.5gal) forlifttruckmodelsH4.0FT5/FT6;H4.5FTS5, H4.5FT6;H5.0-5.5FT(H80,90,100,110,120FT) (N005,P005).Removethedrainplugatthe bottomofthehydraulicoiltank.Draintheoil fromthetank.
3. Putadrainpanunderthepumpassembly. Removeallhydrauliclinesconnectedtothe pumpassembly.Removetheinletandoutletfittingsfromthehydraulicpump.Put capsonallthehosefittingsandhydraulic pumpports.SeeFigure1forlifttruckmodelsS30FT,S35FT,S40FTS(E010),H1.6FT, H1.8FT,2.0FTS(H30FT,H35FT,H40FTS) (F001),S2.0-3.5FT(S40-70FT,S55FTS)(F187); H2.0-3.5FT(H40-70FT)(L177)andFigure2for lifttruckmodelsS4.0,4.5,5.5FT,S5.5FTS,(S80, 100,120FT;S80,100FTBCS;S120FTS;S120FTPRS)(G004)andH4.0FT5/FT6;H4.5FTS5, H4.5FT6;H5.0-5.5FT(H80,90,100,110,120FT) (N005,P005).
4. Holdthepumpassemblytokeepitfromfalling. Removethetwosocketheadscrewsandthelockwashersthatfastenthepumptothetransmissionhousing.Removethepumpassembly.
DISASSEMBLE
1. Putthepumpbodyinavise.Putanalignment markoneachsectionofthepumpbodytoaidin reassembly.
2. Removethecapscrewsthatholdthepumptogether.Removetheflangeendhousing.Remove therearvalvehousing.Donotletthesealsand gearsfall.SeeFigure3.
3. Makeanoteofthepositionoftheplateseals andpressureplates.Carefullyremovetheplate seals,pressureplates,andgearsfromthehousings.Discardplatesealsandbackupseals.Removethesnapringandshaftsealfromtheflange endhousing.
CLEAN WARNING
Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing
cleaningsolvents,alwaysfollowthesolvent manufacturer’srecommendedsafetyprecautions.
WARNING
Compressedaircanmoveparticlessothatthey causeinjurytotheuserortootherpersonnel. Makesurethatthepathofthecompressedair isawayfromallpersonnel.Wearprotective gogglesorafaceshieldtopreventinjurytothe eyes.
Cleanallpartsinsolvent.Drypartswithcompressed air.Donotdrythepartswithacloth.Makesureall surfacesare freeofscratchesandsharpedges.
INSPECT
Checkparts forwearanddamage.Ifanypartsare wornordamaged,replacethedamagedparts.Ifthe pumphousingisdamaged,replacethepump.
ASSEMBLE
1. Coatallpumpcomponentswithhydraulicoil. UsehydraulicoilmeetingspecificationISOVG 46hydraulicoil 15 C(5 F) andabove.
2. Usenewplateandbackupsealsandinstallthe pressureplatesandgears.Makesuretoinstall thepressureplatesasremovedduringdisassembly.Seethenotesmadeduringdisassembly. Makesure allsealsarecompleteandinthe correctpositions.SeeFigure3.
3. Installa newshaftsealintheflangeendhousing. Carefullyinstalltheflangeendhousing.Donot movethepressureplates.Makesurethesealsdo notmove outofthecorrectposition.SeeFigure3.
4. Carefullyinstallthevalveendhousingonthe pumpbodyusingthefourcapscrewsandlockwashers.Makesurethepressureplatesdonot moveand thatthesealsstayinthecorrectposition.Makesurethemarksmadeduringdisassemblyarealigned.Tightenthecapscrewsto46 to49N•m(34to36lbfft).
A. FOREARLYMODELS4.0,4.5,5.5FT,S5.5FTS,(S80,100,120FT;S80,100FTBCS;S120FTS;S120FTPRS) (G004)LIFTTRUCKSONLY
B. FORNEWERMODELS4.0,4.5,5.5FT,S5.5FTS,(S80,100,120FT;S80,100FTBCS;S120FTS; S120FTPRS)(G004)LIFTTRUCKSANDFORALLH4.0FT5/FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT(H80, 90,100,110,120FT)(N005,P005)LIFTTRUCKS
1.TRANSMISSION
2.SOCKETHEADSCREW
3.HYDRAULICPUMP
4.INLETHOSE
5.INLETFITTING
6.OUTLETFITTING
7.OUTLETHOSE
Figure2.HydraulicPumpRemovalforLiftTruckModelsS4.0,4.5,5.5FT,S5.5FTS,(S80,100, 120FT;S80,100FTBCS;S120FTS;S120FTPRS)(G004)andH4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT)(N005,P005)
INSTALL
1. Installinletfittingandtighteninletfittingto88 to98N•m(65to72lbfft)onalllifttruckmodelsexceptS4.0,4.5,5.5FT,S5.5FTS,(S80,100, 120FT;S80,100FTBCS;S120FTS;S120FTPRS) (G004)andH4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT)(N005, P005).
OnlifttruckmodelsS4.0,4.5,5.5FT,S5.5FTS, (S80,100,120FT;S80,100FTBCS;S120FTS; S120FTPRS)(G004)andH4.0FT5/FT6; H4.5FTS5,H4.5FT6;H5.0-5.5FT(H80,90, 100,110,120FT)(N005,P005),tightentheinlet fittingto98to118N•m(72to87lbfft).
2. Installoutletfittingandtightenoutletfittingto 78to88N•m(58to65lbfft).
3. Cleanthepumpflangeandtransmissionmountingsurfacesandputa3-5mm(0.118-0.197in.) beadofLoctite™515(HysterPartNo.264159) onthepumpflangeortransmissionmounting surface.Holdthepumpinthecorrectpositiononthetransmission.Installthesocket headscrewsandlockwashersthatfastenthe pumptothetransmissionhousing.Tighten socketheadscrewsto38N•m(28lbfft).
SeeFigure1forlifttruckmodels,S30FT, S35FT,S40FTS(E010),H1.6FT,H1.8FT,2.0FTS (H30FT,H35FT,H40FTS)(F001),S2.0-3.5FT (S40-70FT,S55FTS)(F187),andH2.0-3.5FT (H40-70FT)(L177)andforlifttruckmodels
S4.0,4.5,5.5FT,S5.5FTS,(S80,100,120FT;S80, 100FTBCS;S120FTS;S120FTPRS)(G004)and H4.0FT5/FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT (H80,90,100,110,120FT)(N005,P005),see Figure2.
4. Connectthehydrauliclines.Positiontheoutlet hydrauliclineasshowninFigure4forlifttrucks modelsS30FT,S35FT,S40FTS(E010),H1.6FT, H1.8FT,2.0FTS(H30FT,H35FT,H40FTS) (F001),S2.0-3.5FT(S40-70FT,S55FTS)(F187), andH2.0-3.5FT(H40-70FT)(L177)andforlift truckmodels,S4.0,4.5,5.5FT,S5.5FTS,(S80, 100,120FT;S80,100FTBCS;S120FTS;S120FTPRS)(G004)andH4.0FT5/FT6;H4.5FTS5, H4.5FT6;H5.0-5.5FT(H80,90,100,110,120FT) (N005,P005),seeFigure5.
5. Removethelifttruckfromtheblocks.Seethe OperatingManual orthe PeriodicMaintenanceManual fortheprocedurestoremovelift
truckfromblocks.FillthetankusingthehydraulicoilshownintheMaintenanceTablelocatedinthe OperatingManual orthe Periodic MaintenanceManual foryourlifttruckmodel. Whentheoilleveliscorrect,operatethesystem andcheckforleaks.Checkthehydraulicoillevel andaddhydraulicoilifnecessary.
A. Z=60 ±5 FOR1-SPEEDTRANSMISSION, LIFTTRUCKMODELSS30FT,S35FT,S40FTS (E010),H1.6FT,H1.8FT,H2.0FTS(H30FT,H35FT, H40FTS)(F001),ANDS2.0-3.5FT(S40-70FT, S55FTS)(F187)
B. Z=75 ±5 FOR2-SPEEDTRANSMISSION, LIFTTRUCKMODELSS2.0-3.5FT(S40-70FT, S55FTS)(F187)
C. Z=50 ±5 FORLIFTTRUCKMODELS H2.0-3.5FT(H40-70FT)(L177)
D. X=10 ±5 FORLIFTTRUCKMODELSS30FT, S35FT,S40FTS(E010);H1.6FT,H1.8FT,2.0FTS (H30FT,H35FT,H40FTS)(F001);S2.0-3.5FT (S40-70FT,S55FTS)(F187);H2.0-3.5FT (H40-70FT)(L177)
1.OUTLET HOSE
2.INLETHOSE
Figure4.InletHoseOrientationforLiftTruck ModelsS30FT,S35FT,S40FTS(E010),H1.6FT, H1.8FT,2.0FTS(H30FT,H35FT,H40FTS) (F001),S2.0-3.5FT(S40-70FT,S55FTS)(F187), andH2.0-3.5FT(H40-70FT)(L177)
LegendforFigure5
A. X=32 ±5 FORALLLIFTTRUCKMODELS EXCEPTS4.0,4.5,5.5FT,S5.5FTS,(S80,100, 120FT;S80,100FTBCS;S120FTS;S120FTPRS) (G004)ANDH4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT)(N005, P005)
B. X=30 ±5 FORLIFTTRUCKMODELSS4.0, 4.5,5.5FT,S5.5FTS,(S80,100,120FT;S80, 100FTBCS;S120FTS;S120FTPRS)(G004)AND H4.0FT5/FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT (H80,90,100,110,120FT)(N005,P005)
1.OUTLETHOSE
2.INLETHOSE
Figure5.InletHoseOrientationforLiftTruck ModelsS4.0,4.5,5.5FT,S5.5FTS,(S80,100, 120FT;S80,100FTBCS;S120FTS;S120FTPRS) (G004)andH4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT)(N005, P005)
TandemGearPumpAssembly REMOVE
WARNING
PUTTING THELIFTTRUCKONBLOCKS
Thelift truckmustbeputonblocksforsome typesof maintenanceandrepair.Theremoval ofthefollowingassemblieswillcauselarge changesinthecenterofgravity:mast,drive axle,engine,transmission,andcounterweight. Whenth elifttruckisputonblocks,putadditionalblocksinthefollowingpositionsto maintainstability:
•Before removingthemastanddriveaxle,put blocks underthecounterweightsothelift truck cannotfallbackward.
•Before removingthecounterweight,put blocksunderthemastassemblysothelift truck cannotfallforward.
Thesurfacemustbesolid,even,andlevelwhen thelifttruckisputonblocks.Makesureany blocksusedtosupportthelifttruckaresolid, one-pieceunits.
NOTE: Wornordamagedsealsarethemostcommon causeofpumpdamage.Thepumpbushings,gears, andshaftsalsowear.Theymustbecheckedduring disassembly.Donotmakeanyrepairstotheparts. Topreventmorefailures,alwaysreplacepartsthat arewornordamaged.Ifseveralmainpartsneed replacing,replacethecompletegroup.
1. Thetandemgearpumpassemblytaskapplies tothefollowinglifttrucks:S6.0FT,S7.0FT, (S135FT,S155FT)(D024,E024)andH6.0FT, H7.0FT(H135FT,H155FT)(H006,J006).Put thelifttruckonblocks.Seethe Operating Manual orthe PeriodicMaintenanceManual foryourlifttruckfortheprocedurestoput thelifttruckonblocks.
2. Placeadrainpanunderthehydraulictank thathasacapacityofapproximately64liter (16.9gal)forlifttruckmodelsS6.0FT,S7.0FT, (S135FT,S155FT)(D024,E024)andH6.0FT, H7.0FT(H135FT,H155FT)(H006,J006).Removethedrainplugatthebottomofthehydraulicoiltank.Draintheoilfromthetank.
3. Putadrainpanunderthetandemgearpump assembly.Removehydraulicoutlethosesatthe fittingsonthetandemgearpumpassembly. Removetheinlethoseclampsandinlethoses fromthetandemgearpumpassembly.See Figure6forlifttruckmodelsS6.0FT,S7.0FT, (S135FT,S155FT)(D024,E024)andH6.0FT, H7.0FT(H135FT,H155FT)(H006,J006).Put capsonallthehosefittingsandhydraulicpump ports.
4. Supportthetandemgearpumpassemblyto keepitfromfalling.Removethetwosockethead screwsandlockwashersthatfastenthetandem gearpumpassemblytothetransmissioncharge pumphousing.Removethetandemgearpump assembly.
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DISASSEMBLE
1. Securethetandemgearpumpassemblyinavise. Putanalignmentmarkoneachsectionofthe pumpbodytoaidinreassembly.
NOTE: Thetandemgearpumpassemblyconsistsof adrivenpumpattachedtoadrivepump.Eachpump hasaninletadapterandoutletfitting.
2. Removeinletadaptersandoutletfittingsfrom drivepumpanddrivenpumpoftandemgear pumpassembly.SeeFigure7.
3. Removetwocapscrewsandwashersattaching drivenpumptodrivepump.SeeFigure8.
NOTE: Drivepumpshaftanddrivenpumpshaftare connectedbyacoupling.
4. Slowlyremovedrivenpumpfromdrivepump. NotepositionofO-ringsoncoupling.Remove O-rings,andcoupling.DiscardO-rings.
5. Placedrivenpumponacleanworkspaceand continuewithdisassemblyofthedrivepump.
6. Removesnapringandoilsealfromdrivepump flangeendhousing.Discardsnapring.
7. Removethesocketheadscrewsandwashersthat holdthepumptogether,andremovefromvise. Removeadapterplate,coverplateandhousing fromdrivepumpflangeendhousing.Donotlet thesealsandgearsfall.
8. Makeanoteofthepositionoftheplateseals andpressureplates.Carefullyremovetheplate seals,backupseals,pressureplates,gearplate, coverplate,oilsealandgearsfromthehousings. Discardplatesealsandbackupseals.
9. Securethedrivenpumpbodyinavise.
10. Removethesocketheadflangescrewsthathold thepumptogether.Removethemountingflange cover.Removetherearvalvehousing.Donotlet thesealsandgearsfall.SeeFigure8.
11. Makeanoteofthepositionoftheplateseals andpressureplates.Carefullyremovetheplate seals,pressureplates,gearplateandgearsfrom thehousings.Discardplatesealsandbackup seals.Removethesnapringfromtheflangeend housing.Discardsnapring.
CLEAN
WARNING
Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowthesolvent manufacturer’srecommendedsafetyprecautions.
WARNING
Compressedaircanmoveparticlessothatthey causeinjurytotheuserortootherpersonnel. Makesurethat thepathofthecompressedair isawayfromallpersonnel.Wearprotective gogglesorafaceshieldtopreventinjurytothe eyes.
Cleanallpartsinsolvent.Drypartswithcompressed air.Donotdrythepartswithacloth.Makesureall surfacesare freeofscratchesandsharpedges.
INSPECT
Checkpartsforwearanddamage.Ifanypartsare wornordamaged,replacethedamagedparts.Ifthe pumphousingisdamaged,replacethepump.
ASSEMBLE
1. Coatallpumpcomponentswithhydraulicoil. UsehydraulicoilmeetingspecificationISOVG 46hydraulicoil 15 C(5 F) andabove.
2. Beginassemblyofthedrivenpump.Usenew plateandbackupsealsandinstallthepressure plates,gearplateandgears.Makesuretoinstallthepressureplatesasremovedduringdisassembly. Seethenotesmadeduringdisassembly.Makesureallsealsareinthecorrectpositions.SeeFigure8.
3. Carefullyinstallthemountingflangecover.Do notmovethepressureplates.Makesurethe sealsdonotmoveoutofthecorrectposition.
4. Carefullyinstalltheflangeendhousingonthe pumpbodyusing thefoursocketheadflange screws.Makesurethepressureplatesdonot moveandthatthesealsstayinthecorrect position.Makesurethemarksmadeduring disassemblyarealigned.Tightenthecapscrews to88to98N•m (65to72lbfft).Installnew snapringinflangeendhousing.
5. Beginassemblyofthedrivepump.Usenewplate andbackupsealsandinstallthepressureplates andgears.Makesuretoinstallthepressure plates,coverplate,housing,oilsealandadapter plateasremovedduringdisassembly.Seethe notesmadeduringdisassembly.Makesureall sealsarein thecorrectpositions.
6. Installanewshaftsealinthedrivepumpflange endhousing.Carefullyinstalltheflangeend housing.Donotmovethepressureplates.Make surethesealsdonotmoveoutofthecorrectposition.
7. Carefully installtheadapterplateonthedrive pumpbodyusingthefoursocketheadscrewsand lockwashers.Makesurethepressureplatesdo notmoveandthatthesealsstayinthecorrect position.Makesurethemarksmadeduringdisassembly arealigned.Tightenthecapscrewsto 123to132 N•m(91to97lbfft).Installnewsnap ringinfrontofshaftseal.
8. Assemble tandemgearpump.Placedrivepump inviseandinstalloilseal,adapter,sleeveand O-ringtoshaftofdrivepump.Fitshaftofdriven pumpintoadapterandinstalltwocapscrewsand washers securingthedrivenpumptothedrive pump.Tightenthecapscrewsto88to98N•m (65to72 lbfft).
9. Repositiontandemgearpumpintheviseand installtwooutlethosefittings.SeeFigure7. Tightenthefittingsto78to88N•m(58to 65lbfft).
10. Installtwoinletadapters,tightento88to 98N•m(65to72lbfft).Removetandemgear pumpfromvise.
INSTALL
1. Cleanthetandemgearpumpflangeandtransmissionchargepumpmountingsurfacesand puta3-5mm(0.118-0.197in.)beadofLoctite™ 515(HysterPartNo.264159)onthepump flangeortransmissionchargepumpmounting surface.Holdthepumpinthecorrectposition onthetransmission.Installthesockethead
screwsandlockwashersthatfastenthepumpto thetransmissionhousing.Tightensockethead screwsto108N•m(80lbfft).SeeFigure6.
2. Looseninlethoseclampsandinstallinlethoses toinlethosefittings.Tighteninlethoseclamps. Installoutlethosestooutlethosefittings.
3. Removethelifttruckfromtheblocks.Seethe OperatingManual orthe PeriodicMaintenanceManual fortheprocedurestoremovelift truckfromblocks.FillthetankusingthehydraulicoilshownintheMaintenanceTablelocatedinthe OperatingManual orthe Periodic MaintenanceManual foryourlifttruckmodel. Whentheoilleveliscorrect,operatethesystem andcheckforleaks.Checkthehydraulicoillevel andaddhydraulicoilifnecessary.
GearPumpSpecifications
Table1.StandardGearPumpforLiftTruckModelsS30FT,S35FT,S40FTS(E010); H1.6FT,H1.8FT,2.0FTS(H30FT,H35FT,H40FTS)(F001);S2.0-3.5FT(S40-70FT, S55FTS)(F187);H2.0-3.5FT(H40-70FT)(L177)