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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]; S4.0,
5.0, 5.50FT ([S80, 100, 120FT]; S80, 100, 120FTBCS;
S120FTPRS) [G004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005]
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 Maintenance 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!
Table of Contents
TABLE OF CONTENTS
General ...............................................................................................................................................................
Gear Pump Assembly Repair ............................................................................................................................
Remove ...........................................................................................................................................................
Disassemble ...................................................................................................................................................
Clean ..............................................................................................................................................................
Inspect ............................................................................................................................................................
Assemble ........................................................................................................................................................
Install .............................................................................................................................................................
Gear Pump Specifications .................................................................................................................................
Torque Specifications .........................................................................................................................................
1
1
1
4
5
5
5
5
7
9
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
General
This section includes a description and the repair
procedures for the hydraulic gear pump assembly.
The following lift truck models, 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
be equipped with one of three different gear pumps:
24 cc/rev, 25.7 cc/rev, or 29.4 cc/rev.
The following lift truck models, S4.0, 5.0, 5.50FT
([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) (G004) and H4.0FT5/FT6;
H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005) can be equipped with one of two different
gear pumps: 41.3 cc/rev, or 51.6 cc/rev.
Lift truck models H4.0FT5/FT6;
H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005) can also be equipped with a 46.5 cc/rev gear
pump.
Figure 1. Hydraulic Pump Removal for Lift Truck Models S30FT, S35FT, S40FTS (E010), H1.6FT,
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS) (F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187), and
H2.0-3.5FT (H40-70FT) (L177)
A. FOR EARLY MODEL S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) (G004) LIFT
TRUCKS ONLY
B. FOR NEWER MODEL S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) (G004)
LIFT TRUCKS AND FOR ALL H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005) LIFT TRUCKS
1.
2.
3.
4.
TRANSMISSION
SOCKET HEAD SCREW
HYDRAULIC PUMP
INLET HOSE
5. INLET FITTING
6. OUTLET FITTING
7. OUTLET HOSE
Figure 2. Hydraulic Pump Removal for Lift Truck Models S4.0, 5.0, 5.50FT ([S80, 100, 120FT];
S80, 100, 120FTBCS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80,
90, 100, 110, 120FT) (N005)
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 together. Remove the flange end housing. Remove
1.
2.
3.
4.
5.
6.
SNAP RING
SHAFT SEAL
FLANGE END HOUSING
PLATE SEAL
PRESSURE PLATE
GEAR HOUSING
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturers recommended safety precautions.
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.
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.
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 disassembly. See the notes made during disassembly.
Make sure all seals are complete and in the
correct positions. See Figure 3.
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 3.
7.
8.
9.
10.
11.
DRIVEN GEAR
DRIVE GEAR
REAR VALVE HOUSING
CAPSCREW
BACKUP SEAL
INSTALL
1. Install inlet fitting and tighten inlet fitting to 88
to 98 Nm (65 to 72 lbf ft) on all lift truck models except S4.0, 5.0, 5.50FT ([S80, 100, 120FT];
S80, 100, 120FTBCS; S120FTPRS) (G004) and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005).
On lift truck models S4.0, 5.0, 5.50FT ([S80,
100, 120FT]; S80, 100, 120FTBCS; S120FTPRS)
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005),
tighten the inlet fitting to 98 to 118 Nm (72 to
87 lbf ft)
2. Install outlet fitting and tighten outlet fitting to
78 to 88 Nm (58 to 65 lbf ft).
3. Clean the pump flange and transmission mounting 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 Nm (28 lbf ft).
See Figure 1 for lift truck models, S30FT,
S35FT, S40FTS (E010), H1.6FT, H1.8FT, 2.0FTS
(H30FT, H35FT, H40FTS) (F001), S2.0-3.5FT
(S40-70FT, S55FTS) (F187), and H2.0-3.5FT
(H40-70FT) (L177) and for lift truck models S4.0,
5.0, 5.50FT ([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) (G004) and H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005), see Figure 2.
2. INLET HOSE
2. INLET HOSE
Displacement
Relief
Pressure
Speed
Weight
LPM (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
46 liter/min
(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
49 liter/min
(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
57 liter/min
(15 gal/min)
Table 2. High Pressure Gear Pump for Lift Truck Models 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)
Model
Displacement
Relief
Pressure
Speed
Weight
LPM (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
46 liter/min
(12 gal/min)
H2.0-3.5FT
(H40-70FT) (L177)
25.7 cc/rev
23.4 MPa
(3393 psi)
3060 rpm
49 liter/min
(13 gal/min)
H2.0-3.5FT
(H40-70FT) (L177)
29.4 cc/rev
23.4 MPa
(3393 psi)
3060 rpm
57 liter/min
(15 gal/min)
Table 3. Standard Gear Pump for Lift Truck Models S4.0, 5.0, 5.50FT ([S80, 100,
120FT]; S80, 100, 120FTBCS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
Model
Displacement
Relief
Pressure
Speed
Weight
LPM (GPM
) @
2000 RPM
41.3 cc/rev
21.4 MPa
(3104 psi)
2450 rpm
8 kg (17.6 lb)
46 liter/min
(12 gal/min)
H4.0FT5/FT6;
H4.5FTS5,
H4.5FT6; H5.05.5FT (H80, 90, 100,
110, 120FT) (N005)
46.5 cc/rev
21.4 MPa
(3104 psi)
2450 rpm
46 liter/min
(12 gal/min)
Table 4. High Pressure Gear Pump for Lift Truck Models S4.0, 5.0, 5.50FT ([S80,
100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
Model
Displacement
Relief
Pressure
Speed
Weight
LPM (GPM) @
2000 RPM
51.6 cc/rev
21.4 MPa
(3104 psi)
2500 rpm
46 liter/min
(12 gal/min)
Torque Specifications
Torque Specifications
Rear Valve End Housing to Gear Pump
Body Capscrews
46 to 49 Nm (34 to 36 lbf ft)
Inlet Fitting - All Lift Trucks Except
S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80,
100, 120FTBCS; S120FTPRS) (G004) and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005)
88 to 98 Nm (65 to 72 lbf ft)
NOTES
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