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SERVICE REPAIR S135FT S155FT [D024]


1900 SRM 1136

Single Gear Pump Assembly Repair

General This section includes a description and the repair procedures for the hydraulic gear pump assembly.

with one of two different tandem gear pumps: 63.3 cc/rev or 68.5 cc/rev.

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 repair procedures are similar for each type of gear pump. When the repair has been completed, see the Gear Pump Specifications section in this manual.

The following lift truck models, 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) 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, P005) can also be equipped with a 46.5 cc/rev gear pump. The following lift truck models, S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024); H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) can be equipped

Repair information for other components of the hydraulic 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 for all lift truck models except S4.0, 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). For lift truck models S4.0, 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 Mast Repairs, 2- and 3-Stage Masts 4000 SRM 1250.

Single 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 additional 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 Periodic Maintenance Manual for your lift truck for the procedures to put the lift truck on blocks. 2. Place a drain pan under the hydraulic tank. The drain pan must have capacity of approximately 30 liter (8 gal) 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), 40 liter (11 gal) for lift truck models S4.0, 4.5, 5.5FT, S5.5FTS, 1


Single Gear Pump Assembly Repair (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004), and 51 liter (13.5 gal) for lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005). Remove the drain plug at the bottom of the hydraulic oil tank. Drain the oil from the tank. 3. Put a drain pan under the pump assembly. Remove 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 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); H2.0-3.5FT (H40-70FT) (L177) and Figure 2 for lift truck models 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). 4. Hold the pump assembly to keep it from falling. Remove the two socket head screws and the lockwashers that fasten the pump to the transmission housing. Remove the pump assembly.

1900 SRM 1136 cleaning solvents, always follow the solvent manufacturer’s 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.

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

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.

2. Remove the capscrews that hold the pump together. Remove the flange end housing. Remove the rear valve housing. Do not let the seals and gears fall. 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.

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 housings. Discard plate seals and backup seals. Remove the snap ring and shaft seal from the flange end housing.

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

DISASSEMBLE

CLEAN WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using

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1900 SRM 1136

Single Gear Pump Assembly Repair

A. EARLY LIFT TRUCK MODELS

B. NEWER LIFT TRUCK MODELS

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 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)

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Single Gear Pump Assembly Repair

1900 SRM 1136

A. FOR EARLY MODEL S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) LIFT TRUCKS ONLY B. FOR NEWER MODEL S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004) LIFT TRUCKS AND FOR ALL H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005) 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, 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)

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1900 SRM 1136

1. 2. 3. 4. 5. 6.

SNAP RING SHAFT SEAL FLANGE END HOUSING PLATE SEAL PRESSURE PLATE GEAR HOUSING

Single Gear Pump Assembly Repair

7. 8. 9. 10. 11.

DRIVEN GEAR DRIVE GEAR REAR VALVE HOUSING CAPSCREW BACKUP SEAL

Figure 3. Hydraulic Pump Assembly

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Single Gear Pump Assembly Repair

INSTALL 1. Install inlet fitting and tighten inlet fitting to 88 to 98 N•m (65 to 72 lbf ft) on all lift truck models except 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).

1900 SRM 1136 truck from blocks. Fill the tank using the hydraulic oil shown in the Maintenance Table located in the Operating Manual or the Periodic Maintenance Manual for your lift truck model. When the oil level is correct, operate the system and check for leaks. Check the hydraulic oil level and add hydraulic oil if necessary.

On lift truck models 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), tighten the inlet fitting to 98 to 118 N•m (72 to 87 lbf ft). 2. Install outlet fitting and tighten outlet fitting to 78 to 88 N•m (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 N•m (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, 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 Figure 2. 4. Connect the hydraulic lines. Position the outlet hydraulic line as shown in Figure 4 for lift trucks 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, 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 Figure 5. 5. Remove the lift truck from the blocks. See the Operating Manual or the Periodic Maintenance Manual for the procedures to remove lift

6

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) D. X = 10 ± 5 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) 1. OUTLET HOSE 2. INLET HOSE Figure 4. Inlet Hose Orientation 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)


1900 SRM 1136

Tandem Gear Pump Assembly Legend for Figure 5 A. X = 32 ± 5 FOR ALL LIFT TRUCK MODELS EXCEPT 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) B. X = 30 ± 5 FOR LIFT TRUCK MODELS 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) 1. OUTLET HOSE 2. INLET HOSE

Figure 5. Inlet Hose Orientation for Lift Truck Models 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)

Tandem Gear Pump Assembly 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 additional 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. The tandem gear pump assembly task applies to the following lift trucks: S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006). Put the lift truck on blocks. See the Operating Manual or the Periodic Maintenance Manual for your lift truck for the procedures to put the lift truck on blocks. 2. Place a drain pan under the hydraulic tank that has a capacity of approximately 64 liter (16.9 gal) for lift truck models S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006). Remove the drain plug at the bottom of the hydraulic oil tank. Drain the oil from the tank.

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Tandem Gear Pump Assembly

1900 SRM 1136

3. Put a drain pan under the tandem gear pump assembly. Remove hydraulic outlet hoses at the fittings on the tandem gear pump assembly. Remove the inlet hose clamps and inlet hoses from the tandem gear pump assembly. See Figure 6 for lift truck models S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006). Put caps on all the hose fittings and hydraulic pump ports.

4. Support the tandem gear pump assembly to keep it from falling. Remove the two socket head screws and lock washers that fasten the tandem gear pump assembly to the transmission charge pump housing. Remove the tandem gear pump assembly.

1. 2. 3. 4.

5. 6. 7. 8.

OUTLET HOSES OUTLET HOSE FITTINGS INLET HOSE CLAMPS INLET HOSES

HEX SOCKET CAPSCREW LOCK WASHER TRANSMISSION CHARGE PUMP TANDEM GEAR PUMP

Figure 6. Hydraulic Pump Removal for Lift Truck Models S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024) and H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)

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1900 SRM 1136

DISASSEMBLE 1. Secure the tandem gear pump assembly in a vise. Put an alignment mark on each section of the pump body to aid in reassembly.

Tandem Gear Pump Assembly 3. Remove two capscrews and washers attaching driven pump to drive pump. See Figure 8. NOTE: Drive pump shaft and driven pump shaft are connected by a coupling.

NOTE: The tandem gear pump assembly consists of a driven pump attached to a drive pump. Each pump has an inlet adapter and outlet fitting.

4. Slowly remove driven pump from drive pump. Note position of O-rings on coupling. Remove O-rings, and coupling. Discard O-rings.

2. Remove inlet adapters and outlet fittings from drive pump and driven pump of tandem gear pump assembly. See Figure 7.

5. Place driven pump on a clean work space and continue with disassembly of the drive pump. 6. Remove snap ring and oil seal from drive pump flange end housing. Discard snap ring. 7. Remove the socket head screws and washers that hold the pump together, and remove from vise. Remove adapter plate, cover plate and housing from drive pump flange end housing. Do not let the seals and gears fall. 8. Make a note of the position of the plate seals and pressure plates. Carefully remove the plate seals, back up seals, pressure plates, gear plate, cover plate, oil seal and gears from the housings. Discard plate seals and backup seals. 9. Secure the driven pump body in a vise. 10. Remove the socket head flange screws that hold the pump together. Remove the mounting flange cover. Remove the rear valve housing. Do not let the seals and gears fall. See Figure 8.

1. 2. 3. 4.

FITTING DRIVEN PUMP ADAPTER DRIVE PUMP Figure 7. Tandem Gear Pump Fittings

11. Make a note of the position of the plate seals and pressure plates. Carefully remove the plate seals, pressure plates, gear plate and gears from the housings. Discard plate seals and backup seals. Remove the snap ring from the flange end housing. Discard snap ring.

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Tandem Gear Pump Assembly

1900 SRM 1136

Figure 8. Tandem Gear Pump Assembly

10


1900 SRM 1136

Tandem Gear Pump Assembly Legend for Figure 8

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

SOCKET HEAD FLANGE SCREW MOUNTING FLANGE COVER PLATE SEAL BACKUP SEAL PRESSURE PLATE GEAR PLATE DOWEL PIN GEARS CAPSCREW WASHER

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 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. Begin assembly of the driven pump. Use new plate and backup seals and install the pressure plates, gear plate and gears. Make sure to install the pressure plates as removed during disassembly. See the notes made during disassembly. Make sure all seals are in the correct positions. See Figure 8.

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

FLANGE END HOUSING SNAP RING O-RING COUPLING SOCKET HEAD SCREW ADAPTER PLATE COVER PLATE HOUSING OIL SEAL DRIVE PUMP FLANGE END HOUSING

3. Carefully install the mounting flange cover. Do not move the pressure plates. Make sure the seals do not move out of the correct position. 4. Carefully install the flange end housing on the pump body using the four socket head flange screws. Make sure the pressure plates do not move and that the seals stay in the correct position. Make sure the marks made during disassembly are aligned. Tighten the capscrews to 88 to 98 N•m (65 to 72 lbf ft). Install new snap ring in flange end housing. 5. Begin assembly of the drive pump. Use new plate and backup seals and install the pressure plates and gears. Make sure to install the pressure plates, cover plate, housing, oil seal and adapter plate as removed during disassembly. See the notes made during disassembly. Make sure all seals are in the correct positions. 6. Install a new shaft seal in the drive pump 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. 7. Carefully install the adapter plate on the drive pump body using the four socket head screws and lock washers. Make sure the pressure plates do not move and that the seals stay in the correct position. Make sure the marks made during disassembly are aligned. Tighten the capscrews to 123 to 132 N•m (91 to 97 lbf ft). Install new snap ring in front of shaft seal. 8. Assemble tandem gear pump. Place drive pump in vise and install oil seal, adapter, sleeve and O-ring to shaft of drive pump. Fit shaft of driven pump into adapter and install two capscrews and washers securing the driven pump to the drive pump. Tighten the capscrews to 88 to 98 N•m (65 to 72 lbf ft).

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Gear Pump Specifications

1900 SRM 1136

9. Reposition tandem gear pump in the vise and install two outlet hose fittings. See Figure 7. Tighten the fittings to 78 to 88 N•m (58 to 65 lbf ft). 10. Install two inlet adapters, tighten to 88 to 98 N•m (65 to 72 lbf ft). Remove tandem gear pump from vise.

INSTALL 1. Clean the tandem gear pump flange and transmission charge pump 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 charge pump 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 108 N•m (80 lbf ft). See Figure 6. 2. Loosen inlet hose clamps and install inlet hoses to inlet hose fittings. Tighten inlet hose clamps. Install outlet hoses to outlet hose fittings. 3. Remove the lift truck from the blocks. See the Operating Manual or the Periodic Maintenance Manual for the procedures to remove lift truck from blocks. Fill the tank using the hydraulic oil shown in the Maintenance Table located in the Operating Manual or the Periodic Maintenance Manual for your lift truck model. 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 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

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)

46 liter/min (12 gal/min)

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