Hyster d024 (s135 ft) forklift service repair manual

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.
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, 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
with one of two different tandem gear pumps: 63.3
cc/rev or 68.5 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.
Repair information for other components of the hy-
draulic 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; S120FT-
PRS) (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,
PRS) (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 ad-
ditional 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 Man-
ual 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 approx-
imately 30 liter (8 gal) for lift truck mod-
els 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 1900 SRM 1136
(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 out-
let fittings from the hydraulic pump. Put
caps on all the hose fittings and hydraulic
pump ports. See Figure 1 for lift truck mod-
els S30FT, S35FT, S40FTS (E010), H1.6FT,
(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,
PRS) (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 lock-
washers that fasten the pump to the transmis-
sion housing. Remove the pump assembly.
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 to-
gether. Remove the flange end housing. Remove
the rear valve housing. Do not let the seals and
gears fall. 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 hous-
ings. Discard plate seals and backup seals. Re-
move the snap ring and shaft seal from the flange
end housing.
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 precau-
tions.
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 disas-
sembly. 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.
4. Carefully install the valve end housing on the
pump body using the four capscrews and lock-
washers. Make sure the pressure plates do not
move and that the seals stay in the correct posi-
tion. Make sure the marks made during disas-
sembly are aligned. Tighten the capscrews to 46
to 49 N•m (34 to 36 lbf ft).
2

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)
3

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. TRANSMISSION
2. SOCKET HEAD SCREW
3. HYDRAULIC PUMP
4. 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)
4

1. SNAP RING
2. SHAFT SEAL
3. FLANGE END HOUSING
4. PLATE SEAL
5. PRESSURE PLATE
6. GEAR HOUSING
7. DRIVEN GEAR
8. DRIVE GEAR
9. REAR VALVE HOUSING
10. CAPSCREW
11. BACKUP SEAL
Figure 3. Hydraulic Pump Assembly
5

INSTALL
1. Install inlet fitting and tighten inlet fitting to 88
to 98 N•m (65 to 72 lbf ft) on all lift truck mod-
els 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).
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 mount-
ing 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 posi-
tion 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,
(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,
PRS) (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 Mainte-
nance Manual for the procedures to remove lift
truck from blocks. Fill the tank using the hy-
draulic oil shown in the Maintenance Table lo-
cated 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.
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,
(F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187),
and H2.0-3.5FT (H40-70FT) (L177)
6

1900 SRM 1136 Tandem Gear Pump Assembly
Figure 5. Inlet Hose Orientation for Lift Truck
Models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
P005)
Legend for Figure 5
A. X = 32 ± 5 FOR ALL LIFT TRUCK MODELS
EXCEPT S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
(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
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 ad-
ditional 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 Man-
ual 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). Re-
move the drain plug at the bottom of the hy-
draulic oil tank. Drain the oil from the tank.
7

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. OUTLET HOSES
2. OUTLET HOSE FITTINGS
3. INLET HOSE CLAMPS
4. INLET HOSES
5. HEX SOCKET CAPSCREW
6. LOCK WASHER
7. TRANSMISSION CHARGE PUMP
8. 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)
8

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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.
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.
2. Remove inlet adapters and outlet fittings from
drive pump and driven pump of tandem gear
pump assembly. See Figure 7.
1. FITTING
2. DRIVEN PUMP
3. ADAPTER
4. DRIVE PUMP
Figure 7. Tandem Gear Pump Fittings
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.
4. Slowly remove driven pump from drive pump.
Note position of O-rings on coupling. Remove
O-rings, and coupling. Discard O-rings.
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.
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.
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.
9

Tandem Gear Pump Assembly 1900 SRM 1136
Figure 8. Tandem Gear Pump Assembly
10

Legend for Figure 8
1. SOCKET HEAD FLANGE SCREW
2. MOUNTING FLANGE COVER
3. PLATE SEAL
4. BACKUP SEAL
5. PRESSURE PLATE
6. GEAR PLATE
7. DOWEL PIN
8. GEARS
9. CAPSCREW
10. WASHER
11. FLANGE END HOUSING
12. SNAP RING
13. O-RING
14. COUPLING
15. SOCKET HEAD SCREW
16. ADAPTER PLATE
17. COVER PLATE
18. HOUSING
19. OIL SEAL
20. DRIVE PUMP FLANGE END HOUSING
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 precau-
tions.
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 in-
stall the pressure plates as removed during dis-
assembly. See the notes made during disassem-
bly. Make sure all seals are in the correct posi-
tions. See Figure 8.
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 po-
sition.
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 dis-
assembly 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).
11

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 trans-
mission 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 Mainte-
nance Manual for the procedures to remove lift
truck from blocks. Fill the tank using the hy-
draulic oil shown in the Maintenance Table lo-
cated 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)
12

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