INTRODUCTION

GENERAL The front cover contains the seal for the input shaft. The
input shaft connects to a driven sprocket, coupling or
This section contains the description and the repair pro- gear by splines or a key.
cedures for several different models of gear pumps used
All the gear pumps have devices that keep the thrust
on the E30ER, E40ER, E50ER, E30FR-24, E30FR,
clearance at a minimum when the pressure increases.
E35FR, E40FR, E45FR, E50FR series of electric lift
When the pressure is low, the clearance increases to pre-
trucks. For removal and installation of individual gear
vent wear. To prevent leakage when the pressure is high,
pumps, see the section THE HYDRAULIC SYSTEM,
the oil from the outlet side of the pump is transferred to a
1900 SRM 883 for E30ER, E40ER and E50ER series
wear plate. The oil pushes the wear plate against the
lift truck and 1900 SRM 844 for E30FR-24, E30FR,
gears.
E35FR, E40FR, E45FR and E50FR series lift trucks.
Gear pumps are designed with the teeth of the gears en-
DESCRIPTION gaged in the center of the pump. When the input shaft is
(See FIGURE 1) turned, the drive gear turns the driven gear. The oil in the
inlet chamber is moved out from the center by the teeth
Gear pumps are made in three or more sections. Each of the rotating gears. The oil between the teeth moves
gear pump has two covers and a gear housing with the around the pumping chamber to the outlet chamber.
gears. Seals prevent leaks between the sections. The in- When the gear teeth begin to engage, they push the oil
let and outlet ports are on the gear housing or rear cover. from the outlet chamber. See FIGURE 2.

3 4

1 2

1. ONE SECTION PUMP

2. DRIVE GEAR
3. TWO SECTION PUMP
4. DRIVEN GEAR

FIGURE 1 – TYPES OF GEAR PUMPS

1
 3
1

3
3 1

1. INLET
2. OUTLET 1. OIL ENTERS GROOVES IN BUSHINGS
3. SEAL MADE BY GEAR TEETH 2. OIL ENTERS INLET CHAMBER

FIGURE 2 – OPERATION OF GEAR PUMPS FIGURE 3 – CHECK BALL & SPRING

1 2
3

4
5

1. INPUT SHAFT
2. BEARING BLOCKS
3. REAR COVER
7 4. DRIVE GEAR
5. CARTRIDGE FLOW CONTROL
6 6. AND RELIEF VALVE
7. DRIVEN GEAR
8. FRONT COVER

FIGURE 4 – BASIC PARTS OF A GEAR PUMP

2
The gears and the bearings are lubricated by oil from the increases, the piston moves to partly open the passage to
outlet side of the pump. A small amount of oil flows past the main control valve. This action keeps the pressure
the gears and into the bearings and to the front seal cav- difference across the orifice constant. A constant pres-
ity. A check ball and spring are installed in some pumps sure difference between both sides of an orifice causes a
to keep pressure on the oil in this passage. constant flow through the orifice.

The oil pressure prevents air leaks through the front seal
and makes sure there is oil to the bearings. When the RELIEF VALVE
pressure increases to the spring setting, the ball moves
from the seat and oil flows to the inlet chamber. See Some pumps have a relief valve installed in a cartridge
FIGURE 3. or in a bore in the rear cover. Relief valves in the pump
prevent the pressure in the flow controlled system from
FLOW CONTROL VALVE increasing beyond the specifications. The relief valve in
the cartridge has a poppet and spring, with the seat for
Some of the pumps have a flow control valve in the rear the poppet in the cartridge. The relief valve and flow
cover. The flow control valve has either a piston and control valve on some pumps are installed in the same
spring or a cartridge with a piston and spring. The piston cartridge. Some of the relief valves that are installed in
has an orifice that permits a constant volume of oil to the pumps are adjustable only with shims. Replace the
flow to the controlled flow port. When the pump speed cartridge if the relief valve has a problem.

REPAIRS

DISASSEMBLY NOTE: The position of the seals is important. In

(See FIGURE 5 and FIGURE 6) some pumps the direction of pump rotation is reversed
by changing the position of the seals and housings. The
1. Remove the gear, sprocket or coupling from the in- holes in the seals must be aligned with the oil passages
put shaft. in the housing sections. The oil passage for the thrust
plates is in the outlet chamber.
2. Before disassembling the pump, make alignment
marks on all the housings. Some of the housings can be CLEANING
assembled in the wrong positions, causing failure or in-
creased wear. Carefully clean the outside of the pump.


NOTE: The inlet ports in most gear pumps are larger Cleaning solvents can be flammable and toxic and
than the outlet ports. can cause skin irritation. When using cleaning sol-
vents, always follow the recommendation of the
3. Remove the capscrews or nuts that hold the housing manufacturer. Wear eye protection.
together. Use a plastic hammer to separate the housings.
Do not damage the machined surfaces. Compressed air can move particles so that they
cause injury to the user or to other personnel. Make
4. Remove the gears and thrust plates. Note the posi- sure that the path of the compressed air is away from
tions of the thrust plates, seals, and gaskets. Do not use a all personnel. Wear protective goggles or a face
punch to mark the parts. Remove any springs and check shield to prevent injury to the eyes.
valves.
Clean all parts of the pump with solvent and thoroughly
5. Remove the front seal. dry the pans. Pieces of the cloth can cause restrictions in
3
the hydraulic system. Make sure the work area and tools viscosity. The wrong viscosity oil can increase leakage
are very clean. within the pump. Leakage inside the pump increases the
oil temperature.
CAUTION 4. Check the thrust plates for wear or grooves. If the
Any dirt that enters the hydraulic system can cause
thrust plate is worn more than 0.05 mm (0.002 in), it
damage to the parts.
must be replaced. Replace the thrust plate if it has
grooves or holes. Dirty oil causes the thrust plate to wear
INSPECTION near where the gears engage. Small holes on the outlet
side of the thrust plate are caused by cavitation. Lack of
1. Inspect the outside edges of the gear teeth for oil can also cause small holes in the thrust plates. If the
grooves or scratches. If the edges are sharp, use emery color of the thrust plates has changed, the pump was too
cloth to break the edges. Replace the gears if there are hot.
deep grooves on the gears.
5. Inspect all the machined surfaces for scratches or
2. If the gear shafts have grooves or are worn more damage. Remove with emery cloth any metal that is
than 0.05 mm (0.002 in), they must be replaced. Wear on above the flat surface. Check the surfaces with a straight
the seal area of the shaft indicates dirt in the oil or a hard edge. Inspect the seal grooves for dirt or scratches.
seal. Inspect the seal to see if it has been too hot. Look
for small cracks in the sealing surface. If the seal was too 6. Inspect the bearings for wear or damage. Replace
hot or the wrong oil was used, the seal will be too hard or the bearings if there are any small holes on the bearing
too soft. Inspect the splines or key groove for damage. surface. Replace the bushing if it is not round.

3. Inspect the gear housing for wear or grooves. Most 7. Look for damaged seals. Replace all the seals and
wear occurs on the inlet side of the gear chamber. Put a O-rings, even if they are in good condition. Look for
straight edge across the inlet side of the gear chamber. If cuts or changes in shape that can cause leaks. Find out
a 0.13 mm (0.005 in) thickness gauge fits between the what caused the pump to fail. A worn thrust plate seal
straight edge and the housing, the gear housing must be can cause the shaft seal to leak. A worn shaft seal can
replaced. If the gear housing is worn, inspect the bear- cause air to enter the hydraulic system.
ings or bushings for wear. If the system pressure is too 8. If any pump parts have damage from dirt in the oil,
high, the gear housings will wear quickly. Grooves in inspect the hydraulic tank. Drain the tank, clean the
the gear chamber indicate dirt is in the oil. Small holes in screen and tank, and replace the filter. Use only Hyster
the outlet side of the gear chamber indicate that cavita- approved hydraulic oil.
tion has occurred. Make sure the inlet hose, fittings and
tank have no restrictions. Cavitation can also occur CAUTION
when the motor speed is too high. Do not permit dirty oil to enter the gear pump.
If the surfaces of the gear chamber or gear teeth have 9. Inspect the inlet hose to the gear pump. Use a lamp
blue marks, the pump was too hot. Heat damage in the to look inside the hose. Look for pieces of the rubber that
pump can be caused by hot oil or lack of oil. Check the are separating from the hose. Inspect the hose for restric-
front seal surface to see if air was entering the pump tions at the bends. Check for loose fittings or damaged
through the front seal. Make sure the oil is the correct O-rings.

4
 3
4
2
3

3
3
1
2
4

5
6

7
8
11
14 12 9
15 13

8
10
1. END COVER 6. WASHER 11. BOLT
2. SEAL 7. END PLATE 12. WASHERS
3. BEARING 8. SEAL 13. GASKET
4. GEARS AND SHAFT 9. PUMP BODY 14. BEARING
5. BOLT 10. SEAL 15. SNAP RING

FIGURE 5 – TYPICAL SINGLE HYDRAULIC PUMP

ASSEMBLY
CAUTION
Make sure the holes in the gaskets and seals are
1. Lubricate all parts with hydraulic oil before instal-
aligned with the holes in the output side of the pump.
ling them into the pump.
The pump will not operate correctly if the oil from
the outlet chamber cannot flow to the thrust plate.
CAUTION
Make sure no dirt enters the pump during assembly. 4. Align the marks on the gear housing with the marks
on the covers. Use a plastic hammer to join the sections.
2. Install the seal on the front cover. Make sure the seal
is installed correctly. 5. Install the capscrews or studs and tighten with your
fingers. Rotate the driveshaft to make sure the pump is
3. Assemble the gears, thrust plate, gaskets, seals, O- assembled correctly. Tighten the capscrews or nuts to
rings and other parts of the pump according to the dia- the recommended specifications using an “X” se-
grams. See FIGURE 5 and FIGURE 6. quence.

5
 22

23
20
21
15

23
9
14
13 22

10 8 18 19
7 17
9
6
5 16

11 12
15
8

2 3
1 1. PUMP COUPLING 13. PIN, DRIVE SHAFT
2. SPRING COUPLING 14. GASKET
3. GREASE SEAL 15. GEAR AND HOUSING SET
4. COVER–FRONT 16. O-RING, SEAL
5. SPRING AND BALL 17. DOWEL PIN
6. ADJUSTMENT SCREW 18. COVER–BACK
7. HEX. CAP ASSEMBLY 19. PLASTIC PLUG
8. NEEDLE BEARING 20. PLASTIC PLUG
9. SNAP RING 21. WELCH PLUG
10. SHAFT–DRIVE 22. WASHER HD. SCREW
11. SHAFT–IDLER 23. WASHER HD. SCREW
12. BALL

FIGURE 6 – POWER STEERING PUMP FOR THE E30ER, E40ER, E50ER SERIES TRUCKS

CHECKS AND ADJUSTMENTS

NOTE: Always install a new filter when repairs are CHECKING THE OUTPUT OF THE PUMP
made to the hydraulic system. Drain and replace the hy- (See FIGURE 7 and FIGURE 8)
draulic oil if the oil is dirty or burned.

CAUTION Two methods are given for checking the volume of flow
Do not operate any valve until the pump has run for from the pump. The first method uses a flow meter, a
three minutes at low pressure and low speed. Do not pressure gauge, and a needle valve. The second method
permit hot oil to enter a cold pump. uses a needle valve, pressure gauge, container and timer.
6
1. If a flow meter is available, install the flow meter at the maximum speed for 5 seconds. Stop the motor.
between a needle valve and the outlet port of the pump. Measure the volume of oil that entered the container in 5
The pressure gauge must be between the needle valve seconds. Multiply the quantity in the container by 12 to
and the pump. When the hydraulic oil is at operating find the output per minute. Compare the pump output
temperature, run the motor with no load on the hydraulic rate with the specifications found in the section, CAPA-
system. Note the reading of the flow meter. Compare the CITIES AND SPECIFICATIONS, 8000 SRM 882
output rate of the pump with the specification found in (for E30ER, E40ER and E50ER series) and CAPACI-
the section, CAPACITIES AND SPECIFICATIONS, TIES AND SPECIFICATIONS, 8000 SRM 902 (for
8000 SRM 882 (for E30ER, E40ER and E50ER series) E30FR-24, E30FR, E35FR, E40FR, E45FR and E50FR
and CAPACITIES AND SPECIFICATIONS, 8000 series). The pump output and rate must be within 20% of
SRM 902 (for E30FR-24, E30FR, E35FR, E40FR, the specifications.
E45FR and E50FR series).
5. Run the motor. Close the needle valve until the pres-
2. Run the motor at the maximum speed. Slowly close sure increases to just below the relief valve setting. Mea-
the needle valve until the gauge indicates a pressure just sure the volume of fluid the pump moves in 5 seconds.
below the specification for the relief valve setting. The Compare this quantity with the results from the test of
pump output at the high pressure point must be within the pump output at low pressure. The output of the pump
25% of the output with no load. If the output at high at high pressure must be within 25% of the volume of oil
pressure is less than 75% of the low pressure output, the moved at low pressure.
pump is damaged.
CHECKING FOR AIR IN THE

 HYDRAULIC SYSTEM
Hydraulic oil can be hot. Do not touch the oil during
the tests.
If the pump makes noise or does not move the correct
3. Another method of checking the pump output is to amount of oil, check for air in the system. Run the motor
measure the amount of oil moved in a given amount of until the oil is warm. Remove the filter cap and look into
time. Run the motor until the oil is between 54C to the tank. If there are bubbles in the oil, air is in the hy-
65C (130
to 150
F). Disconnect the line from the draulic system. The most common place of air entry is in
outlet port of the pump. Install the needle valve on the the inlet hose to the pump. Check for air leaks by pour-
end of the hose. Connect another hose to the needle ing oil over the fittings and hose when the motor is run-
valve. Put the other end of the hose in a container with an ning. If the noise decreases, the leak is in that area. See
18 litre (5 gallon) capacity and a cover. Make sure the the section TROUBLESHOOTING for other causes of
truck hydraulic tank is full. air in the hydraulic system.

CAUTION SPECIFICATIONS
This test must be done quickly to prevent the hy-
draulic tank from becoming empty. Do not operate
E30ER, E40ER and E50ER
the motor when there is no oil in the hydraulic tank.
Hydraulic pump 36 N
m (26 lbf ft)
4. The needle valve must be fully open. Run the motor Steering pump 18 N
m (13 lbf ft)

7
 1. PUMP
2. INLET PORT
3. OUTLET PORT
4
4. HYDRAULIC TANK
5. PRESSURE GAUGE
1 6. TEE FITTING
7. FLOW METER
2 8. NEEDLE VALVE
5

6 7 8

FIGURE 7 – CHECKING THE PUMP OUTPUT WITH A FLOW METER

5
2

6 7
3

8
1. PUMP
2. INLET PORT
3. OUTLET PORT
4. HYDRAULIC TANK
5. PRESSURE GAUGE
6. TEE FITTING
7. NEEDLE VALVE
8. CONTAINER
9. TIMER

FIGURE 8 – CHECKING THE PUMP OUTPUT

8
 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE

Pump makes too much noise Air in system.

Bearings or gears damaged.

Pump housing capscrews loose.

Tank valve closed.

Pump mount capscrews loose.

Tank oil level low.

Oil viscosity too high.

Motor speed too fast.

Inlet hose restricted.

Inlet hose twisted.

Relief valve damaged.

Screen in tank restricted.

Oil too cold.

Breather on tank restricted.

Seal for pump shaft damaged.

Pump drive damaged.

System pressure too low.

Relief valve damaged.

Flow regulator damaged.

Leak inside cylinder.

Pump output too low.

System pressure is too low Air in hydraulic system.

Inlet hose restricted.

Tank oil level low.

Inlet line restricted.

Inlet hose twisted.

Worn pump.

Oil viscosity too high.

Oil too cold.

9
 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE

System pressure is too low (continued) Motor speed too slow.

Pump drive damaged.

Tank screen restricted.

Restriction in breather for tank.

Pump assembled wrong.

Tank valve closed.

Pump is too hot Leaks inside pump.

Oil too hot.

Relief valve in pump damaged.

Relief valve set too high.

Flow control valve in pump damaged.

Fitting on pump has restriction.

Oil level in tank too low.

Air in hydraulic oil.

Pump damaged.

Tank valve closed.

Hose fitting installed wrong.

Outlet line twisted.

Loose housing capscrews.

Pump wears too quickly Dirt in oil.

Oil level too low.

Oil viscosity too low.

Oil temperature too high.

Pump too hot.

Relief valve damaged.

Motor speed too fast.

Pump mount capscrews loose.

Pump housing capscrews loose.

Pump drive damaged.

10
 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE

Pump wears too fast (continued) Cavitation from restriction in inlet line.

Tank valve closed.

Pump shaft not aligned with pump drive.

Air is in hydraulic system Tank oil level low.

Inlet hose leak.

Inlet fitting loose.

Breather on tank damaged.

Tank valve closed.

Inlet hose restricted.

Inlet hose twisted.

Front seal damaged.

Check valve in pump damaged.

Pump housing capscrews loose.

Pump has leaks Front seal damaged.

Input shaft damaged.

Pump housing capscrews loose.

O-rings damaged.

Inside leaks case front seal damage.

Fittings loose or O-rings damaged.

Relief valve damaged.

Relief valve hose restriction.

Pump housing cracked.

Check valve in pump damaged.

11