INTRODUCTION

GENERAL
This section has a description and the repair procedures
for several different types of hydraulic vane pumps.
While the number and type of parts can be different, the
operation of the vane pumps is the same.
DESCRIPTION (See FIGURE 1.)
The vane pump can have one or two pump sections.
The pump or pump sections have a housing, a pressure
plate, a cam ring, a rotor with vanes and a shaft. Some
of the pumps also have a relief valve. The cam ring,
pressure plate, rotor and vanes fit between the hous-
ings. The rotor and vanes rotate within the cam ring.
OPERATION
Pump (See FIGURE 2.)
The pump is driven by an engine or an electric motor.
When the shaft rotates, the rotor turns within the cam
ring. Either the rotor or the surface of the cam ring is
not equally round. As the rotor turns, there is a varia-
tion in volume between the rotor and cam ring. Centri-
fugal force causes the vanes to follow the inside surface
of the cam ring. The pressure from the oil behind the
vanes make the vanes keep a tight fit with the cam ring.
The ports for the inlet and the outlet are on opposite
sides of the cam ring. As the rotor turns past the inlet
port, the volume is increasing between the vanes.
This increase in volume causes a decrease in the pres-
sure or a vacuum at the inlet port. Because of the dif-
ference in the pressures the oil flows into the inlet port.
The oil between the rotating vanes is moved to the out-
let port. The volume between the vanes decreases near
the outlet port and the pressure increases. Oil is dis-
charged into the system at a higher pressure.

8383

1. HOUSING 9. ORIFICE
2. INLET 10. BEARING
3. OUTLET 11. SHAFT
4. CAM RING 12. SEAL
5. VANE 13. FLEXIBLE PLATE
6. ROTOR 14. SUPPORT PLATE
7. PRESSURE PLATE 15. VANE SUPPORT
8. RELIEF VALVE

FIGURE 1. VANE PUMPS

1
 ROTATION

ROTATION

1. INLET
2. OUTLET
3. CAM RING
4. VANE
5. ROTOR
6. SHAFT
8385

FIGURE 2. OPERATION OF THE PUMP

Relief Valve (See FIGURE 3.)
The relief valve is installed in the housing for the
pump. The valve controls the amount and the pressure
of the oil for the system. During Slow Operation of
the pump, all the oil flows through the orifice to the
system. During Normal Operation the flow of oil
from the pump pushes the spool from the seat. Oil for
the system flows through the orifice. The remainder of
the oil flows past the spool and returns to the tank.
When the pressure of the oil is more than the setting of
the valve, the valve operates as shown in Relief Op-
eration. The increase in pressure causes the pilot pop-
pet to move from the seat in the spool. The oil in the
chamber for the spring flows through the spool to the
tank. This flow causes a difference in the pressure on
the spool. The spool compresses the spring and lets all
the oil from the pump to go to the tank.

TO THE TANK TO THE TANK

NORMAL RELIEF
OPERATION OPERATION

SLOW
OPERATION
8384
TO THE SYSTEM FROM THE TO THE SYSTEM TO THE SYSTEM
PUMP
1. SPOOL SPRING 4. ORIFICE
2. RELIEF VALVE SPOOL 5. PILOT VALVE
3. RELIEF VALVE SPRING
FIGURE 3. OPERATION OF THE RELIEF VALVE

2
 REPAIRS
NOTE: Worn or damaged seals, bearings and vanes are
the most common cause of failures of the pump. Make
sure to check all parts during disassembly. Do not make
any repairs to the parts. To prevent more failures,
always replace parts that are worn or have damage. If
several parts are worn or have damage, replace the com-
plete pump.
REMOVAL
1. If there is a shutoff valve on the hydraulic tank,
close the valve. Disconnect the lines at the pump. Put
caps on the lines. Put caps on the ports of the pump.
2. On electric lift trucks disconnect the battery connec-
tor. Remove the motor and pump as an assembly. Re-
move the pump from the motor.
3. On other lift trucks remove the pump from the en-
gine or from the bracket for the pump.
DISASSEMBLY (See FIGURE 4.)
1. Make sure that the outside of the pump is clean.
Make marks on the housings so that the parts will be
assembled correctly. Put the pump in a vise with soft
jaws.
2. If equipped, remove the pulley or gear from the shaft
of the pump.
3. Remove the capscrews that hold the housings to-
gether. Separate the housings.
4. For pumps with the rotor and cam ring as a unit, re-
move the unit. Make marks for identification on the
covers. Separate the cam ring and covers. Remove the
support plates, flexible plates and the rotor and vanes.
5. On other pumps remove the pressure plate and the
spring. Remove the cam ring and the rotor and vanes.
6. Remove the Orings, seals and bearings.
7. If equipped, remove the relief valve.

1. HOUSING 8. PIN
2. SPRING 9. HOUSING
3. PRESSURE PLATE 10. BEARING
4. ORING 11. SEAL*
5. CAM RING 12. SHAFT
6. ROTOR 13. SNAP RING
*NOT USED ON ALL TRUCKS 7. VANE

FIGURE 4. VANE PUMPS (Sheet 1 of 2)

3
 8386

9. SPRING
10. PRESSURE PLATE
11. PIN
12. CAM RING
13. ROTOR
14. VANE
15. ORING
1. HOUSING 16. HOUSING
2. SPOOL SPRING 17. ROLLER BEARING
3. RELIEF VALVE 18. BALL BEARING
4. ORING 19. SHAFT
5. PLUG 20. SNAP RING
6. PIN 21. KEY
7. CAPSCREW 22. WASHER
8. GASKET 23. MANIFOLD

FIGURE 4. VANE PUMPS (Sheet 2 of 2)

ASSEMBLY (See FIGURE 4.)
NOTE: Replace the Orings, seals, and bearings during
the assembly procedures. Lubricate all the parts with
clean hydraulic oil.
a. Install the vanes in the rotor. Install the rotor in the
cam ring.
b. Install the flexible plates and the support plates.
Install the covers.

1. Replace the complete rotor and cam ring unit if any c. Install the seals and bearings in the covers. Install
parts of the unit are damaged. Assemble the unit as fol- the unit in the housing. Install the shaft in the ro-
lows: tor.

4
1200 to 1350 psi2. Assemble the other pumps as fol-
lows:
a. Install the seals and bearings in the housing.
Install the bearing on the shaft.
b. Install the shaft in the housing. Install the snap
ring
c. Install the Orings in the shaft housing. Install the
rotor on the shaft. Install the vanes in the rotor.
d. Install the cam ring and pins. Install the pressure
plate and the spring.
e. Install the housing on the end of the pump.
f. If equipped, install the relief valve.
g. If equipped, install the manifold on the housing.
Use Loctite
on the capscrews for the manifold.
INSTALLATION
1. On electric lift trucks, install the pump as follows:
a. Install a new Oring between the motor and the
pump. Install the pump on the motor. Tighten the
capscrews.
b. Install the motor and pump assembly. Connect the
oil lines and the electric cables.
c. Make sure the hydraulic tank is full, then remove
the air from the System as specified in CHECKS
CHECKS AND ADJUSTMENTS
CHECKING THE RELIEF PRESSURE OF
THE RELIEF VALVE
Lift Trucks With Internal Combustion Engines
1. Install a fitting in the outlet line of the pump. Con-
nect a 0 to 20 MPa (0 to 3000 psi) gauge to the fitting.
Connect a tachometer to the engine.
NOTE: If the pump is driven by a belt, make sure the
belt is correctly adjusted.
2. Operate the hydraulic system until the temperature
of the oil reaches 54 to 65C (130 to 150F).
3. Start the engine and run it at 2500 rpm. Put a block
between the wheel and the frame or axle. Make sure
the wheel is not against the stop on the axle. Turn the
AND ADJUSTMENTS in this section. Run the
pump at a low speed and check for leaks and cor-
rect operation. Check the relief valve as specified
in CHECKS AND ADJUSTMENTS in this sec-
tion.
2. On lift trucks with internal combustion engines,
install the pump as follows:
a. If equipped, install the gear or pulley on the shaft
of the pump.
b. If the pump is installed on an engine, install a new
gasket or Oring between the engine and pump.
Tighten the capscrews.
c. If the pump is installed in a bracket, install the
pump and tighten the capscrews. If the pump is
driven by a belt, adjust the belt so that it has the
correct tension.
d. Connect the hydraulic lines to the pump.
e. Make sure the hydraulic tank is full, then remove
the air from the system as specified in CHECKS
AND ADJUSTMENTS in this section. Run the
pump at a low speed and check for leaks and cor-
rect operation. Check the relief valve as specified
in CHECKS AND ADJUSTMENTS in this sec-
tion.
steering wheel and check the reading on the gauge. The
correct pressures are shown in Table 1.
CAUTION
Do not keep the system at a pressure so that the relief
valve opens for more than 20 seconds. This action
will damage the pump.
4. If the pressure for opening the relief valve is not
within the specifications, replace the valve. The valve
is not adjustable.
Electric Lift Trucks
1. Install a fitting in the outlet line of the pump. Con-
nect a 0 to 20 MPa (0 to 3000 psi) gauge to the fitting.
2. Operate the hydraulic system until the temperature
of the oil reaches 54 to 65C (130 to 150F).
5
3. Turn the steering wheel until it stops moving, then
check the reading on the gauge. The correct pressures
are shown in Table 1.
CAUTION
Do not keep the system at a pressure so that the relief
valve opens for more than 20 seconds. This action
will damage pump and the motor.
4. If the pressure for opening the relief valve is not
within the specifications, replace the valve. The valve
is not adjustable.
Electric Lift Trucks With Adjustable Relief
Valve (See FIGURE 5.)
1. Connect a 0 to 20 MPa (3000 psi) gauge to the check
port shown in FIGURE 5.
2. Operate the motor for the steering pump until the oil
reaches 54 to 65C (130 to 150F).
3. Turn the steering wheel until it stops moving, then
check the reading on the gauge. The correct pressures
are shown in Table 1.
CAUTION
Do not keep the system at a pressure so that the relief
valve opens for more than 20 seconds. This action
will damage the pump and the motor.
4. To adjust the pressure, remove the relief valve from
the system. Use a 3/32 inch Allen wrench and adjust
the set screw. One fourth of a turn equals approximate-
ly 0.690 MPa (100 psi). Turn the set screw to the right
to increase the pressure.
5. Install the valve and check the pressure.

11 1 2 3 4 5

1775
10 9 8 7 6

12
1. ORING 8. CHECK BALL
2. METERING PIN 9. PISTON SPRING
3. PISTON 10. ORIFICE PLUG
4. METERING SPRING 11. HOUSING
13
5. INNER VALVE 12. PRESSURE CHECK PORT
6. ORING 13. RELIEF VALVE
7. SET SCREW

FIGURE 5. RELIEF VALVE

6
 SPECIFICATIONS
TABLE 1. PRESSURE RELIEF VALVE

LIFT TRUCK PRESSURE

S3050C (All) 7.6 to 8.6 MPA (1100 to 1250 psi) @ 2500 rev/min
S60100B (All) 6.6 to 7.6 MPa (950 to 1100 psi) @ 2500 rev/min
S125150A (Oil Clutch) 9.7 to 10.7 MPa (1400 to 1550 psi) @ 2500 rev/min
H6090C (All) 6.6 to 7.6 MPa (950 to 1100 psi) @ 2500 rev/min
H110150F (All) 8.6 MPa (1250 psi) @ 2500 rev/min
H6.007.00XL (H135155XL) 12.06 to 12.11 MPa (1736 to 1808 psi) @ 2500 rev/min
KE (All) 7.4 to 8.5 MPa (1075 to 1225 psi) @ 2500 rev/min
J2535A 8.6 to 9.3 MPa (1250 to 1350 psi)
J4060A, J5060AS 8.6 to 9.3 MPa (1250 to 1350 psi)
N3050BA, N3040BR 5.5 to 6.2 MPa (800 to 900 psi)
N3050CA, N3040CR 13.8 to 14.5 MPa (2000 to 2100 psi)
R30B/BA/BR, R30C/CA/CR 4.8 to 5.5 MPa (700 to 800 psi)
E20100A, E20120B 8.3 to 9.3 MPa (1200 to 1350 psi)
E3060AC, E3060BC 8.3 to 9.3 MPa (1200 to 1350 psi)

TROUBLE
There is no output from the pump.
There is not enough pressure from
the pump.
The pump makes noise.
TROUBLESHOOTING
POSSIBLE CAUSE
There is no oil in the tank.
The shaft or drive belt is damaged.
The drive belt does not rotate the
pump.
There are leaks at the inlet of the
pump.
The relief valve is open.
The vane(s) do not move freely in
the rotor.
The internal parts (vanes and rotor)
are worn.
The relief valve is damaged.
There is a restriction in the inlet of
the pump.
There are air leaks at the inlet of
the seals of the pump.
The drive speed of the pump is not
correct.
The drive gear, pulley or the cou-
pler is not aligned with the motor or
engine.
PROCEDURE OR ACTION
Fill tank to the correct level. Check
for leaks.
Replace shaft or drive belt.
Adjust or replace drive belt.
Tighten clamp, replace hose or
pump.
Repair or replace relief valve.
Repair or replace pump.
Repair or replace pump.
Repair or replace relief valve.
Remove object restricting flow or
replace damaged component.
Tighten clamp, replace hose or
pump.
Replace incorrect pulleys.
Replace motor mounts, replace
mounting brackets.