COOLING SYSTEM

RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH,

RS46-30IH, RS46-36CH, RS46-33IH First Used

on 1563, 1566, 1567, 1568, 1570, and Up [A222]

PART NO. 1597925

0700 SRM 1211

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 Mainte-
nance 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!

Cooling System

Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

1

Description .........................................................................................................................................................

1

Radiator..........................................................................................................................................................

2

Radiator Cap ..................................................................................................................................................

2

Thermostat.....................................................................................................................................................

2

Water Pump ...................................................................................................................................................

2

Fan and Fan Shroud......................................................................................................................................

2

Cooling System Checks......................................................................................................................................

3

Radiator..........................................................................................................................................................

3

Thermostat.....................................................................................................................................................

3

Water Pump ...................................................................................................................................................

3

Exhaust Leaks Into Cooling System ............................................................................................................

4

Fan and Fan Shroud......................................................................................................................................

4

Radiator Hoses...............................................................................................................................................

4

Cooling System Repair ......................................................................................................................................

4

Remove ...........................................................................................................................................................

4

Install .............................................................................................................................................................

5

Radiator Cleaning ..............................................................................................................................................

6

Drain ..............................................................................................................................................................

6

Clean ..............................................................................................................................................................

6

Fill ..................................................................................................................................................................

6

Troubleshooting..................................................................................................................................................

7

This section is for the following models:

RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH, RS46-36CH,

RS46-33IH First Used on 1563, 1566, 1567, 1568, 1570, and Up [A222]

©2005 HYSTER COMPANY

i

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

0700 SRM 1211

Description

General

This section describes the complete repair of the cool-
ing system. There are two cooling systems attached
to the ReachStacker

®

. Procedures for cleaning the

radiator and troubleshooting are also included in this
section.

Located within the hydraulic tank platform is the hy-
draulic system oil cooler. The hydraulic tank plat-
form is installed on the left side of the frame.

Description

The purpose of the cooling system in the frame is
to control the operating temperature of the engine,
brakes, transmission, and charge air. A centrifugal
water pump circulates coolant through passages in
the engine block and the radiator. A thermostat is
installed in the water outlet fitting on the engine. As
the coolant flows through the radiator, the fan moves
air through the radiator to help cool the system. See
Figure 1 for the main parts of the cooling system.

The coolant is a mixture of water and antifreeze. The
antifreeze prevents the coolant from freezing in cold

weather which prevents damage to the engine and
radiator. The antifreeze also prevents rust and lu-
bricates the water pump.

The purpose of the cooling system located inside the
hydraulic tank platform is to control the operating
temperature of the hydraulic oil. The cooling takes
place with a fan and causes air to flow through the
heat exchanger reducing the operating temperature
of the hydraulic oil.

1.

MOUNTING BRACKET

2.

MOUNTING BRACKET

3.

RADIATOR COOLANT LEVEL SWITCH

4.

RADIATOR CAP

5.

ENGINE COOLANT COOLER CORE

6.

BAFFLE WELDMENT

7.

BRAKE OIL COOLER CORE

8.

CHARGED AIR COOLER CORE

9.

TRANSMISSION OIL COOLER CORE

10. ISOLATOR
11. RADIATOR SEAL

Figure 1. Cooling System

1

Description

0700 SRM 1211

RADIATOR

The radiator is the heat exchanger for the cooling sys-
tem and is located in the frame. The fan causes air to
flow through the radiator reducing the temperature
of the coolant. The cooling system contains four cool-
ing cores as follows:
• Charged Air Cooler Core
• Engine Coolant Cooler Core
• Transmission Oil Cooler Core
• Brake Oil Cooler Core

RADIATOR CAP

The radiator cap is a pressure-vent type that lets the
pressure in the cooling system increase to 103 kPa
(15 psi). The pressure in the system prevents va-
por from forming in the coolant flowing to the wa-
ter pump. This action maintains the efficiency of the
water pump and the performance of the cooling sys-
tem. The increase in pressure also raises the boiling
point of the coolant mixture to approximately 125 C
(257 F) at sea level.

The radiator cap has a pressure valve and a vac-
uum valve. The pressure valve is held against its
seat by a spring. The pressure valve opens when
the pressure in the cooling system exceeds 103 kPa
(15 psi). The vacuum valve is held against its seat
by another spring. The vacuum valve opens to re-
lieve the vacuum created when the coolant temper-
ature decreases. In certain conditions, this vacuum
can cause the radiator or top hose to collapse.

THERMOSTAT

The thermostat is a device that controls coolant flow
by opening and closing to regulate coolant temper-
ature. The thermostat uses a wax pellet to control
its operation.

The wax pellet expands when it is

heated and contracts when it is cold. When heated,
the wax pellet pushes on the piston, causing the valve
in the thermostat to open. As the wax pellet cools,
it contracts and lets a spring close the valve. When
the engine is first started and the coolant is cold,
the thermostat remains closed. During this time the
coolant circulates through the engine, letting it warm
quickly. As the engine becomes warm the thermostat
opens, letting coolant circulate through the radiator.

The opening and closing of the thermostat helps keep
the coolant within the operating limits of the system.
The same thermostat is used for summer and winter
seasons. Do not operate the engine without a ther-
mostat. The engine will take longer to get warm and
may run improperly. See Figure 2.

1.

PISTON

2.

VALVE SEAT

3.

SPRING

4.

DIAPHRAGM

5.

WAX PELLET

6.

FRAME

7.

FLANGE

8.

VENT HOLE

Figure 2. Typical Thermostat

WATER PUMP

The centrifugal-type water pump is installed at the
front of the engine block. The inlet for the pump is
connected to the bottom of the radiator by a hose.
From the pump, coolant passes through the passages
in the engine block to the top of the radiator. The
thermostat controls the flow of coolant through the
engine and radiator.

FAN AND FAN SHROUD

The fan is used to provide airflow through the radia-
tor at all engine speeds. The fan is a puller-type and
can be installed on the water pump or on a separate
hub. The fan is driven by a drive belt from the engine
crankshaft.

2

0700 SRM 1211

Cooling System Checks

Cooling System Checks

RADIATOR

WARNING

During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury.

To check for water flow restrictions in the radiator,
run engine until it is warm.

WARNING

The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of
the cooling system.

Shut engine OFF and feel the radiator. The temper-
ature must be even across the radiator. (The radiator
will be hotter near the top radiator hose.) Cold spots
on radiator indicate restrictions.

If radiator has leaks, either replace the radiator or
have it repaired by trained personnel.

THERMOSTAT

WARNING

During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury.

CAUTION

DO NOT operate the engine without a ther-
mostat. The engine and cooling system can be
damaged.

NOTE: Repair procedures for the thermostat are in
the Engine section.

1.

Remove thermostat from cooling system.

See

Figure 3.

2.

Mix solution of water with 33% antifreeze. Heat
solution to 14 C (57 F) above temperature on
thermostat.

1.

FAN

2.

SPACER

3.

HUB/PULLEY

4.

WATER PUMP

5.

THERMOSTAT

6.

THERMOSTAT
HOUSING

Figure 3. Cooling System Components Typical

Arrangement

3.

Hold thermostat with wire and put it in solution.
Stir solution. If operating correctly, thermostat
will open.

4.

Remove thermostat and put in same solution at

12 C (10 F) below temperature on thermostat.

Valve must close completely.

WATER PUMP

WARNING

During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury.

WARNING

The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury.

Run engine until it is warm. Check the operation of
water pump by holding the top radiator hose. If the
pump is operating, there will be pressure surges in
the hose.

3

Cooling System Repair

0700 SRM 1211

Check for leaks around the timing belt cover near the
base of the oil filter.

Check the weep hole where water can drain by the oil
filter. If there is a drip, check the pump shaft seal and
water pump. Replacement of the pump shaft seal or
water pump may be necessary.

EXHAUST LEAKS INTO COOLING SYSTEM

WARNING

During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury.

To check for exhaust leaks into the cooling system,
use a Combustion Leak Test Kit for this purpose. Fol-
low the manufacturer’s instructions when doing the
test.

FAN AND FAN SHROUD

WARNING

During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury.

WARNING

DO NOT try to repair a damaged fan. If a fan
has a bent blade or is cracked, install a new fan.

A damaged fan can break during use and cause
damage or serious injury.

1.

When installing fan, verify correct spacers are
installed and mounting capscrews are tight.

2.

When installing fan shroud, verify correct seals
are on shroud. Before tightening capscrews, ver-
ify clearance around circumference of fan is even
with shroud. Also verify 1/3 to 1/2 of cross-sec-
tion of fan blade extends into fan shroud.

3.

Verify WARNING labels are installed on shroud.

RADIATOR HOSES

WARNING

The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of
the cooling system.

Inspect all radiator hoses. If they feel spongy or have
visible cracks, replace hoses.

Cooling System Repair

REMOVE

NOTE: For easy access to the cooling system, turn
steering wheel until steering wheel spindle is against
stop on axle to the left or right side. See Figure 4.

1.

Place the ReachStacker

®

on a solid, level surface.

2.

Shut down the engine.

3.

Apply parking brake.

CAUTION

Remove the ground cable first or damage to the
ReachStacker may occur.

4.

Disconnect the cables at the battery.

WARNING

Coolant must be at room temperature before
draining the radiator or personal injury may
occur.

5.

Put drain pan under radiator.

6.

Remove the rear hood panel assembly.

7.

Disconnect the electrical connector of the horn.

8.

Remove the baffle weldment at the underside of
the radiator.

9.

Disconnect the radiator coolant level switch.

10. Remove radiator cap.

4

0700 SRM 1211

Cooling System Repair

Figure 4. Cooling System Access

11. Remove drain plug and drain radiator.

12. Disconnect engine coolant hoses from engine oil

cooler core.

13. Disconnect charged air cooler hoses from charged

air cooler core.

14. Disconnect transmission oil lines from transmis-

sion oil cooler core.

15. Disconnect brake lines from the brake oil cooler

core.

16. Place caps on all open lines.

WARNING

Verify cables at the battery are disconnected
when working near the fan. Sudden start of the
fan can cause serious personal injury.

17. Remove fan capscrews.

18. Remove fan.

WARNING

Verify the lifting device has the rated capac-
ity to lift the cooling system or personal injury
may occur.

19. Place a lifting device just above cooling system

for support and lowering.

20. Use the lifting eyes on the cooling system and

create tension with the lifting device.

21. Remove the radiator seals.

22. Remove the capscrews from the mounting brack-

ets attached to the frame and remove the brack-
ets.

23. Remove the capscrews that hold the mounting

brackets to the radiator and remove the brackets.

24. Remove the cooling system and place it carefully

on the ground.

INSTALL

1.

Use a lifting device to lift the cooling system.

2.

Install the cooling system in the frame.

3.

Install the two mounting brackets to the cooling
system with capscrews.

4.

Install the two mounting brackets to the frame
with capscrews.

5.

Install the radiator seals.

6.

Install the isolators between the mounting
bracket of the cooling system and the mounting
bracket on the frame on both sides.

7.

Install the fan.

8.

Connect the brake lines to the brake oil cooler
core.

9.

Connect the transmission oil lines to the trans-
mission oil cooler core.

10. Connect charged air cooler hoses to charged air

cooler core.

11. Connect engine coolant hoses to engine coolant

core.

12. Install drain plug.

13. Connect the radiator coolant level switch.

14. Fill the radiator with coolant. See the Mainte-

nance Schedule in the section Periodic Main-
tenance, Tier 2 Emission Engine 8000 SRM
1051 for quantity and coolant requirements.

5

Radiator Cleaning

0700 SRM 1211

15. Install the radiator cap.

16. Install the baffle weldment at the underside of

the radiator.

17. Connect the electrical connector to the horn.

18. Install the rear hood panel assembly.

CAUTION

Connect the power cable first or damage to the
ReachStacker may occur.

19. Connect the cables at the battery.

Radiator Cleaning

DRAIN

WARNING

DO NOT remove the radiator cap from the radi-
ator when the engine is hot. When the radiator
cap is removed, the pressure is released from
the system. If the system is hot, the steam and
boiling coolant can cause burns.

CAUTION

Disposal of lubricants and fluids must meet lo-
cal environmental regulations.

1.

Let coolant cool to room temperature.

2.

Put drain pan under radiator.

3.

Remove radiator cap.

4.

Open drain valve or remove bottom radiator
hose.

5.

Remove drain plug from engine block to drain
engine.

CLEAN

CAUTION

Disposal of lubricants and fluids must meet lo-
cal environmental regulations.

1.

Drain cooling system.

2.

Fill cooling system with clean water.

3.

Install radiator cap.

4.

Run engine until top radiator hose is hot.

5.

Stop engine and let engine cool.

6.

Drain water from radiator. If water is dirty, fill
system with water and repeat procedure until
water is clean.

CAUTION

Follow the manufacturer’s instructions when
using a chemical radiator cleaner.

7.

If water does not clean system, use chemical ra-
diator cleaner.

CAUTION

Follow the manufacturer’s instructions when
using special equipment to reverse clean the
radiator.

8.

If radiator or cooling system is very dirty or has
restriction, use reverse cleaning method. This
method uses air pressure to force water through
radiator in opposite direction of normal flow.

WARNING

Compressed air can move particles so they
cause injury to the user or to other personnel.
Verify the path of the compressed air is away
from all personnel. Wear protective goggles or
a face shield to prevent injury to the eyes.

9.

Check radiator fins. Clean exterior of radiator
with compressed air or water as needed.

FILL

1.

Install drain plug in engine block.

2.

Close drain valve or install bottom radiator hose
as needed.

6

0700 SRM 1211

Troubleshooting

WARNING

Do not use an alcohol or methanol-based an-
tifreeze.

They are flammable and can cause

personal injury or damage to the Reach-
Stacker

®

.

3.

Fill the radiator with coolant. See the Mainte-
nance Schedule in the section Periodic Main-
tenance, Tier 2 Emission Engine 8000 SRM
1051 for quantity and antifreeze requirements.

4.

Install radiator cap.

5.

Start and run engine until thermostat opens.
(Top radiator hose will be warm.)

Troubleshooting

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

Coolant leaks.

There is a leak in the radiator.

Repair radiator.

There is a leak in a radiator hose or
coolant hose.

Install new hoses.

There is a leak from a plug or sensor
in the engine block.

Check sensors and plugs, and repair
leaks.

Water pump leaks.

Install new water pump.

Thermostat housing leaks.

Install

new

thermostat

housing.

Check for correct installation of ther-
mostat.

Cylinder head gasket is damaged.

Install new head gasket.

Cylinder head is cracked.

Install new cylinder head.

Engine block is cracked.

Install new cylinder block.

The engine is too hot during
operation.

There is not enough coolant in the
cooling system.

Check coolant level in radiator and
coolant recovery bottle. Add coolant
to correct level.

The radiator is dirty.

Drain and clean radiator. Clean ra-
diator fins with low pressure air or
water in reverse direction of normal
airflow. Be careful not to bend fins.
Refill with clean coolant.

The drive belt for water pump is not
adjusted correctly, worn, or broken.

Check water pump drive belt. Adjust
or install new belt as required.

The thermostat is wrong heat range
or does not operate correctly.

Check heat range. Install new ther-
mostat.

The cooling system has restrictions.

Drain and back-flush engine and ra-
diator. Refill with clean coolant.

7

Troubleshooting

0700 SRM 1211

PROBLEM

POSSIBLE CAUSE

PROCEDURE OR ACTION

The engine is too hot during
operation. (Cont.)

The water pump is worn or damaged.

Install new water pump.

The exhaust system has restrictions.

Check exhaust system. Remove re-
strictions.

Ignition timing is not correct.

Check and adjust timing.

Exhaust leaks into coolant.

Head gasket(s) leaks.

Install new gasket(s).

Cylinder head is damaged.

Install new cylinder head.

8

TECHNICAL PUBLICATIONS

700 SRM 1211

3/05 Printed in United Kingdom