COOLING SYSTEM
S30FT, S35FT, S40FTS [E010];
H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]
PART NO. 1580505 700 SRM 1123
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
Cooling System Checks...................................................................................................................................... 1
Exhaust Leaks Into Cooling System ............................................................................................................ 1
Water Flow Restrictions in Radiator ............................................................................................................ 1
Radiator Hoses............................................................................................................................................... 1
Water Pump ................................................................................................................................................... 1
Radiator Replacement ....................................................................................................................................... 2
Cooling System, Clean................................................................................................................................... 2
Radiator, Remove........................................................................................................................................... 3
Radiator, Install............................................................................................................................................. 3
Fan Assembly Replacement .............................................................................................................................. 6
Remove ........................................................................................................................................................... 6
Inspect ............................................................................................................................................................ 9
Install ............................................................................................................................................................. 9
This section is for the following models:
S30FT, S35FT, S40FTS [E010];
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS ) [F187];
H2.0-3.5FT (H40-70FT) [L177]
©2005 HYSTER COMPANY i
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
700 SRM 1123 Cooling System Checks
General
This section contains the repair and replacement assembly (puller type), fan shroud, coolant hoses,
instructions for the radiator, coolant level sensor, fan coolant recovery bottle, and optional debris screen.
Cooling System Checks
EXHAUST LEAKS INTO COOLING SYSTEM RADIATOR HOSES
WARNING WARNING
During engine operation, be careful not to The radiator or other parts of the cooling sys-
touch the fan, pulleys, or drive belts. Contact tem may be hot or under pressure and can
with these parts can cause serious injury. cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
To check for exhaust leaks into the cooling system,
the radiator with your hand. If the radiator is
use a Combustion Leak Test Kit for this purpose. Fol-
still hot to the touch, wait another 30 minutes
low the manufacturer s instructions when doing the
before attempting to check or fix any part of
test.
the cooling system.
WATER FLOW RESTRICTIONS IN
Inspect all radiator hoses. If they feel spongy or have
visible cracks, replace hoses.
RADIATOR
WATER PUMP
WARNING
During engine operation, be careful not to
WARNING
touch the fan, pulleys, or drive belts. Contact
During engine operation, be careful not to
with these parts can cause serious injury.
touch the fan, pulleys, or drive belts. Contact
To check for water flow restrictions in the radiator,
with these parts can cause serious injury.
run engine until it is warm.
WARNING
WARNING
The radiator or other parts of the cooling sys-
The radiator or other parts of the cooling sys- tem may be hot or under pressure and can
tem may be hot or under pressure and can
cause serious injury.
cause serious injury. Wait 30 minutes for the
Run engine until it is warm. Check the operation of
radiator to cool. Do a touch test by touching
water pump by holding the top radiator hose. If the
the radiator with your hand. If the radiator is
pump is operating, there will be pressure surges in
still hot to the touch, wait another 30 minutes
the hose.
before attempting to check or fix any part of
the cooling system.
Check for leaks around the timing belt cover near the
base of the oil pump.
Shut engine OFF and feel the radiator. The temper-
aturemust beevenacrosstheradiator. (Theradiator
Check the weep hole where water can drain by the oil
will be hotter near the top radiator hose.) Cold spots
filter. If there is a drip, check the pump shaft seal and
on radiator indicate restrictions.
water pump. Replacement of the pump shaft seal or
water pump may be necessary.
If radiator has leaks, either replace the radiator or
have it repaired by trained personnel.
For repair procedures for the GM 2.4L water pump,
refer to the section GM Engine Repair, GM 2.4
Liter Engine 600 SRM 1121.
1
Radiator Replacement 700 SRM 1123
For repair procedures for the Mazda 2.0L and 2.2L For repair procedures for the Yanmar 2.6L and 3.3L
water pump, refer to the section Mazda Engine, water pump, refer to the section Yanmar Diesel En-
2.0L and 2.2L 600 SRM 1122. gines 600 SRM 1205.
Radiator Replacement
COOLING SYSTEM, CLEAN 2. Drain cooling system. Fill cooling system with
clean water. See the Radiator, Remove section
for more information.
WARNING
Compressed air can move particles so that they
3. Install radiator cap. Run engine until top radia-
cause injury to the user or to other personnel.
tor hose is hot. Stop engine and let engine cool.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog- 4. Drain water from radiator. If water is dirty, fill
system with water and repeat procedure until
gles or a face shield to prevent injury to the
water is clean.
eyes.
CAUTION
WARNING
Follow the manufacturer s instructions when
The radiator fins on the radiator are very
using a chemical radiator cleaner.
sharp and can cause serious injury. Wear
gloves while checking the radiator fins.
5. If water does not clean system, use a chemical
radiator cleaner.
1. Check radiator fins. Clean exterior of radiator
with compressed air or water as needed.
CAUTION
Follow the manufacturer s instructions when
WARNING
using special equipment to reverse clean the
DO NOT remove the radiator cap from the radi-
radiator.
ator when the engine is hot. When the radiator
cap is removed, the pressure is released from
6. If radiator or cooling system is very dirty or
the system. If the system is hot, the steam and
has a restriction, use reverse cleaning method.
boiling coolant can cause burns.
This method uses water pressure to force water
through radiator in opposite direction of normal
WARNING
flow.
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
CAUTION
cause serious injury. Wait 30 minutes for the
Additives may damage the cooling system. Be-
radiator to cool. Do a touch test by touching
fore using additives, contact your local Hyster
the radiator with your hand. If the radiator is
dealer.
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of
7. Fill cooling system with a mixture of 50 percent
the cooling system.
water and 50 percent ethylene glycol boron free
antifreeze. The 50/50 mixture will protect cool-
ing system to 37 C( 35 F). Add coolant as nec-
CAUTION
essary to keep level between the ADD and FULL
Disposal of lubricants and fluids must meet lo-
marks on the reservoir.
cal environmental regulations.
2
700 SRM 1123 Radiator Replacement
RADIATOR, REMOVE 9. Remove battery and battery tray.
10. Disconnect electrical connector to the coolant
WARNING
level sensor.
The radiator or other parts of the cooling sys-
NOTE: For Mazda LPG engine, the LPG converter
tem may be hot or under pressure and can
bracket needs to be moved for clearance of radiator.
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
11. Remove screws from the radiator shroud and
the radiator with your hand. If the radiator is
move shroud out of the way.
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of
12. Remove fan, fan spacer, and pulley.
the cooling system.
13. Remove upper radiator bracket. See Figure 1.
1. Turn OFF truck.
14. Remove radiator from truck.
2. Remove the hood and seat combination. See the
section Frame 100 SRM 1120.
15. If necessary, remove the coolant level sensor.
RADIATOR, INSTALL
WARNING
Always disconnect the cable at the negative
1. If removed, install the coolant level sensor.
terminal first. Install a tag on the battery ter-
minals so that no one connects the cables on
2. Install radiator into truck.
the terminals.
3. Install upper radiator bracket.
3. Disconnect the negative battery cable.
4. Install fan, fan spacer, and pulley.
4. Disconnect the positive battery cable.
5. Install the radiator shroud.
WARNING
6. Connect the electrical connector to the coolant
DO NOT remove the radiator cap from the radi-
level sensor.
ator when the engine is hot. When the radiator
NOTE: For Mazda LPG engine, the LPG converter
cap is removed, the pressure is released from
bracket and screws must be installed to hold the con-
the system. If the system is hot, the steam and
verter.
boiling coolant can cause burns.
7. Uncap radiator and reservoir ports and install
5. Let coolant cool to room temperature. Put a drain
the auxiliary coolant reservoir.
pan under radiator. Remove radiator cap.
8. Connect the auxiliary coolant reservoir hose to
CAUTION
the radiator.
Disposal of lubricants and fluids must meet lo-
9. Uncap the top radiator hose and connect the hose
cal environmental regulations.
to radiator.
6. Open the drain plug or disconnect the bottom ra-
10. Close the drain plug or install bottom radiator
diator hose.
hose.
7. Cap radiator hoses.
8. Disconnect hose to auxilary coolant reservoir and
remove reservoir.
3
Radiator Replacement 700 SRM 1123
Figure 1. Cooling System
4
700 SRM 1123 Radiator Replacement
Legend for Figure 1
A. RADIATOR WITH EXTERNAL COOLER
B. RADIATOR WITH INTERNAL COOLER, MODINE SHOWN
1. RADIATOR 15. NUT-CLIP, S2.0-3.5FT (S40-70FT, S55FTS) [F187]
2. CAP 16. ISOLATOR
3. UPPER HOSE 17. COOLANT LEVEL SENSOR
4. LOWER HOSE 18. RESERVOIR
5. CLAMP 19. TUBE
6. SHROUD 20. OUTLET
7. CLIP 21. HOSE
8. WASHER 22. RESERVOIR OUTLET
9. SCREW 23. CAP
10. CLIP 24. BUSHING
11. UPPER BRACKET 25. SCREEN ASSEMBLY (OPTIONAL)
12. CAPSCREW, S2.0-3.5FT (S40-70FT, S55FTS) 26. HEAT SHIELD
[F187] 27. RESERVOIR BRACKET
13. INSERT 28. HEAT SHIELD, H2.0-3.5FT (H40-70FT) [L177]
14. LOWER BRACKET, S2.0-3.5FT (S40-70FT,
S55FTS) [F187]
WARNING
Do not use an alcohol or methanol base an-
tifreeze. They are flammable and cause per-
sonal injury or damage to the lift truck.
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
11. Fill cooling system with a mixture of 50 percent
water and 50 percent ethylene glycol boron-free
antifreeze. The 50/50 mixture will protect cool-
ing system to 37 C( 35 F).
12. Use the same coolant mixture and fill the aux-
iliary coolant reservoir between the ADD and
FULL marks. See Figure 2.
13. Install battery and battery tray.
14. Connect the positive battery cable.
15. Connect negative battery cable.
Legend for Figure 2
1. AUXILIARY COOLANT RESERVOIR
2. ADD MARK
3. FULL MARK
Figure 2. Auxiliary Coolant Reservoir
5
Fan Assembly Replacement 700 SRM 1123
16. Install the hood and seat combination. See the 19. Check coolant level at the auxiliary coolant reser-
section Frame 100 SRM 1120. voir. Add coolant as necessary to keep level be-
tween the ADD and FULL marks on the reser-
voir.
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.
17. Start and run engine until thermostat opens.
(The top radiator hose will be warm.)
18. On lift trucks equipped with a GM 2.4L engine,
bleed air from the cooling system by opening the
bleed screw located on the left side behind the
alternator. When the air has been bled from the
system close the bleed screw. See Figure 3.
CAUTION
Additives may damage the cooling system. Be-
1. MANIFOLD
fore using additives, contact your local Hyster
2. COOLANT HOSES
dealer.
3. BLEED SCREW
4. RADIATOR HOSE
Figure 3. Bleed Screw, GM 2.4L Engine
Fan Assembly Replacement
REMOVE
WARNING
The radiator fins on the radiator are very
WARNING
sharp and can cause serious injury. Wear
During engine operation, be careful not to gloves while removing fan assembly.
touch the fan, pulleys, or drive belts. Contact
NOTE: The fan that is used is a puller type fan. Do
with these parts can cause serious injury.
not replace with a pusher type fan.
WARNING
1. Turn OFF lift truck.
The radiator or other parts of the cooling sys-
2. If equipped, turn the LPG tank valve to the OFF
tem may be hot or under pressure and can
position.
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
3. If equipped, release the LPG tank bracket and
the radiator with your hand. If the radiator is
swing tank away from the lift truck.
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of
4. Release the steering tilt latch and move the steer-
the cooling system.
ing wheel forward.
5. Release the seat latch and move the seat forward.
6
700 SRM 1123 Fan Assembly Replacement
6. Release engine cover latch on engine cover and current flow from the battery can cause an
swing engine cover up. injury or parts damage.
7. Disconnect the negative battery cable from the
WARNING
negative battery terminal.
To prevent a short circuit during fan belt re-
8. Remove screws and washers from the radiator
moval, disconnect the battery negative cable
shroud. For the GM 2.4L and Yanmar 2.6L and
at the battery negative terminal. Install a lock
3.3L, see Figure 4. For the Mazda 2.0L and 2.2L,
or tag on the connector to prevent connection.
see Figure 5. Lean radiator shroud toward the
A tool could cause a short circuit, the high
fan.
1. FAN 5. SCREW
2. SPACER 6. RADIATOR SHROUD
3. WASHER 7. RADIATOR
4. CAPSCREW
Figure 4. GM 2.4L and Yanmar 2.6L and 3.3L Fan Removal
7
Fan Assembly Replacement 700 SRM 1123
1. SPACER, H1.6FT, H1.8FT, H2.0FTS (H30FT, 4. WASHER
H35FT, H40FTS) [F001] AND H2.0-3.5FT 5. SCREW
(H40-70FT) [L177] LIFT TRUCKS ONLY 6. WASHER
2. FAN 7. RADIATOR SHROUD
3. CAPSCREW 8. RADIATOR
Figure 5. Mazda 2.0L and 2.2L Fan Removal
8
700 SRM 1123 Fan Assembly Replacement
9. For GM 2.4L and Yanmar 2.6L and 3.3L engines, 2. For the GM 2.4L and Yanmar 2.6L and 3.3L, in-
remove capscrews, washers, and spacer from the stall the spacer, washers, and capscrews to the
fan pulley. fan. Tighten the capscrews to 52 N" m (38 lbf).
See Figure 4.
10. For H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) [F001] and H2.0-3.5FT (H40-70FT) 3. For H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
[L177] lift trucks with Mazda 2.0L and 2.2L H40FTS) [F001] and H2.0-3.5FT (H40-70FT)
engines, remove capscrews, washers, and spacer [L177] lift trucks with Mazda 2.0L and 2.2L en-
from the fan pulley. gines, install the spacer, washers, and capscrews
to the fan. Tighten the capscrews to 27 N" m
11. For S30FT, S35FT, S40FTS (E010) and
(20 lbf ft). See Figure 5.
S2.0-3.5FT (S40-70FT, S55FTS) [F187] lift
trucks with Mazda 2.0L and 2.2L engines, re- 4. For S30FT, S35FT, S40FTS (E010) and
move the capscrews and washers retaining the S2.0-3.5FT (S40-70FT, S55FTS) [F187] lift
fan. trucks with Mazda 2.0L and 2.2L engines, place
the fan in position and intsall capscrews and
12. Remove the fan.
washers. Tighten the capscrews to 27 N" m
(20 lbf ft). See Figure 5.
INSPECT
5. Lean the radiator shroud back toward the radia-
tor. Install the radiator shroud cover.
WARNING
DONOT try to repair a damaged fan. If a fan
6. Install the screws and washers and tighten.
has a bent blade or is cracked, install a new fan.
A damaged fan can break during use and cause
7. Reconnect the negative battery cable to the neg-
damage or serious injury.
ative terminal of the battery.
1. Inspect the fan for any damage.
8. Pull engine cover down and re-latch with engine
cover latch.
2. If the fan is damaged, replace the entire fan.
9. Move the seat back.
INSTALL
10. Release the steering wheel tilt latch and move
the steering wheel back.
WARNING
The radiator fins on the radiator are very
11. If equipped, swing the LPG tank bracket back
sharp and can cause serious injury. Wear
toward the truck and re-latch.
gloves while installing fan assembly.
12. If equipped, turn the LPG tank valve to the ON
1. Install the lower portion of the shroud in the re-
position.
taining clips and lean the shroud toward the en-
gine.
9
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
10
TECHNICAL PUBLICATIONS
700 SRM 1123 5/05 (12/04) Printed in U.S.A.