This document provides instructions for servicing and repairing components in the cooling system, including checking for issues, flushing the system, and replacing the radiator. It describes:
- Checking for exhaust leaks, water flow restrictions, and issues with the radiator hoses and water pump.
- Flushing the cooling system by draining the water, cleaning internally with water or chemicals, and refilling with a coolant mixture.
- Removing the radiator by draining the coolant, disconnecting hoses and electrical connections, removing mounting brackets, and taking out the radiator.
- Diagrams of typical cooling system layouts and component identification for different truck models.
2. 700 SRM 1123 Cooling System Checks
General
This section contains the repair and replacement in-
structions for the radiator, coolant level sensor, fan
assembly (pusher type), fan shroud, coolant hoses,
coolant recovery bottle, and optional debris screen.
Cooling System Checks
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.
WATER FLOW RESTRICTIONS IN
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.
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.
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.
Check for leaks around the timing belt cover near the
base of the oil pump.
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.
1
3. Flushing the Cooling System 700 SRM 1123
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.
For repair procedures for the Mazda 2.0L and 2.2L
water pump, refer to the section Mazda Engine,
2.0L and 2.2L 600 SRM 1122.
For replacement procedures for the Yanmar 2.6L
and 3.3L water pump, refer to the section Yanmar
Diesel Engines, 2.6L and 3.3L 600 SRM 1205.
For replacement procedures for the GM 4.3L water
pump, refer to the section GM Engines, 4.3 Liter
V-6 600 SRM 1251.
For repair procedures for the Cummins 4.5L and
QSB 3.3L water pump, contact your local Hyster
dealer or see Hyster Hypass Online.
Flushing the Cooling System
COOLING SYSTEM, CLEAN
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
eyes.
WARNING
The radiator fins on the radiator are very
sharp and can cause serious injury. Wear
gloves while checking the radiator fins.
1. Check radiator fins. Clean exterior of radiator
with compressed air or water as needed.
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.
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.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
2. Drain cooling system. Fill cooling system with
clean water. See the Radiator, Remove for
Lift Trucks 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),
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) section
for more information.
3. Drain cooling system. Fill cooling system with
clean water. See the Radiator, Remove for Lift
Truck Models S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024) and see Radiator, Remove for
Lift Truck Models H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006) section for more informa-
tion.
4. Install radiator cap. Run engine until top radia-
tor hose is hot. Stop engine and let engine cool.
2
4. 700 SRM 1123 Radiator Replacement
5. 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.
6. If water does not clean system, use a chemical
radiator cleaner.
CAUTION
Follow the manufacturer’s instructions when
using special equipment to reverse clean the
radiator.
7. If radiator or cooling system is very dirty or
has a restriction, use reverse cleaning method.
This method uses water pressure to force water
through radiator in opposite direction of normal
flow.
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
8. 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). Add coolant as nec-
essary to keep level between the ADD and FULL
marks on the reservoir.
Radiator Replacement
RADIATOR, REMOVE FOR LIFT TRUCKS
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), 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)
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.
1. Turn OFF truck.
2. Remove the hood and seat combination. See
the section Frame 100 SRM 1120 for 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) lift trucks, and Frame 100
SRM 1243 for S4.0, 4.5, 5.5FT; S5.5FTS (S80,
100, 120FT; S80, 100FTBCS; S120FTS, S120FT-
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005) lift trucks.
WARNING
Always disconnect the cable at the negative
terminal first. Install a tag on the battery ter-
minals so that no one connects the cables on
the terminals.
3. Disconnect the negative battery cable.
4. Disconnect the positive battery cable.
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.
5. Let coolant cool to ambient temperature. Place a
drain pan with a capacity greater than the capac-
ity of the cooling system under radiator. Remove
radiator cap.
3
5. Radiator Replacement 700 SRM 1123
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
6. Open the drain plug or disconnect the bottom ra-
diator hose.
7. Lift trucks equipped with a Cummins QSB 3.3L
diesel engine: Loosen clamps and disconnect the
charge air cooler hoses from radiator. See Fig-
ure 4.
8. Cap radiator hoses.
9. Disconnect hose to auxiliary coolant reservoir
and remove reservoir.
10. Remove battery and battery tray.
11. Disconnect electrical connector to the coolant
level sensor.
NOTE: For Mazda LPG engine, the LPG converter
bracket needs to be moved for clearance of radiator.
12. Remove screws from the radiator shroud and
move shroud out of the way.
13. Remove fan, fan spacer, and pulley.
14. Remove upper radiator bracket. See Figure 1
for 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) lift trucks. See
Figure 2 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) lift trucks. See Figure 3 for H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005) lift trucks. See
Figure 4 for truck equipped with a Cummins
QSB 3.3L H4.5FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005),
S6.6FT, S7.0FT (S135FT, S155FT) (E024), and
H6.0FT, H7.0FT (H135FT, H155FT) (J006).
15. Remove radiator from truck.
16. If necessary, remove the coolant level sensor.
Legend for Figure 1
A. RADIATOR WITH EXTERNAL COOLER B. RADIATOR WITH INTERNAL COOLER, MODINE
SHOWN
1. RADIATOR
2. CAP
3. UPPER HOSE
4. LOWER HOSE
5. CLAMP
6. SHROUD
7. CLIP
8. WASHER
9. SCREW
10. CLIP
11. UPPER BRACKET
12. CAPSCREW, S2.0-3.5FT (S40-70FT, S55FTS)
[F187]
13. INSERT
14. LOWER BRACKET, S2.0-3.5FT (S40-70FT,
S55FTS) [F187]
15. NUT-CLIP, S2.0-3.5FT (S40-70FT, S55FTS) [F187]
16. ISOLATOR
17. COOLANT LEVEL SENSOR
18. RESERVOIR
19. TUBE
20. OUTLET ASSEMBLY
21. HOSE
22. RESERVOIR OUTLET
23. CAP
24. BUSHING
25. SCREEN ASSEMBLY (OPTIONAL)
26. HEAT SHIELD
27. RESERVOIR BRACKET
28. HEAT SHIELD, H2.0-3.5FT (H40-70FT) [L177]
4
12. 700 SRM 1123 Radiator Replacement
RADIATOR, REMOVE FOR LIFT TRUCK
MODELS S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024)
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.
1. Turn off truck.
WARNING
Always disconnect the cable at the negative
terminal first. Install a tag on the battery ter-
minals so that no one connects the cables on
the terminals.
2. Disconnect the negative battery cable.
3. Disconnect the positive battery cable.
4. Remove radiator cover. See Figure 5.
5. Remove debris cover.
CAUTION
The counterweight cover is extremely heavy
185 kg (408 lb). Make sure that the eyebolts
and lifting device have sufficient capacity to
lift the weight.
6. Remove two bolts from counterweight cover.
7. Install two eyebolts in the hole on each end of the
counterweight cover. Connect a suitable lifting
device to the eyebolts and carefully remove the
counterweight cover from lift truck.
8. Remove four capscrews from upper radiator
bracket. Remove bracket. See Figure 10.
9. If necessary, disconnect electrical connector from
the coolant level sensor.
10. Remove screws, washers, and clip nuts from the
shroud and radiator and move shroud out of the
way.
11. Remove fan. See Fan Removal procedures.
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.
12. Let coolant cool to ambient temperature. Place
a drain pan with a capacity greater than the ca-
pacity of the cooling system under the radiator.
Remove radiator cap.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
13. Open drain plug or loosen clamps and disconnect
and cap the lower radiator hoses from radiator to
allow coolant to drain into a suitable container.
See Figure 5.
14. Lift trucks equipped with a Cummins QSB 3.3L
diesel engine: Loosen clamps and disconnect the
charge air cooler hoses from radiator. See Fig-
ure 4.
15. Loosen clamp and disconnect and cap remote re-
fill hose from radiator.
NOTE: Tag the transmission lines before disconnect-
ing from oil cooler.
16. Disconnect and cap transmission lines from oil
cooler and allow transmission oil to drain from
oil cooler into a suitable container, then cap the
oil cooler ports.
NOTE: Removing the radiator from lift truck requires
two people.
17. Remove radiator from lift truck frame.
18. If necessary, remove the coolant level sensor from
radiator. See Figure 10.
11
13. Radiator Replacement 700 SRM 1123
1. DEBRIS COVER
2. COUNTERWEIGHT COVER
3. RADIATOR COVER
4. UPPER BRACKET
5. CAPSCREWS
6. REMOTE FILL HOSE
7. HOSE CLAMPS
8. OIL COOLER
9. TRANSMISSION OIL COOLER LINES
10. FITTINGS
11. UPPER HOSE
12. LOWER HOSE
13. REMOTE FILL
14. RADIATOR CAP
Figure 5. Radiator Removal for Lift Truck
Models S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024)
RADIATOR, REMOVE FOR LIFT TRUCK
MODELS H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)
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.
1. Turn off truck.
WARNING
Always disconnect the cable at the negative
terminal first. Install a tag on the battery ter-
minals so that no one connects the cables on
the terminals.
2. Disconnect the negative battery cable.
3. Disconnect the positive battery cable.
4. Open hood and loosen clamp and disconnect in-
let hose that attaches to the hood support. See
Figure 11.
5. Lift trucks equipped with GM 4.3L (Gas/LPG)
engine. Loosen clamp and disconnect inlet hose
from air filter and remove inlet hose.
6. Lift trucks equipped with the Cummins 4.5L
or QSB 3.3L diesel engine. Loosen clamp and
disconnect inlet hose from silencer. Remove
silencer.
NOTE: Before lifting the hood assembly from the lift
truck frame. Make sure to use a lifting device and
lifting straps as shown in Figure 6. The hood assem-
bly weighs approximately 45.6 kg (101 lb).
7. Remove hood assembly. For hood assembly re-
moval procedures. See Frame 100 SRM 1321.
12
14. 700 SRM 1123 Radiator Replacement
Figure 6. Hood Assembly Removal
8. Disconnect and cap auxiliary coolant reservoir
hose. See Figure 11.
9. Remove capscrews from the auxiliary coolant
reservoir bracket and upper bracket. Remove
auxiliary coolant reservoir assembly.
10. Remove the four capscrews from the upper radi-
ator bracket. Remove bracket.
11. If necessary, disconnect electrical connector from
the coolant level sensor.
12. Remove screws, washer and clip nut from the
shroud and move shroud out of the way.
13. Remove capscrews, washer, fan, fan spacer, and
shroud. For Fan Removal procedures, see Fig-
ure 17.
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.
14. Let coolant cool to ambient temperature. Place
a drain pan with a capacity equal to or greater
than the capacity of the cooling system under the
radiator. Remove radiator cap.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
15. Open drain plug or loosen clamp and disconnect
lower radiator hose to allow coolant to drain. See
Figure 11.
16. Lift trucks equipped with a Cummins QSB 3.3L
diesel engine: Loosen clamps and disconnect the
charge air cooler hoses from radiator. See Fig-
ure 4.
17. Disconnect and cap upper radiator hose.
NOTE: Tag the transmission lines before disconnect-
ing from oil cooler.
18. Disconnect and cap transmission lines from oil
cooler and allow transmission oil to drain from
oil cooler into a suitable container, then cap the
oil cooler ports.
NOTE: Removing the radiator from lift truck requires
two people.
19. Remove radiator from lift truck frame.
20. If necessary, remove the coolant level sensor from
radiator.
13
15. Radiator Replacement 700 SRM 1123
RADIATOR, INSTALL 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), 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. If removed, install the coolant level sensor.
2. Install radiator into truck.
3. Install upper radiator bracket.
4. Install fan, fan spacer, and pulley.
5. Install the radiator shroud.
6. Connect the electrical connector to the coolant
level sensor.
NOTE: For Mazda LPG engine, the LPG converter
bracket and screws must be installed to hold the con-
verter.
7. Uncap radiator and reservoir ports and install
the auxiliary coolant reservoir.
8. Connect the auxiliary coolant reservoir hose to
the radiator.
9. Uncap the charge air cooler hoses and connect
the hoses to radiator. See Figure 4.
10. Uncap the top radiator hose and connect the hose
to radiator.
11. Close the drain plug or install bottom radiator
hose.
WARNING
Do not use an alcohol or methanol base an-
tifreeze. They are flammable and could cause
personal injury or damage to the lift truck.
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
12. 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).
1. AUXILIARY COOLANT RESERVOIR
2. ADD MARK
3. FULL MARK
Figure 7. Auxiliary Coolant Reservoir 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)
13. Use the same coolant mixture and fill the
auxiliary coolant reservoir between the ADD
and FULL marks. See Figure 7, for 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
14
16. 700 SRM 1123 Radiator Replacement
(H40-70FT) (L177) lift trucks, and Figure 8, for
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) lift
trucks.
1. AUXILIARY COOLANT RESERVOIR
2. FULL "HOT" MARK
3. FULL "COLD" MARK
4. ADD "COLD" MARK
Figure 8. Auxiliary Coolant Reservoir for
Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (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)
14. Install battery and battery tray.
15. Connect the positive battery cable.
16. Connect negative battery cable.
17. Install the hood and seat combination. See
the section Frame 100 SRM 1120 for 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) lift trucks, and Frame 100
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005). lift trucks.
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.
18. Start and run engine until thermostat opens.
(The top radiator hose will be warm.)
19. 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 9.
1. MANIFOLD
2. COOLANT HOSES
3. BLEED SCREW
4. RADIATOR HOSE
Figure 9. Bleed Screw, GM 2.4L Engine
15
17. Radiator Replacement 700 SRM 1123
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
20. Check coolant level at the auxiliary coolant reser-
voir. Add coolant as necessary to keep level be-
tween the ADD and FULL marks on the reser-
voir.
RADIATOR, INSTALL FOR LIFT TRUCK
MODELS S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024)
1. If necessary, install coolant level sensor.
NOTE: Installing the radiator into lift truck frame
requires two people.
2. Install radiator into lift truck frame.
3. Remove caps from the oil cooler and transmission
lines and connect lines into oil cooler. See Fig-
ure 5.
4. Uncap and connect remote refill hose onto radia-
tor and tighten hose clamp. See Figure 5.
5. Close drain plug and uncap the upper and lower
radiator hoses and connect hoses onto radiator
and tighten hose clamp. See Figure 5.
6. Uncap the charge air cooler hoses and connect
the hoses to radiator. See Figure 4.
7. Install fan. See Fan Installation procedures.
8. Align shroud to radiator and install two cap-
screws, washers and clip nuts. See Figure 10.
9. If necessary, connect electrical connector onto the
coolant level sensor.
10. Install upper radiator bracket and install four
capscrews.
CAUTION
The counterweight cover is extremely heavy
185 kg (408 lb). Make sure that the eyebolts
and lifting device have sufficient capacity to
lift the weight.
11. If removed, install two eyebolts in the hole on
each end of the counterweight cover. Connect a
suitable lifting device to the eyebolts and care-
fully install the counterweight cover into the lift
truck frame. See Figure 5.
12. Install two bolts to counterweights cover.
Tighten to 38 N•m (28 lbf ft).
13. Install debris cover.
14. Install radiator cover.
15. Connect positive battery cable.
16. Connect negative battery cable.
WARNING
Do not use an alcohol or methanol base an-
tifreeze. They are flammable and could cause
personal injury or damage to the lift truck.
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact you local Hyster
dealer.
17. Fill cooling system with a mixture of 50 percent
waster and 50 percent ethylene glycol boron-free
antifreeze. The 50/50 mixture will protect cool-
ing system to 37 C ( 35 F).
18. Install radiator cap.
19. Use the same coolant mixture and fill the aux-
iliary coolant reservoir between the ADD and
FULL marks. See Figure 8.
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 cause
serious injury.
20. Start and run the engine until thermostat opens
(The upper radiator hose will be warm).
16
18. 700 SRM 1123 Radiator Replacement
A. LOWER HOSE (CUMMINS 4.5L DIESEL)
B. LOWER HOSE (GAS AND LPG)
C. UPPER HOSE (GAS AND LPG)
D. UPPER HOSE (CUMMINS 4.5L DIESEL)
1. RADIATOR (WITH
EXTERNAL OIL
COOLER)
2. SHROUD
3. WASHER
4. SCREW
5. CLIP NUT
6. CLIP SPRING
7. CLAMP
8. UPPER RADIATOR
BRACKET
9. CAPSCREW
10. INSERT
11. ISOLATOR
12. AUXILIARY
COOLANT
RESERVOIR
13. BRACKET
(COOLANT FILL)
14. OUTLET ASSEMBLY
15. OUTLET
16. CAP
17. BUSHING
18. HOSE
19. HOSE
20. REMOTE FILL HOSE
21. REMOTE FILL
22. RADIATOR CAP
23. SCREEN
24. COOLANT LEVEL
SENSOR
25. DRAIN PLUG
Figure 10. Cooling System for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)
17
19. Radiator Replacement 700 SRM 1123
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact you local Hyster
dealer.
21. Check coolant level at the auxiliary coolant reser-
voir. Add coolant as necessary to keep level be-
tween the ADD and FULL marks on the reser-
voir.
22. Shut down the engine for one minute or longer
prior to checking the transmission oil level. If the
transmission oil is low, add JDM J20C transmis-
sion oil to the transmission at the dipstick tube
at the correct level indicated on the dipstick.
RADIATOR, INSTALL FOR LIFT TRUCK
MODELS H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006)
1. If necessary, install coolant level sensor.
NOTE: Installing the radiator into lift truck frame
requires two people.
2. Install radiator into lift truck frame.
3. Install upper radiator bracket and install four
capscrews. See Figure 11.
4. Install coolant reservoir bracket and coolant
reservoir assembly onto upper bracket and
tighten capscrews.
5. Uncap and connect auxiliary coolant reservoir
hose and tighten clamp.
6. Remove caps from the oil cooler and transmission
lines and connect lines into oil cooler.
7. Close drain plug and uncap the lower radiator
hose and connect hose onto radiator and tighten
clamp.
8. Uncap and connect upper radiator hose and
tighten clamp.
9. Uncap the charge air cooler hoses and connect
the hoses to the radiator. See Figure 4.
10. Install fan. See Fan Installation procedures.
11. Align shroud to radiator and install capscrews,
washers and clip nuts. See Figure 11.
12. If necessary, connect electrical connector onto the
coolant level sensor.
13. Lift truck equipped GM 4.3L (Gas/LPG) engine.
Install air intake hose to air filter and tighten
clamp.
14. Lift trucks equipped with Cummins 4.5L or QSB
3.3L diesel engine. Install silencer and connect
hose from air filter side and tighten clamp. See
Figure 11.
15. Install hood assembly. For hood install proce-
dures. See frame Frame 100 SRM 1321.
16. Lift truck equipped GM 4.3L (Gas/LPG) engine.
Open hood assembly and connect intake hose to
hood support and tighten clamp. See Figure 11.
17. Lift trucks equipped with Cummins 4.5L or QSB
3.3L diesel engine. Open hood assembly and con-
nect hose to hood support and tighten clamp. See
Figure 11.
18. Connect positive battery cable.
19. Connect negative battery cable.
WARNING
Do not use an alcohol or methanol base an-
tifreeze. They are flammable and could cause
personal injury or damage to the lift truck.
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact you local Hyster
dealer.
20. Fill cooling system with a mixture of 50 percent
waster and 50 percent ethylene glycol boron-free
antifreeze. The 50/50 mixture will protect cool-
ing system to 37 C ( 35 F).
21. Install radiator cap.
22. Use the same coolant mixture and fill the aux-
iliary coolant reservoir between the ADD and
FULL marks. See Figure 8.
18
20. 700 SRM 1123 Radiator Replacement
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 cause
serious injury.
23. Start and run the engine until thermostat opens
(The upper radiator hose will be warm).
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact you local Hyster
dealer.
24. Check coolant level at the auxiliary coolant reser-
voir. Add coolant as necessary to keep level be-
tween the ADD and FULL marks on the reser-
voir.
25. Shut down the engine for one minute or longer
prior to checking the transmission oil level. If the
transmission oil is low, add JDM J20C transmis-
sion oil to the transmission at the dipstick tube
at the correct level indicated on the dipstick.
19
21. Radiator Replacement 700 SRM 1123
Figure 11. Cooling System for Lift Truck Models H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006) (Sheet 1 of 2)
20
22. 700 SRM 1123 Radiator Replacement
Figure 11. Cooling System for Lift Truck Models H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006) (Sheet 2 of 2)
21
23. Fan Assembly Replacement 700 SRM 1123
Legend for Figure 11
A. GM 4.3L (GAS/LPG) B. CUMMINS 4.5L (DIESEL)
1. AIR INTAKE (WITHOUT PRE-CLEANER)
2. PRE-CLEANER
3. HOOD ASSEMBLY
4. CLAMP
5. INLET HOSE
6. SILENCER (DIESEL)
7. AIR FILTER
8. UPPER RADIATOR BRACKET
9. ISOLATOR
10. INSERT
11. CAPSCREW
12. RADIATOR (WITH EXTERNAL OIL COOLER)
13. UPPER HOSE
14. LOWER HOSE
15. CLIP NUT
16. WASHER
17. SCREW
18. SHROUD
19. FAN
20. FAN SPACER
21. TRANSMISSION LINES
22. AUXILIARY COOLANT RESERVOIR AND
BRACKET ASSEMBLY
23. OUTLET
24. CAP
25. BUSHING
26. HOSE
27. AUXILIARY COOLANT RESERVOIR HOSE
28. DRAIN PLUG
29. RADIATOR CAP
30. HOOD SUPPORT
Fan Assembly Replacement
FAN REMOVAL
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. 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.
WARNING
The radiator fins on the radiator are very
sharp and can cause serious injury. Wear
gloves while removing fan assembly.
NOTE: The fan that is used is a pusher-type fan. Do
not replace with a puller-type fan.
1. Turn OFF lift truck.
2. If equipped, turn the LPG tank valve to the OFF
position.
3. If equipped, release the LPG tank bracket and
swing tank away from the lift truck.
4. Release the steering tilt latch and move the steer-
ing wheel forward.
5. Release the seat latch and move the seat forward.
6. Release engine cover latch on engine cover and
swing engine cover up.
WARNING
To prevent a short circuit during fan belt re-
moval, disconnect the battery negative cable at
the battery negative terminal. Install a lock or
tag on the connector to prevent connection. A
tool could cause a short circuit, the high cur-
rent flow from the battery can cause an injury
or parts damage.
7. Disconnect the negative battery cable from the
negative battery terminal.
8. Remove screws and washers from the radiator
shroud. For the GM 2.4L and Yanmar 2.6L and
3.3L, see Figure 12. For the Mazda 2.0L and
2.2L, see Figure 13. For GM 4.3L engine, for lift
truck models S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), see Figure 14. For Cummins 4.5L
22
24. 700 SRM 1123 Fan Assembly Replacement
engine, for lift truck models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005), see Figure 15. For GM 4.3L
and Cummins 4.5L engines, for lift truck models
S6.0FT, S7.0FT, (S135FT,S155FT) (D024), see
Figure 16. For GM 4.3L and Cummins 4.5L
engines, for lift truck models H6.0FT, H7.0FT
(H135FT, H155FT) (H006), see Figure 17. For
Cummins QSB 3.3L diesel engines, for lift trucks
models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005),
S6.0FT, S7.0FT (S135FT, S155FT) (E024), and
H6.0FT, H7.0FT (H135FT, H155FT) (J006), see
Figure 18. Lean radiator shroud toward the fan.
1. FAN
2. SPACER
3. WASHER
4. CAPSCREW
5. SCREW
6. RADIATOR SHROUD
7. RADIATOR
Figure 12. GM 2.4L and Yanmar 2.6L and 3.3L Fan Removal
23
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