Beruflich Dokumente
Kultur Dokumente
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]; S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) [G004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005]
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 ............................................................................................................................................................... Cooling System Checks...................................................................................................................................... Exhaust Leaks Into Cooling System ............................................................................................................ Water Flow Restrictions in Radiator ............................................................................................................ Radiator Hoses............................................................................................................................................... Water Pump ................................................................................................................................................... Radiator Replacement ....................................................................................................................................... Cooling System, Clean................................................................................................................................... Radiator, Remove........................................................................................................................................... Radiator, Install............................................................................................................................................. Fan Assembly Replacement .............................................................................................................................. Remove ........................................................................................................................................................... Inspect ............................................................................................................................................................ Install ............................................................................................................................................................. 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]; S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) [G004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005] 1 1 1 1 1 1 2 2 3 8 10 10 13 13
General
This section contains the repair and replacement instructions for the radiator, coolant level sensor, fan assembly (pusher type), fan shroud, coolant hoses, coolant recovery bottle, and optional debris screen.
WARNING WARNING
The radiator or other parts of the cooling system 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 temperature 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. The radiator or other parts of the cooling system 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. 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.
Radiator Replacement 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.
700 SRM 1123 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 water pump, contact your local Hyster dealer or see Hyster Hypass Online.
Radiator Replacement
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 goggles or a face shield to prevent injury to the eyes. 2. Drain cooling system. Fill cooling system with clean water. See the Radiator, Remove section for more information. 3. Install radiator cap. Run engine until top radiator hose is hot. Stop engine and let engine cool. 4. Drain water from radiator. If water is dirty, fill system with water and repeat procedure until water is clean.
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.
CAUTION
Follow the manufacturers instructions when using a chemical radiator cleaner. 5. If water does not clean system, use a chemical radiator cleaner.
CAUTION WARNING
DO NOT remove the radiator cap from the radiator 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. Follow the manufacturers instructions when using special equipment to reverse clean the radiator. 6. 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.
WARNING
The radiator or other parts of the cooling system 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
Additives may damage the cooling system. Before using additives, contact your local Hyster dealer. 7. Fill cooling system with a mixture of 50 percent water and 50 percent ethylene glycol boron-free antifreeze. The 50/50 mixture will protect cooling system to 37 C ( 35 F). Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.
CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.
Radiator Replacement 5. Let coolant cool to room temperature. Put a drain pan under radiator. Remove radiator cap.
CAUTION
Disposal of lubricants and fluids must meet local environmental regulations. 6. Open the drain plug or disconnect the bottom radiator hose. 7. Cap radiator hoses. 8. Disconnect hose to auxiliary coolant reservoir and remove reservoir. 9. Remove battery and battery tray. 10. 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. 11. Remove screws from the radiator shroud and move shroud out of the way. 12. Remove fan, fan spacer, and pulley. 13. 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, Figure 2 for S4.0, 5.0, 5.50FT([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) (G004) and Figure 3 for H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) lift trucks. 14. Remove radiator from truck. 15. If necessary, remove the coolant level sensor.
WARNING
Always disconnect the cable at the negative terminal first. Install a tag on the battery terminals 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 radiator 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.
Radiator Replacement
Figure 1. Cooling System, 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)
700 SRM 1123 Legend for Figure 1 A. RADIATOR WITH EXTERNAL COOLER B. RADIATOR WITH INTERNAL COOLER, MODINE SHOWN 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. RADIATOR CAP UPPER HOSE LOWER HOSE CLAMP SHROUD CLIP WASHER SCREW CLIP UPPER BRACKET CAPSCREW, S2.0-3.5FT (S40-70FT, S55FTS) [F187] 13. INSERT 14. LOWER BRACKET, S2.0-3.5FT (S40-70FT, S55FTS) [F187] 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
Radiator Replacement
NUT-CLIP, S2.0-3.5FT (S40-70FT, S55FTS) [F187] ISOLATOR COOLANT LEVEL SENSOR RESERVOIR TUBE OUTLET HOSE RESERVOIR OUTLET CAP BUSHING SCREEN ASSEMBLY (OPTIONAL) HEAT SHIELD RESERVOIR BRACKET HEAT SHIELD, H2.0-3.5FT (H40-70FT) [L177]
Radiator Replacement
Figure 2. Cooling System, S4.0, 5.0, 5.50FT([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) (G004)
700 SRM 1123 Legend for Figure 2 A. RADIATOR WITH EXTERNAL COOLER B. RADIATOR WITH INTERNAL COOLER 1. 2. 3. 4. 5. 6. 7. 8. RADIATOR SHROUD WASHER SCREW CLIP NUT CLIP UPPER HOSE LOWER HOSE 9. 10. 11. 12. 13. 14. 15. CLAMP UPPER BRACKET INSERT CAPSCREW ISOLATOR RESERVOIR RESERVOIR BRACKET 16. 17. 18. 19. 20. 21. 22. 23. OUTLET ASSEMBLY OUTLET CAP BUSHING HOSE TUBE STRAP NUT
Radiator Replacement
SCREEN BAFFLE (RH AND LH) RADIATOR CAP COOLANT LEVEL SENSOR
Figure 3. Cooling System, H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
Radiator Replacement Legend for Figure 3 NOTE: RADIATOR WITH INTERNAL COOLER SHOWN 1. 2. 3. 4. 5. 6. 7. 8. CAPSCREW INSERT RADIATOR BRACKET RADIATOR CAP ISOLATOR CLIP NUT COOLANT LEVEL SENSOR RADIATOR 9. 10. 11. 12. 13. 14. 15. 16. CLIP RADIATOR SHROUD CLAMP HOSE SCREW WASHER SCREEN STRAP 17. 18. 19. 20. 21. 22. 23.
RADIATOR, INSTALL
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 converter. 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 top radiator hose and connect the hose to radiator. 10. Close the drain plug or install bottom radiator hose.
12. Use the same coolant mixture and fill the auxiliary coolant reservoir between the ADD and FULL marks. See Figure 4 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 Figure 5 for S4.0, 5.0, 5.50FT([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) lift trucks. 13. Install battery and battery tray. 14. Connect the positive battery cable. 15. Connect negative battery cable. 16. 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, 5.0, 5.50FT([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) (G004) andH4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005) lift trucks.
WARNING
Do not use an alcohol or methanol base antifreeze. They are flammable and cause personal injury or damage to the lift truck.
WARNING
During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.
CAUTION
Additives may damage the cooling system. Before 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 cooling system to 37 C ( 35 F).
WARNING
The radiator or other parts of the cooling system 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.)
Radiator Replacement 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 6.
CAUTION
Additives may damage the cooling system. Before using additives, contact your local Hyster dealer. 19. Check coolant level at the auxiliary coolant reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.
1. AUXILIARY COOLANT RESERVOIR 2. ADD MARK 3. FULL MARK Figure 4. Auxiliary Coolant Reservoir, 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)
1. 2. 3. 4.
AUXILIARY COOLANT RESERVOIR FULL "HOT" MARK FULL "COLD" MARK ADD "COLD" MARK
Figure 5. GM 4.3L Auxiliary Coolant Reservoir, S4.0, 5.0, 5.50FT([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) (G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
Fan Assembly Replacement Legend for Figure 6 1. 2. 3. 4. MANIFOLD COOLANT HOSES BLEED SCREW RADIATOR HOSE
WARNING
The radiator or other parts of the cooling system 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
To prevent a short circuit during fan belt removal, 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 current flow from the battery can cause an injury or parts damage. 7. Disconnect the negative battery cable from the negative battery terminal.
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.
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700 SRM 1123 8. Remove screws and washers from the radiator shroud. For the GM 2.4L and Yanmar 2.6L and 3.3L, see Figure 7. For the Mazda 2.0L and 2.2L, see Figure 8. For the GM 4.3L, see Figure 9 and for the Cummins 4.5L, see Figure 10. Lean radiator shroud toward the fan.
Fan Assembly Replacement 9. For GM 2.4L, Yanmar 2.6L and 3.3L, see Figure 7, for GM 4.3L engines, see Figure 9 and for Cummins 4.5L, see Figure 10. Remove capscrews, washers, and spacer from the fan pulley.
1. 2. 3. 4.
5. SCREW 6. RADIATOR SHROUD 7. RADIATOR Figure 7. GM 2.4L and Yanmar 2.6L and 3.3L Fan Removal
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1. SPACER, H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001] AND H2.0-3.5FT (H40-70FT) [L177] LIFT TRUCKS ONLY 2. FAN 3. CAPSCREW
4. 5. 6. 7. 8.
Figure 8. Mazda 2.0L and 2.2L Fan Removal 10. For H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001] and H2.0-3.5FT (H40-70FT) [L177] lift trucks with Mazda 2.0L and 2.2L engines, remove capscrews, washers, and spacer from the fan pulley. See Figure 8. 11. For S30FT, S35FT, S40FTS (E010) and S2.0-3.5FT (S40-70FT, S55FTS) [F187] lift trucks with Mazda 2.0L and 2.2L engines, remove the capscrews and washers retaining the fan. See Figure 8. 12. Remove the fan.
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1. 2. 3. 4.
INSPECT 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. Inspect the fan for any damage. 2. If the fan is damaged, replace the entire fan.
INSTALL WARNING
The radiator fins on the radiator are very sharp and can cause serious injury. Wear gloves while installing fan assembly. 1. Install the lower portion of the shroud in the retaining clips and lean the shroud toward the engine.
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1. 2. 3. 4. 5.
6. 7. 8. 9.
Figure 10. Cummins 4.5L Fan Removal 2. For the GM 2.4L, Cummins 4.5L and Yanmar 2.6L and 3.3L, install the spacer, washers, and capscrews to the fan. Tighten the capscrews to 52 Nm (38 lbf). See Figure 7 and Figure 10. 3. For H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001] and H2.0-3.5FT (H40-70FT) [L177] lift trucks with Mazda 2.0L and 2.2L engines, install the spacer, washers, and capscrews to the fan. Tighten the capscrews to 27 Nm (20 lbf ft). See Figure 8. 4. For S30FT, S35FT, S40FTS (E010) and S2.0-3.5FT (S40-70FT, S55FTS) [F187] lift trucks with Mazda 2.0L and 2.2L engines, place the fan in position of the pulley and intsall capscrews and washers. Tighten the capscrews to 27 Nm (20 lbf ft). See Figure 8. 5. For S4.0, 5.0, 5.50FT([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS) (G004) install the spacer, washers, and capscrews to the fan.
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700 SRM 1123 Tighten the capscrews to 55 Nm (40.5 lbf). See Figure 9. 6. Lean the radiator shroud back toward the radiator. Install the radiator shroud cover. 7. Install the screws and washers and tighten. 8. Reconnect the negative battery cable to the negative terminal of the battery. 9. Pull engine cover down and re-latch with engine cover latch.
Fan Assembly Replacement 10. Move the seat back. 11. Release the steering wheel tilt latch and move the steering wheel back. 12. If equipped, swing the LPG tank bracket back toward the truck and re-latch. 13. If equipped, turn the LPG tank valve to the ON position.
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NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________
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TECHNICAL PUBLICATIONS
700 SRM 1123 10/06 (6/06)(3/06)(5/05)(12/04) Printed in United Kingdom