Cooling System Hyster

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]; S4.0, 4.5, 5.50FT; 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]; H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006]

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 Maintenance 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 hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

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 ................................................................................................................................................... Flushing the Cooling System ............................................................................................................................ Cooling System, Clean................................................................................................................................... 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) ..................................................................................................................................... Radiator, Remove 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) ................... 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) ..................................................................................................................................... Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)........................ Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) ..................... Fan Assembly Replacement .............................................................................................................................. Fan Removal .................................................................................................................................................. Inspect ............................................................................................................................................................ Fan Installation .............................................................................................................................................

1 1 1 1 1 1 2 2 3

3 11 12

14 16 18 22 22 26 28

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, 4.5, 5.50FT; 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]; H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006]

©2008 HYSTER COMPANY

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"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

700 SRM 1123

Cooling System Checks

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.

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.

RADIATOR HOSES WARNING

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

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.

WATER FLOW RESTRICTIONS IN RADIATOR

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

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.

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 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.

1

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 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 Mazda 2.0L and 2.2L water pump, refer to the section Mazda Engine, 2.0L and 2.2L 600 SRM 1122.

For repair procedures for the Cummins 4.5L and QSB 3.3L water pump, contact your local Hyster dealer or see Hyster Hypass Online.

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.

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 goggles 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 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.

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

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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 local 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 information. 4. Install radiator cap. Run engine until top radiator hose is hot. Stop engine and let engine cool.

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

This method uses water pressure to force water through radiator in opposite direction of normal flow.

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.

Additives may damage the cooling system. Before 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 cooling system to 37 C ( 35 F). Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.

7. If radiator or cooling system is very dirty or has a restriction, use reverse cleaning method.

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 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. 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, S120FTPRS) (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 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. 5. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than the capacity of the cooling system under radiator. Remove radiator cap.

3

Radiator Replacement

700 SRM 1123 12. Remove screws from the radiator shroud and move shroud out of the way.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 6. Open the drain plug or disconnect the bottom radiator 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 Figure 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.

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.

NOTE: For Mazda LPG engine, the LPG converter bracket needs to be moved for clearance of radiator.

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. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

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]

4

NUT-CLIP, S2.0-3.5FT (S40-70FT, S55FTS) [F187] ISOLATOR COOLANT LEVEL SENSOR RESERVOIR TUBE OUTLET ASSEMBLY HOSE RESERVOIR OUTLET CAP BUSHING SCREEN ASSEMBLY (OPTIONAL) HEAT SHIELD RESERVOIR BRACKET HEAT SHIELD, H2.0-3.5FT (H40-70FT) [L177]

700 SRM 1123

Radiator Replacement

Figure 1. Cooling System 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)

5

Radiator Replacement

700 SRM 1123

Figure 2. Cooling System for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004)

6

700 SRM 1123

Radiator Replacement Legend for Figure 2

A. RADIATOR WITH EXTERNAL COOLER

B. RADIATOR WITH INTERNAL COOLER

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

RADIATOR SHROUD WASHER SCREW CLIP NUT CLIP UPPER HOSE LOWER HOSE CLAMP UPPER BRACKET INSERT CAPSCREW ISOLATOR RESERVOIR

RESERVOIR BRACKET OUTLET ASSEMBLY OUTLET CAP BUSHING HOSE TUBE STRAP NUT SCREEN BAFFLE (RH AND LH) RADIATOR CAP COOLANT LEVEL SENSOR

7

Radiator Replacement

700 SRM 1123

Figure 3. Cooling System for H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005)

8

700 SRM 1123

Radiator Replacement Legend for Figure 3

A. RADIATOR WITH INTERNAL COOLER

B. RADIATOR WITH EXTERNAL COOLER

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

CAPSCREW INSERT RADIATOR BRACKET RADIATOR CAP ISOLATOR CLIP NUT COOLANT LEVEL SENSOR RADIATOR CLIP RADIATOR SHROUD CLAMP LOWER HOSE SCREW

WASHER SCREEN STRAP RESERVOIR BRACKET RESERVOIR OUTLET ASSEMBLY OUTLET CAP BUSHING TUBE UPPER HOSE DRAIN PLUG OIL COOLER

9

Radiator Replacement

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

RADIATOR RADIATOR CAP HARNESS CLIP UPPER RADIATOR BRACKET INSERT ISOLATOR CAPSCREW CLAMP TUBE UPPER RADIATOR HOSE CLAMP CHARGE AIR COOLER HOSE CLAMP CHARGE AIR COOLER HOSE SHROUD

700 SRM 1123

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

CLAMP CHARGE AIR COOLER HOSE SCREW WASHER CLIP LOWER RADIATOR HOSE COOLANT RESERVOIR BUSHING RESERVOIR CAP RESERVOIR OUTLET HOSE TUBE COOLANT LEVEL SENSOR SEAL

Figure 4. Cummins 3.3L Cooling System With Charge Air Cooler for 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)

10

700 SRM 1123

RADIATOR, REMOVE FOR LIFT TRUCK MODELS S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)

Radiator Replacement 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 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. 1. Turn off truck.

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. 12. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than the capacity of the cooling system under the radiator. Remove radiator cap.

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. 2. Disconnect the negative battery cable. 3. Disconnect the positive battery cable.

CAUTION Disposal of lubricants and fluids must meet local 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.

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.

14. Lift trucks equipped with a Cummins QSB 3.3L diesel engine: Loosen clamps and disconnect the charge air cooler hoses from radiator. See Figure 4. 15. Loosen clamp and disconnect and cap remote refill hose from radiator. NOTE: Tag the transmission lines before disconnecting 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

Radiator Replacement

700 SRM 1123

RADIATOR, REMOVE FOR LIFT TRUCK MODELS H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) 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. 1. Turn off truck.

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. 2. Disconnect the negative battery cable. 3. Disconnect the positive battery cable. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

DEBRIS COVER COUNTERWEIGHT COVER RADIATOR COVER UPPER BRACKET CAPSCREWS REMOTE FILL HOSE HOSE CLAMPS OIL COOLER TRANSMISSION OIL COOLER LINES FITTINGS UPPER HOSE LOWER HOSE REMOTE FILL RADIATOR CAP

Figure 5. Radiator Removal for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)

4. Open hood and loosen clamp and disconnect inlet 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 assembly weighs approximately 45.6 kg (101 lb). 7. Remove hood assembly. For hood assembly removal procedures. See Frame 100 SRM 1321.

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700 SRM 1123

Radiator Replacement 13. Remove capscrews, washer, fan, fan spacer, and shroud. For Fan Removal procedures, see Figure 17.

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. 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 local 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 Figure 4. Figure 6. Hood Assembly Removal

17. Disconnect and cap upper radiator hose.

8. Disconnect and cap auxiliary coolant reservoir hose. See Figure 11.

NOTE: Tag the transmission lines before disconnecting from oil cooler.

9. Remove capscrews from the auxiliary coolant reservoir bracket and upper bracket. Remove auxiliary coolant reservoir assembly.

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.

10. Remove the four capscrews from the upper radiator 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.

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

Radiator Replacement

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)

700 SRM 1123 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 cooling system to 37 C ( 35 F).

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 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 antifreeze. They are flammable and could cause personal injury or damage to the lift truck.

CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer.

14

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

700 SRM 1123

Radiator Replacement 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.

(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.

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 system 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. 2. 3. 4.

AUXILIARY COOLANT RESERVOIR FULL "HOT" MARK FULL "COLD" MARK 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,

1. 2. 3. 4.

MANIFOLD COOLANT HOSES BLEED SCREW RADIATOR HOSE Figure 9. Bleed Screw, GM 2.4L Engine

15

Radiator Replacement

CAUTION Additives may damage the cooling system. Before using additives, contact your local Hyster dealer.

700 SRM 1123 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 carefully install the counterweight cover into the lift truck frame. See Figure 5.

20. Check coolant level at the auxiliary coolant reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.

12. Install two bolts to counterweights cover. Tighten to 38 N•m (28 lbf ft).

RADIATOR, INSTALL FOR LIFT TRUCK MODELS S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)

14. Install radiator cover.

13. Install debris cover.

15. Connect positive battery cable. 16. Connect negative battery cable.

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 Figure 5. 4. Uncap and connect remote refill hose onto radiator and tighten hose clamp. See Figure 5.

WARNING Do not use an alcohol or methanol base antifreeze. They are flammable and could cause personal injury or damage to the lift truck.

CAUTION Additives may damage the cooling system. Before using additives, contact you local Hyster dealer.

5. Close drain plug and uncap the upper and lower radiator hoses and connect hoses onto radiator and tighten hose clamp. See Figure 5.

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 cooling system to 37 C ( 35 F).

6. Uncap the charge air cooler hoses and connect the hoses to radiator. See Figure 4.

18. Install radiator cap.

7. Install fan. See Fan Installation procedures.

19. Use the same coolant mixture and fill the auxiliary coolant reservoir between the ADD and FULL marks. See Figure 8.

8. Align shroud to radiator and install two capscrews, washers and clip nuts. See Figure 10.

WARNING 9. If necessary, connect electrical connector onto the coolant level sensor. 10. Install upper radiator bracket and install four capscrews.

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

WARNING 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.

16

The radiator or other parts of the cooling system 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).

700 SRM 1123

Radiator Replacement

A. LOWER HOSE (CUMMINS 4.5L DIESEL) B. LOWER HOSE (GAS AND LPG) 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

C. UPPER HOSE (GAS AND LPG) D. UPPER HOSE (CUMMINS 4.5L DIESEL) 13. BRACKET (COOLANT FILL) 14. OUTLET ASSEMBLY 15. OUTLET 16. CAP 17. BUSHING 18. HOSE 19. HOSE

20. 21. 22. 23. 24.

REMOTE FILL HOSE REMOTE FILL RADIATOR CAP SCREEN COOLANT LEVEL SENSOR 25. DRAIN PLUG

Figure 10. Cooling System for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024)

17

Radiator Replacement

CAUTION Additives may damage the cooling system. Before using additives, contact you local Hyster dealer. 21. Check coolant level at the auxiliary coolant reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir. 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 transmission 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.

18

700 SRM 1123 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 procedures. 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 connect 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 antifreeze. They are flammable and could cause personal injury or damage to the lift truck.

CAUTION Additives may damage the cooling system. Before 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 cooling system to 37 C ( 35 F). 21. Install radiator cap. 22. Use the same coolant mixture and fill the auxiliary coolant reservoir between the ADD and FULL marks. See Figure 8.

700 SRM 1123

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 system 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).

Radiator Replacement

CAUTION Additives may damage the cooling system. Before using additives, contact you local Hyster dealer. 24. Check coolant level at the auxiliary coolant reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir. 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 transmission oil to the transmission at the dipstick tube at the correct level indicated on the dipstick.

19

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

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

Fan Assembly Replacement

700 SRM 1123 Legend for Figure 11

A. GM 4.3L (GAS/LPG)

B. CUMMINS 4.5L (DIESEL)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

17. 18. 19. 20. 21. 22.

AIR INTAKE (WITHOUT PRE-CLEANER) PRE-CLEANER HOOD ASSEMBLY CLAMP INLET HOSE SILENCER (DIESEL) AIR FILTER UPPER RADIATOR BRACKET ISOLATOR INSERT CAPSCREW RADIATOR (WITH EXTERNAL OIL COOLER) UPPER HOSE LOWER HOSE CLIP NUT WASHER

23. 24. 25. 26. 27. 28. 29. 30.

SCREW SHROUD FAN FAN SPACER TRANSMISSION LINES AUXILIARY COOLANT RESERVOIR AND BRACKET ASSEMBLY OUTLET CAP BUSHING HOSE AUXILIARY COOLANT RESERVOIR HOSE DRAIN PLUG RADIATOR CAP 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 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 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.

22

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 steering 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 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. 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; S120FTPRS) (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

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

1. 2. 3. 4.

FAN SPACER WASHER CAPSCREW

(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.

5. SCREW 6. RADIATOR SHROUD 7. RADIATOR Figure 12. GM 2.4L and Yanmar 2.6L and 3.3L Fan Removal

23

Fan Assembly Replacement

700 SRM 1123

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.

WASHER SCREW WASHER RADIATOR SHROUD RADIATOR

Figure 13. Mazda 2.0L and 2.2L Fan Removal 9. For GM 2.4L, Yanmar 2.6L and 3.3L, see Figure 12. For GM 4.3L engines, for lift truck models 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), see Figure 14. For Cummins 4.5L engines, for lift truck models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)

24

(N005), see Figure 15. For GM 4.3L engines 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. Remove capscrews, washers, and spacer from the fan pulley.

700 SRM 1123

1. 2. 3. 4.

FAN SPACER WASHER CAPSCREW

Fan Assembly Replacement

5. SCREW 6. RADIATOR SHROUD 7. RADIATOR

Figure 14. GM 4.3L Fan Removal for Lift Truck Models 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) 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 13.

trucks with Mazda 2.0L and 2.2L engines, remove the capscrews and washers retaining the fan. See Figure 13. 12. Remove the fan.

11. For S30FT, S35FT, S40FTS (E010) and S2.0-3.5FT (S40-70FT, S55FTS) [F187] lift

25

Fan Assembly Replacement

1. 2. 3. 4. 5.

SPACER FAN WASHER CAPSCREW RADIATOR SHROUD

700 SRM 1123

6. 7. 8. 9.

SCREW LOCKWASHER CLIP NUT RADIATOR

Figure 15. Cummins 4.5L Fan Removal for Lift truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

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

26

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.

700 SRM 1123

Fan Assembly Replacement

A. GM 4.3L (GAS AND LPG)

B. CUMMINS 4.5L (DIESEL)

1. 2. 3. 4.

5. SCREW 6. SHROUD 7. RADIATOR

FAN FAN SPACER WASHER CAPSCREW

Figure 16. Fan Removal for Engines GM 4.3L and Cummins 4.5L for Lift truck Models S6.0FT, S7.0FT, (S135FT,S155FT) (D024, E024)

27

Fan Assembly Replacement

700 SRM 1123

A. GM 4.3L (GAS AND LPG)

B. CUMMINS 4.5L (DIESEL)

1. 2. 3. 4.

5. SCREW 6. SHROUD 7. RADIATOR

FAN FAN SPACER WASHER CAPSCREW

Figure 17. Fan Removal for Engines GM 4.3L and Cummins 4.5L for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006)

FAN INSTALLATION WARNING The radiator fins on the radiator are very sharp and can cause serious injury. Wear gloves while installing fan assembly.

28

1. Install the lower portion of the shroud in the retaining clips and lean the shroud toward the engine. 2. For the GM 2.4L, Cummins 4.5L and QSB 3.3L, and Yanmar 2.6L and 3.3L, install the spacer, washers, and capscrews to the fan. Tighten the capscrews to 52 N•m (38 lbf). See Figure 12, Figure 15, Figure 16, Figure 17, and Figure 18.

700 SRM 1123

1. 2. 3. 4.

SPACER FAN SCREW WASHER

Fan Assembly Replacement

5. 6. 7. 8.

WASHER CAPSCREW SHROUD RADIATOR

Figure 18. Fan Removal for Cummins QSB 3.3L for Lift Truck 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) 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 N•m (20 lbf ft). See Figure 13. 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 install capscrews and washers. Tighten the capscrews to 27 N•m (20 lbf ft). See Figure 13. 5. For lift trucks 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,

29

Fan Assembly Replacement H155FT) (H006, J006) equipped with GM 4.3L (Gas/LPG) engine. Install the spacer, washers, and capscrews to the fan. Tighten the capscrews to 27 N•m (20 lbf ft). See Figure 14, Figure 16, Figure 17, and Figure 18.

700 SRM 1123 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), see Step 9 though Step 12. 9. Lower the hood and ensure that the hood latches.

6. Lean the radiator shroud back toward the radiator. Install the radiator shroud cover.

10. Move the seat back.

7. Install the screws and washers and tighten.

11. Release the steering wheel tilt latch and move the steering wheel back.

8. Reconnect the negative battery cable to the negative terminal of the battery. NOTE: 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,

30

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.

TECHNICAL PUBLICATIONS 700 SRM 1123

4/08 (3/07)(10/06)(6/06)(3/06)(5/05)(12/04) Printed in U.S.A.