Hyster P005 (H80, H90, H100, H110, H120FT) Forklift Service Repair Workshop Manual
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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
Cooling System Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Cooling System Checks...................................................................................................................................... 1
Exhaust Leaks Into Cooling System ............................................................................................................ 1
Water Flow Restrictions in Radiator ............................................................................................................ 1
Radiator Hoses ............................................................................................................................................... 1
Water Pump ................................................................................................................................................... 1
Flushing the Cooling System ............................................................................................................................ 2
Cooling System, Clean................................................................................................................................... 2
Radiator Replacement ....................................................................................................................................... 3
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) ..................................................................................................................................... 3
Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) ...................... 11
Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) ................... 12
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) ..................................................................................................................................... 14
Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024) ........................ 16
Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006) ..................... 18
Fan Assembly Replacement .............................................................................................................................. 22
Fan Removal .................................................................................................................................................. 22
Inspect ............................................................................................................................................................ 26
Fan Installation ............................................................................................................................................. 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 i
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
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
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
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
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. RADIATOR
2. SHROUD
3. WASHER
4. SCREW
5. CLIP NUT
6. CLIP
7. UPPER HOSE
8. LOWER HOSE
9. CLAMP
10. UPPER BRACKET
11. INSERT
12. CAPSCREW
13. ISOLATOR
14. RESERVOIR
15. RESERVOIR BRACKET
16. OUTLET ASSEMBLY
17. OUTLET
18. CAP
19. BUSHING
20. HOSE
21. TUBE
22. STRAP
23. NUT
24. SCREEN
25. BAFFLE (RH AND LH)
26. RADIATOR CAP
27. 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
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$52.99
Get the comprehensive repair manual for the Hyster Class 5 Internal Combustion Engine Trucks - Pneumatic Tire Hyster P005 (H80, H90, H100, H110, H120FT) Forklift. This service manual is a complete informational book with easy-to-read text sections, top quality diagrams, and instructions. It covers a wide range of topics including brake system, calibration procedures, cooling system, diagnostic trouble codes, electrical system, frame, gasoline and LPG fuel systems, hydraulic gear pump, mast repairs, periodic maintenance, powershift transmission, and more. The manual is compatible with all versions of Windows & Mac and is available in English language. It requires Adobe Reader & Win to access. This manual is essential for professional mechanics and DIY enthusiasts alike, providing everything needed to efficiently and effectively perform maintenance and repairs on the Hyster P005 (H80, H90, H100, H110, H120FT) Forklift.
