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 back-
ground. The CAUTION symbol and word are on yellow background.
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

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
700 SRM 1123 Cooling System Checks

General
This section contains the repair and replacement in- assembly (pusher type), fan shroud, coolant hoses,
structions for the radiator, coolant level sensor, fan coolant recovery bottle, and optional debris screen.

Cooling System Checks

EXHAUST LEAKS INTO COOLING SYSTEM RADIATOR HOSES

WARNING WARNING
During engine operation, be careful not to The radiator or other parts of the cooling sys-
touch the fan, pulleys, or drive belts. Contact tem may be hot or under pressure and can
with these parts can cause serious injury. cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
To check for exhaust leaks into the cooling system, the radiator with your hand. If the radiator is
use a Combustion Leak Test Kit for this purpose. Fol- still hot to the touch, wait another 30 minutes
low the manufacturer’s instructions when doing the before attempting to check or fix any part of
test. the cooling system.

WATER FLOW RESTRICTIONS IN Inspect all radiator hoses. If they feel spongy or have
RADIATOR visible cracks, replace hoses.

WARNING WATER PUMP

During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact WARNING
with these parts can cause serious injury. During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
To check for water flow restrictions in the radiator, with these parts can cause serious injury.
run engine until it is warm.
WARNING
WARNING The radiator or other parts of the cooling sys-
The radiator or other parts of the cooling sys- tem may be hot or under pressure and can
tem may be hot or under pressure and can cause serious injury.
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching Run engine until it is warm. Check the operation of
the radiator with your hand. If the radiator is water pump by holding the top radiator hose. If the
still hot to the touch, wait another 30 minutes pump is operating, there will be pressure surges in
before attempting to check or fix any part of the hose.
the cooling system.
Check for leaks around the timing belt cover near the
Shut engine OFF and feel the radiator. The temper- base of the oil pump.
ature must be even across the radiator. (The radiator
Check the weep hole where water can drain by the oil
will be hotter near the top radiator hose.) Cold spots
filter. If there is a drip, check the pump shaft seal and
on radiator indicate restrictions.
water pump. Replacement of the pump shaft seal or
If radiator has leaks, either replace the radiator or water pump may be necessary.
have it repaired by trained personnel.

1
Flushing the Cooling System 700 SRM 1123

For repair procedures for the GM 2.4L water pump, For replacement procedures for the GM 4.3L water
refer to the section GM Engine Repair, GM 2.4 pump, refer to the section GM Engines, 4.3 Liter
Liter Engine 600 SRM 1121. V-6 600 SRM 1251.

For repair procedures for the Mazda 2.0L and 2.2L For repair procedures for the Cummins 4.5L and
water pump, refer to the section Mazda Engine, QSB 3.3L water pump, contact your local Hyster
2.0L and 2.2L 600 SRM 1122. 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 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
WARNING
the cooling system.
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 CAUTION
away from all personnel. Wear protective gog- Disposal of lubricants and fluids must meet lo-
gles or a face shield to prevent injury to the cal environmental regulations.
eyes.
2. Drain cooling system. Fill cooling system with
clean water. See the Radiator, Remove for
WARNING Lift Trucks Models S30FT, S35FT, S40FTS
The radiator fins on the radiator are very (E010); H1.6FT, H1.8FT, 2.0FTS (H30FT,
sharp and can cause serious injury. Wear H35FT, H40FTS) (F001); S2.0-3.5FT (S40-70FT,
gloves while checking the radiator fins. S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177),
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
1. Check radiator fins. Clean exterior of radiator
100FTBCS; S120FTS; S120FTPRS) (G004) and
with compressed air or water as needed.
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005, P005) section
WARNING for more information.
DO NOT remove the radiator cap from the radi-
ator when the engine is hot. When the radiator 3. Drain cooling system. Fill cooling system with
cap is removed, the pressure is released from clean water. See the Radiator, Remove for Lift
the system. If the system is hot, the steam and Truck Models S6.0FT, S7.0FT (S135FT, S155FT)
boiling coolant can cause burns. (D024, E024) and see Radiator, Remove for
Lift Truck Models H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006) section for more informa-
WARNING tion.
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can 4. Install radiator cap. Run engine until top radia-
cause serious injury. Wait 30 minutes for the tor hose is hot. Stop engine and let engine cool.
radiator to cool. Do a touch test by touching

2
700 SRM 1123 Radiator Replacement

5. Drain water from radiator. If water is dirty, fill This method uses water pressure to force water
system with water and repeat procedure until through radiator in opposite direction of normal
water is clean. flow.

CAUTION CAUTION
Follow the manufacturer’s instructions when Additives may damage the cooling system. Be-
using a chemical radiator cleaner. fore using additives, contact your local Hyster
dealer.
6. If water does not clean system, use a chemical
radiator cleaner. 8. Fill cooling system with a mixture of 50 percent
water and 50 percent ethylene glycol boron-free
CAUTION antifreeze. The 50/50 mixture will protect cool-
ing system to 37 C ( 35 F). Add coolant as nec-
Follow the manufacturer’s instructions when
essary to keep level between the ADD and FULL
using special equipment to reverse clean the
marks on the reservoir.
radiator.

7. If radiator or cooling system is very dirty or

has a restriction, use reverse cleaning method.

Radiator Replacement
RADIATOR, REMOVE FOR LIFT TRUCKS (H40-70FT) (L177) lift trucks, and Frame 100
MODELS S30FT, S35FT, S40FTS (E010); SRM 1243 for S4.0, 4.5, 5.5FT; S5.5FTS (S80,
H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, 100, 120FT; S80, 100FTBCS; S120FTS, S120FT-
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H40FTS) (F001); S2.0-3.5FT (S40-70FT, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
S55FTS) (F187); H2.0-3.5FT (H40-70FT) (N005, P005) lift trucks.
(L177), S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; WARNING
S120FTPRS) (G004) AND H4.0FT5/FT6; Always disconnect the cable at the negative
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, terminal first. Install a tag on the battery ter-
100, 110, 120FT) (N005, P005) minals so that no one connects the cables on
the terminals.

WARNING 3. Disconnect the negative battery cable.

The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can 4. Disconnect the positive battery cable.
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching WARNING
the radiator with your hand. If the radiator is DO NOT remove the radiator cap from the radi-
still hot to the touch, wait another 30 minutes ator when the engine is hot. When the radiator
before attempting to check or fix any part of cap is removed, the pressure is released from
the cooling system. the system. If the system is hot, the steam and
boiling coolant can cause burns.
1. Turn OFF truck.
5. Let coolant cool to ambient temperature. Place a
2. Remove the hood and seat combination. See
drain pan with a capacity greater than the capac-
the section Frame 100 SRM 1120 for S30FT,
ity of the cooling system under radiator. Remove
S35FT, S40FTS (E010); H1.6FT, H1.8FT, 2.0FTS
radiator cap.
(H30FT, H35FT, H40FTS) (F001); S2.0-3.5FT
(S40-70FT, S55FTS) (F187); H2.0-3.5FT

3
Radiator Replacement 700 SRM 1123

12. Remove screws from the radiator shroud and

CAUTION move shroud out of the way.
Disposal of lubricants and fluids must meet lo-
cal environmental regulations. 13. Remove fan, fan spacer, and pulley.

6. Open the drain plug or disconnect the bottom ra- 14. Remove upper radiator bracket. See Figure 1
diator hose. for S30FT, S35FT, S40FTS (E010); H1.6FT,
H1.8FT, 2.0FTS (H30FT, H35FT, H40FTS)
7. Lift trucks equipped with a Cummins QSB 3.3L (F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187);
diesel engine: Loosen clamps and disconnect the H2.0-3.5FT (H40-70FT) (L177) lift trucks. See
charge air cooler hoses from radiator. See Fig- Figure 2 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
ure 4. 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004) lift trucks. See Figure 3 for H4.0FT5/FT6;
8. Cap radiator hoses. H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005) lift trucks. See
9. Disconnect hose to auxiliary coolant reservoir
Figure 4 for truck equipped with a Cummins
and remove reservoir.
QSB 3.3L H4.5FT5/FT6; H4.5FTS5, H4.5FT6;
10. Remove battery and battery tray. H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005),
S6.6FT, S7.0FT (S135FT, S155FT) (E024), and
11. Disconnect electrical connector to the coolant H6.0FT, H7.0FT (H135FT, H155FT) (J006).
level sensor.
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. RADIATOR 15. NUT-CLIP, S2.0-3.5FT (S40-70FT, S55FTS) [F187]
2. CAP 16. ISOLATOR
3. UPPER HOSE 17. COOLANT LEVEL SENSOR
4. LOWER HOSE 18. RESERVOIR
5. CLAMP 19. TUBE
6. SHROUD 20. OUTLET ASSEMBLY
7. CLIP 21. HOSE
8. WASHER 22. RESERVOIR OUTLET
9. SCREW 23. CAP
10. CLIP 24. BUSHING
11. UPPER BRACKET 25. SCREEN ASSEMBLY (OPTIONAL)
12. CAPSCREW, S2.0-3.5FT (S40-70FT, S55FTS) 26. HEAT SHIELD
[F187] 27. RESERVOIR BRACKET
13. INSERT 28. HEAT SHIELD, H2.0-3.5FT (H40-70FT) [L177]
14. LOWER BRACKET, S2.0-3.5FT (S40-70FT,
S55FTS) [F187]

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 15. RESERVOIR BRACKET
2. SHROUD 16. OUTLET ASSEMBLY
3. WASHER 17. OUTLET
4. SCREW 18. CAP
5. CLIP NUT 19. BUSHING
6. CLIP 20. HOSE
7. UPPER HOSE 21. TUBE
8. LOWER HOSE 22. STRAP
9. CLAMP 23. NUT
10. UPPER BRACKET 24. SCREEN
11. INSERT 25. BAFFLE (RH AND LH)
12. CAPSCREW 26. RADIATOR CAP
13. ISOLATOR 27. COOLANT LEVEL SENSOR
14. RESERVOIR

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. CAPSCREW 14. WASHER
2. INSERT 15. SCREEN
3. RADIATOR BRACKET 16. STRAP
4. RADIATOR CAP 17. RESERVOIR BRACKET
5. ISOLATOR 18. RESERVOIR
6. CLIP NUT 19. OUTLET ASSEMBLY
7. COOLANT LEVEL SENSOR 20. OUTLET
8. RADIATOR 21. CAP
9. CLIP 22. BUSHING
10. RADIATOR SHROUD 23. TUBE
11. CLAMP 24. UPPER HOSE
12. LOWER HOSE 25. DRAIN PLUG
13. SCREW 26. OIL COOLER

9
Radiator Replacement 700 SRM 1123

1. RADIATOR 16. CLAMP

2. RADIATOR CAP 17. CHARGE AIR COOLER HOSE
3. HARNESS CLIP 18. SCREW
4. UPPER RADIATOR BRACKET 19. WASHER
5. INSERT 20. CLIP
6. ISOLATOR 21. LOWER RADIATOR HOSE
7. CAPSCREW 22. COOLANT RESERVOIR
8. CLAMP 23. BUSHING
9. TUBE 24. RESERVOIR CAP
10. UPPER RADIATOR HOSE 25. RESERVOIR OUTLET
11. CLAMP 26. HOSE
12. CHARGE AIR COOLER HOSE 27. TUBE
13. CLAMP 28. COOLANT LEVEL SENSOR
14. CHARGE AIR COOLER HOSE 29. SEAL
15. SHROUD

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 Replacement

RADIATOR, REMOVE FOR LIFT TRUCK 10. Remove screws, washers, and clip nuts from the
MODELS S6.0FT, S7.0FT (S135FT, S155FT) shroud and radiator and move shroud out of the
(D024, E024) way.

11. Remove fan. See Fan Removal procedures.

WARNING
The radiator or other parts of the cooling sys- WARNING
tem may be hot or under pressure and can DO NOT remove the radiator cap from the radi-
cause serious injury. Wait 30 minutes for the ator when the engine is hot. When the radiator
radiator to cool. Do a touch test by touching cap is removed, the pressure is released from
the radiator with your hand. If the radiator is the system. If the system is hot, the steam and
still hot to the touch, wait another 30 minutes boiling coolant can cause burns.
before attempting to check or fix any part of
the cooling system. 12. Let coolant cool to ambient temperature. Place
a drain pan with a capacity greater than the ca-
1. Turn off truck. pacity of the cooling system under the radiator.
Remove radiator cap.
WARNING
Always disconnect the cable at the negative CAUTION
terminal first. Install a tag on the battery ter-
Disposal of lubricants and fluids must meet lo-
minals so that no one connects the cables on
cal environmental regulations.
the terminals.
13. Open drain plug or loosen clamps and disconnect
2. Disconnect the negative battery cable.
and cap the lower radiator hoses from radiator to
3. Disconnect the positive battery cable. allow coolant to drain into a suitable container.
See Figure 5.
4. Remove radiator cover. See Figure 5.
14. Lift trucks equipped with a Cummins QSB 3.3L
5. Remove debris cover. diesel engine: Loosen clamps and disconnect the
charge air cooler hoses from radiator. See Fig-
CAUTION ure 4.
The counterweight cover is extremely heavy 15. Loosen clamp and disconnect and cap remote re-
185 kg (408 lb). Make sure that the eyebolts fill hose from radiator.
and lifting device have sufficient capacity to
lift the weight. NOTE: Tag the transmission lines before disconnect-
ing from oil cooler.
6. Remove two bolts from counterweight cover.
16. Disconnect and cap transmission lines from oil
7. Install two eyebolts in the hole on each end of the cooler and allow transmission oil to drain from
counterweight cover. Connect a suitable lifting oil cooler into a suitable container, then cap the
device to the eyebolts and carefully remove the oil cooler ports.
counterweight cover from lift truck.
NOTE: Removing the radiator from lift truck requires
8. Remove four capscrews from upper radiator two people.
bracket. Remove bracket. See Figure 10.
17. Remove radiator from lift truck frame.
9. If necessary, disconnect electrical connector from
the coolant level sensor. 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 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.

1. DEBRIS COVER 4. Open hood and loosen clamp and disconnect in-
2. COUNTERWEIGHT COVER
3. RADIATOR COVER let hose that attaches to the hood support. See
4. UPPER BRACKET Figure 11.
5. CAPSCREWS
6. REMOTE FILL HOSE 5. Lift trucks equipped with GM 4.3L (Gas/LPG)
7. HOSE CLAMPS engine. Loosen clamp and disconnect inlet hose
8. OIL COOLER from air filter and remove inlet hose.
9. TRANSMISSION OIL COOLER LINES
10. FITTINGS 6. Lift trucks equipped with the Cummins 4.5L
11. UPPER HOSE
12. LOWER HOSE or QSB 3.3L diesel engine. Loosen clamp and
13. REMOTE FILL disconnect inlet hose from silencer. Remove
14. RADIATOR CAP silencer.

Figure 5. Radiator Removal for Lift Truck NOTE: Before lifting the hood assembly from the lift
Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, truck frame. Make sure to use a lifting device and
E024) 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
700 SRM 1123 Radiator Replacement

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.
Figure 6. Hood Assembly Removal 17. Disconnect and cap upper radiator hose.
8. Disconnect and cap auxiliary coolant reservoir NOTE: Tag the transmission lines before disconnect-
hose. See Figure 11. ing from oil cooler.
9. Remove capscrews from the auxiliary coolant 18. Disconnect and cap transmission lines from oil
reservoir bracket and upper bracket. Remove cooler and allow transmission oil to drain from
auxiliary coolant reservoir assembly. oil cooler into a suitable container, then cap the
oil cooler ports.
10. Remove the four capscrews from the upper radi-
ator bracket. Remove bracket. NOTE: Removing the radiator from lift truck requires
two people.
11. If necessary, disconnect electrical connector from
the coolant level sensor. 19. Remove radiator from lift truck frame.
12. Remove screws, washer and clip nut from the 20. If necessary, remove the coolant level sensor from
shroud and move shroud out of the way. radiator.

13
Radiator Replacement 700 SRM 1123

RADIATOR, INSTALL FOR LIFT TRUCK 12. Fill cooling system with a mixture of 50 percent
MODELS S30FT, S35FT, S40FTS (E010); water and 50 percent ethylene glycol boron-free
H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, antifreeze. The 50/50 mixture will protect cool-
ing system to 37 C ( 35 F).
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 1. AUXILIARY COOLANT RESERVOIR
hose. 2. ADD MARK
3. FULL MARK

WARNING Figure 7. Auxiliary Coolant Reservoir for

Do not use an alcohol or methanol base an- Lift Truck Models S30FT, S35FT, S40FTS
tifreeze. They are flammable and could cause (E010); H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,
personal injury or damage to the lift truck. H40FTS) (F001); S2.0-3.5FT (S40-70FT, S55FTS)
(F187); H2.0-3.5FT (H40-70FT) (L177)

CAUTION 13. Use the same coolant mixture and fill the
Additives may damage the cooling system. Be- auxiliary coolant reservoir between the ADD
fore using additives, contact your local Hyster and FULL marks. See Figure 7, for S30FT,
dealer. 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
700 SRM 1123 Radiator Replacement

(H40-70FT) (L177) lift trucks, and Figure 8, for 100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
100FTBCS; S120FTS; S120FTPRS) (G004) and H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (N005, P005). lift trucks.
(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. 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 1. MANIFOLD

the section Frame 100 SRM 1120 for S30FT, 2. COOLANT HOSES
S35FT, S40FTS (E010); H1.6FT, H1.8FT, 2.0FTS 3. BLEED SCREW
(H30FT, H35FT, H40FTS) (F001); S2.0-3.5FT 4. RADIATOR HOSE
(S40-70FT, S55FTS) (F187); H2.0-3.5FT
Figure 9. Bleed Screw, GM 2.4L Engine
(H40-70FT) (L177) lift trucks, and Frame 100
SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80,

15
Radiator Replacement 700 SRM 1123

11. If removed, install two eyebolts in the hole on

CAUTION each end of the counterweight cover. Connect a
Additives may damage the cooling system. Be- suitable lifting device to the eyebolts and care-
fore using additives, contact your local Hyster fully install the counterweight cover into the lift
dealer. truck frame. See Figure 5.

20. Check coolant level at the auxiliary coolant reser- 12. Install two bolts to counterweights cover.
voir. Add coolant as necessary to keep level be- Tighten to 38 N•m (28 lbf ft).
tween the ADD and FULL marks on the reser-
voir. 13. Install debris cover.

RADIATOR, INSTALL FOR LIFT TRUCK 14. Install radiator cover.

MODELS S6.0FT, S7.0FT (S135FT, S155FT) 15. Connect positive battery cable.
(D024, E024)
16. Connect negative battery cable.
1. If necessary, install coolant level sensor.

NOTE: Installing the radiator into lift truck frame WARNING

requires two people. Do not use an alcohol or methanol base an-
tifreeze. They are flammable and could cause
2. Install radiator into lift truck frame. personal injury or damage to the lift truck.

3. Remove caps from the oil cooler and transmission

lines and connect lines into oil cooler. See Fig- CAUTION
ure 5. Additives may damage the cooling system. Be-
fore using additives, contact you local Hyster
4. Uncap and connect remote refill hose onto radia- dealer.
tor and tighten hose clamp. See Figure 5.
17. Fill cooling system with a mixture of 50 percent
5. Close drain plug and uncap the upper and lower waster and 50 percent ethylene glycol boron-free
radiator hoses and connect hoses onto radiator antifreeze. The 50/50 mixture will protect cool-
and tighten hose clamp. See Figure 5. ing system to 37 C ( 35 F).
6. Uncap the charge air cooler hoses and connect 18. Install radiator cap.
the hoses to radiator. See Figure 4.
19. Use the same coolant mixture and fill the aux-
7. Install fan. See Fan Installation procedures. iliary coolant reservoir between the ADD and
FULL marks. See Figure 8.
8. Align shroud to radiator and install two cap-
screws, washers and clip nuts. See Figure 10.
WARNING
9. If necessary, connect electrical connector onto the During engine operation, be careful not to
coolant level sensor. touch the fan, pulleys, or drive belts. contact
10. Install upper radiator bracket and install four with these parts can cause serious injury.
capscrews.
WARNING
CAUTION The radiator or other parts of the cooling sys-
tem may be hot or under pressure and cause
The counterweight cover is extremely heavy
serious injury.
185 kg (408 lb). Make sure that the eyebolts
and lifting device have sufficient capacity to 20. Start and run the engine until thermostat opens
lift the weight. (The upper radiator hose will be warm).

16
700 SRM 1123 Radiator Replacement

A. LOWER HOSE (CUMMINS 4.5L DIESEL) C. UPPER HOSE (GAS AND LPG)
B. LOWER HOSE (GAS AND LPG) D. UPPER HOSE (CUMMINS 4.5L DIESEL)
1. RADIATOR (WITH 8. UPPER RADIATOR 13. BRACKET 20. REMOTE FILL HOSE
EXTERNAL OIL BRACKET (COOLANT FILL) 21. REMOTE FILL
COOLER) 9. CAPSCREW 14. OUTLET ASSEMBLY 22. RADIATOR CAP
2. SHROUD 10. INSERT 15. OUTLET 23. SCREEN
3. WASHER 11. ISOLATOR 16. CAP 24. COOLANT LEVEL
4. SCREW 12. AUXILIARY 17. BUSHING SENSOR
5. CLIP NUT COOLANT 18. HOSE 25. DRAIN PLUG
6. CLIP SPRING RESERVOIR 19. HOSE
7. CLAMP

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

17
Radiator Replacement 700 SRM 1123

12. If necessary, connect electrical connector onto the

CAUTION coolant level sensor.
Additives may damage the cooling system. Be-
fore using additives, contact you local Hyster 13. Lift truck equipped GM 4.3L (Gas/LPG) engine.
dealer. Install air intake hose to air filter and tighten
clamp.
21. Check coolant level at the auxiliary coolant reser-
voir. Add coolant as necessary to keep level be- 14. Lift trucks equipped with Cummins 4.5L or QSB
tween the ADD and FULL marks on the reser- 3.3L diesel engine. Install silencer and connect
voir. hose from air filter side and tighten clamp. See
Figure 11.
22. Shut down the engine for one minute or longer
prior to checking the transmission oil level. If the 15. Install hood assembly. For hood install proce-
transmission oil is low, add JDM J20C transmis- dures. See frame Frame 100 SRM 1321.
sion oil to the transmission at the dipstick tube
16. Lift truck equipped GM 4.3L (Gas/LPG) engine.
at the correct level indicated on the dipstick.
Open hood assembly and connect intake hose to
RADIATOR, INSTALL FOR LIFT TRUCK hood support and tighten clamp. See Figure 11.
MODELS H6.0FT, H7.0FT (H135FT, H155FT) 17. Lift trucks equipped with Cummins 4.5L or QSB
(H006, J006) 3.3L diesel engine. Open hood assembly and con-
nect hose to hood support and tighten clamp. See
1. If necessary, install coolant level sensor. Figure 11.
NOTE: Installing the radiator into lift truck frame 18. Connect positive battery cable.
requires two people.
19. Connect negative battery cable.
2. Install radiator into lift truck frame.

3. Install upper radiator bracket and install four WARNING

capscrews. See Figure 11. Do not use an alcohol or methanol base an-
tifreeze. They are flammable and could cause
4. Install coolant reservoir bracket and coolant personal injury or damage to the lift truck.
reservoir assembly onto upper bracket and
tighten capscrews.
CAUTION
5. Uncap and connect auxiliary coolant reservoir Additives may damage the cooling system. Be-
hose and tighten clamp. fore using additives, contact you local Hyster
dealer.
6. Remove caps from the oil cooler and transmission
lines and connect lines into oil cooler. 20. Fill cooling system with a mixture of 50 percent
waster and 50 percent ethylene glycol boron-free
7. Close drain plug and uncap the lower radiator
antifreeze. The 50/50 mixture will protect cool-
hose and connect hose onto radiator and tighten
ing system to 37 C ( 35 F).
clamp.
21. Install radiator cap.
8. Uncap and connect upper radiator hose and
tighten clamp. 22. Use the same coolant mixture and fill the aux-
iliary coolant reservoir between the ADD and
9. Uncap the charge air cooler hoses and connect
FULL marks. See Figure 8.
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 Radiator Replacement

WARNING CAUTION
During engine operation, be careful not to Additives may damage the cooling system. Be-
touch the fan, pulleys, or drive belts. contact fore using additives, contact you local Hyster
with these parts can cause serious injury. dealer.

24. Check coolant level at the auxiliary coolant reser-

WARNING voir. Add coolant as necessary to keep level be-
The radiator or other parts of the cooling sys- tween the ADD and FULL marks on the reser-
tem may be hot or under pressure and cause voir.
serious injury.
25. Shut down the engine for one minute or longer
23. Start and run the engine until thermostat opens prior to checking the transmission oil level. If the
(The upper radiator hose will be warm). 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
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. AIR INTAKE (WITHOUT PRE-CLEANER) 17. SCREW
2. PRE-CLEANER 18. SHROUD
3. HOOD ASSEMBLY 19. FAN
4. CLAMP 20. FAN SPACER
5. INLET HOSE 21. TRANSMISSION LINES
6. SILENCER (DIESEL) 22. AUXILIARY COOLANT RESERVOIR AND
7. AIR FILTER BRACKET ASSEMBLY
8. UPPER RADIATOR BRACKET 23. OUTLET
9. ISOLATOR 24. CAP
10. INSERT 25. BUSHING
11. CAPSCREW 26. HOSE
12. RADIATOR (WITH EXTERNAL OIL COOLER) 27. AUXILIARY COOLANT RESERVOIR HOSE
13. UPPER HOSE 28. DRAIN PLUG
14. LOWER HOSE 29. RADIATOR CAP
15. CLIP NUT 30. HOOD SUPPORT
16. WASHER

Fan Assembly Replacement

FAN REMOVAL 3. If equipped, release the LPG tank bracket and
swing tank away from the lift truck.
WARNING 4. Release the steering tilt latch and move the steer-
During engine operation, be careful not to ing wheel forward.
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury. 5. Release the seat latch and move the seat forward.

6. Release engine cover latch on engine cover and

WARNING swing engine cover up.
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 WARNING
radiator to cool. Do a touch test by touching To prevent a short circuit during fan belt re-
the radiator with your hand. If the radiator is moval, disconnect the battery negative cable at
still hot to the touch, wait another 30 minutes the battery negative terminal. Install a lock or
before attempting to check or fix any part of tag on the connector to prevent connection. A
the cooling system. tool could cause a short circuit, the high cur-
rent flow from the battery can cause an injury
or parts damage.
WARNING
The radiator fins on the radiator are very 7. Disconnect the negative battery cable from the
sharp and can cause serious injury. Wear negative battery terminal.
gloves while removing fan assembly.
8. Remove screws and washers from the radiator
NOTE: The fan that is used is a pusher-type fan. Do shroud. For the GM 2.4L and Yanmar 2.6L and
not replace with a puller-type fan. 3.3L, see Figure 12. For the Mazda 2.0L and
2.2L, see Figure 13. For GM 4.3L engine, for lift
1. Turn OFF lift truck. truck models S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
2. If equipped, turn the LPG tank valve to the OFF
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
position.
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), see Figure 14. For Cummins 4.5L

22
700 SRM 1123 Fan Assembly Replacement

engine, for lift truck models H4.0FT5/FT6; (H135FT, H155FT) (H006), see Figure 17. For
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, Cummins QSB 3.3L diesel engines, for lift trucks
110, 120FT) (N005), see Figure 15. For GM 4.3L models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
and Cummins 4.5L engines, for lift truck models H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005),
S6.0FT, S7.0FT, (S135FT,S155FT) (D024), see S6.0FT, S7.0FT (S135FT, S155FT) (E024), and
Figure 16. For GM 4.3L and Cummins 4.5L H6.0FT, H7.0FT (H135FT, H155FT) (J006), see
engines, for lift truck models H6.0FT, H7.0FT Figure 18. Lean radiator shroud toward the fan.

1. FAN 5. SCREW
2. SPACER 6. RADIATOR SHROUD
3. WASHER 7. RADIATOR
4. CAPSCREW

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, 4. WASHER

H35FT, H40FTS) [F001] AND H2.0-3.5FT 5. SCREW
(H40-70FT) [L177] LIFT TRUCKS ONLY 6. WASHER
2. FAN 7. RADIATOR SHROUD
3. CAPSCREW 8. RADIATOR

Figure 13. Mazda 2.0L and 2.2L Fan Removal

9. For GM 2.4L, Yanmar 2.6L and 3.3L, see Fig- (N005), see Figure 15. For GM 4.3L engines
ure 12. For GM 4.3L engines, for lift truck and Cummins 4.5L engines, for lift truck models
models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, S6.0FT, S7.0FT, (S135FT,S155FT) (D024), see
120FT; S80, 100FTBCS; S120FTS; S120FTPRS) Figure 16. For GM 4.3L and Cummins 4.5L
(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6; engines, for lift truck models H6.0FT, H7.0FT
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005), (H135FT, H155FT) (H006), see Figure 17. Re-
see Figure 14. For Cummins 4.5L engines, move capscrews, washers, and spacer from the
for lift truck models H4.0FT5/FT6; H4.5FTS5, fan pulley.
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)

24
700 SRM 1123 Fan Assembly Replacement

1. FAN 5. SCREW
2. SPACER 6. RADIATOR SHROUD
3. WASHER 7. RADIATOR
4. CAPSCREW

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, trucks with Mazda 2.0L and 2.2L engines, re-
H40FTS) [F001] and H2.0-3.5FT (H40-70FT) move the capscrews and washers retaining the
[L177] lift trucks with Mazda 2.0L and 2.2L fan. See Figure 13.
engines, remove capscrews, washers, and spacer
from the fan pulley. 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 700 SRM 1123

1. SPACER 6. SCREW
2. FAN 7. LOCKWASHER
3. WASHER 8. CLIP NUT
4. CAPSCREW 9. RADIATOR
5. RADIATOR SHROUD

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 A damaged fan can break during use and cause

damage or serious injury.
WARNING 1. Inspect the fan for any damage.
DO NOT try to repair a damaged fan. If a fan
has a bent blade or is cracked, install a new fan. 2. If the fan is damaged, replace the entire fan.

26
700 SRM 1123 Fan Assembly Replacement

A. GM 4.3L (GAS AND LPG) B. CUMMINS 4.5L (DIESEL)

1. FAN 5. SCREW
2. FAN SPACER 6. SHROUD
3. WASHER 7. RADIATOR
4. 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. FAN 5. SCREW
2. FAN SPACER 6. SHROUD
3. WASHER 7. RADIATOR
4. 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)

1. Install the lower portion of the shroud in the re-

taining clips and lean the shroud toward the en-
FAN INSTALLATION gine.

2. For the GM 2.4L, Cummins 4.5L and QSB 3.3L,

WARNING
and Yanmar 2.6L and 3.3L, install the spacer,
The radiator fins on the radiator are very washers, and capscrews to the fan. Tighten the
sharp and can cause serious injury. Wear capscrews to 52 N•m (38 lbf). See Figure 12,
gloves while installing fan assembly. Figure 15, Figure 16, Figure 17, and Figure 18.

28
700 SRM 1123 Fan Assembly Replacement

1. SPACER 5. WASHER
2. FAN 6. CAPSCREW
3. SCREW 7. SHROUD
4. WASHER 8. 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, the fan in position of the pulley and install cap-
H40FTS) [F001] and H2.0-3.5FT (H40-70FT) screws and washers. Tighten the capscrews to
[L177] lift trucks with Mazda 2.0L and 2.2L en- 27 N•m (20 lbf ft). See Figure 13.
gines, install the spacer, washers, and capscrews
to the fan. Tighten the capscrews to 27 N•m 5. For lift trucks S4.0, 4.5, 5.5FT, S5.5FTS,
(20 lbf ft). See Figure 13. (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004), H4.0FT5/FT6; H4.5FTS5,
4. For S30FT, S35FT, S40FTS (E010) and H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
S2.0-3.5FT (S40-70FT, S55FTS) [F187] lift (N005, P005), S6.0FT, S7.0FT, (S135FT,S155FT)
trucks with Mazda 2.0L and 2.2L engines, place (D024, E024), and H6.0FT, H7.0FT (H135FT,

29
Fan Assembly Replacement 700 SRM 1123

H155FT) (H006, J006) equipped with GM 4.3L 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
(Gas/LPG) engine. Install the spacer, washers, S120FTS; S120FTPRS) (G004) and H4.0FT5/FT6;
and capscrews to the fan. Tighten the capscrews H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
to 27 N•m (20 lbf ft). See Figure 14, Figure 16, 120FT) (N005, P005), see Step 9 though Step 12.
Figure 17, and Figure 18.
9. Lower the hood and ensure that the hood latches.
6. Lean the radiator shroud back toward the radia-
tor. 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 neg-
ative terminal of the battery. 12. If equipped, swing the LPG tank bracket back
toward the truck and re-latch.
NOTE: For lift truck models S30FT, S35FT, S40FTS
(E010); H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT, 13. If equipped, turn the LPG tank valve to the ON
H40FTS) (F001); S2.0-3.5FT (S40-70FT, S55FTS) position.
(F187); H2.0-3.5FT (H40-70FT) (L177), S4.0, 4.5,

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700 SRM 1123 4/08 (3/07)(10/06)(6/06)(3/06)(5/05)(12/04) Printed in U.S.A.