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]; H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) [A299]

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) and
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299)............................................................ 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) and
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299)............................................................ 18
Fan Assembly Replacement .............................................................................................................................. 23
Fan Removal .................................................................................................................................................. 23
Inspect ............................................................................................................................................................ 32
Fan Installation ............................................................................................................................................. 32

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];
H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299]

©2009 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
700 SRM 1123
General
This section contains the repair and replacement in-
structions for the radiator, coolant level sensor, fan
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.
Cooling System Checks
assembly (pusher type), fan shroud, coolant hoses,
coolant recovery bottle, and optional debris screen.
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 coolant that leaks past
the water pump seal can be drained before reaching
the water pump bearings. 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
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.
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.
2
700 SRM 1123
For replacement procedures for the GM 4.3L water
pump, refer to the section GM Engines, 4.3 Liter
V-6 600 SRM 1251.
For repair procedures for the Cummins 4.5L and
QSB 3.3L water pump, contact your local Hyster
dealer or see Hyster Hypass Online.
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) and H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299)
section for more information.
4. Install radiator cap. Run engine until top radia-
tor hose is hot. Stop engine and let engine cool.
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.
700 SRM 1123
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.
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.
Radiator Replacement
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.
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.
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.
3
Radiator Replacement 700 SRM 1123

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 Fig-
ure 4 for H4.5FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (P005),
S6.6FT, S7.0FT (S135FT, S155FT) (E024),
H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006), and H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299) lift trucks equipped
with a Cummins QSB 3.3L diesel engine.
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 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),
H6.0FT, H7.0FT (H135FT, H155FT) (J006) and H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299)

10
700 SRM 1123
RADIATOR, REMOVE FOR LIFT TRUCK
MODELS S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024)
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of
the cooling system.
1. Turn off truck.
WARNING
Always disconnect the cable at the negative
terminal first. Install a tag on the battery ter-
minals so that no one connects the cables on
the terminals.
2. Disconnect the negative battery cable.
3. Disconnect the positive battery cable.
4. Remove radiator cover. See Figure 5.
5. Remove debris cover.
CAUTION
The counterweight cover is extremely heavy
185 kg (408 lb). Make sure that the eyebolts
and lifting device have sufficient capacity to
lift the weight.
6. Remove two bolts from counterweight cover.
7. Install two eyebolts in the hole on each end of the
counterweight cover. Connect a suitable lifting
device to the eyebolts and carefully remove the
counterweight cover from lift truck.
8. Remove four capscrews from upper radiator
bracket. Remove bracket. See Figure 10.
9. If necessary, disconnect electrical connector from
the coolant level sensor.
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
DO NOT remove the radiator cap from the radi-
ator when the engine is hot. When the radiator
cap is removed, the pressure is released from
the system. If the system is hot, the steam and
boiling coolant can cause burns.
12. Let coolant cool to ambient temperature. Place
a drain pan with a capacity greater than the ca-
pacity of the cooling system under the radiator.
Remove radiator cap.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
13. Open drain plug, loosen clamps and disconnect
the lower radiator hoses from radiator to allow
coolant to drain into a suitable container. Install
caps on hoses. See Figure 5.
14. Lift trucks equipped with a Cummins QSB 3.3L
diesel engine: Loosen clamps and disconnect the
charge air cooler hoses from radiator. See Fig-
ure 4.
15. Loosen clamp and disconnect remote refill hose
from radiator. Install cap on hose.
NOTE: Tag the transmission lines before disconnect-
ing from oil cooler.
16. Disconnect transmission lines from oil cooler. In-
stall caps on transmission lines. Drain transmis-
sion oil from oil cooler into a suitable container.
Install caps on 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

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.

NOTE: Perform Step 4 for lift truck models H6.0FT,

H7.0FT (H135FT, H155FT) (H006, J006) and Step 5
for lift truck model H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299).

4. Open hood and loosen clamp and disconnect in-

let hose that attaches to the hood support. See
Figure 11.
1. DEBRIS COVER
2. COUNTERWEIGHT COVER 5. Open hood, loosen clamp, and disconnect dirty
3. RADIATOR COVER air hose attached to hood support. See Figure 12.
4. UPPER BRACKET
5. CAPSCREWS 6. Lift trucks equipped with GM 4.3L (Gas/LPG)
6. REMOTE FILL HOSE engine. Loosen clamp and disconnect inlet hose
7. HOSE CLAMPS
8. OIL COOLER from air filter and remove inlet hose.
9. TRANSMISSION OIL COOLER LINES
10. FITTINGS NOTE: Perform Step 7 for lift truck models H6.0FT,
11. UPPER HOSE H7.0FT (H135FT, H155FT) (H006, J006).
12. LOWER HOSE
13. REMOTE FILL 7. Lift trucks equipped with the Cummins 4.5L
14. RADIATOR CAP or QSB 3.3L diesel engine. Loosen clamp and
disconnect inlet hose from silencer. Remove
Figure 5. Radiator Removal for Lift Truck silencer.
Models S6.0FT, S7.0FT (S135FT, S155FT) (D024,
E024) NOTE: Before lifting the hood assembly from the lift
truck frame. Make sure to use a lifting device and
RADIATOR, REMOVE FOR LIFT TRUCK lifting straps as shown in Figure 6. The hood assem-
MODELS H6.0FT, H7.0FT (H135FT, H155FT) bly weighs approximately 45.6 kg (101 lb).
(H006, J006) AND H8.0FT, H8.0FT9, H9.0FT
8. Remove hood assembly. For hood assembly re-
(H170FT, H175FT36, H190FT) (A299) moval procedures. See Frame 100 SRM 1321.

WARNING 9. Disconnect and cap auxiliary coolant reservoir

hose. See Figure 11.
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can

12
700 SRM 1123
Figure 6. Hood Assembly Removal
10. Remove capscrews from the auxiliary coolant
reservoir bracket and upper bracket. Remove
auxiliary coolant reservoir assembly.
11. Remove the four capscrews from the upper radi-
ator bracket. Remove bracket.
12. If necessary, disconnect electrical connector from
the coolant level sensor.
13. Remove screws, washers and clip nuts from the
shroud and move shroud out of the way.
NOTE: Perform Step 14 for lift truck models H6.0FT,
H7.0FT (H135FT, H155FT) (H006, J006) and Step 15
for lift truck model H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299).
14. Remove capscrews, washers, fan, fan spacer, and
shroud. See Figure 11. For Fan Removal proce-
dures, see Figure 18.
Radiator Replacement
15. Remove capscrews, washer, fan, fan spacers, and
shroud. See Figure 12. For Fan Removal proce-
dures, see Figure 18.
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.
16. 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.
17. Open drain plug or loosen clamp and disconnect
lower radiator hose to allow coolant to drain. See
Figure 11 and Figure 12.
18. 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.
19. Disconnect and cap upper radiator hose.
NOTE: Tag the transmission lines before disconnect-
ing from oil cooler.
20. 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.
21. Remove radiator from lift truck frame.
22. If necessary, remove the coolant level sensor from
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. Lift trucks equipped with Cummins QSB 3.3L

engine, uncap the charge air cooler hoses and
connect the hoses to radiator. See Figure 4.

10. Uncap the top radiator hose and connect the hose
to radiator.
11. Close the drain plug or install bottom radiator
hose.
WARNING
Do not use an alcohol or methanol base an-
tifreeze. They are flammable and could cause
personal injury or damage to the lift truck.
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

CAUTION auxiliary coolant reservoir between the ADD
Additives may damage the cooling system. Be- and FULL marks. See Figure 7, for S30FT,
fore using additives, contact your local Hyster S35FT, S40FTS (E010); H1.6FT, H1.8FT, 2.0FTS
dealer. (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 SRM 1243 for S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
100FTBCS; S120FTS; S120FTPRS) (G004) and PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(H80, 90, 100, 110, 120FT) (N005, P005) lift (N005, P005). lift trucks.
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), H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006) and H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299)

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

15
Radiator Replacement
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact your local Hyster
dealer.
20. Check coolant level at the auxiliary coolant reser-
voir. Add coolant as necessary to keep level be-
tween the ADD and FULL marks on the reser-
voir.
RADIATOR, INSTALL FOR LIFT TRUCK
MODELS S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024)
1. If necessary, install coolant level sensor.
NOTE: Installing the radiator into lift truck frame
requires two people.
2. Install radiator into lift truck frame.
3. Remove caps from the oil cooler and transmission
lines and connect lines into oil cooler. See Fig-
ure 5.
4. Uncap and connect remote refill hose onto radia-
tor and tighten hose clamp. See Figure 5.
5. Close drain plug and uncap the upper and lower
radiator hoses and connect hoses onto radiator
and tighten hose clamp. See Figure 5.
6. Uncap the charge air cooler hoses and connect
the hoses to radiator. See Figure 4.
7. Install fan. See Fan Installation procedures.
8. Align shroud to radiator and install two cap-
screws, washers and clip nuts. See Figure 10.
9. If necessary, connect electrical connector onto the
coolant level sensor.
10. Install upper radiator bracket and install four
capscrews.
CAUTION
The counterweight cover is extremely heavy
185 kg (408 lb). Make sure that the eyebolts
and lifting device have sufficient capacity to
lift the weight.
11. If removed, install two eyebolts in the hole on
each end of the counterweight cover. Connect a
16
700 SRM 1123
suitable lifting device to the eyebolts and care-
fully install the counterweight cover into the lift
truck frame. See Figure 5.
12. Install two bolts to counterweights cover.
Tighten to 38 N•m (28 lbf ft).
13. Install debris cover.
14. Install radiator cover.
15. Connect positive battery cable.
16. Connect negative battery cable.
WARNING
Do not use an alcohol or methanol base an-
tifreeze. They are flammable and could cause
personal injury or damage to the lift truck.
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact you local Hyster
dealer.
17. Fill cooling system with a mixture of 50 percent
waster and 50 percent ethylene glycol boron-free
antifreeze. The 50/50 mixture will protect cool-
ing system to 37 C ( 35 F).
18. Install radiator cap.
19. Use the same coolant mixture and fill the aux-
iliary coolant reservoir between the ADD and
FULL marks. See Figure 8.
WARNING
During engine operation, be careful not to
touch the fan, pulleys, or drive belts. contact
with these parts can cause serious injury.
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and cause
serious injury.
20. Start and run the engine until thermostat opens
(The upper radiator hose will be warm).
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
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact you local Hyster
dealer.
21. Check coolant level at the auxiliary coolant reser-
voir. Add coolant as necessary to keep level be-
tween the ADD and FULL marks on the reser-
voir.
22. Shut down the engine for one minute or longer
prior to checking the transmission oil level. If the
transmission oil is low, add JDM J20C transmis-
sion oil to the transmission at the dipstick tube
at the correct level indicated on the dipstick.
RADIATOR, INSTALL FOR LIFT TRUCK
MODELS H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006) AND H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299)
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 four cap-
screws. See Figure 11 and Figure 12.
4. Install coolant reservoir bracket and coolant
reservoir assembly onto upper bracket and
tighten capscrews. See Figure 11 and Figure 12.
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 and Fig-
ure 12.
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. Lift trucks equipped with Cummins QSB 3.3L
diesel engine. Connect dirty air hose to hood
support and install and tighten clamp. See Fig-
ure 12.
16. Install hood assembly. For hood install proce-
dures. See frame Frame 100 SRM 1321.
17. 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.
18. Lift trucks equipped with Cummins 4.5L or QSB
3.3L diesel engine. Open hood assembly and con-
nect hose to hood support and tighten clamp. See
Figure 11 and Figure 12.
19. Connect positive battery cable.
20. Connect negative battery cable.
WARNING
Do not use an alcohol or methanol base an-
tifreeze. They are flammable and could cause
personal injury or damage to the lift truck.
CAUTION
Additives may damage the cooling system. Be-
fore using additives, contact you local Hyster
dealer.
21. Fill cooling system with a mixture of 50 percent
waster and 50 percent ethylene glycol boron-free
antifreeze. The 50/50 mixture will protect cool-
ing system to 37 C ( 35 F).
22. Install radiator cap.
23. Use the same coolant mixture and fill the aux-
iliary coolant reservoir between the ADD and
FULL marks. See Figure 8.
700 SRM 1123 Radiator Replacement

Figure 11. Cooling System for Lift Truck Models H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006) (Sheet 1 of 2)

19
Radiator Replacement 700 SRM 1123

Figure 11. Cooling System for Lift Truck Models H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006) (Sheet 2 of 2)

20
700 SRM 1123 Radiator Replacement

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

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.

25. 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.
26. Shut down the engine for one minute or longer
24. 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.

21
Radiator Replacement 700 SRM 1123

1. PRE-CLEANER 17. COOLANT LEVEL SENSOR

2. CLAMP 18. UPPER BRACKET
3. HOOD SUPPORT 19. RADIATOR ISOLATOR
4. HOOD ASSEMBLY 20. RADIATOR
5. DIRTY AIR HOSE 21. CAC HOSE
6. CLEAN AIR HOSE 22. CAC TUBE
7. AIR FILTER 23. INSULATED CLAMP
8. AIR CLEANER BRACKET 24. LOWER RADIATOR HOSE
9. CAPSCREW 25. UPPER RADIATOR HOSE
10. NUT 26. SHROUD AND BAFFLE
11. AUXILIARY COOLANT RESERVOIR HOSE 27. WASHER
12. RESERVOIR OUTLET 28. FAN
13. CAP 29. SPACER
14. BUSHING 30. AUXILIARY COOLANT RESERVOIR ASSEMBLY
15. COOLANT RECOVERY RESERVOIR 31. CLIP NUT
16. TUBE

Figure 12. Cooling System Cummins QSB 3.3L Diesel Engine for Lift Truck Model H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299)

22
700 SRM 1123
Fan Assembly Replacement
FAN REMOVAL
WARNING
During engine operation, be careful not to
touch the fan, pulleys, or drive belts. Contact
with these parts can cause serious injury.
WARNING
The radiator or other parts of the cooling sys-
tem may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the
radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is
still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of
the cooling system.
WARNING
The radiator fins on the radiator are very
sharp and can cause serious injury. Wear
gloves while removing fan assembly.
NOTE: The fan that is used is a pusher-type fan. Do
not replace with a puller-type fan.
1. Turn OFF lift truck.
2. If equipped, turn the LPG tank valve to the OFF
position.
3. If equipped, release the LPG tank bracket and
swing tank away from the lift truck.
4. Release the steering tilt latch and move the steer-
ing wheel forward.
5. Release the seat latch and move the seat forward.
6. Release engine cover latch on engine cover and
swing engine cover up.
Fan Assembly Replacement
WARNING
To prevent a short circuit during fan belt re-
moval, disconnect the battery negative cable at
the battery negative terminal. Install a lock or
tag on the connector to prevent connection. A
tool could cause a short circuit, the high cur-
rent flow from the battery can cause an injury
or parts damage.
7. Disconnect the negative battery cable from the
negative battery terminal.
8. Remove screws and washers from the radiator
shroud. For the GM 2.4L and Yanmar 2.6L and
3.3L, see Figure 13. For the Mazda 2.0L and
2.2L, see Figure 14. For GM 4.3L engine, for lift
truck models S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), see Figure 15. For Cummins 4.5L
engine, for lift truck models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005), see Figure 16. For GM 4.3L
and Cummins 4.5L engines, for lift truck models
S6.0FT, S7.0FT, (S135FT,S155FT) (D024), see
Figure 17. For GM 4.3L and Cummins 4.5L
engines, for lift truck models H6.0FT, H7.0FT
(H135FT, H155FT) (H006), see Figure 18. 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),
H6.0FT, H7.0FT (H135FT, H155FT) (J006),
see Figure 19. For Cummins QSB 3.3L diesel
engines, for lift truck model H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299)
see Figure 20. Lean radiator shroud toward the
fan.
23
Fan Assembly Replacement 700 SRM 1123

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

Figure 13. GM 2.4L and Yanmar 2.6L and 3.3L Fan Removal

24
700 SRM 1123 Fan Assembly Replacement

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 14. Mazda 2.0L and 2.2L Fan Removal

25
Fan Assembly Replacement 700 SRM 1123

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

Figure 15. 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)

26
700 SRM 1123 Fan Assembly Replacement

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

Figure 16. 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)

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 S6.0FT,
S7.0FT, (S135FT,S155FT) (D024, E024)

28
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 18. Fan Removal for Engines GM 4.3L and Cummins 4.5L for Lift Truck Models H6.0FT,
H7.0FT (H135FT, H155FT) (H006, J006)

29
Fan Assembly Replacement 700 SRM 1123

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

Figure 19. 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)

30
700 SRM 1123
1. RADIATOR SHROUD
2. SCREW
3. WASHER
4. SPACER
Figure 20. Fan Removal for Cummins QSB 3.3L for Lift Truck Model H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT) (A299)
9. Remove capscrews, washers, and spacer from
the fan pulley. For GM 2.4L, Yanmar 2.6L and
3.3L, see Figure 13. For GM 4.3L engines, for
lift truck models S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004) and H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), see Figure 15. 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) (N005), see Figure 16. For GM
4.3L engines and Cummins 4.5L engines, for lift
truck models S6.0FT, S7.0FT, (S135FT,S155FT)
(D024), see Figure 17. For GM 4.3L and Cum-
mins 4.5L engines, for lift truck models H6.0FT,
Fan Assembly Replacement
5. CAPSCREW
6. FAN
7. RADIATOR
H7.0FT (H135FT, H155FT) (H006, J006), see
Figure 18.
10. For H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299) lift trucks with
Cummins QSB 3.3L diesel engines, remove cap-
screws, washers, and spacers from fan. See
Figure 20.
11. 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 14.
31
Fan Assembly Replacement
12. For S30FT, S35FT, S40FTS (E010) and
S2.0-3.5FT (S40-70FT, S55FTS) [F187] lift
trucks with Mazda 2.0L and 2.2L engines, re-
move the capscrews and washers retaining the
fan. See Figure 14.
13. Remove the fan.
INSPECT
WARNING
DO NOT try to repair a damaged fan. If a fan
has a bent blade or is cracked, install a new fan.
A damaged fan can break during use and cause
damage or serious injury.
1. Inspect the fan for any damage.
2. If the fan is damaged, replace the entire fan.
FAN INSTALLATION
WARNING
The radiator fins on the radiator are very
sharp and can cause serious injury. Wear
gloves while installing fan assembly.
1. Install the lower portion of the shroud in the re-
taining clips and lean the shroud toward the en-
gine.
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 13,
Figure 16, Figure 17, Figure 18, and Figure 19.
3. For H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299) lift trucks with
Cummins QSB 3.3L diesel engines, install spac-
ers, washers, and capscrews onto fan. See
Figure 20.
4. 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 en-
gines, install the spacer, washers, and capscrews
to the fan. Tighten the capscrews to 27 N•m
(20 lbf ft). See Figure 14.
32
700 SRM 1123
5. 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 cap-
screws and washers. Tighten the capscrews to
27 N•m (20 lbf ft). See Figure 14.
6. 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,
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 15, Figure 17,
Figure 18, and Figure 19.
7. Lean the radiator shroud back toward the radia-
tor. Install the radiator shroud cover.
8. Install the screws and washers and tighten.
9. Reconnect the negative battery cable to the neg-
ative 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,
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 10 though Step 13.
10. Lower the hood and ensure that the hood latches.
11. Move the seat back.
12. Release the steering wheel tilt latch and move
the steering wheel back.
13. If equipped, swing the LPG tank bracket back
toward the truck and re-latch.
14. If equipped, turn the LPG tank valve to the ON
position.
 TECHNICAL PUBLICATIONS

700 SRM 1123 4/09 (4/08)(3/07)(10/06)(6/06)(3/06)(5/05)(12/04) Printed in United Kingdom