sstema de refrigracion por aire.pdf

7/28/2019 SSTEMA DE REFRIGRACION POR AIRE.pdf

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COOLING SYSTEMS30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT, H2.0FTS(H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT (S40-70FT,

S55FTS ) [F187]; H2.0-3.5FT (H40-70FT) [L177]; S4.0,

5.0, 5.50FT ([S80, 100, 120FT]; S80, 100, 120FTBCS;

S120FTPRS) [G004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005]

PART NO. 1580505 700 SRM 1123


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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 Mainte-

nance 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:

WARNINGIndicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!


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Cooling System Table of Contents

TABLE OF CONTENTS

General ...............................................................................................................................................................

Cooling System Checks......................................................................................................................................

Exhaust Leaks Into Cooling System ............................................................................................................

Water Flow Restrictions in Radiator ............................................................................................................

Radiator Hoses...............................................................................................................................................Water Pump ...................................................................................................................................................

Radiator Replacement ....................................................................................................................................... 2

Cooling System, Clean................................................................................................................................... 2

Radiator, Remove........................................................................................................................................... 3

Radiator, Install............................................................................................................................................. 8

Fan Assembly Replacement .............................................................................................................................. 10

Remove ........................................................................................................................................................... 10

Inspect ............................................................................................................................................................ 13

Install ............................................................................................................................................................. 13

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];

S2.0-3.5FT (S40-70FT, S55FTS ) [F187];

H2.0-3.5FT (H40-70FT) [L177];

S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100, 120FTBCS;

S120FTPRS) [G004];

H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,

100, 110, 120FT) [N005]

2006 HYSTER COMPANY


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"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS


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700 SRM 1123 Cooling System Checks

General

This section contains the repair and replacement in-

structions for the radiator, coolant level sensor, fan

assembly (pusher type), fan shroud, coolant hoses

coolant recovery bottle, and optional debris screen.

Cooling System ChecksEXHAUST 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 forthis purpose. Fol-

low the manufacturers instructions when doing the

test.

WATER FLOW RESTRICTIONS IN

RADIATOR

WARNING




To check for water flow restrictions in the radiator,

run engine until it is warm.

WARNINGThe radiator or other parts of the cooling sys-

tem may be hot or under pressure and can

cause serious injury. Wait 30 minutes for the

radiator to cool. Do a touch test by touching

the radiator with your hand. If the radiator is

still hot to the touch, wait another 30 minutes

before attempting to check or fix any part of

the cooling system.

Shut engine OFF and feel the radiator. The temper-

ature must be even across the radiator. (The radiator

will be hotter near the top radiator hose.) Cold spots

on radiator indicate restrictions.

If radiator has leaks, either replace the radiator or

have it repaired by trained personnel.

RADIATOR HOSES

WARNING

The radiator or other parts of the cooling sys


cause serious injury. Wait 30 minutes for th


the radiator with your hand. If the radiator i

still hot to the touch, wait another 30 minute

before attempting to check or fix any part o

the cooling system.

Inspect all radiator hoses. If they feel spongy or hav

visible cracks, replace hoses.

WATER PUMP

WARNING

During engine operation, be careful not t

touch the fan, pulleys, or drive belts. Contac


WARNING

The radiator or other parts of the cooling sys


cause serious injury.

Run engine until it is warm. Check the operation o

water pump by holding the top radiator hose. If th

pump is operating, there will be pressure surges in

the hose.

Check for leaks around the timing belt cover near th

base of the oil pump.

Check the weep hole where water can drain by the oi

filter. If there is a drip, check the pump shaft seal andwater pump. Replacement of the pump shaft seal o

water pump may be necessary.

For repair procedures for the GM 2.4L water pump

refer to the section GM Engine Repair, GM 2.4

Liter Engine 600 SRM 1121.


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Radiator Replacement 700 SRM 1123

For repair procedures for the Mazda 2.0L and 2.2L

water pump, refer to the section Mazda Engine,

2.0L and 2.2L 600 SRM 1122.

For replacement procedures for the Yanmar 2.6L

and 3.3L water pump, refer to the section Yanmar

Diesel Engines, 2.6L and 3.3L 600 SRM 1205.

For replacement procedures for the GM 4.3L water

pump, refer to the section GM Engines, 4.3 Liter

V-6 600 SRM 1251.

For repair procedures for the Cummins 4.5L water

pump, contact your local Hyster dealer or see Hys-

ter Hypass Online.

Radiator Replacement

COOLING SYSTEM, CLEAN

WARNING

Compressed air can move particles so that they

cause injury to the user or to other personnel.

Make sure the path of the compressed air is

away from all personnel. Wear protective 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-





still hot to the touch, wait another 30 minutesbefore attempting to check or fix any part of

the cooling system.

CAUTION

Disposal of lubricants and fluids must meet lo-

cal environmental regulations.

2. Drain cooling system. Fill cooling system with

clean water. See the Radiator, Remove section

for more information.

3. Install radiator cap. Run engine until top radia-

tor hose is hot. Stop engine and let engine cool.

4. Drain water from radiator. If water is dirty, fill

system with water and repeat procedure until

water is clean.

CAUTION

Follow the manufacturers instructions when

using a chemical radiator cleaner.

5. If water does not clean system, use a chemical

radiator cleaner.

CAUTION

Follow the manufacturers instructions when

using special equipment to reverse clean the

radiator.

6. If radiator or cooling system is very dirty or

has a restriction, use reverse cleaning method.

This method uses water pressure to force water

through radiator in opposite direction of normal

flow.

CAUTIONAdditives may damage the cooling system. Be-

fore using additives, contact your local Hyster

dealer.

7. Fill cooling system with a mixture of 50 percent

water and 50 percent ethylene glycol boron-free

antifreeze. The 50/50 mixture will protect 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.

2


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700 SRM 1123 Radiator Replacemen

RADIATOR, REMOVE

WARNING








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 Frame100 SRM 1243 for S4.0, 5.0, 5.50FT([S80, 100,

120FT]; S80, 100, 120FTBCS; S120FTPRS)

(G004) and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

lift trucks.

WARNINGAlways 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 room temperature. Puta drain

pan 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. Cap radiator hoses.

8. Disconnect hose to auxiliary coolant reservoi

and remove reservoir.

9. Remove battery and battery tray.

10. Disconnect electrical connector to the coolan

level sensor.

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

11. Remove screws from the radiator shroud an

move shroud out of the way.

12. Remove fan, fan spacer, and pulley.

13. Remove upper radiator bracket. See Figure

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, Fig

ure 2 for S4.0, 5.0, 5.50FT([S80, 100, 120FTS80, 100, 120FTBCS; S120FTPRS) (G004) and

Figure 3 for H4.0FT5/FT6; H4.5FTS5, H4.5FT6

H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005

lift trucks.

14. Remove radiator from truck.

15. If necessary, remove the coolant level sensor.

3


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Figure 1. Cooling System, S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, 2.0FTS (H30FT, H35FT,H40FTS) (F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177)

4


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Legend for Figure 1

A. RADIATOR WITH EXTERNAL COOLERB. RADIATOR WITH INTERNAL COOLER, MODINE SHOWN

1. RADIATOR2. CAP3. UPPER HOSE4. LOWER HOSE5. CLAMP6. SHROUD7. CLIP8. WASHER9. SCREW10. CLIP11. UPPER BRACKET12. CAPSCREW, S2.0-3.5FT (S40-70FT, S55FTS)

[F187]13. INSERT14. LOWER BRACKET, S2.0-3.5FT (S40-70FT,

S55FTS) [F187]

15. NUT-CLIP, S2.0-3.5FT (S40-70FT, S55FTS) [F18716. ISOLATOR17. COOLANT LEVEL SENSOR18. RESERVOIR19. TUBE20. OUTLET21. HOSE22. RESERVOIR OUTLET23. CAP24. BUSHING25. SCREEN ASSEMBLY (OPTIONAL)26. HEAT SHIELD27. RESERVOIR BRACKET28. HEAT SHIELD, H2.0-3.5FT (H40-70FT) [L177]

5


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Figure 2. Cooling System, S4.0, 5.0, 5.50FT([S80, 100, 120FT]; S80, 100, 120FTBCS; S120FTPRS)(G004)

6


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Legend for Figure 2

A. RADIATOR WITH EXTERNAL COOLERB. RADIATOR WITH INTERNAL COOLER

1. RADIATOR2. SHROUD3. WASHER4. SCREW5. CLIP NUT6. CLIP7. UPPER HOSE8. LOWER HOSE

9. CLAMP10. UPPER BRACKET11. INSERT12. CAPSCREW13. ISOLATOR14. RESERVOIR15. RESERVOIR

BRACKET

16. OUTLET ASSEMBLY17. OUTLET18. CAP19. BUSHING20. HOSE21. TUBE22. STRAP23. NUT

24. SCREEN25. BAFFLE (RH AND LH26. RADIATOR CAP27. COOLANT LEVEL

SENSOR

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

(N005)

7


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Legend for Figure 3

NOTE: RADIATOR WITH INTERNAL COOLER SHOWN

1. CAPSCREW2. INSERT3. RADIATOR BRACKET

4. RADIATOR CAP5. ISOLATOR6. CLIP NUT7. COOLANT LEVEL SENSOR8. RADIATOR

9. CLIP10. RADIATOR SHROUD11. CLAMP

12. HOSE13. SCREW14. WASHER15. SCREEN16. STRAP

17. RESERVOIR BRACKET18. RESERVOIR19. OUTLET ASSEMBLY

20. OUTLET21. CAP22. BUSHING23. TUBE

RADIATOR, INSTALL

1. If removed, install the coolant level sensor.

2. Install radiator into truck.

3. Install upper radiator bracket.

4. Install fan, fan spacer, and pulley.

5. Install the radiator shroud.

6. Connect the electrical connector to the coolant

level sensor.

NOTE: For Mazda LPG engine, the LPG converter

bracket and screws must be installed to hold the 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 top radiator hose and connect the hose

to radiator.

10. Close the drain plug or install bottom radiator

hose.

WARNING

Do not use an alcohol or methanol base an-

tifreeze. They are flammable and cause per-

sonal injury or damage to the lift truck.

CAUTION

Additives may damage the cooling system. Be-

fore using additives, contact your local Hyster

dealer.

11. Fill cooling system with a mixture of 50 percent

water and 50 percent ethylene glycol boron-free

antifreeze. The 50/50 mixture will protect cool-

ing system to 37 C ( 35 F).

12. Use the same coolant mixture and fill the

auxiliary coolant reservoir between the ADD

and FULL marks. See Figure 4 for S30FT,


(H30FT, H35FT, H40FTS) (F001); S2.0-3.5FT

(S40-70FT, S55FTS) (F187); H2.0-3.5FT

(H40-70FT) (L177) lift trucks, and Figure 5

for S4.0, 5.0, 5.50FT([S80, 100, 120FT]; S80,

100, 120FTBCS; S120FTPRS) (G004) andH4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT

(H80, 90, 100, 110, 120FT) (N005) lift trucks.

13. Install battery and battery tray.

14. Connect the positive battery cable.

15. Connect negative battery cable.

16. Install the hood and seat combination. See

the section Frame 100 SRM 1120 for S30FT,


(H30FT, H35FT, H40FTS) (F001); S2.0-3.5FT

(S40-70FT, S55FTS) (F187); H2.0-3.5FT

(H40-70FT) (L177) lift trucks, and Frame

100 SRM 1243 for S4.0, 5.0, 5.50FT([S80, 100,

120FT]; S80, 100, 120FTBCS; S120FTPRS)

(G004) andH4.0FT5/FT6; H4.5FTS5, H4.5FT6;

H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)

lift trucks.

WARNINGDuring engine operation, be careful not to



WARNINGThe radiator or other parts of the cooling sys-


cause serious injury.

17. Start and run engine until thermostat opens.

(The top radiator hose will be warm.)

8


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1. AUXILIARY COOLANT RESERVOIR2. ADD MARK3. FULL MARK

Figure 4. Auxiliary Coolant Reservoir, S30FT,S35FT, S40FTS (E010); H1.6FT, H1.8FT, 2.0FTS

(H30FT, H35FT, H40FTS) (F001); S2.0-3.5FT(S40-70FT, S55FTS) (F187); H2.0-3.5FT

(H40-70FT) (L177)

18. On lift trucks equipped with a GM 2.4L engine

bleed air from the cooling system by opening th

bleed screw located on the left side behind the

alternator. When the air has been bled from th

system close the bleed screw. See Figure 6.

CAUTIONAdditives may damage the cooling system. Be

fore using additives, contact your local Hyste

dealer.

19. 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.

1. AUXILIARY COOLANT RESERVOIR2. FULL "HOT" MARK3. FULL "COLD" MARK4. ADD "COLD" MARK

Figure 5. GM 4.3L Auxiliary Coolant ReservoirS4.0, 5.0, 5.50FT([S80, 100, 120FT]; S80,

100, 120FTBCS; S120FTPRS) (G004) and

H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT

(H80, 90, 100, 110, 120FT) (N005)

9


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Fan Assembly Replacement 700 SRM 1123

Figure 6. Bleed Screw, GM 2.4L Engine

Legend for Figure 6

1. MANIFOLD2. COOLANT HOSES3. BLEED SCREW4. RADIATOR HOSE

Fan Assembly Replacement

REMOVE

WARNING




WARNING








the cooling system.

WARNINGThe 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 andmove 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.

WARNINGTo prevent a short circuit during fan belt re-

moval, disconnect the battery negative cable at

the battery negative terminal. Install a lock ortag 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.

10


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700 SRM 1123 Fan Assembly Replacemen

8. Remove screws and washers from the radiator

shroud. For the GM 2.4L and Yanmar 2.6L and

3.3L, see Figure 7. For the Mazda 2.0L and 2.2L,

see Figure 8. For the GM 4.3L, see Figure 9 and

for the Cummins 4.5L, see Figure 10. Lean radi-

ator shroud toward the fan.

9. For GM 2.4L, Yanmar 2.6L and 3.3L, see Fig

ure 7, for GM 4.3L engines, see Figure 9 an

for Cummins 4.5L, see Figure 10. Remove cap

screws, washers, and spacer from the fan pulley

1. FAN

2. SPACER3. WASHER4. CAPSCREW

5. SCREW

6. RADIATOR SHROUD7. RADIATOR

Figure 7. GM 2.4L and Yanmar 2.6L and 3.3L Fan Removal

1


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1. SPACER, H1.6FT, H1.8FT, H2.0FTS (H30FT,H35FT, H40FTS) [F001] AND H2.0-3.5FT(H40-70FT) [L177] LIFT TRUCKS ONLY

2. FAN3. CAPSCREW

4. WASHER5. SCREW6. WASHER7. RADIATOR SHROUD8. RADIATOR

Figure 8. Mazda 2.0L and 2.2L Fan Removal

10. For H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,H40FTS) [F001] and H2.0-3.5FT (H40-70FT)

[L177] lift trucks with Mazda 2.0L and 2.2L

engines, remove capscrews, washers, and spacer

from the fan pulley. See Figure 8.

11. For S30FT, S35FT, S40FTS (E010) and

S2.0-3.5FT (S40-70FT, S55FTS) [F187] lift

trucks with Mazda 2.0L and 2.2L engines, re-move the capscrews and washers retaining the

fan. See Figure 8.

12. Remove the fan.

12


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1. FAN2. SPACER3. WASHER4. CAPSCREW

5. SCREW6. RADIATOR SHROUD7. RADIATOR

Figure 9. GM 4.3L Fan Removal

INSPECT

WARNING

DO NOT try to repair a damaged fan. If a fanh a s a bent blade or is cracked, install a new fan.

A damaged fan can break during use and cause

damage or serious injury.

1. Inspect the fan for any damage.

2. If the fan is damaged, replace the entire fan.

INSTALL

WARNING

The radiator fins on the radiator are verysharp and can cause serious injury. Wea

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.

13


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1. SPACER2. FAN3. WASHER4. CAPSCREW5. RADIATOR SHROUD

6. SCREW7. LOCKWASHER8. CLIP NUT9. RADIATOR

Figure 10. Cummins 4.5L Fan Removal

2. For the GM 2.4L, Cummins 4.5L and Yanmar

2.6L and 3.3L, install the spacer, washers, and

capscrews to the fan. Tighten the capscrews to

52 Nm (38 lbf). See Figure 7 and Figure 10.

3. For H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,

H40FTS) [F001] and H2.0-3.5FT (H40-70FT)

[L177] lift trucks with Mazda 2.0L and 2.2L en-

gines, install the spacer, washers, and capscrews

to the fan. Tighten the capscrews to 27 Nm

(20 lbf ft). See Figure 8.

4. For S30FT, S35FT, S40FTS (E010) and

S2.0-3.5FT (S40-70FT, S55FTS) [F187] lift

trucks with Mazda 2.0L and 2.2L engines, place

the fan in position of the pulley and intsall cap-

screws and washers. Tighten the capscrews to

27 Nm (20 lbf ft). See Figure 8.

5. For S4.0, 5.0, 5.50FT([S80, 100, 120FT]; S80,

100, 120FTBCS; S120FTPRS) (G004) install

the spacer, washers, and capscrews to the fan.

14


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Tighten the capscrews to 55 Nm (40.5 lbf). See

Figure 9.

6. Lean the radiator shroud back toward the radia-

tor. Install the radiator shroud cover.

7. Install the screws and washers and tighten.

8. Reconnect the negative battery cable to the neg-

ative terminal of the battery.

9. Pull engine cover down and re-latch with engine

cover latch.

10. Move the seat back.

11. Release the steering wheel tilt latch and mov

the steering wheel back.

12. If equipped, swing the LPG tank bracket back

toward the truck and re-latch.

13. If equipped, turn the LPG tank valve to the ON

position.

15


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NOTES

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