HMM070001

Cooling System
H1.5-1.8TX, H2.0TXS [B475];
H2.0-3.5TX [B466]

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 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), 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 condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!

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 GENERAL
This section contains the repair and replacement instructions for the radiator, fan assembly (pusher
type), fan shroud, coolant hoses, coolant recovery bottle, and optional debris screen.

COOLING SYSTEM CHECKS

[1] 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.
Follow the manufacturer’s instructions when doing the test.

[2] 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 system may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of the cooling system.

Shut engine OFF and feel the radiator. The temperature must be even across the radiator. (The
radiator will be hotter near the top radiator hose.) Cold spots on radiator indicate restrictions.

If radiator has leaks, either replace the radiator or have it repaired by trained personnel.

[3] Radiator Hoses

WARNING
The radiator or other parts of the cooling system may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching

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the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of the cooling system.

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

[4] 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 system may be hot or under pressure and can
cause serious injury.

Run engine until it is warm. Check the operation of water pump by holding the top radiator hose.
If the pump is operating, there will be pressure surges in the hose.

Check for leaks around the timing belt cover near the base of the oil pump.

Check the weep hole where water can drain by the oil filter. If there is a drip, check the pump
shaft seal and water pump. Replacement of the pump shaft seal or water pump may be
necessary.

For repair procedures for the Mazda M4-2.0G and M4-2.2G water pump, refer to the section
Mazda Engine, M4-2.0G and M4-2.2G.

For repair procedures for the Yanmar 2.7L and 3.3L water pump, refer to the section Yanmar
Diesel Engines.

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 RADIATOR REPLACEMENT

[1] Cooling System, Clean

WARNING
Compressed air can move particles so that they cause injury to the user or to other
personnel. Make sure the path of the compressed air is away from all personnel. Wear
protective goggles or a face shield to prevent injury to the eyes.

WARNING
The radiator fins on the radiator are very sharp and can cause serious injury. Wear gloves
while checking the radiator fins.

1. Check radiator fins. Clean exterior of radiator with compressed air or water as needed.

WARNING
DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator
cap is removed, the pressure is released from the system. If the system is hot, the steam
and boiling coolant can cause burns.

WARNING
The radiator or other parts of the cooling system may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of the cooling system.

CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.

2. Drain cooling system. Fill cooling system with clean water. See the Radiator, Remove
section for more information.
3. Install radiator cap. Run engine until top radiator 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 manufacturer’s instructions when using a chemical radiator cleaner.

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

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 CAUTION
Follow the manufacturer’s 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.

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

7. Fill cooling system with a mixture of 60 percent water and 40 percent ethylene glycol boron
free antifreeze. The 60/40 mixture will protect cooling system to –20°C (–4°F). Add coolant as
necessary to keep level between the ADD and FULL marks on the reservoir.

[2] Radiator, Remove

WARNING
The radiator or other parts of the cooling system may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of the cooling system.

1. Turn OFF truck.

2. Remove the radiator cover. See the section Frame.

WARNING
Always disconnect the cable at the negative terminal first. Install a tag on the battery
terminals so that no one connects the cables on the terminals.

3. Disconnect the negative battery cable.

4. Disconnect the positive battery cable.

WARNING
DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator
cap is removed, the pressure is released from the system. If the system is hot, the steam
and boiling coolant can cause burns.

5. Let coolant cool to room temperature. Put a drain pan under radiator. Remove radiator cap.

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 CAUTION
Disposal of lubricants and fluids must meet local environmental regulations.

6. Open the drain plug or disconnect the bottom radiator hose.

7. Cap radiator hoses.
8. Disconnect hose to auxilary coolant reservoir and remove reservoir.
9. Remove battery and battery tray.

NOTE: For LPG engine, the LPG hoses and air cleaner need to be moved for clearance of radiator.

10. Remove screws from the radiator shroud and lean radiator shroud toward the fan.
11. Remove radiator from truck.

[3] Radiator, Install

1. Install radiator into truck.

2. Install the radiator shroud.
3. Uncap radiator and reservoir parts and install the auxiliary coolant reservoir.
4. Connect the auxiliary coolant reservoir hose to the radiator.
5. Uncap the top radiator hose and connect the hose to radiator.
6. Close the drain plug or install bottom radiator hose.

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

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

8. Fill cooling system with a mixture of 60 percent water and 40 percent ethylene glycol boron-
free antifreeze. The 60/40 mixture will protect cooling system to –20°C (–4°F).
9. Use the same coolant mixture and fill the auxiliary coolant reservoir between the ADD and
FULL marks. See Figure 2.
10. Install battery and battery tray.
11. Connect the positive battery cable.
12. Connect negative battery cable.
13. Install the radiator cover. See the section Frame.

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 Figure 1. Cooling System

15. BRACKET RADIATOR LH 51. RADIATOR ASSY

16. BRACKET RADIATOR RH 53. FAN SHROUND WLDMT
17. WA HEX HEAD BOLT 54. HOUSE RADIATOR LOWER
18. TANK RESERVOIR 55. HOUSE RADIATOR UPPER
19. HOSE CLAMP 56. BRACKET RESERVE TANK
57. WA HEX HEAD BOLT M8*1. 25*12 S

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

WARNING
The radiator or other parts of the cooling system may be hot or under pressure and can
cause serious injury.

14. Start and run engine until thermostat opens. (The top radiator hose will be warm.)

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

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

Figure 2. Auxiliary Coolant Reservoir

1. AUXILIARY COOLANT RESERVOIR

2. ADD MARK
3. FULL MARK

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 FAN ASSEMBLY REPLACEMENT

[1] Remove

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

WARNING
The radiator or other parts of the cooling system may be hot or under pressure and can
cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching
the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes
before attempting to check or fix any part of the cooling system.

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

NOTE: The fan that is used is a pusher type fan.

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 steering wheel forward.
5. Release the seat latch and move the seat forward.
6. Release engine cover latch on engine cover and swing engine cover up.

WARNING
To prevent a short circuit during fan belt removal, disconnect the battery negative cable at
the battery negative terminal. Install a lock or tag on the connector to prevent connection. A
tool could cause a short circuit, the high current flow from the battery can cause an injury
or parts damage.

7. Disconnect the negative battery cable from the negative battery terminal.
8. Remove screws and washers from the radiator shroud. For the Yanmar 2.7L and 3.3L, see
Figure 4. For the Mazda M4-2.0G and M4-2.2G, see Figure 5. Lean radiator shroud toward
the fan.

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 Figure 4. Yanmar 2.7L and 3.3L Fan Removal

15. BRACKET RADIATOR LH 53. FAN SHROUND WLDMT

16. BRACKET RADIATOR RH 54. HOUSE RADIATOR LOWER
17. WA HEX HEAD BOLT 55. HOUSE RADIATOR UPPER
18. TANK RESERVOIR 56. BRACKET RESERVE TANK
19. HOSE CLAMP 57. WA HEX HEAD BOLT M8*1. 25*12 S
51. RADIATOR ASSY

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 Figure 5. Mazda M4-2.0G and M4-2.2G Fan Removal

1. RADIATOR ASSY 16. BRACKET RADIATOR RH

3. FAN SHROUD WLDMT 17. WA HEX HEAD BOLT M8*1. 25*12 S
4. HOSE RADIATOR LOWER 18. TANK RESERVOIR
5. HOSE RADIATOR UPPER 19. WA45 HOSE CLAMP
15. BRACKET RADIATOR LH

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 9. For Yanmar 2.7L and 3.3L engines, remove capscrews, washers, and spacer from the fan
pulley.
10. For Mazda M4-2.0G and M4-2.2G engines, remove the capscrews and washers retaining the
fan.
11. Remove the fan.

[2] 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.

[3] Install

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 retaining clips and lean the shroud toward the
engine.
2. For the Yanmar 2.7L and 3.3L, install the spacer, washers, and capscrews to the fan. Tighten
the capscrews to 25.5 N·m (18.8 lbf·ft). See Figure 4.
3. For Mazda M4-2.0G and M4-2.2G engines, place the fan in position and intsall capscrews
and washers. Tighten the capscrews to 9.5 N·m (7 lbf·ft). See Figure 5.
4. Lean the radiator shroud back toward the radiator. Install the radiator shroud cover.
5. Install the screws and washers and tighten.
6. Reconnect the negative battery cable to the negative terminal of the battery.
7. Pull engine cover down and re-latch with engine cover latch.
8. Move the seat back.
9. Release the steering wheel tilt latch and move the steering wheel back.
10. If equipped, swing the LPG tank bracket back toward the truck and re-latch.
11. If equipped, turn the LPG tank valve to the ON position.

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