COOLING SYSTEM

RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L

CH, RS46-41S CH, RS46-41LS CH, RS45-24IH,
RS45-28IH, RS46-33IH, RS46-38L IH, RS46-38S IH,
RS46-38LS IH (RS45-27, RS45-31, RS46-36,
RS46-41L, RS46-41S, RS46-41LS) [C222];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L
CH, RS46-41S CH, RS46-41LS CH, RS45-24IH,
RS45-28IH, RS46-33IH, RS46-38L IH, RS46-38S IH,
RS46-38LS IH (RS45-27 CH, RS45-31 CH,
RS46-36 CH, RS46-41L CH, RS46-41S CH,
RS46-41LS CH) [D222];
H36XMS-12, H40XM-12, H44XM-12, H48XM-12
(H800HD, H1050HD) [B917];
H36XMS-12, H40XM-12, H40XMS-12, H44XM-12,
H44XMS-12, H48XM-12, H48XMS-12
(H900HD, H970HD, H1050HD, H800HDS,
H900HDS, H970HDS, H1050HDS) [C917];
H40XM-16CH, H44XM-16CH, H48-16CH, H50-16CH,
H52XM-16CH
(H1050HD, H1150HD) [G117];
H40.00-52.00XM-16CH
(H1050HD-16CH, H1150HD-16CH) [H117]

PART NO. 4038565 0700 SRM 1530

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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 ex-
ceed 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 flamma-
ble. 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.
 Table of Contents

TABLE OF CONTENTS

General .....................................................................................................................................................................1
Description ...............................................................................................................................................................1
Air Flow ............................................................................................................................................................... 1
Fan Drive System ............................................................................................................................................... 2
Pump Supply ...................................................................................................................................................2
Fan Drive ........................................................................................................................................................ 2
Hydraulic Oil Filtration ................................................................................................................................. 3
Thermostatic Valve .........................................................................................................................................4
Brake Cooling System .................................................................................................................................... 4
Fan Drive Control System ..................................................................................................................................4
Temperature Sensor Locations ...................................................................................................................... 5
Cooling Performance ...................................................................................................................................... 5
Cooling Cores .......................................................................................................................................................6
Engine Cooling System .......................................................................................................................................7
Water Pump .................................................................................................................................................... 7
Coolant ............................................................................................................................................................ 7
Ethylene Glycol .......................................................................................................................................... 7
Water ...........................................................................................................................................................7
Additives ..................................................................................................................................................... 8
Coolant Quality Requirements .................................................................................................................. 8
Cab Heater ...................................................................................................................................................... 8
Expansion Tank ..............................................................................................................................................8
Thermostat ......................................................................................................................................................9
Charge Air Cooling System ................................................................................................................................ 9
Hydraulic Oil Cooling System .......................................................................................................................... 10
Transmission Oil Cooling System .................................................................................................................... 10
DEF System .......................................................................................................................................................10
Engine Cooling System Checks ............................................................................................................................ 10
Basic Checks ......................................................................................................................................................10
Coolant Quality Checks .................................................................................................................................... 10
Expansion Tank Inspection .........................................................................................................................10
Coolant Visual Test ...................................................................................................................................... 11
Acid Level (pH) Test ..................................................................................................................................... 11
Freeze Protection Test ..................................................................................................................................11
Coolant Flow Checks .........................................................................................................................................11
Thermostat ....................................................................................................................................................11
Water Pump ................................................................................................................................................. 12
Radiator Core ................................................................................................................................................12
Leak Test ........................................................................................................................................................... 12
External Leak Test ........................................................................................................................................... 12
Internal Leak Test ............................................................................................................................................ 13
Coolant Leak Into the Engine Oil Sump ..................................................................................................... 13
Combustion Leak ..........................................................................................................................................13
Fan Drive System Checks ................................................................................................................................ 14
Brake Cooling System Checks ..........................................................................................................................15
Cooling System Repairs ........................................................................................................................................ 16
Drain the Engine Cooling System ....................................................................................................................16
Refill the Engine Cooling System .................................................................................................................... 16
Flushing the Engine Cooling System ...............................................................................................................17
Clean the Engine Cooling System ....................................................................................................................17

©2014 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Fan and Fan Motor ........................................................................................................................................... 18

Remove .......................................................................................................................................................... 18
Replace .......................................................................................................................................................... 18
Cooling Assembly .............................................................................................................................................. 18
Remove .......................................................................................................................................................... 18
Disassemble .................................................................................................................................................. 18
Assemble ....................................................................................................................................................... 18
Replace .......................................................................................................................................................... 19
Cooler Core Replacement for Transmission and Hydraulic System .............................................................. 19
Remove .......................................................................................................................................................... 19
Assemble ....................................................................................................................................................... 19
Troubleshooting .....................................................................................................................................................20

This section is for the following models:

RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS

CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS
IH (RS45-27, RS45-31, RS46-36, RS46-41L, RS46-41S, RS46-41LS) [C222];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S CH, RS46-41LS
CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-38L IH, RS46-38S IH, RS46-38LS
IH (RS45-27 CH, RS45-31 CH, RS46-36 CH, RS46-41L CH, RS46-41S CH,
RS46-41LS CH) [D222];
H36XMS-12, H40XM-12, H44XM-12, H48XM-12 (H800HD, H1050HD) [B917];
H36XMS-12, H40XM-12, H40XMS-12, H44XM-12, H44XMS-12, H48XM-12,
H48XMS-12 (H900HD, H970HD, H1050HD, H800HDS, H900HDS, H970HDS,
H1050HDS) [C917];
H40XM-16CH, H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH (H1050HD,
H1150HD) [G117];
H40.00-52.00XM-16CH (H1050HD-16CH, H1150HD-16CH) [H117]

ii
0700 SRM 1530 General

General
This SRM describes the operation and the operation and diagnostics 1300SRM1220. The
replacement procedures for the components of the cab heater and air conditioning system are
cooling system for engine coolant, engine intake air, described in Cab Heater 0100SRM1459.
and hydraulic oil. The cooling system for the
transmission is described in Transmission

Description
Heat is generated at various components during op- AIR FLOW
eration of the truck. Most of these components can
sufficiently dissipate the generated heat to the sur- A puller fan draws cooling air into the cooler cores
rounding air. A cooling system is required for the from under the counterweight through a screen.
engine, hydraulic system and the transmission, be- The screen prevents that big particles coming from
cause of the big and fluctuating volume of heat to the steer tires would damage the cooler cores. The
be dissipated and the need for a controlled operat- screen also prevents that large sheets of paper or
ing temperature. plastic would obstruct air flow.

The heat is dissipated in cooler cores by an airflow Once air has flown past the cores, the fan blows
that is induced by a hydraulically-driven fan. Fan most of the air through a grating above the engine
speed is regulated by the hydraulic control system compartment. Some of the air flow passes over a
according the input from different temperature sen- separator plate to expel hot air from the engine
sors. compartment.

1. COOLING SYSTEM 7. COOLING FAN

2. EXPANSION TANK 8. CHARGE AIR COOLER
3. RADIATOR CAP 9. RADIATOR
4. UPPER RADIATOR HOSE 10. HYDRAULIC OIL COOLER
5. LOWER RADIATOR HOSE 11. TRANSMISSION OIL COOLER
6. HYDRAULIC FAN MOTOR

Figure 1. Cooling Sections

1
Description 0700 SRM 1530

FAN DRIVE SYSTEM Minimum pump supply has the purpose to prevent
the wet brakes from overheating during warming
A separate variable displacement pump, on the hy- up. Maximum pump supply has the purpose to re-
draulic schematic indicated by Pump 3’, provides act to extreme situations and also serves as a fail-
the oil flow for the fan drive, which is connected in safe mode.
series with the systems for oil filtration, oil cooling
and brake cooling. Pump supply volume therefore An overview of the different speeds and pressures
relates directly to fan speed, and the volume for oil is shown under Fan Drive System Checks.
filtration, oil cooling and brake cooling. Below is a
short description for each of these subsystems. Fan Drive

Pump Supply The fan is mounted on a hydraulic motor that ro-

tates proportional to pump supply. A frame bolted
Generally, variable displacement pumps deliver a to the cooler assembly keeps the fan in the correct
volume depending on the sensed pressure in the hy- position to the shroud. A relief valve inside the hy-
draulic circuit. The delivered volume depends on draulic motor prevents cavitation when fan motor
pump displacement (volume per pump revolution) speed requires a bigger oil supply compared with
and on pump speed, which varies with engine actual pump supply. This situation can occur when
speed. When reaching a certain pump pressure, the the fan is at speed and engine speed drops quickly.
load sensing system reduces pump displacement. See Figure 3.
At that point, engine speed and pump displacement
match oil demand at that particular pressure.

In this cooling system, maximum pump pressure is

regulated by an electric solenoid, which is installed
on the pressure regulator of the pump. See Fig-
ure 2. The electric solenoid receives a PWM signal
from the hydraulic controller, which reacts to spe-
cific inputs. See Fan Drive Control System.

At start up, pump displacement begins at its maxi-

mum and gradually reduces, until the pressure has
been reached that matches the PWM signal. Nor-
mally the pressure is varied between
3.4 MPa (490 psi) and 24.5 MPa (3,550 psi). Under
circumstances pump pressure can reach
26.5 MPa (3,800 psi).

Actual fan speed increases with increasing pump

supply (engine speed) until air flow resistance has
reached the pump pressure required for that fan
speed. There are two distinct fan speeds that can be
1. SOLENOID
verified: 2. CONNECTOR
• Minimum fan speed of 700 rpm at 3. PRESSURE REGULATOR
3.4 MPa (490 psi), requiring engine speeds 4. PUMP 3
5. PUMP 2
from idle and higher.
• Maximum fan speed of 2100 rpm at Figure 2. Solenoid on Pump 3
26.5 MPa (3,800 psi), requiring engine
speeds of 1500 rpm and higher.

2
0700 SRM 1530 Description

Hydraulic Oil Filtration

A five micron hydraulic filter element provides fil-

tration of pump supply volume. The filter is protec-
ted by a 0.34 MPa (49.3 psi) bypass valve. When
pressure drop over the filter exceeds
0.5 MPa (72.5 psi), a pressure sender provides a
signal to the hydraulic controller to indicate a clog-
ged filter. Provided oil temperature exceeds
40°C (104°F), the controller will activate a warning
light on the instrument panel. At temperatures be-
low 40°C (104°F) the warning light is not activated
to exclude a false alarm caused by the higher oil
viscosity. See Figure 4.

1. FILTER ADAPTER
2. HOSE FROM COOLER
3. HOSE TO COOLER
4. HOSE FROM FAN DRIVER
1. SERVICE BRAKE 5. FILTER ELEMENT
2. BRAKE MANIFOLD 6. PRESSURE SENDER
3. HYDRAULIC COOLER 7. HOSE TO BRAKE MANIFOLD
4. THERMOSTATIC VALVE
5. BRAKE FILTER ADAPTER Figure 4. Hydraulic Filter
6. PUMP
7. ENGINE
8. COOLING FAN DRIVE
9. TEMPERATURE SENSOR

Figure 3. Fan Drive Schematic

3
Description 0700 SRM 1530

Thermostatic Valve

The hydraulic filter adapter includes a thermo-

static valve which starts opening at 65°C (149°F).
When completely opened at 80°C (176°F), all oil is
directed to the hydraulic cooler. Oil from the cooler
is first returned to the filter adapter and from there
connected with the brake cooling system at the wet
brake manifold. Except for the filter element, none
of the components are serviced separately. Replace
the entire filter assembly if one of its components
fails.

Brake Cooling System

The brake manifold connects supply and return for

the service brake system and the brake cooling sys-
tem with the LH and RH wheel brake assemblies.
The manifold includes a 0.14 MPa (20.3 psi) relief
valve that protects the seals in the brake housing.

On C917, H117 and D222 series, the Brake Mani- 1. BRAKE MANIFOLD
fold includes a temperature sensor, which replaces 2. PBL – TO WHEEL BRAKE LEFT
the two temperature sensors at the service brakes 3. XBL – TO SERVICE BRAKE LEFT
on previous series B917, G117 and C222. The brake 4. TBL – FROM WHEEL BRAKE LEFT
5. TEMPERATURE SENSOR
temperature sensors have a warning function only 6. TBR – FROM WHEEL BRAKE RIGHT
and do not provide an input signal to the hydraulic 7. XBR – TO SERVICE BRAKE RIGHT
controller. 8. PBR – TO WHEEL BRAKE RIGHT
9. XX – SERVICE BRAKE PRESSURE
Return oil from the brake manifold returns to tank 10. R – RELIEF TANK RETURN
11. P – FROM HYDRAULIC FILTER HOUSING
directly. Exception is the G117 series, which has a 12. T – TO TANK
20-micron brake return filter. In case this filter is
clogged, a 35 kPa (5 psi) bypass valve in the filter Figure 5. Brake Manifold
head opens. See Figure 5.

FAN DRIVE CONTROL SYSTEM Temperatures below the minimum temperature re-
sult in an output signal that corresponds with 10%
Four temperature sensors provide input signals for cooling performance. Temperatures between mini-
the fan drive control system. These sensors meas- mum and maximum temperature result in output
ure the temperature of engine coolant, charge air, signals between 10% and 90% cooling performance.
transmission and hydraulic tank oil. Temperature If any of the maximum temperatures is exceeded,
sensor for hydraulic tank oil connects directly with the output signal for the fan drive is set at 100%
the hydraulic controller. The three other tempera- cooling performance.
ture sensors are connected with the controllers for
the transmission or the engine, which transfer When the sensors for engine and transmission tem-
these inputs as a CAN bus signal to the hydraulic perature reach the limit temperature, the engine
controller. controller will de-rate and eventually stop the en-
gine. The transmission will shift to neutral. When
Each temperature sensor influences hydraulic con- hydraulic oil temperature reaches the limit temper-
troller output within specific temperature ranges. ature, the optional high temperature protection
See Table 1. Hydraulic controller output is based on limits truck speed to 10 km/h (6.2 mph) to reduce
the input signal requiring highest cooling perform- the generated heat at the brakes.
ance.

4
0700 SRM 1530 Description

A high PWM output signal is required to obtain a opening. The transmission temperature sensor is
low regulated pump pressure. For highest pump located close to port 31. See Transmission Opera-
pressures, no PWM signal is required. This pro- tion and Diagnostics 1300SRM1566. The hy-
vides the opportunity to simply remove the connec- draulic oil temperature sensor is located in the hy-
tor from the solenoid to create a failsafe mode. See draulic tank.
Table 2.
The brake temperature sensors have a warning
For information on settings and electrical connec- function only and do not provide an input signal to
tions, see Hydraulic Control System the hydraulic controller. On B917, G117 and C222
1900SRM1534. series, the brake temperature sensors are installed
in each brake housing. On C917, H117 and D222
Temperature Sensor Locations series, the brake temperature sensor is installed in
the brake manifold.
The engine coolant sensor is located in the cylinder
head, above the water pump. The charge air sensor
is in the intake manifold, close to the air supply

Table 1. Temperature Input

Temperature Input Minimum Maximum Temperature Limit

Temperature Temperature
Transmission Oil 95°C (203°F) 110°C (230°F) 120°C (248°F)
Engine Coolant 90°C (194°F) 99°C (210°F) 107°C (225°F)
Engine Charged Air 55°C (131°F) 66°C (151°F) 93°C (199°F)
Hydraulic Oil 75°C (167°F) 85°C (185°F) 90°C (194°F)

Cooling Performance For information on settings and electrical connec-

tions see Hydraulic Control System
The table that follows shows the relation between 1900SRM1534.
PWM output signal, regulated pressure and cooling
performance.

Table 2. Cooling Performance

PWM Signal Regulated Pressure Cooling Performance Maximum Fan Speed

600 mA 3.4 MPa (490 psi) 10% 700 RPM
250 mA 24.5 MPa (3550 psi) 90% 2000 RPM
0 mA 26.5 MPa (3800 psi) 100% 2100 RPM

5
Description 0700 SRM 1530

COOLING CORES For the location of core entry and core exit ports see
Figure 6. Note that the core sizes for charge air and
The cooling cores transfer the heat from the fluid engine radiator are different for Tier 3 and Tier 4i
inside to the air outside. The fluid (coolant, oil, or engines.
charge air) is in contact with the core, which trans-
fers its heat to the air that is pulled through the
cooling core by the fan. The amount of heat dissipa-
ted depends on the size and design of the core, but
also depends on following factors:
• Temperature difference between the air
pulled through the cooling core and the cool-
ing core itself.
• Amount of air pulled through the cooling
core, which depends on fan speed. Environ-
mental debris such as paper, straw or lint
can restrict air flow. Operating conditions
determine the required core cleaning fre-
quency.
• Core external isolation, which results from
(dust) particles forming an isolating deposit
on the outside of the core. The deposit im-
pedes heat transfer from core to the air. Op-
erating conditions determine the required 1. CHARGE AIR COOLER
core cleaning frequency. 2. ENGINE RADIATOR
3. HYDRAULIC OIL COOLER
• Amount of fluid passing through the core. 4. TRANSMISSION OIL COOLER
Generally, more fluid passes at higher en- 5. FAN MOTOR
gine speeds when thermostats are fully open.
The flow of charge air increases when more Figure 6. Cooler Assembly
engine power is delivered.
• Core internal isolation, which results from
deposits at the inside of the cooling core, The table that follows shows the temperature dif-
which impedes heat transfer from the fluid ference to be obtained between core entry and core
to the core. The hydraulic and transmission exit, when fan and engine run at maximum speed
oil cooler are unlikely associated with inter- at an ambient temperature of 50°C (122°F). Cooling
nal deposits because of the properties of oil results are 3% better for every 10°C (18°F) that am-
and the oil filtration system. The charge air bient temperature is lower.
cooler may collect dust that has reached the
core over time due to imperfect air filtration.
Normally, internal cleaning of the charge air
cooler is not required until engine overhaul.

Core Temperature Charge Engine Hydraulic Transmission

Differences Air Radiator Oil Oil
Tier 3 140°C (252°F) 5°C (9°F) 17°C (30°F) 18°C (32°F)
Tier 4i, Tier 4F 150°C (270°F) 9°C (16°F) 17°C (30°F) 18°C (32°F)

6
0700 SRM 1530 Description

ENGINE COOLING SYSTEM tween 40% and 50%, for optimum thermal capacity
and boiling point elevation. Ethylene glycol content
Water Pump has to be established with a portable refractometer.
Content can be raised by adding pure ethylene gly-
The water pump is a centrifugal pump, which is col or can be lowered by adding pure water to the
belt driven by the crankshaft pulley. Pump supply cooling system. Ethylene glycol degrades over time,
relates to engine speed but does not increase pro- but degrades more rapidly with pH values lower
portionally with engine speed. For proper function- than 7.0. When ethylene glycol degrades, acidic
ality it is essential that the suction side of the components are formed lowering pH-values at a
pump is completely filled with coolant. Any vapor rapid rate. Additives in the coolant compensate for
at the suction side of the pump reduces pump sup- the negative effects of degrading ethylene glycol.
ply and causes damage through cavitation. To pre-
vent formation of vapor, cooling system pressure is
maintained at a raised level by the radiator cap.
The only wear item of the pump is the seal at the
impeller shaft. A worn seal exposes itself through
loss of coolant. Other possible areas for coolant
leakage are the hose connections and the gasket at
the mounting flange.

Coolant

Coolant is a mixture of water (48%), ethylene glycol

(48%), and some additives (4%). Water is a fluid
with the highest heat capacity and lowest cost, but
has disadvantages for its limited thermal usage,
and for its tendency to enhance corrosion. The limi-
ted thermal usage is extended by adding ethylene
glycol. The tendency to enhance corrosion is sup-
pressed by additives. These additives are not avail- A. FREEZE POINT TEMPERATURE
able for replenishment. This implies that the entire B. PERCENTAGE OF ETHYLENE GLYCOL TO
coolant system has to be drained and refilled when WATER
the additives are depleted. Water and/or ethylene
Figure 7. Coolant Mixture Ratios
glycol can be added separately to correct their rela-
tive contents.

Ethylene Glycol Water

NOTE: The pH is a measure of acidity or alkaline. The water quality requirement for coolant is distil-
PH numbers lower than 7.0 indicate an acidic envi- led or deionized water, with little or no minerals.
ronment, which promotes corrosion. The pH num- Minerals increase corrosion, form deposits and de-
bers higher than 7.0 indicate an alkaline environ- plete some of the additives. If distilled or deionized
ment, which reduces corrosion. water is not available, test strips must be used to
establish acceptable water quality. Limiting values
Coolant consists of three main ingredients: water, are:
ethylene glycol, and additives. Mixing ratio be-
tween water and ethylene glycol is normally 50/50. Total Solids 340 ppm "MAX"
Other mixing ratios influence the freezing point,
Total Hardness 170 ppm "MAX"
boiling point and fluidity of the mixtures. See Fig-
(CaCo3, MgCo3)
ure 7. Higher concentrations ethylene glycol reduce
fluidity and heat capacity, but raise the boiling Chloride (Cl) 40 ppm "MAX"
point. Operation of the lift truck within arctic con- Sulfate (SO4) 100 ppm "MAX"
ditions justify ethylene glycol contents of 50% or
more. Most common ethylene glycol content is be- pH 7.0 to 8.0

7
Description 0700 SRM 1530

Additives - Chemicals to be included: Nitrite to a mini-

mum of 2000 ppm, or alternatively: Nitrite in
The additive package in the coolant contains sev- combination with Molybdate to a minimum
eral components, each with a different function. of 1300 ppm.
Most important function is corrosion protection and - Chemicals to be excluded: Chromates, Bo-
maintaining a predetermined acidic level (pH rates (Boron), Silicates, Phosphates and
value). Further functions are scale inhibition, de- Amines.
foaming, and liner pitting protection.
Examples of such products are:
The acidic level (pH value) of coolant in the lift
trucks is maintained by chemicals that are catego- - Shell Rotella ELC
rized as OAT (Organic Acid Technology). One of the - Eurol Coolant XL-NM
characteristics of OAT type coolant is that the pH
value is maintained for several years at a stable Cab Heater
level. Once the additives are depleted, the pH level
will drop. When pH level is 7.7 or lower, the coolant The cab heater uses the heat contained in the cool-
must be replaced. ant that flows through the heater core to heat the
cab, but has no effect on cooling system capacity.
Do not mix coolant with different coolants or addi-
tives as it can seriously affect the properties of cool- Expansion Tank
ant. Examples are:
- Deactivation of some of the protecting addi- The function of the expansion tank is to allow ex-
tives. pansion of the coolant when the engine gets warm,
regulate pressure in the cooling system, and facili-
- Formation of gel, blocking coolant flow. tate removal of gasses that may have formed. Cool-
- Formation of deposits, impeding heat trans- ant expands with rising temperature. The in-
fer in the engine block and the radiator core. creased volume of coolant flows through the expan-
sion hose to the expansion tank, where it com-
The engine cooling system in the lift truck has been presses the contained air, causing cooling system
factory filled with an additive package categorized pressure to rise.
as OAT (Organic Acid Technology) and allows a
service life up to 5 years, provided it passes the 6 The purpose of raising system pressure is to raise
monthly coolant quality checks. the boiling temperature of coolant. A raised boiling
temperature is required for circumstances when
The factory filled coolant allows mixing with other coolant flow is limited. For instance when returning
OAT (Organic Acid Technology) type coolants to a to idle after full power operation, or when turning
maximum of 25%, provided the added coolant off a warm engine.
meets the coolant quality requirements. Do not use
or mix with conventional coolants or coolants based If the coolant were to boil, it would form gas bub-
on SCAs (Supplemental Cooling Additives). bles which reduce the contact area of coolant with
the engine, and reduce the coolant flow that can
Coolant Quality Requirements pass a certain area. As a result, temperature in
that affected engine area will rise even further,
When replacing the entire coolant volume, refill which may lead to component failure.
with an OAT (Organic Acid Technology) based
product meeting Cummins requirement CES 14603 In particular in the turbo and in the EGR housing,
and Cummins bulletin 3666132. coolant may start boiling when coolant flow stalls
suddenly. This may result in big volumes of steam
Essential properties of these OAT type coolants pushing coolant out of the expansion tank.
are:
- Acidity (pH) level between 8.0 and 9.0. Re-
serve Alkalinity at least 2.5. Total Dissolved
Solids maximum 3000 ppm.

8
0700 SRM 1530 Description

For a sufficiently quick pressure increase it is nec- starts opening the connection to the radiator and
essary that the air volume in the expansion tank is simultaneously starts closing the bypass between
limited. For this reason coolant in the expansion engine and water pump. At 93°C (200°F) the con-
tank must at least reach the lower end of the filler nection to the radiator is completely opened and
tube. the bypass is completely closed. A leaking bypass
affects coolant flow to the radiator. To completely
Pressure in the cooling system is regulated by the close the bypass, the thermostat must have exten-
radiator cap. The pressure valve in the radiator cap ded 9.7 mm (0.38 in.) and have seals that are in
relieves pressure at 103 kPa (15 psi). The vacuum good condition.
valve admits outside air, when vacuum in the ex-
pansion tank is between 7 to 12 kPa (1.0 to 1.7 psi).
A failed pressure valve is indicated by loss of cool-
ant. A failed vacuum valve is indicated by a col-
lapsed coolant hose when the engine is cold.

A bigger diameter hose connects the bottom of the

expansion tank with the suction side of the water
pump to provide some compensation for pressure
surges caused by engine speed changes.

De-aeration hoses connect the top of the expansion

tank with the cylinder head and the highest point
of the engine radiator. An additional de-aeration
hose connects with the water pump outlet hose to
relieve trapped air when refilling the engine cooling
system.

A fluid level sensor is fitted at the bottom of the ex-

pansion tank to monitor a minimum coolant level.
When coolant level is low, the ECM will shut off the Figure 8. Thermostat
engine within 30 seconds.

Thermostat CHARGE AIR COOLING SYSTEM

The turbocharger uses the energy from the exhaust
CAUTION gas stream to compress the intake air. The result-
DO NOT operate the engine without a thermostat. ing temperature increase of the intake air would re-
Without a thermostat, coolant will not flow to the duce the engine performance and influence emis-
radiator, and the engine will overheat. See Fig- sions. By cooling the intake air in the charge air
ure 8. cooler the engine can reach its rated performance
and its certified emission levels.
The thermostat is a device that controls coolant
flow by opening and closing to regulate coolant tem- On Tier 4i and 4F engines the EGR system mixes
perature of the engine. When the coolant is cold, exhaust gases with air from the charge air cooler,
the thermostat is closed. Coolant is circulated by just before the inlet manifold. For a sufficient cool-
the water pump through the engine and reenters ing of the EGR mechanism, some of the engine cool-
via a bypass to the inlet of the water pump. When ant flows through small passages in the EGR hous-
coolant has reached 82°C (180°F) the thermostat ing.

9
Description 0700 SRM 1530

HYDRAULIC OIL COOLING SYSTEM TRANSMISSION OIL COOLING SYSTEM

Heat generated at the various hydraulic compo- Refer to the manual Transmission operation
nents is absorbed by the hydraulic oil, which re- and diagnostics 1300SRM1220 for the description
turns to tank. During truck operation, oil in the and troubleshooting of the transmission cooling
tank will rise to operating temperature. With fur- system.
ther increasing oil temperature, the oil flow gener-
ated by Pump 3 will directly provide the brake as- DEF SYSTEM
semblies with cooled oil from the cooling core. Tank
oil temperature changes more gradually and de- On Tier 4F engines, some of the engine coolant
pends on the balance between cooling capacity and flows through the DEF injection manifold and
applied hydraulic functions and braking actions. through the DEF tank manifold, when tempera-
Normally tank oil temperature remains well below tures are below freezing point. The passages
the maximum allowed limit. See also Fan Drive through hoses and components require proper de-
Control System. aeration to obtain the required coolant flow.

Engine Cooling System Checks

BASIC CHECKS 4. If the fan belt must be replaced, make sure
that the water pump and belt hub bearings are
Perform the below checks in the sequence shown to not worn. The indication of worn bearings is re-
find the cause of a cooling problem. Before starting sistance during rotation and too much bearing
a repair, try to find additional symptoms that con- free play.
firm the indicated cause of failure.
COOLANT QUALITY CHECKS

WARNING Expansion Tank Inspection

Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure The inside of the expansion tank must be free of de-
the path of the compressed air is away from all posits and rust. Deposits and rust indicate a seri-
personnel. Wear protective goggles or a face ous coolant quality problem that may have caused
shield to prevent injury to the eyes. the buildup of an isolation barrier inside the entire
cooling system. Do a leak test to establish if a gas-
1. Radiator Core: Make sure the outside of the ra- ket problem caused the coolant to deteriorate. See
diator is clean. Using compressed air remove the section External Leak Test for the procedure.
dust and debris that may have accumulated on
the exterior of the radiator. Repair any leakage, clean the entire cooling sys-
tem, flush and refill with new coolant. See the sec-
2. Coolant Level: Coolant level must reach the tion Flushing the Engine Cooling System for the
filler tube in the expansion tank when the en- procedure.
gine is cold. Follow the procedures under Exter-
nal Leak Test if more than 1 liter per 1000
hours must be added.

3. Drive belt, belt tensioner, and water pump:

Check the drive belt for wear and damage.
Check that the belt tensioner functions ade-
quately.

10
0700 SRM 1530 Engine Cooling System Checks

Coolant Visual Test

Remove a small amount of coolant from the expan-

sion tank and poor into a sight glass. Coolant must
be a clear fluid with no cloudiness, floating debris,
or oil. Oil in the coolant, cloudiness, or floating deb-
ris indicate a possible head gasket or cylinder liner
failure. Do a leak test and replace the head gasket
or cylinder liners if required. See the section Exter-
nal Leak Test for the procedure. Clean, flush, and
refill the system with new coolant. See the section
Flushing the Engine Cooling System for the proce-
dure.

Cloudiness and floating debris can also indicate

that additives in the coolant are depleted or that
too many incompatible additives have been mixed.
A. FREEZE POINT TEMPERATURE
Acid Level (pH) Test B. PERCENTAGE OF ETHYLENE GLYCOL TO
WATER
Use a test strip to establish acid level of the cool-
Figure 9. Coolant Mixture Ratios
ant. Flush and refill the cooling system with new
coolant if pH level is lower than 8.0. See the sec-
tionFlushing the Engine Cooling System for the
procedure. for procedure.
COOLANT FLOW CHECKS
Thermostat
When pH level is lower than 8.0, the additives in
the coolant are depleted. Perform a leak test if the
The thermostat must start opening at 82°C (180°F),
pH level dropped below 8.0 within 3 years of serv-
and must be completely opened at 93°C (200°F).
ice. See the section External Leak Test for the pro-
Use a digital thermometer or an infrared thermom-
cedure.
eter to measure the temperatures.
Freeze Protection Test When the engine is overheating, a failed thermo-
stat is indicated by a much lower temperature of
Check ethylene glycol content with a portable re-
the upper radiator hose, compared with engine
fractometer. Ethylene glycol content must be at
temperature. When the engine remains too cold, a
least 40%, depending on lowest ambient tempera-
failed thermostat is indicated by a simultaneous
ture. See Coolant Mixture Ratios. Raise ethylene
temperature change of the engine and the upper ra-
glycol content by adding ethylene glycol. Lower the
diator hose.
ethylene glycol content by adding distilled or deion-
ized water.
If a failed thermostat is suspected, remove the ther-
mostat from the engine, and replace with a new
When circumstances allow, maintain ethylene gly-
one. For replacement procedures for the Cummins
col content between 40% and 50%. Ethylene glycol
thermostat, contact your local Hyster dealer or re-
levels higher than 50% affect the cooling capacity of
fer to Hyster Hypass Online.
coolant.

11
Engine Cooling System Checks 0700 SRM 1530

Water Pump • More than 1 liter (0.26 gal) of coolant had to

be added during the past 1000 running
hours.
WARNING
• Coolant quality failed the visual test.
During engine operation, stay clear of the fan, pul-
leys, and drive belts. Contact with these parts can • Coolant pH level dropped below 8.0 within 3
cause serious injury. years of service.
• Coolant is present in the engine oil.
WARNING • Excessive steam emission from the exhaust,
The radiator core or other parts of the cooling possibly accompanied by difficult starting.
system may be hot or under pressure and can
cause serious injury. EXTERNAL LEAK TEST
1. Make sure the engine and components of the
A sudden supply failure caused by the water pump
cooling system are dry on the outside. Also
itself is unlikely.
clean and dry the weep hole on the side of the
water pump. Attach the pressure tester to the
1. Run the engine until coolant temperature has
expansion tank and apply 140 kPa (20 psi) of
reached 90°C (194°F). At this point the thermo-
air pressure for 5 minutes. See Figure 10.
stat should be fully open.
Maintain pressure and check for external leaks
2. When pressure surges can be felt, the water at connections, hoses, water pump, radiator,
pump functions sufficiently. and engine. Any drop in pressure indicates a
leak. Repair leaking components as necessary.
3. If no pressure surges can be felt, remove the Replace the water pump if any coolant escapes
water pump for inspection. from the weep hole of the water pump during
the pressure test. Remove the pressure tester
For replacement procedures for the Cummins water from the expansion tank and reinstall the radi-
pump, contact your local Hyster dealer or refer to ator cap. Do an internal leak test if no external
Hyster Hypass Online. leak has been observed.

Radiator Core 2. Check functionality of the radiator cap. The ra-

diator cap must relieve pressure at
This test is to verify if any fins in the radiator core 103 kPa (15 psi), and allow air in the system
have restricted flow. Use a digital thermometer or when vacuum is between 7 to 12 kPa (1.0 to
an infrared thermometer to measure temperatures. 1.7 psi). Remove and re-install the radiator cap
to relieve pressure. Pressurize the overflow
1. Run the engine until the radiator core is warm. tube to measure the opening pressure of the
vacuum valve. Pressurize the tank side of the
2. Shut the engine OFF. radiator cap to measure the relief pressure of
the cap.
3. Remove the rear cover to access the radiator.
• If the relief pressure is too low, it will
4. Measure the outside temperature of the core lead to coolant loss through the radiator
from top to bottom and search for temperature cap and a lowered boiling point of the
differences. Relatively colder spots indicate a coolant, which will reduce cooling capa-
restricted coolant flow. bility.
• If the cooling system pressure is too high,
5. If flow restrictions have been found, clean and
it can result in gasket failures with the
flush the radiator. See the section Flushing the
water pump, cylinder liners, and the cyl-
Engine Cooling System for the procedure.
inder head.
LEAK TEST • A failed vacuum valve causes a slow
build up of pressure, which promotes cor-
Perform a leak test if one of following observations rosion in the water pump and at the cyl-
has been made: inder liners.

12
0700 SRM 1530 Engine Cooling System Checks

However, absence of ethylene glycol does

NOT exclude that coolant has leaked into
the engine oil. The reason is that ethyl-
ene glycol can react with certain additive
components in the engine oil, become vol-
atile, and boil off at sump temperatures.
Secondly, deteriorated glycol reacts with
bearing and bushing materials to form
elevated levels of lead in the oil.
• Water in the oil may be the result of con-
densation. Investigate if operating condi-
tions have promoted condensation.

Combustion Leak

Obtain a commercially available combustion leak

test kit to check if combustion gases have leaked
into the cooling system. Note that test kits that re-
act on the presence of sulphur may not provide
good results when sulphur level in diesel fuel is
low.

Follow the manufacturer’s instructions when doing

the test. Repair the engine if exhaust gases are
leaking into the cooling system.
1. OVERFLOW TUBE
2. RADIATOR CAP If no combustion leak test kit is available, perform
3. PRESSURE TESTER following steps to establish a combustion gas leak.
4. EXPANSION TANK

Figure 10. Radiator and Expansion Tank Pressure WARNING

Test
During engine operation, stay clear of the fan, pul-
leys, and drive belts. Contact with these parts can
cause serious injury.
INTERNAL LEAK TEST
Coolant Leak Into the Engine Oil Sump CAUTION
1. Take an oil sample from the bottom of the oil If a combustion leak is present, pressure may
pan. It is important to include any aqueous build up quickly and exceed the maximum allowa-
substances that are in the sample taken. ble pressure. Immediately relieve cooling system
pressure if pressure reaches 140 kPa (20 psi) dur-
2. Have the sample examined in a laboratory and ing this test.
repair the engine if coolant is present in the oil
sample. 1. Attach a pressure tester to the expansion tank.
Observe the pressure gauge, while your assis-
• Coolant contamination is identified from tant starts the engine. If pressure builds up
abnormal levels of an corrosion inhibitor quickly, there is a serious combustion leak. Im-
in the coolant, that leaks into the oil. mediately relieve the pressure from the cooling
• Presence of ethylene glycol in the sample system and stop the engine. Repair the engine
does indicate coolant contamination. if pressure builds up quickly

13
Engine Cooling System Checks 0700 SRM 1530

2. If there is a slow pressure build up, apply Pull connector from pump solenoid. Observe
103 kPa (15 psi) air pressure to the cooling sys- that fan speed immediately increases. If not
tem. Make sure coolant temperature is OK, the pump can have a defect.
80°C (175°F) or lower. Observe the pressure
gauge, while your assistant starts the engine 4. Pull the connector from the pump solenoid.
and accelerates the engine three times rapidly Start the engine, measure engine and fan
to 2000 rpm, followed by 1 minute of idling. speeds and compare with the values below in
Stop the engine. Repair the engine if pressure Table 3.
in the cooling system has raised while revving
If fan speeds are acceptable, reinstall the connec-
the engine.
tor on the pump solenoid and check the hy-
FAN DRIVE SYSTEM CHECKS draulic control system.

1. Check presence of fault codes. Look up any dis- If fan speeds are not acceptable, connect a pres-
played code in the relevant fault code guide and sure gauge and a flow gauge. Measure at least
use the provided information to rectify the the fan speeds at an engine speed of 1600 rpm
fault. and 900 rpm.

2. Check fan motor. Verify with a stopped engine Check functionality of the pump if oil flow is be-
the virtually free rotation of the fan in the anti- low the normal value.
clockwise direction. Verify with a stopped en-
Check functionality of the motor if oil flow is
gine, that manually rotating the fan clockwise
above the normal value, and oil pressure is below
involves resistance. If not OK, the fan motor
the normal value.
can have a defect.

3. Start engine. Observe immediate fan rotation

during starting. Run the cold engine at high
idle (+/−1200 rpm).

Table 3. Engine/Fan Speed

Engine Speed (RPM) Fan Speed (RPM) Pump Pressure Oil Flow
MPa ( psi) liter/min ( gal/min)
Engine Cold
900 670 3.4 MPa (490 psi) 25 liter/min (6.7 gal/min)
1100 and Up 700 3.6 MPa (530 psi) 26 liter/min (7.0 gal/min)
Disconnected Signal at Pump Solenoid
900 1360 12.8 MPa (1860 psi) 52 liter/min (13.7 gal/
min)
1000 1500 15.5 MPa (2250 psi) 57 liter/min (15.1 gal/
min)
1100 1680 19.0 MPa (2750 psi) 64 liter/min (16.8 gal/
min)
1200 1820 21.7 MPa (3150 psi) 69 liter/min (18.3 gal/
min)

14
0700 SRM 1530 Engine Cooling System Checks

Table 3. Engine/Fan Speed (Continued)

Engine Speed (RPM) Fan Speed (RPM) Pump Pressure Oil Flow
MPa ( psi) liter/min ( gal/min)
1300 1960 24.4 MPa (3540 psi) 74 liter/min (19.7 gal/
min)
1400 2040 25.6 MPa (3710 psi) 78 liter/min (20.5 gal/
min)
1500 2110 26.5 MPa (3840 psi) 80 liter/min (21.2 gal/
min)
1600 2120 26.5 MPa (3840 psi) 81 liter/min (21.3 gal/
min)

BRAKE COOLING SYSTEM CHECKS 4. Verify cooling effect of the cooling core. Meas-
ure the temperature difference between cooler
1. Make sure the truck has passed the Fan Drive in and cooler out connections. The value meas-
System Checks. ured should at least reach the value shown in
Table 4. Clean or replace the cooler if the meas-
2. Make sure the service brakes operate correctly.
ured temperature difference is less than stated.
Verify absence of residual pressure when the
brakes are released. Verify that both brake as- 5. Verify oil supply to the brake assemblies. Meas-
semblies have equal braking performance. Ver- ure flow resistance of the brake return filter.
ify that operator releases brake pedal com- Replace brake return filter if return pressure
pletely when no braking is required. exceeds 20 kPa (2.9 psi). Establish that the
140 kPa (20.3 psi) relief valve in the brake
3. Verify correct operation of the thermostatic by-
manifold closes. Remove the hose from port R.
pass at the Filter Head. Measure that cooling
Replace the brake manifold if oil escapes from
core supply line remains cold until oil at the fil-
port R at engine idle speed. Measure the tem-
ter head has reached 65°C (149°F). Measure
perature difference between ports TBL and
that there is no temperature difference between
TBR at the brake manifold. Investigate oil flow
the two OUT-ports on the filter head, when oil
resistance of the brake assembly with the high-
supply temperature is above 80°C (176°F). Re-
est temperature.
place the filter head if the thermostatic bypass
does not function correctly.

Table 4. Core Temperature Difference

Core Temperature Charge Engine Hydraulic Transmission

Differences Air Radiator Oil Oil
Tier 3 140°C (284°F) 5°C (41°F) 17°C (62.6°F) 18°C (64.4°F)
Tier 4i and 4F 150°C (302°F) 9°C (48°F) 17°C (62.6°F) 18°C (64.4°F)

15
Cooling System Repairs 0700 SRM 1530

Cooling System Repairs

DRAIN THE ENGINE COOLING SYSTEM 6. After the thermostat has opened (top radiator
hose will be warm), start revving the engine in-
termittently. Keep adding coolant until level in
WARNING the expansion tank has stabilized. Coolant ca-
DO NOT remove the radiator cap from the expan- pacity for QSM11 engines is 40 liter (10.5 gal)
sion tank when the engine is hot. When the radia- Coolant capacity for QSL8.9 engines is 44 li-
tor cap is removed, the pressure is released from ter (11.5 gal).
the system. If the system is hot, the steam and
boiling coolant can cause burns. 7. Install the radiator cap.

Remark: Monitor coolant level in the expan-

CAUTION sion tank after a few shifts. Trapped air in the
Disposal of lubricants and fluids must meet local system may have escaped into the expansion
environmental regulations. tank, causing a lower coolant level in the
tank.
1. Turn the heater knob for the cabin in the full
heat position.

2. Let coolant cool below 40°C (104°F).

3. Remove the radiator cap from the expansion

tank.

NOTE: Use a drain pan to catch the coolant ca-

pacity of 40 liter (9 gal).

4. Remove the radiator return hose from the wa-

ter pump and open the coolant drain valve at
the left side of the engine and drain the cooling
system. See Figure 11.

REFILL THE ENGINE COOLING SYSTEM

1. Close the coolant drain valve and refit the radi-
ator return hose to the water pump.

2. Fill the cooling system through the radiator cap

opening in the expansion tank. When refilling
with coolant, use a product that meets the spec-
ification as mentioned in the section Coolant.

3. Make sure that air can escape through the radi-

ator cap opening. Make sure that the coolant
level has stabilized at the lower end of the filler
tube in the expansion tank.

4. Verify the correct course of the de-aeration ho-

ses for the EGR and turbo. Make sure these ho-
ses rise continuously up to the expansion tank. 1. COOLANT DRAIN VALVE
2. RADIATOR RETURN HOSE
5. Turn the heater knob for the cabin in the full 3. RADIATOR SUPPLY HOSE
hot position. Start the engine and retain engine
speed at idle. Continue filling coolant to main- Figure 11. Engine Coolant Drain Valve (QSM 11
tain level just below the filler neck. Shown)

16
0700 SRM 1530 Cooling System Repairs

FLUSHING THE ENGINE COOLING 11. If the water is contaminated, investigate the
SYSTEM cause of the contamination and take appropri-
ate action.
WARNING
DO NOT remove the radiator cap from the expan-
sion tank when the engine is hot. When the radia-
tor cap is removed, the pressure is released from
the system. If the system is hot, the steam and
boiling coolant can cause burns.

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

1. Let coolant cool to 40°C (104°F).

2. Remove the radiator cap from the expansion

tank.

NOTE: Use a drain pan to catch the coolant ca-

pacity of 35 liter (9 gal).

3. Open the coolant drain valve at the left side of

the engine and drain the cooling system. See
Figure 11.

4. Close the coolant drain valve at the left side of 1. RADIATOR DRAIN VALVE
the engine. See Figure 11. Figure 12. Radiator Drain Valve

CAUTION
Disposal of lubricants and fluids must meet local
CLEAN THE ENGINE COOLING SYSTEM
environmental regulations. 1. Flush the cooling system. See Flushing the En-
gine Cooling System and Refill the Engine
5. Fill the radiator core and expansion tank with
Cooling System for the procedures.
clean water.

6. Install the radiator cap on the expansion tank. CAUTION

7. Run the engine until the top radiator hose is Maximum recommended time with any type of
hot. cleaner is 3 hours. Any prolonged usage may
cause damage to system elastomers and corrode
8. Stop the engine and let the engine cool to room system soft metals.
temperature.
2. Refill the cooling system with cleaner and fol-
9. Remove the radiator cap from the expansion low the manufacturer’s instructions.
tank.
3. Flush the system twice before refilling with
10. Open the coolant drain valve and drain the wa- coolant. See Flushing the Engine Cooling Sys-
ter from the radiator core. See Figure 12. tem for the procedures.

17
Cooling System Repairs 0700 SRM 1530

FAN AND FAN MOTOR COOLING ASSEMBLY

Remove Remove
1. Remove the grid and the cover above the radia- 1. Loosen the four bolts that hold the cooler screen
tor. to the frame. Lift and remove the screen from
the bolts.
2. Remove and plug the hoses connecting with the
fan motor. Plug the ports on the fan motor. 2. Remove the three bolts that connect the formed
plate between cooler assembly and separator
3. Attach a lifting device to the frame that holds plate between engine and cooler area.
the fan and the fan motor.
3. Drain the engine cooling system.
4. Remove the four M10 bolts that retain the
frame to the core assembly and lift the fan as- 4. Remove the cover and the grid above the radia-
sembly. Lead the frame ends past the radiator tor.
hoses. Put the fan assembly on a work bench.
5. Remove the fan assembly.
5. Remove the 12 nuts that retain the fan to the
fan pulley. 6. Put a drain pan under the radiator assembly.

6. Remove the central nut from the pulley and 7. Remove and plug the hoses for charge air cool-
pull the pulley from the motor shaft. Retain the ing, engine coolant, hydraulic and transmission
key. oil. Put caps on the radiator fittings.

7. Remove the two M12 bolts that retain the mo- 8. Connect a lifting device to the lifting eyes on
tor to the frame. the cooler assembly.

9. Remove the nuts and washers from the four iso-

Replace
lators at the cooler assembly brackets.
1. Install the motor on the frame. Tighten the two
10. Lift and guide the cooler assembly from the iso-
bolts.
lators. The cooler assembly will tend to position
2. Position the key in the motor shaft and slide itself horizontally.
the fan pulley on the shaft. Install the locking
11. Lower the cooler assembly on a pallet. Remove
nut and torque to 45 N•m (33 lbf ft).
the pallet from under the truck.
3. Install the fan on the pulley and tighten the 12
nuts. Disassemble

4. Attach a lifting device to the frame that holds 1. Remove the two side plates from the cooler as-
the fan and fan motor. sembly by removing the attaching bolts: 2 times
3 bolts at the suction side, 5 bolts at each of the
5. Lift the assembly and position on the cooler as- assembly sides, and 2 times 2 bolts at the fan
sembly. Insert the four M10 bolts. side.

6. Make sure there is even play between fan and 2. Remove and replace the individual cores as nec-
shroud. Tighten the four bolts. essary.

7. Remove the plugs and install the hoses on the Assemble

motor.
1. Put the cores and the two side plates into the
8. Replace the cover and the grid above the radia- correct position.
tor.

18
0700 SRM 1530 Cooling System Repairs

2. Insert and tighten the bolts that retain the 2. Remove the 3 bolts that connect the formed
cores to the side plates. Tighten to plate between cooler assembly and separator
20 N•m (14.7 lbf ft). plate between engine and cooler area.

Replace 3. Remove the 6 bolts that retain the formed plate

to the transmission core.
1. Place the cooler assembly on a pallet and move
it under the truck. 4. Put a drain pan under the radiator assembly to
catch the transmission oil and hydraulic oil
2. Connect a lifting device to the lifting eyes on from the cores.
the cooler assembly.
5. Remove the hoses from the cores for transmis-
3. Lift and guide the cooler assembly on the isola- sion and hydraulic system. Plug the hoses and
tors. Position the lower brackets on the lower the fittings of the cores.
isolators first.
6. Remove two bolts at each side of the transmis-
4. Install the washers and nuts and tighten. sion cooler and slide the transmission core out
of the side plates.
5. Remove the plugs from radiators and hoses and
install the hoses for charge air cooling, engine 7. Remove the two lower bolts that hold the frame
coolant, hydraulic and transmission oil. for the fan assembly.

6. Replace the fan assembly. See Fan and Fan 8. Loosen the two upper bolts that hold the frame
MotorReplace. for the fan assembly sufficiently to allow tilting
the fan assembly up.
7. Refill the engine cooling system, and top up the
transmission and hydraulic oil level as neces- 9. Remove the six bolts that retain the hydraulic
sary. Start the engine and check for leaks. Stop core to the side plates. Tilt the frame of the fan
the engine. assembly up to allow sliding the core out of the
side plates.
8. Install the three bolts that connect the formed
plate between cooler assembly and separator Assemble
plate.
1. Slide the hydraulic core into position and fasten
9. Replace the radiator screen at the steer wheel the six retaining bolts. Tilt the frame of the fan
area. Tighten the bolts that retain the screen to assembly to allow the core fittings to pass.
the frame.
2. Check alignment of the fan in the shroud and
10. Replace the cover and the grid above the radia- fasten the four bolts that retain the frame for
tor. the fan assembly.
11. De-aerate the engine cooling system 3. Slide the transmission core into position and
tighten the two bolts at each side.
COOLER CORE REPLACEMENT FOR
TRANSMISSION AND HYDRAULIC 4. Remove the plugs and connect the hoses to the
SYSTEM core fittings.

It is possible to replace the transmission core and 5. Install the 6 bolts that retain the formed plate
hydraulic oil core without first removing the fan to the transmission core.
and the cooler assembly.
6. Install the 3 bolts that connect the formed plate
Remove between cooler assembly and separator plate.

1. Loosen the four bolts that hold the cooler screen 7. Replace the radiator screen at the steer wheel
to the frame. Lift and remove the screen from area. Tighten the bolts that retain the screen to
the bolts. the frame.

19
Troubleshooting 0700 SRM 1530

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Coolant leaks. There is a leak in the radiator. Pressure test radiator and expan-
sion tank. If leak cannot be re-
paired, replace radiator. See Ex-
ternal Leak Test. For radiator re-
placement, see Cooling Assembly.

There is a leak in a radiator hose Pressure test radiator and expan-

or coolant hose. sion tank. Replace leaking hose.
See External Leak Test.

There is a leak from a plug or Check sensors and plugs, and re-
sensor in the engine block. pair leaks.

Water pump leaks. Install new water pump.

Thermostat housing leaks. Inspect thermostat housing for

damage. Replace, if necessary.
Remove the housing and check
the thermostat housing gasket
for damage. Replace, before rein-
stalling. Check for proper instal-
lation of thermostat and O-ring.

Cylinder head gasket is dam- Install new head gasket.

aged.

Cylinder head is cracked. Install new cylinder head.

Engine block is cracked. Install new cylinder block.

The engine is too hot during oper- There is not enough coolant in Check coolant level in radiator
ation. the cooling system. and expansion tank. Add coolant
to correct level.

The radiator is clogged. Remove the screen behind the ra-

diator and clean the radiator
with high pressure air.

The radiator is dirty. Drain and clean radiator. Clean

radiator fins with low pressure
air or water in reverse direction
of normal airflow. Be careful not
to bend fins. Refill with clean
coolant.

20
0700 SRM 1530 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The thermostat is wrong heat Check heat range. Install new

range or does not operate cor- thermostat.
rectly.

The cooling system has restric- Drain and back-flush engine and
tions. radiator. Refill with clean cool-
ant.

The water pump is worn or dam- Install new water pump.

aged.

The exhaust system has restric- Check exhaust system. Remove

tions. restrictions.

Fan is not running. Check the fan and mounting to

the fan motor. Replace if re-
quired.

Fan is running slow Remove the connector from the

fan pump (VDP3). The fan should
run on it's maximum speed now.
Replace fan motor or fan pump.
See Hydraulic System
1900SRM1476.

Exhaust leaks into coolant. Head gasket(s) leaks. Install new gasket(s).

Cylinder head is damaged. Install new cylinder head.

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 NOTES

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 TECHNICAL PUBLICATIONS

0700 SRM 1530 10/14 (8/14)(8/12)(5/12)(1/12)(9/11)