Hyster K007 User manual

Hyster K007 (H190HD2, H210HD2, H230HD2,
H230HDS2, H250HD2, H280HD2) Forklift Service
Repair Manual

COOLING SYSTEM
H8-12XM-6, H10XMS-6 (H190-280HD2,
H230HDS) [K007];
H13-16XM-6, H10-12XM-12EC (H300-360HD2,
H360HD2-EC) [J019];
H16XM-9, H16XM-12, H18XM-7.5, H18XM-9
(H360-36HD, H360-48HD) [A238]
PART NO. 4059554 0700 SRM 1595

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.

©2013 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Cooling System Description ................................................................................................................................1
Cooling Cores .................................................................................................................................................. 1
Fan ...................................................................................................................................................................2
Fan Clutch .................................................................................................................................................. 2
Fan Clutch Engagement ............................................................................................................................ 2
Shroud ............................................................................................................................................................. 3
Engine Cooling System ...................................................................................................................................4
Water Pump ................................................................................................................................................4
Thermostat ................................................................................................................................................. 4
Expansion Tank And Radiator Cap .......................................................................................................... 5
Cab Heater ..................................................................................................................................................5
Coolant ........................................................................................................................................................6
Charge Air Cooling System ............................................................................................................................7
Transmission Oil Cooling System ..................................................................................................................7
Hydraulic Oil Cooling System ........................................................................................................................8
Hydraulic Oil Cooling .................................................................................................................................8
Oil Filtration and Oil Cooling ....................................................................................................................9
Brake Cooling ............................................................................................................................................. 9
Hydraulic Control System ......................................................................................................................... 9
Service and Repair ................................................................................................................................................ 10
Cooling System Checks .....................................................................................................................................10
Basic Checks ................................................................................................................................................. 10
Coolant Quality Checks ................................................................................................................................10
Coolant Flow Checks .................................................................................................................................... 11
Thermostat ............................................................................................................................................... 11
Water Pump ..............................................................................................................................................12
Cooling Core Efficiency ............................................................................................................................ 12
Cooling Core Flow Restrictions ............................................................................................................... 13
Engine Leak Tests ........................................................................................................................................ 13
External Leak Test ...................................................................................................................................13
Check for Coolant Leak Into The Engine Oil Sump ...............................................................................14
Combustion Leak Test ............................................................................................................................. 15
Engine Cooling System Maintenance ..........................................................................................................15
Draining the Engine Cooling System ......................................................................................................15
Filling the Engine Cooling System ..........................................................................................................16
Flushing the Engine Cooling System ......................................................................................................16
Cleaning the Engine Cooling System ......................................................................................................17
Remove and Replace Procedures ..........................................................................................................................17
Drive Belt .......................................................................................................................................................... 17
Remove .......................................................................................................................................................... 17
Install ............................................................................................................................................................ 17
Belt Tensioner ................................................................................................................................................... 18
Inspect ........................................................................................................................................................... 18
Remove .......................................................................................................................................................... 19
Install ............................................................................................................................................................ 19
Water Pump ...................................................................................................................................................... 19
Inspect ........................................................................................................................................................... 19
Remove .......................................................................................................................................................... 19
Install ............................................................................................................................................................ 19
Cooling System Table of Contents
i

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TABLE OF CONTENTS (Continued)
Thermostat ........................................................................................................................................................ 20
Remove .......................................................................................................................................................... 20
Inspect ........................................................................................................................................................... 20
Install ............................................................................................................................................................ 20
Cooling Core Assembly ..................................................................................................................................... 20
Removal .........................................................................................................................................................21
Cooling Cores ................................................................................................................................................ 27
Disassembly ..............................................................................................................................................27
Assembly ...................................................................................................................................................27
Install ........................................................................................................................................................27
This section is for the following models:
H8-12XM-6, H10XMS-6 (H190-280HD2, H230HDS) [K007];
H13-16XM-6, H10-12XM-12EC (H300-360HD2, H360HD2-EC) [J019];
H16XM-9, H16XM-12, H18XM-7.5, H18XM-9 (H360-36HD, H360-48HD)
[A238]
Table of Contents Cooling System
ii

General
This manual describes the cooling system and the
removal and replacement procedures for its main
components.
The cooling system for the transmission is
described in Transmission 1300SRM1455.
The hydraulic control system for the K007, J019,
and A238 truck is described in Hydraulic Control
System 2200SRM1481.
COOLING SYSTEM DESCRIPTION
When the truck operates, heat is generated in vari-
ous truck components. Most of these components
can sufficiently dissipate the generated heat to the
surrounding air. A cooling system is required for
the engine, hydraulic system and the transmission,
because of the big and fluctuating volume of heat to
be dissipated and the need for a controlled operat-
ing temperature. Each of these systems has its own
cooling core.
The cores are mounted in a cooling core assembly
(together with the charge air cooler). In this assem-
bly, the heat is dissipated by an airflow which is
pulled through the cooling cores by a belt-driven
fan.
Cooling Cores
The cooling cores transfer the heat from the fluid
inside to the air outside. The fluid (coolant or oil) or
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. Depending on how much
heat is dissipated, depends on the size and design
of the core, but also on the following factors:
• Temperature difference between the air
pulled through the cooling core and the cool-
ing core itself.
• Volume 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 necessary core cleaning fre-
quency.
• Core external insulation, which results from
(dust) particles forming an insulating deposit
on the outside of the core. The deposit im-
pedes heat transfer from the core to the air.
Operating conditions determine the neces-
sary core cleaning frequency.
• Volume of fluid passing through the core.
Generally, more fluid passes at higher en-
gine speeds when thermostats are fully open.
The flow of charge air increases when more
engine power is delivered.
• Core internal insulation, which results from
deposits inside the cooling core, which im-
pede heat transfer from the fluid to the core.
The hydraulic and transmission oil coolers
are unlikely to contain internal deposits be-
cause of the properties of oil and the oil fil-
tration system. The charge air cooler may
collect dust that has reached the core over
time due to imperfect air filtration. Nor-
mally, internal cleaning of the charge air
cooler is not required until engine overhaul.
For the location of core entry and exit ports, see
Figure 1.
0700 SRM 1595 General
1

1. TRANSMISSION OIL COOLER
2. HYDRAULIC OIL COOLER
3. ENGINE RADIATOR
4. CHARGE AIR COOLER
Figure 1. Cooling Cores, K007/J019
Fan
The fan pulls air through the cooling core assembly.
On trucks with Tier 3/Stage III A engines, the fan
is directly connected with the fan pulley and turns
proportional to engine speed.
Trucks with Tier 4i/Stage III B engines have a fan
clutch that reduces fan speed when circumstances
allow a lower cooling capacity. The advantage is in
reduced power consumption and a reduced noise
level of the fan.
Fan Clutch
The fan clutch is mounted between fan pulley and
fan. The fan clutch is a viscous coupling that varies
clutch engagement between 30% and 95%, depend-
ing on engine speed and an electrical Pulse Width
Modulation (PWM) signal from the Engine Control
Module (ECM).
Fan Clutch Engagement
The fan clutch consists of a rotor that is connected
with the engine pulley and a housing that carries
the fan. Engagement of the rotor and the housing is
obtained by viscous oil that is present between ro-
tor and housing.
At higher rotation speeds of the rotor, viscous oil is
centrifuged away from the space between rotor and
housing and returns through a bore into an oil
chamber. From this oil chamber, oil returns
through a valve to the space between rotor and
housing.
When the valve closes, oil will NOT return to the
rotor. Existing oil at the rotor will be centrifuged
away, reducing clutch engagement.
By varying the valve opening, the clutch engage-
ment will change.
Maximum engagement is 95%. Lowest engagement
is 30% of engine (pulley) speed.
The valve in the clutch closes against spring force,
when activating the magnet coil in the anti-rotation
bracket. The activated magnet coil attracts the ac-
tuator ring which is connected with the valve
through a pin. The resulting flow of oil changes fan
speed, which is measured by a speed sensor in the
anti-rotation bracket and communicated to the
ECM. Depending on the difference between actual
and required fan speed, the ECM will change acti-
vation of the magnet coil. See Figure 2.
The PWM signal to the magnet coil depends on the
temperature inputs for engine coolant, intake air,
and transmission oil. These inputs are received by
the ECM and result in a programmed signal to the
magnet coil. The actual engagement can be checked
with a laptop through the Cummins programme
called Insite’.
When the magnet coil is de-activated, spring force
will open the valve. This means that in case of an
electric failure, the engagement of the clutch will be
at maximum.
Cooling System 0700 SRM 1595
2

Clutch engagement is also influenced by actual vis-
cosity of the viscous oil. Engagement is higher at
lower temperatures. Engagement is lower at higher
temperatures. The ECM compensates for differen-
ces in engagement, but at extremely cold tempera-
tures the normally lowest engagement of 30% may
remain at a higher level because of the higher vis-
cosity.
The reaction time for a changed engagement de-
pends on actual viscosity and rotor speed (engine
speed). This is particularly noticeable when com-
paring the start of a cold engine and a warm en-
gine. After cold starting the engine, it will take at
least 30 seconds at high idle before the oil at the ro-
tor has disappeared, disengaging the clutch. The
fan clutch of a warm engine will disengage in less
than 20 seconds after the engine has been started.
1. FAN FLANGE
2. FAN RETAINER BOLT
3. FAN CLUTCH HOUSING
4. ROTOR
5. OIL CHAMBER
6. SEPARATING WALL
7. COIL BRACKET BEARING
8. CLUTCH HOUSING BEARING
9. VALVE
10. HEXAGON NUT
11. MAGNET COIL
12. ACTUATOR RING
13. RETURN BORE
14. ANTI-ROTATION BRACKET
Figure 2. Fan Clutch
Shroud
The shroud on the cooling core assembly raises the
efficiency of the fan and ensures that air is pulled
through the cooling cores only. Fan efficiency is
raised by a narrow clearance between fan and
shroud. One third of the fan is outside the shroud,
to allow centrifuged air to escape. This increases
the propelled air volume.
The warmed air flows away underneath and at the
front of the truck. Seals between the frame and the
core assembly prevent the recirculation of warmed
air to the suction side of the core assembly.
0700 SRM 1595 Cooling System
3

Engine Cooling System
During operation of the truck, heat is generated in
the engine. The engine cooling system regulates the
dissipation of this heat in order to maintain the en-
gine at the desired operating temperature. The
coolant is pumped in a closed circuit, where it ab-
sorbs heat from the engine and dissipates heat in
the cooling core. The cooling capacity of the radia-
tor and the fan is sufficient to keep coolant temper-
ature well below the maximum temperature, even
at ambient temperatures reaching 50°C (122°F).
The main components of the engine cooling system
are:
• Water Pump
• Thermostat
• Expansion Tank And Radiator Cap
• Cooling Core
• Cab Heater
• Coolant
The functional description of these components is
below.
Water Pump
The water pump circulates the coolant through the
engine cooling system and the (optional) cab heater.
The pump is belt driven by the crankshaft pulley.
See Figure 3.
Pump supply relates to engine speed but does not
increase proportionally with engine speed.
It is essential that the suction side of the pump is
completely filled with coolant. Any vapor at the
suction side of the pump would reduce pump supply
and cause damage through cavitation. To prevent
the formation of vapor, the cooling system is kept
at a higher pressure by the radiator cap.
1. FAN PULLEY
2. WATER PUMP
3. CRANKSHAFT PULLEY
4. BELT TENSIONER
5. DRIVE BELT
6. COOLANT OUTLET
Figure 3. Drive Belt
Thermostat
CAUTION
DO NOT operate the engine without a thermostat.
Without a thermostat, coolant at the outlet flange
will partially recirculate through the bypass, caus-
ing the engine to overheat.
The thermostat controls coolant flow to the cooling
core.
The thermostat is located at the top of the cylinder
block, and is held in place by the coolant outlet
flange.
When coolant is cold, the thermostat closes the con-
nection with the radiator and forces coolant from
the engine to return to the suction side of the water
pump through a bypass.
When coolant temperature reaches 82°C (179°F),
the thermostat starts opening the connection to the
cooling core, while closing the bypass between en-
gine and water pump.
Cooling System 0700 SRM 1595
4

At 91°C (196°F), the connection to the cooling core
is completely open and the bypass is completely
closed. At that temperature, all coolant passes
through the cooling core before re-entering the en-
gine. See Figure 4.
A. COOLANT FLOW FROM ENGINE
B. BYPASS FLOW TO WATER PUMP
C. COOLANT FLOW TOWARDS COOLING CORE
Figure 4. Coolant Thermostat
Expansion Tank And Radiator Cap
The function of the expansion tank is:
• To allow expansion of the engine coolant
when the engine warms up.
• To regulate pressure in the engine cooling
system.
• To allow the removal of gasses that may
have formed in the coolant.
Coolant expands as it warms up. The increased vol-
ume of coolant flows through the expansion hose to
the expansion tank, where it compresses the con-
tained air, causing cooling system pressure to rise.
The rising system pressure raises the boiling point
of the coolant. A higher boiling point is required for
circumstances when coolant flow is limited. For in-
stance when returning to idle after full power oper-
ation, or when turning off a warm engine. If the
coolant were to boil in those circumstances, it
would form gas bubbles. Those bubbles would re-
duce the contact area of the coolant with the en-
gine. The bubbles would also restrict coolant flow
through the engine. As a result, temperature in the
affected part of the engine would rise even further,
which might lead to component failure.
For a sufficiently quick pressure increase, the air
volume in the expansion tank must be limited. For
this reason, the expansion tank must be filled to at
least the minimum level mark “MIN”.
The pressure in the cooling system is regulated by
the cap on the expansion tank, the so-called “radia-
tor cap”. This cap houses a pressure valve, which
releases pressure from the expansion tank between
90 kPa (13 psi) and 110 kPa (16 psi).
The valve admits outside air, when vacuum in the
expansion tank is between 2 kPa (0.3 psi) and
7 kPa (1 psi).
A bigger diameter hose connects the cooling core to
the bottom of the expansion tank to provide some
compensation for pressure surges caused by engine
speed changes.
To allow de-aeration when the engine cooling sys-
tem is filled, the cylinder head and the engine cool-
ing core are both connected to the expansion tank
by a de-aeration hose.
A fluid level sensor in the expansion tank sends a
signal to the ECM (Engine Control Module) when
the minimum coolant level has been reached. In
that case, the ECM will switch the engine off
within 30 seconds.
Cab Heater
The cab heater is located under the cab floor, un-
derneath the seat. Heated coolant flows from the
cylinder head through a hose to the heater. Coolant
flow is controlled by the water valve in the heater
assembly. Coolant leaves the heater through a hose
which is connected to the suction side of the water
pump.
The cab heater is described in Cab Heater
0100SRM1459. See Figure 5.
0700 SRM 1595 Cooling System
5

1. CAB HEATER
2. HOT COOLANT HOSE (TOWARDS HEATER)
3. COLD COOLANT HOSE (FROM HEATER)
4. ENGINE COOLANT INLET
Figure 5. Cab Heater
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 the lowest cost.
However, water has only limited thermal usage and
tends to enhance corrosion.
This limited thermal usage is extended by the addi-
tion of ethylene glycol. The tendency to enhance
corrosion is suppressed by additives. These addi-
tives are not available for replenishment. This im-
plies that the entire coolant system has to be
drained and refilled when the additives are deple-
ted. Water and/or ethylene glycol can be added sep-
arately to correct their relative contents.
Ethylene Glycol
The mixing ratio of water and ethylene glycol
for optimum thermal capacity and boiling
point elevation is normally 50/50. Other mix-
ing ratios influence the freezing point, boil-
ing point and fluidity of the mixtures. See
Figure 6.
Higher concentrations of ethylene glycol re-
duce fluidity and heat capacity, but raise the
boiling point. Operation of the lift truck in
arctic conditions justifies ethylene glycol con-
tents of 50% or more. See Figure 6.
Ethylene glycol content can be established
with a portable refractometer. This content
can be raised by adding pure ethylene glycol
or can be lowered by adding distilled water
to the cooling system. Ethylene glycol de-
grades over time, but degrades more rapidly
with a pH below 7.0. When ethylene glycol
degrades, acidic components are formed,
which rapidly lower the pH. Additives in the
coolant compensate for the negative effects of
degrading ethylene glycol.
Remark: pH is a measure of acidity or alka-
linity. A pH lower than 7.0 indicates an
acidic environment, which promotes corro-
sion. A pH higher than 7.0 indicates an alka-
line or basic environment, which reduces cor-
rosion.
A. FREEZE POINT TEMPERATURE
B. PERCENTAGE OF ETHYLENE GLYCOL IN
COOLANT
Figure 6. Coolant Mixture Ratios
Water
The water quality requirement for coolant is
distilled or deionized water, with little or no
minerals. Minerals increase corrosion, form
deposits and deplete some of the additives. If
distilled or deionized water is not available,
test strips must be used to establish the wa-
ter quality. For limiting values, see Table 1.
Table 1. Limiting Values
Total Solids 340 ppm maximum
Total Hardness (CaCO3,
MgCO3)
170 ppm maximum
Chloride (Cl) 40 ppm maximum
Sulfate (SO4) 100 ppm maximum
Cooling System 0700 SRM 1595
6

Table 1. Limiting Values (Continued)
pH 7.0 to 8.0
Additives
The additives package in the coolant con-
tains several components, each with a differ-
ent function. The most important function is
corrosion protection and maintaining a pre-
determined acidity (pH). Other functions are
scale inhibition, de-foaming, and liner pitting
protection.
The acidity (pH) of coolant in this truck is
maintained by chemicals that are catego-
rized as Organic Acid Technology (OAT). One
of the characteristics of OAT type coolant is
that the pH remains stable for up to 5 years,
provided it passes the 6-month quality
checks.
Once the additives are depleted, the pH will
drop. When the pH is 7.7 or lower, the cool-
ant must be replaced.
Do not mix coolant with different coolants or
additives, as that may have consequences for
coolant quality, such as:
• De-activation of some of the protecting
additives
• Formation of gel, which blocks coolant
flow
• Formation of deposits, which impede
heat transfer in the engine block and
the cooling core.
The factory filled coolant allows mixing with
other OAT type coolants to a maximum of
25%, provided the added coolant meets the
coolant quality requirements. Do not use or
mix with conventional coolants or coolants
based on Supplemental Cooling Additives
(SCAs).
Coolant Quality Requirements
When replacing the entire coolant volume,
refill with an Organic Acid Technology (OAT)
based product, which meets Cummins re-
quirement CES 14603 and Cummins bulletin
3666132.
Essential properties of these OAT type cool-
ants are:
• Acidity (pH) between 8.0 and 9.0
Reserve alkalinity at least 2.5
Total of dissolved solids maximum
3,000 ppm.
• Chemicals to be included:
Nitrite with a minimum of 2,000 ppm,
or alternatively: nitrite in combination
with molybdate with a minimum of
1,300 ppm.
• Chemicals to be excluded:
Chromates
Borates
Silicates
Phosphates
Amines
Examples of acceptable products are:
Shell Rotella ELC
Eurol Coolant XL-NM
Shell HD Premium Coolant
Table 2. Coolant Fill Quantities
K007 Engine, Tier 3/
Stage III A
25.5 liter (6.7 gal)
K007 Engine, Tier 4i/
Stage III B
19 liter (5 gal)
J019 Engine, Tier 3/
Stage III A
25.5 liter (6.7 gal)
J019 Engine, Tier 4i/
Stage III B
22 liter (5.8 gal)
A238 Engine, Tier 4i/
Stage III B
24 liter (6.3 gal)
Charge Air Cooling System
The turbocharger uses the energy from the exhaust
gas stream to compress the intake air, which can
heat up to well over 100 to 160°C (212 to 320°F).
Compressed intake air is cooled by leading it
through the charge air cooler before it enters the
engine. Cooling the intake air improves engine per-
formance and lowers emission values.
Transmission Oil Cooling System
The cooling system for the transmission is descri-
bed in Transmission 1300SRM1455.
0700 SRM 1595 Cooling System
7

The transmission oil cooling system contains a
thermostat valve, which is installed between the
torque converter outlet port and the transmission
cooling core. This thermostat starts opening at
87°C (189°F) and is completely opened at
102°C (216°F). At temperatures below
87°C (189°F), oil flow is directly returned to the
transmission. At temperatures above
102°C (216°F), the entire oil flow from the outlet
port passes through the transmission cooling core
before it is returned to the transmission.
Hydraulic Oil Cooling System
General
Heat generated in the various hydraulic compo-
nents is absorbed by the hydraulic oil, which re-
turns to the hydraulic tank.
Hydraulic Oil Cooling
A separate gear pump provides an oil flow through
the in series connected systems for oil filtration, oil
cooling and brake cooling. See Figure 7.
The hydraulic control system signals and provides
some protection when extreme temperatures are
reached.
Below is a short description for these subsystems in
the hydraulic cooling system.
A component location overview is shown on Fig-
ure 8.
1. HYDRAULIC OIL TANK
2. GEAR PUMP
3. FILTER ADAPTER
4. THERMOSTAT
5. HYDRAULIC COOLING CORE
6. WET BRAKE MANIFOLD
7. DRIVE AXLE
8. SERVICE BRAKE CONNECTION
Figure 7. Hydraulic Cooling System
Cooling System 0700 SRM 1595
8

1. GEAR PUMP
2. HYDRAULIC FILTER
3. HYDRAULIC TANK
4. COOLER
5. SERVICE BRAKES
6. BRAKE FLOW DISTRIBUTION MANIFOLD
Figure 8. Hydraulic Oil Cooling System
Components
Oil Filtration and Oil Cooling
Pump supply is filtered by a 5 micron filter element
which is mounted on a filter adapter. The filter is
protected by a 340 kPa (49 psi) bypass valve.
The hydraulic filter adapter includes a thermo-
static valve which starts opening at 65°C (149°F).
When this valve is fully open at 80°C (176°F), all oil
flowing through the filter assembly is directed to
the hydraulic oil cooling core. Oil from the cooling
core returns to the filter adapter, and flows further
to the brake manifold. See Figure 9.
1. FILTER ELEMENT
2. PUMP SUPPLY HOSE TO FILTER ADAPTER
3. RETURN HOSE FROM FILTER ADAPTER
4. FILTER ADAPTER
5. COOLING CORE RETURN HOSE TO FILTER
ADAPTER
6. COOLING CORE SUPPLY HOSE FROM FILTER
ADAPTER
7. HYDRAULIC OIL COOLING CORE
Figure 9. Hydraulic Filter and Connecting Hoses
Brake Cooling
The brake manifold connects the supply and return
hoses for the service brake system and the wet
brake cooling system. The manifold includes a
140 kPa (20 psi) relief valve, which protects the
seals in the brake housing.
None of the components of the brake manifold are
serviced separately.
Hydraulic Control System
The hydraulic control system activates a fault code
and may also reduce engine or vehicle speed when
extreme hydraulic oil temperatures are detected.
h-hot is displayed when oil temperature in the
tank exceeds 90°C (194°F). In addition, the option-
ally available High Temperature Protection limits
vehicle speed to 10 km/h to reduce the heat gener-
ated during braking.
0700 SRM 1595 Service and Repair
9

h-cold is displayed when oil temperature in the
tank is below -5°C (23°F). Depending on the hy-
draulic temperature, engine speed is reduced pro-
portionally to protect the hydraulic pumps against
cavitation.
Service and Repair
COOLING SYSTEM CHECKS
WARNING
DO NOT operate a lift truck that needs repairs. Re-
port the need for repairs immediately. If repair is
necessary, put a DO NOT OPERATE tag in the op-
erators area. Remove the key from the key switch.
During engine operation, stay clear of the fan, pul-
leys, and drive belts. Contact with these parts can
cause serious injury.
Compressed air can move particles so 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.
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components. Hy-
draulic oil can be injected into the body by pres-
sure.
Basic Checks
Perform the checks listed below in the sequence
shown to find the cause of a cooling problem. Before
starting a repair, try to find additional symptoms
that confirm the suspected cause of failure.
Put the lift truck on a level surface. Lower the car-
riage and forks, stop the engine, and apply the
parking brake.
1. Cooling cores:
Make sure the outside of the cooling core as-
sembly is clean. Use compressed air to re-
move dust and debris that may have accu-
mulated on the exterior of the cores. Check
for signs of moisture and oil on the cooling
cores.
If any leakage is found, the leaking cooling
core(s) must be replaced. See Cooling Core
Replacement.
2. Coolant level:
Coolant level must be above the "MIN" mark
in the expansion tank when the engine is
cold. Follow the procedures under External
Leak Test if more than 1 liter (0.26 gal) per
1,000 hours must be added.
3. Drive belt:
Check the belt for excessive wear and dam-
age and for hardening, and check the belt
tension. For replacement instructions, see
Drive Belt Replacement.
4. Fan condition:
Check the fan blades for wear and damage.
Replace the fan if necessary.
5. Collapsed hoses:
Check if one or more coolant hoses are col-
lapsed when the engine is cold. Collapsed ho-
ses indicate a defective vacuum valve in the
radiator cap. See External Leak Test.
Coolant Quality Checks
1. Expansion Tank
The inside of the expansion tank should be
free of deposits and rust.
Deposits and rust indicate a serious coolant
quality problem that may have caused the
buildup of insulating deposits inside the en-
tire cooling system. Do a leak test to estab-
lish if a gasket problem caused the coolant to
deteriorate. See the section External Leak
Test for the procedure.
Repair any leakage, clean the entire cooling
system, flush and refill with new coolant. See
Flushing the Engine Cooling System for the
procedure.
2. Visual Test
Service and Repair 0700 SRM 1595
10

Take a small quantity of coolant from the ex-
pansion tank and pour it into a sight glass.
Coolant should be a clear fluid without
cloudiness, floating debris or oil. Oil in the
coolant, cloudiness, or floating debris indi-
cates a possible head gasket or cylinder liner
defect. Do a leak test and replace the head
gasket or cylinder liners if defective. See the
section External Leak Test for the procedure.
Clean, flush, and refill the system with new
coolant. See Flushing the Engine Cooling
System for the procedure.
Cloudiness and floating debris can also indi-
cate that additives in the coolant are deple-
ted or that incompatible additives have been
mixed. In that case, clean, flush and refill
the system with new coolant.
3. Coolant Acidity (pH) Test
Use a test strip to establish the acidity of the
coolant. Flush and refill the cooling system
with new coolant if the pH is lower than 7.7.
See Flushing the Engine Cooling System for
the procedure.
When the pH is lower than 7.7, the additives
in the coolant are depleted. Perform a leak
test if the pH has dropped below 7.7 within 3
years of service. See External Leak Test for
the procedure.
4. Freeze Protection Test
Check the ethylene glycol content with a
portable refractometer. Ethylene glycol con-
tent must be 40% or more, depending on low-
est ambient temperature. An ethylene glycol
content of more than 50% affects the cooling
capacity of the coolant. Raise the ethylene
glycol content by adding ethylene glycol.
Lower the ethylene glycol content by adding
distilled water. See Figure 10.
A. FREEZE POINT TEMPERATURE
B. PERCENTAGE OF ETHYLENE GLYCOL IN
COOLANT
Figure 10. Coolant Mixture Ratios
Coolant Flow Checks
Thermostat
CAUTION
DO NOT operate the engine without a thermostat.
Without a thermostat, coolant will not flow to the
radiator, and the engine will overheat.
Failure of a thermostat results in either too low or
too high operating temperatures.
When a thermostat opens at too high a tempera-
ture, the system will overheat, while the cooling
core remains relatively cold.
When a thermostat opens at too low a temperature
the system will not reach its normal operating tem-
perature. The temperature at core entry is similar
to actual system temperature.
If a malfunctioning engine thermostat is suspected,
replace it with a new one. See thermostat replace-
ment.
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The thermostats for transmission and hydraulics
are not serviced separately. For a replacement, the
entire assembly needs to be exchanged. Make sure
to have established that a thermostat malfunctions,
before replacing the transmission bypass valve or
the hydraulic filter assembly.
See Table 3 which lists the temperatures at which
the thermostats should start opening and at which
they should be completely open.
Table 3. Thermostat Operating Temperatures
Thermostat Starts to open at Is fully open at
Engine 82°C (180°F) 91°C (196°F)
Transmission 87°C (189°F) 102°C (216°F)
Hydraulic 65°C (149°F) 80°C (176°F)
Water Pump
WARNING
During engine operation, stay clear of the fan, pul-
leys, and drive belts. Contact with these parts can
cause serious injury.
The radiator core or other parts of the cooling
system may be hot or under pressure and can
cause serious injury.
To find the cause of a sudden coolant flow problem,
perform the following tests in the sequence shown:
1. Run the engine until the coolant temperature
reaches 91 to 103°C (196 to 218°F). At this tem-
perature, the thermostat should be completely
open.
2. Put on an insulated leather glove and squeeze
the upper radiator hose, while an assistant revs
the engine several times. For the location of the
upper radiator hose, see Figure 13.
3. When pressure surges can be felt, the water
pump functions sufficiently.
4. If no pressure surges can be felt, remove the
water pump for inspection. For instructions, see
Water Pump, Inspect, and Install.
Cooling Core Efficiency
Table 4 shows the temperature difference to be ob-
tained between core entry and core exit, under the
following conditions:
- Fluids and air have reached the tabled core
entry temperatures. Lower entry tempera-
tures result in smaller temperature differen-
ces.
- Fan and engine run at maximum speed.
- Results are for an ambient temperature of
50°C (122°F). Temperature differences im-
prove with 3% for every 10°C (18°F) that am-
bient temperature is lower than
50°C (122°F).
If the required temperature difference cannot be
obtained, clean and flush the cooling core. See
Cleaning the Engine Cooling System and Flushing
the Engine Cooling System.
Table 4. Temperature Differences Between Core Entry and Core Exit
Charge Air Engine Coolant Hydraulic Oil Transmission Oil
Core Entry Tempera-
ture
200°C (360°F) 105°C (190°F) 90°C (160°F) 120°C (215°F)
Temperature Difference
Service and Repair 0700 SRM 1595
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Table 4. Temperature Differences Between Core Entry and Core Exit (Continued)
Charge Air Engine Coolant Hydraulic Oil Transmission Oil
K007/J019 Tier 3/
Stage III A
90°C (160°F) 6°C (11°F) 18°C (64°F) 11°C (20°F)
K007 Tier 4i/Stage III
B
90°C (160°F) 6°C (11°F) 18°C (64°F) 11°C (20°F)
J019 Tier 4i/Stage III
B
75°C (135°F) 7°C (13°F) 18°C (64°F) 11°C (20°F)
A238 Tier 4i/Stage III
B
75°C (135°F) 7°C (13°F) 18°C (64°F) 11°C (20°F)
Cooling Core Flow Restrictions
This test helps to find out if any fins in the cooling
core have restricted flow. Use a digital thermome-
ter or an infrared thermometer to measure temper-
atures.
1. Run the engine until the engine cooling core is
warm.
2. Switch OFF the engine.
3. Open the rear cover to access the radiator.
4. Measure the outside temperature of the core
from top to bottom and search for temperature
differences. Relatively cold spots indicate a re-
stricted coolant flow.
5. If flow restrictions have been found, clean and
flush the radiator. See Cleaning the Engine
Cooling System and Flushing the Engine Cool-
ing System.
Engine Leak Tests
Perform a leak test if one of the following observa-
tions has been made:
• More than 1 liter (0.25 gal) of coolant had to
be added during the past 3,000 running
hours.
• Coolant quality failed the visual test.
• Coolant pH has dropped below 7.7 within 3
years of service.
• Coolant is present in the engine oil.
• Excessive steam emission from the exhaust,
possibly accompanied by difficult starting.
External Leak Test
NOTE: : If the pressure tester has no cap that fits
the thread on the expansion tank, disconnect the
radiator de-aeration hose from the expansion tank.
Connect the hose of the tester to the now open tank
connection flange. Before testing, securely plug the
free end of the radiator de-aeration hose. Connect a
piece of hose to the overflow tube on the radiator
cap and plug this hose to prevent pressure release
through the radiator cap.
After testing, remove all tools and materials used.
In particular, remove the plugs from the radiator
de-aeration hose and from the overflow tube.
1. Make sure the engine and components of the
cooling system are dry on the outside. Also
clean and dry the weephole, which is situated
just below the water pump’s impeller shaft. At-
tach a pressure tester to the expansion tank
and apply 140 kPa (20 psi) for 5 minutes. Any
drop in pressure indicates a leak.
If pressure drops, check for coolant leaks at con-
nections, hoses, water pump, cooler core, and en-
gine. Repair leaking components as necessary.
Replace the water pump if any coolant escapes
from the weephole of the water pump during the
pressure test. Remove the pressure tester from
the expansion tank and reinstall the radiator
cap. Perform an internal leak test if no external
leak was found. See Figure 11.
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1. O-RING
2. WEEP HOLE
3. WATER PUMP
4. CAPSCREWS
Figure 11. Water Pump
2. Check the functionality of the radiator cap.
• Measure the relief pressure of the cap by
pressurizing the tank side of the radiator
cap. Disconnect the cooling core de-aera-
tion hose from the expansion tank. Con-
nect the hose of the tester to the now
open tank connection tube. Before test-
ing, securely plug the free end of the ra-
diator de-aeration hose. The radiator cap
should release pressure at
103 kPa (15 psi). If the relief pressure is
too low, it will lead to coolant loss
through the radiator cap and a lowered
boiling point of the coolant, which will re-
duce cooling capacity. If the cooling sys-
tem pressure is too high, it can result in
gasket failures at the water pump, cylin-
der liners, and cylinder head.
• Measure the opening pressure of the vac-
uum valve. Release pressure from the
cooling system and reinstall the radiator
cap. Connect the hose of the pressure
tester to the overflow tube. To measure
the opening pressure of the vacuum
valve, pressurize the overflow tube.
This valve should open and allow air into
the system when 7 to 12 kPa (1.0 to
1.7 psi) is applied. A malfunctioning vac-
uum valve causes a slow buildup of pres-
sure, which promotes corrosion in the
water pump and at the cylinder liners.
See Figure 12.
1. EXPANSION TANK
2. RADIATOR CAP
3. PRESSURE TESTER
4. CYLINDER HEAD DE-AERATION HOSE
5. COOLING CORE DE-AERATION HOSE
Figure 12. Radiator Cap and Expansion Tank Test
Check for Coolant Leak Into The Engine Oil
Sump
1. Take out the oil gauge and insert a small diam-
eter hose, attached to a suction pump. Be sure
to take an oil sample from the bottom of the oil
pan, where any coolant will collect.
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