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]H36XMS-12,
H40XM-12, H44XM-12, H48XM-12
(H800HD, H1050HD) [B917];
H40XM-16CH, H44XM-16CH,
H48-16CH, H50-16CH, H52XM-16CH
(H1050HD, H1150HD) [G117]

PART NO. 4038565 700 SRM 1530

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Cooling System Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Air Flow.......................................................................................................................................................... 1
Fan Drive System .......................................................................................................................................... 2
Pump Supply ............................................................................................................................................. 2
Fan Drive ................................................................................................................................................... 3
Hydraulic Oil Filtration ............................................................................................................................ 4
Hydraulic Oil Cooling................................................................................................................................ 4
Brake Cooling System ............................................................................................................................... 5
Fan Drive Control System............................................................................................................................. 6
Temperature Input Signal ........................................................................................................................ 6
Cooling Performance ................................................................................................................................. 6
Cooling Cores ................................................................................................................................................. 7
Engine Cooling System ................................................................................................................................. 8
Water Pump ............................................................................................................................................... 8
Coolant ....................................................................................................................................................... 8
Ethylene Glycol ..................................................................................................................................... 8
Water ..................................................................................................................................................... 8
Additives................................................................................................................................................ 9
Coolant Quality Requirements............................................................................................................. 9
Cab Heater................................................................................................................................................. 9
Expansion Tank......................................................................................................................................... 9
Thermostat ................................................................................................................................................ 10
Charge Air Cooling System ........................................................................................................................... 10
Hydraulic Oil Cooling System....................................................................................................................... 10
Transmission Oil Cooling System................................................................................................................. 10
Engine Cooling System Checks ......................................................................................................................... 11
Basic Checks .................................................................................................................................................. 11
Coolant Quality Checks................................................................................................................................. 11
Expansion Tank Inspection ...................................................................................................................... 11
Coolant Visual Test ................................................................................................................................... 11
Acid Level (pH) Test .................................................................................................................................. 11
Freeze Protection Test............................................................................................................................... 11
Coolant Flow Checks ..................................................................................................................................... 12
Thermostat ................................................................................................................................................ 12
Water Pump ............................................................................................................................................... 12
Radiator Core ............................................................................................................................................ 12
Leak Test........................................................................................................................................................ 12
External Leak Test ........................................................................................................................................ 13
Internal Leak Test ......................................................................................................................................... 13
Coolant Leak Into the Engine Oil Sump.................................................................................................. 13
Combustion Leak....................................................................................................................................... 14
Fan Drive System Checks ............................................................................................................................. 14
Brake Cooling System Checks ...................................................................................................................... 14
Cooling System Repairs..................................................................................................................................... 16
Drain the Engine Cooling System ................................................................................................................ 16
Refill the Engine Cooling System ................................................................................................................. 16
Flushing the Engine Cooling System ........................................................................................................... 16
Clean the Engine Cooling System ................................................................................................................ 17
Fan and Fan Motor ........................................................................................................................................ 18
Remove....................................................................................................................................................... 18

©2012 HYSTER COMPANY i

Table of Contents Cooling System

TABLE OF CONTENTS (Continued)

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]
H36XMS-12, H40XM-12, H44XM-12, H48XM-12 (H800HD, H1050HD) [B917];
H40XM-16CH, H44XM-16CH, H48-16CH, H50-16CH, H52XM-16CH
(H1050HD, H1150HD) [G117]

ii
700 SRM 1530 Description

General
This SRM describes the operation and the replace- is described in Transmission operation and diag-
ment procedures for the components of the cooling nostics, (TE27 and TE32) 1300 SRM 1220. The cab
system for engine coolant, engine intake air, and hy- heater and air conditioning system are described in
draulic oil. The cooling system for the transmission Cab Heater, (After Oct. 2008) 100 SRM 1459.

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. The
engine, hydraulic system and the transmission, be- screen prevents that big particles coming from the
cause of the big and fluctuating volume of heat to steer tires would damage the cooler cores. The screen
be dissipated and the need for a controlled operat- also prevents that large sheets of paper or plastic
ing temperature. would obstruct air flow.

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

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 700 SRM 1530

FAN DRIVE SYSTEM At a pressure of 26.5 MPa (3840 psi) the driving force
of the motor matches the air flow resistance of the fan
A separate variable displacement pump, on the hy- turning at a speed of 2100 rpm.
draulic schematic indicated by ‘Pump 3’, provides the
oil flow for the fan drive, which is connected in se- At lowest solenoid signal and above 1500 engine
ries with the systems for oil filtration, oil cooling and rpm, the maximum regulated pump pressure re-
brake cooling. Pump supply volume therefore relates duces pump supply volume, keeping fan speed at
directly to fan speed, and the volume for oil filtra- 2100 rpm.
tion, oil cooling and brake cooling. Below is a short
description for each of these subsystems. At lowest solenoid signal and below 1500 engine rpm,
the fan speed is proportional to engine speed.
Pump Supply
An overview of the different speeds and pressures is
Generally, variable displacement pumps deliver a shown under Fan Drive System Checks.
volume depending on the sensed flow resistance
of the hydraulic circuit. The pump pressure to be
reached is determined by the pressure signal from
the Load Sense line. Given a certain flow resistance,
the pumped oil volume will increase when the reg-
ulator allows pump pressure to rise. Instead of a
LS line, the delivered pressure of Pump 3 varies
according an electric signal to a solenoid, which is
fitted on the pressure regulator. See Figure 2.

When the truck is cold and no fan rotation is re-

quired, the hydraulic controller sends its highest
PWM signal to the solenoid, which results in a reg-
ulated pressure of 3.6 MPa (520 psi). The resulting
oil flow is required to prevent the wet brakes from
overheating during warming up. At this relatively
low pressure, the fan will rotate at about 700 rpm,
which represents a cooling performance of 10%.

During normal operation, the hydraulic controller

sends a signal that results in a cooling performance
between 10% and 90%. See Fan Drive Control Sys- 1. SOLENOID
tem. 2. CONNECTOR
3. PRESSURE REGULATOR
At a required cooling performance of 100%, the hy- 4. PUMP 3
draulic controller sends its lowest PMW signal to the 5. PUMP 2
solenoid (= no signal) allowing pump pressure to rise
up to 26.5 MPa (3840 psi), which is the maximum Figure 2. Solenoid on Pump 3
regulated pump pressure.

2
700 SRM 1530 Description

Fan Drive
The fan is mounted on a hydraulic motor that ro-
tates proportional to pump supply. A frame bolted to
the cooler assembly keeps the fan in the correct posi-
tion to the shroud. A relief valve inside the hydraulic
motor prevents cavitation when fan motor speed re-
quires a bigger oil supply compared with actual pump
supply. This situation can occur when the fan is at
speed and engine speed drops quickly. See Figure 3.

Legend for Figure 3

1. PUMP 3
2. FAN DRIVE
3. FILTER ADAPTER
4. THERMOSTATIC VALVE
5. BRAKE MANIFOLD
6. DRIVE AXLE
7. SERVICE BRAKE CONNECTION
8. BRAKE RETURN FILTER
9. HYDRAULIC COOLER

Figure 3. Fan Drive Schematic

3
Description 700 SRM 1530

Hydraulic Oil Filtration

A five micron hydraulic filter element provides filtra-
tion of pump supply volume. The filter is protected
by a 0.34 MPa (49.3 psi) bypass valve. When pres-
sure drop over the filter exceeds 0.20 MPa (46.4 psi),
a pressure sender provides a signal to the hydraulic
controller to indicate a clogged filter. Provided oil
temperature exceeds 40°C (104°F), the controller will
activate a warning light on the instrument panel. At
temperatures below 40°C (104°F) the warning light
is not activated to exclude a false alarm caused by
the higher oil viscosity. See Figure 4.

Hydraulic Oil Cooling

The hydraulic filter adapter includes a thermostatic
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 re-
turned to the filter adapter and from there connected
with the brake cooling system at the wet brake man-
ifold. Except for the filter element, none of the com-
ponents are serviced separately. Replace the entire
filter assembly if one of its components fails.

A. TOP VIEW B. SIDE VIEW

1. FILTER ADAPTER
2. HOSE FROM COOLER
3. HOSE TO COOLER
4. HOSE FROM MOTOR
5. HOSE TO BRAKE MANIFOLD
6. FILTER ELEMENT
7. PRESSURE SENDER

Figure 4. Hydraulic Filter

4
700 SRM 1530 Description

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.
Return oil from the brake manifold first passes a
20-micron filter before returning to tank. In case the
brake filter is clogged, a 35 kPa (5 psi) bypass valve
in the filter head opens. None of the components for
the brake manifold and brake return filter housing
are serviced separately. See Figure 5.

XX Service Brake Pressure

R Relief Tank Return
P From Hydraulic Filter Housing
T To Brake Return Filter
TBL From Wheel Brake Left
XBL To Service Brake Left
PBL To Wheel Brake Left
TBR From Wheel Brake Right
XBR To Service Brake Right
PBR To Wheel Brake Right

Figure 5. Brake Manifold

5
Description 700 SRM 1530

FAN DRIVE CONTROL SYSTEM Abnormalities in the engine, transmission and hy-
draulic system result in a fault code on the hour me-
Four temperature sensors provide the input signals ter display. The fault code guides for engine, trans-
to the hydraulic controller, which determines the out- mission and hydraulic system provide further infor-
put signal to the fan drive system. The output signal mation to rectify these faults.
from the hydraulic controller to the pressure regula-
tor solenoid, conforms with the highest required cool- Temperatures below the ‘Minimum Temperature’ re-
ing performance that any of these four temperature sult in an output signal that corresponds with a 10%
senders would require. cooling performance. The Minimum and Maximum
Input temperatures determine the normal operating
The hydraulic temperature sender is located at the range, whereby the Minimum Input corresponds to
bottom of the hydraulic tank. The engine coolant 10% cooling performance and the Maximum Input
sender is located above the water pump, in the cylin- corresponds to 90% cooling performance.
der head. The charge air temperature sensor is in the
intake manifold close to the air supply opening. The When one of the temperature inputs exceeds the
transmission temperature sender is located close to Maximum Temperature input, the output for the fan
the transmission pump drive gear. drive is set at 100% cooling performance.

Temperature Input Signal When transmission respectively engine temperature

reach the Limit Temperature, their controllers will
The temperature senders for transmission, engine shift to neutral, respectively de-rate and stop the en-
coolant and charge air send their input signals to the gine. When hydraulic temperature reaches the Limit
transmission and engine controller, which generate a Temperature, the optional High Temperature Protec-
can bus signal that is sent to the hydraulic controller. tion limits truck speed to 10 km/h (6.2 mph) to reduce
the generated heat at the brakes. See Table 1.
The hydraulic oil temperature sender has a resis-
tance between 700 and 200 Ohm and is directly con-
nected with the hydraulic controller.

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 1900 SRM
The following table shows the relation between PWM 1534.
output signal, regulated pressure and cooling perfor-
mance.

PWM Signal Regulated Pressure Cooling Performance

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

6
700 SRM 1530 Description

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 cool-
ing core by the fan. The amount of heat dissipated
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 cooling core itself.
• Amount of air pulled through the cooling core,
which depends on fan speed. Environmental de-
bris such as paper, straw or lint can restrict air
flow. Operating conditions determine the required
core cleaning frequency.
• Core external isolation, which results from (dust)
particles forming an isolating deposit on the out-
side of the core. The deposit impedes heat transfer
from core to the air. Operating conditions deter-
mine the required core cleaning frequency.
• Amount of fluid passing through the core. Gen-
erally, more fluid passes at higher engine speeds
when thermostats are fully open. The flow of 1. CHARGE AIR COOLER
charge air increases when more engine power is 2. ENGINE RADIATOR
3. HYDRAULIC OIL COOLER
delivered.
4. TRANSMISSION OIL COOLER
• Core internal isolation, which results from de- 5. FAN MOTOR
posits at the inside of the cooling core, which
impedes heat transfer from the fluid to the core. Figure 6. Cooler Assembly
The hydraulic and transmission oil cooler are un-
likely associated with internal deposits because of The following table shows the temperature difference
the properties of oil and the oil filtration system. to be obtained between core entry and core exit, when
The charge air cooler may collect dust that has fan and engine run at maximum speed at an ambient
reached the core over time due to imperfect air fil- temperature of 50°C (122°F). Cooling results are 3%
tration. Normally, internal cleaning of the charge better for every 10°C (18°F) that ambient tempera-
air cooler is not required until engine overhaul. ture is lower.

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 150°C (270°F) 9°C (16°F) 17°C (30°F) 18°C (32°F)

7
Description 700 SRM 1530

ENGINE COOLING SYSTEM and 50%, for optimum thermal capacity and boiling
point elevation. Ethylene glycol content has to be
Water Pump established with a portable refractometer. Content
can be raised by adding pure ethylene glycol or
The water pump is a centrifugal pump, which is belt can be lowered by adding pure water to the cooling
driven by the crankshaft pulley. Pump supply relates system. Ethylene glycol degrades over time, but
to engine speed but does not increase proportionally degrades more rapidly with pH values lower than
with engine speed. For proper functionality it is 7.0. When ethylene glycol degrades, acidic compo-
essential that the suction side of the pump is com- nents are formed lowering pH-values at a rapid rate.
pletely filled with coolant. Any vapor at the suction Additives in the coolant compensate for the negative
side of the pump reduces pump supply and causes effects of degrading ethylene glycol.
damage through cavitation. To prevent formation
of vapor, cooling system pressure is maintained at Water
a raised level by the radiator cap. The only wear
item of the pump is the seal at the impeller shaft. The water quality requirement for coolant is distilled
A worn seal exposes itself through loss of coolant. or deionized water, with little or no minerals. Min-
Other possible areas for coolant leakage are the hose erals increase corrosion, form deposits and deplete
connections and the gasket at the mounting flange. some of the additives. If distilled or deionized water
is not available, test strips must be used to establish
Coolant acceptable water quality. Limiting values are:

Coolant is a mixture of water (48%), ethylene glycol Total Solids 340 ppm "MAX"
(48%), and some additives (4%). Water is a fluid with Total Hardness 170 ppm "MAX"
the highest heat capacity and lowest cost, but has (CaCo3, MgCo3)
disadvantages for its limited thermal usage, and for
its tendency to enhance corrosion. The limited ther- Chloride (Cl) 40 ppm "MAX"
mal usage is extended by adding ethylene glycol. The Sulfate (SO4) 100 ppm "MAX"
tendency to enhance corrosion is suppressed by ad-
ditives. These additives are not available for replen- pH 7.0 to 8.0
ishment. This implies that the entire coolant system
has to be drained and refilled when the additives are
depleted. Water and/or ethylene glycol can be added
separately to correct their relative contents.

Ethylene Glycol

NOTE: The pH is a measure of acidity or alkaline. PH

numbers lower than 7.0 indicate an acidic environ-
ment, which promotes corrosion. The pH numbers
higher than 7.0 indicate an alkaline environment,
which reduces corrosion.

Coolant consists of three main ingredients: water,

ethylene glycol, and additives. Mixing ratio between
water and ethylene glycol is normally 50/50. Other
mixing ratios influence the freezing point, boiling
point and fluidity of the mixtures. See Figure 7.
Higher concentrations ethylene glycol reduce flu-
A. FREEZE POINT TEMPERATURE
idity and heat capacity, but raise the boiling point. B. PERCENTAGE OF ETHYLENE GLYCOL TO
Operation of the lift truck within arctic conditions WATER
justify ethylene glycol contents of 50% or more. Most
common ethylene glycol content is between 40% Figure 7. Coolant Mixture Ratios

8
700 SRM 1530 Description

Additives Examples of such products are:

– Shell Rotella ELC
The additive package in the coolant contains several – Eurol Coolant XL-NM
components, each with a different function. Most
important function is corrosion protection and main- Cab Heater
taining a predetermined acidic level (pH value). Fur-
ther functions are scale inhibition, de-foaming, and The cab heater uses the heat contained in the coolant
liner pitting protection. that flows through the heater core to heat the cab,
but has no effect on cooling system capacity.
The acidic level (pH value) of coolant in the lift trucks
is maintained by chemicals that are categorized as Expansion Tank
OAT (Organic Acid Technology). One of the charac-
teristics of OAT type coolant is that the pH value is The function of the expansion tank is to allow expan-
maintained for several years at a stable level. Once sion of the coolant when the engine gets warm, reg-
the additives are depleted, the pH level will drop. ulate pressure in the cooling system, and facilitate
When pH level is 7.7 or lower, the coolant must be removal of gasses that may have formed. Coolant
replaced. expands with rising temperature. The increased vol-
ume of coolant flows through the expansion hose to
Do not mix coolant with different coolants or ad- the expansion tank, where it compresses the con-
ditives as it can seriously affect the properties of tained air, causing cooling system pressure to rise.
coolant. Examples are:
– Deactivation of some of the protecting additives. The purpose of raising system pressure is to raise
– Formation of gel, blocking coolant flow. the boiling temperature of coolant. A raised boil-
– Formation of deposits, impeding heat transfer in ing temperature is required for circumstances when
the engine block and the radiator core. coolant flow is limited. For instance when returning
to idle after full power operation, or when turning off
The engine cooling system in the lift truck has been a warm engine.
factory filled with an additive package categorized as
OAT (Organic Acid Technology) and allows a service If the coolant were to boil, it would form gas bubbles
life up to 5 years, provided it passes the 6 monthly which reduce the contact area of coolant with the en-
coolant quality checks. gine, and reduce the coolant flow that can pass a cer-
tain area. As a result, temperature in that affected
The factory filled coolant allows mixing with other engine area will rise even further, which may lead to
OAT (Organic Acid Technology) type coolants to a component failure.
maximum of 25%, provided the added coolant meets
the coolant quality requirements. Do not use or mix For a sufficiently quick pressure increase it is neces-
with conventional coolants or coolants based on SCAs sary that the air volume in the expansion tank is lim-
(Supplemental Cooling Additives). ited. For this reason coolant in the expansion tank
must reach the lower end of the filler tube.
Coolant Quality Requirements
Pressure in the cooling system is regulated by the ra-
When replacing the entire coolant volume, refill with diator cap. The pressure valve in the radiator cap
an OAT (Organic Acid Technology) based product relieves pressure at 103 kPa (15 psi). The vacuum
meeting Cummins requirement CES 14603 and valve admits outside air, when vacuum in the expan-
Cummins bulletin 3666132. sion tank is between 7 to 12 kPa (1.0 to 1.7 psi). A
failed pressure valve is indicated by loss of coolant.
Essential properties of these OAT type coolants are: A failed vacuum valve is indicated by a collapsed
– Acidity (pH) level between 8.0 and 9.0. Reserve Al- coolant hose when the engine is cold.
kalinity at least 2.5. Total Dissolved Solids maxi-
mum 3000 ppm. A bigger diameter hose connects the bottom of the ex-
– Chemicals to be included: Nitrite to a minimum of pansion tank with the suction side of the water pump
2000 ppm, or alternatively: Nitrite in combination to provide some compensation for pressure surges
with Molybdate to a minimum of 1300 ppm. caused by engine speed changes.
– Chemicals to be excluded: Chromates, Borates
(Boron), Silicates, Phosphates and Amines.

9
Description 700 SRM 1530

De-aeration hoses connect the top of the expansion CHARGE AIR COOLING SYSTEM
tank with the cylinder head and the highest point of
the engine radiator. An additional de-aeration hose The turbocharger uses the energy from the exhaust
connects with the water pump outlet hose to relieve gas stream to compress the intake air. The resulting
trapped air when refilling the engine cooling system. temperature increase of the intake air would reduce
the engine performance and influence emissions. By
A fluid level sensor is fitted at the bottom of the ex- cooling the intake air in the charge air cooler the en-
pansion tank to monitor a minimum coolant level. gine can reach its rated performance and its certified
When coolant level is low, the ECM will shut off the emission levels.
engine within 30 seconds.
On Tier 4i engines the EGR system mixes exhaust
Thermostat gases with air from the charge air cooler, just before
the inlet manifold. For a sufficient cooling of the EGR
mechanism, some of the engine coolant flows through
CAUTION small passages in the EGR housing.
DO NOT operate the engine without a ther-
mostat. Without a thermostat, coolant will HYDRAULIC OIL COOLING SYSTEM
not flow to the radiator, and the engine will
overheat. See Figure 8. Heat generated at the various hydraulic components
is absorbed by the hydraulic oil, which returns to
The thermostat is a device that controls coolant flow tank. During truck operation, oil in the tank will
by opening and closing to regulate coolant tempera- rise to operating temperature. With further in-
ture of the engine. When the coolant is cold, the ther- creasing oil temperature, the oil flow generated by
mostat is closed. Coolant is circulated by the water Pump 3 will directly provide the brake assemblies
pump through the engine and reenters via a bypass with cooled oil from the cooling core. Tank oil tem-
to the inlet of the water pump. When coolant has perature changes more gradually and depends on
reached 82°C (180°F) the thermostat starts opening the balance between cooling capacity and applied
the connection to the radiator and simultaneously hydraulic functions and braking actions. Normally
starts closing the bypass between engine and water tank oil temperature remains well below the max-
pump. At 93°C (200°F) the connection to the radia- imum allowed limit. See also Fan Drive Control
tor is completely opened and the bypass is completely System.
closed. A leaking bypass affects coolant flow to the
radiator. To completely close the bypass, the thermo- TRANSMISSION OIL COOLING SYSTEM
stat must have extended 9.7 mm (0.38 in.) and have
seals that are in good condition. Refer to the manual Transmission operation and
diagnostics, (TE27 and TE32) 1300 SRM 1220 for
the description and troubleshooting of the transmis-
sion cooling system.

Figure 8. Thermostat

10
700 SRM 1530 Engine Cooling System Checks

Engine Cooling System Checks

BASIC CHECKS Repair any leakage, clean the entire cooling system,
flush and refill with new coolant. See the section
Perform the below checks in the sequence shown to Flushing the Engine Cooling System for the proce-
find the cause of a cooling problem. Before starting a dure.
repair, try to find additional symptoms that confirm
the indicated cause of failure. Coolant Visual Test

WARNING Remove a small amount of coolant from the expan-

sion tank and poor into a sight glass. Coolant must
Compressed air can move particles so they
be a clear fluid with no cloudiness, floating debris, or
cause injury to the user or to other personnel.
oil. Oil in the coolant, cloudiness, or floating debris
Make sure the path of the compressed air is
indicate a possible head gasket or cylinder liner fail-
away from all personnel. Wear protective gog-
ure. Do a leak test and replace the head gasket or
gles or a face shield to prevent injury to the
cylinder liners if required. See the section External
eyes.
Leak Test for the procedure. Clean, flush, and refill
1. Radiator Core: Make sure the outside of the radi- the system with new coolant. See the section Flush-
ator is clean. Using compressed air remove dust ing the Engine Cooling System for the procedure.
and debris that may have accumulated on the ex-
Cloudiness and floating debris can also indicate that
terior of the radiator.
additives in the coolant are depleted or that too many
2. Coolant Level: Coolant level must reach the filler incompatible additives have been mixed.
tube in the expansion tank when the engine is
cold. Follow the procedures under External Leak Acid Level (pH) Test
Test if more than 1 liter per 1000 hours must be
Use a test strip to establish acid level of the coolant.
added.
Flush and refill the cooling system with new coolant
3. Drive belt, belt tensioner, and water pump: if pH level is lower than 8.0. See the sectionFlush-
Check the drive belt for wear and damage. ing the Engine Cooling System for the procedure. for
Check that the belt tensioner functions ade- procedure.
quately.
When pH level is lower than 8.0, the additives in the
4. If the fan belt must be replaced, make sure that coolant are depleted. Perform a leak test if the pH
the water pump and belt hub bearings are not level dropped below 8.0 within 3 years of service. See
worn. The indication of worn bearings is resis- the section External Leak Test for the procedure.
tance during rotation and too much bearing free
play. Freeze Protection Test
Check ethylene glycol content with a portable refrac-
COOLANT QUALITY CHECKS tometer. Ethylene glycol content must be at least
40%, depending on lowest ambient temperature. See
Expansion Tank Inspection
Coolant Mixture Ratios. Raise ethylene glycol con-
The inside of the expansion tank must be free of de- tent by adding ethylene glycol. Lower the ethylene
posits and rust. Deposits and rust indicate a seri- glycol content by adding distilled or deionized water.
ous coolant quality problem that may have caused
When circumstances allow, maintain ethylene gly-
the buildup of an isolation barrier inside the entire
col content between 40% and 50%. Ethylene glycol
cooling system. Do a leak test to establish if a gasket
levels higher than 50% affect the cooling capacity of
problem caused the coolant to deteriorate. See the
coolant.
section External Leak Test for the procedure.

11
Engine Cooling System Checks 700 SRM 1530

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

A sudden supply failure caused by the water pump

itself is unlikely.

1. Run the engine until coolant temperature has

reached 90°C (194°F). At this point the thermo-
stat should be fully open.

2. When pressure surges can be felt, the water

pump functions sufficiently.

3. If no pressure surges can be felt, remove the wa-

ter pump for inspection.
A. FREEZE POINT TEMPERATURE
B. PERCENTAGE OF ETHYLENE GLYCOL TO For replacement procedures for the Cummins water
WATER pump, contact your local Hyster dealer or refer to
Hyster Hypass Online.
Figure 9. Coolant Mixture Ratios
Radiator Core
COOLANT FLOW CHECKS
This test is to verify if any fins in the radiator core
Thermostat have restricted flow. Use a digital thermometer or an
infrared thermometer to measure temperatures.
The thermostat must start opening at 82°C (180°F),
and must be completely opened at 93°C (200°F). Use 1. Run the engine until the radiator core is warm.
a digital thermometer or an infrared thermometer to
measure the temperatures. 2. Shut the engine OFF.

When the engine is overheating, a failed thermostat 3. Remove the rear cover to access the radiator.
is indicated by a much lower temperature of the up-
4. Measure the outside temperature of the core
per radiator hose, compared with engine tempera-
from top to bottom and search for temperature
ture. When the engine remains too cold, a failed ther-
differences. Relatively colder spots indicate a
mostat is indicated by a simultaneous temperature
restricted coolant flow.
change of the engine and the upper radiator hose.
5. If flow restrictions have been found, clean and
If a failed thermostat is suspected, remove the ther-
flush the radiator. See the section Flushing the
mostat from the engine, and replace with a new one.
Engine Cooling System for the procedure.
For replacement procedures for the Cummins ther-
mostat, contact your local Hyster dealer or refer to
LEAK TEST
Hyster Hypass Online.
Perform a leak test if one of following observations
Water Pump has been made:
• More than 1 liter (0.26 gal) of coolant had to be
WARNING added during the past 1000 running hours.
During engine operation, stay clear of the fan, • Coolant quality failed the visual test.
pulleys, and drive belts. Contact with these • Coolant pH level dropped below 8.0 within 3 years
parts can cause serious injury. of service.
• Coolant is present in the engine oil.
• Excessive steam emission from the exhaust, possi-
bly accompanied by difficult starting.

12
700 SRM 1530 Engine Cooling System Checks

EXTERNAL LEAK TEST • Presence of ethylene glycol in the sample does

indicate coolant contamination. However, ab-
1. Make sure the engine and components of the cool- sence of ethylene glycol does NOT exclude that
ing system are dry on the outside. Also clean and coolant has leaked into the engine oil. The rea-
dry the weep hole on the side of the water pump. son is that ethylene glycol can react with cer-
Attach the pressure tester to the expansion tank tain additive components in the engine oil, be-
and apply 140 kPa (20 psi) of air pressure for 5 come volatile, and boil off at sump tempera-
minutes. See Figure 10. Maintain pressure and tures.
check for external leaks at connections, hoses, Secondly, deteriorated glycol reacts with bear-
water pump, radiator, and engine. Any drop in ing and bushing materials to form elevated lev-
pressure indicates a leak. Repair leaking com- els of lead in the oil.
ponents as necessary. Replace the water pump if • Water in the oil may be the result of condensa-
any coolant escapes from the weep hole of the wa- tion. Investigate if operating conditions have
ter pump during the pressure test. Remove the promoted condensation.
pressure tester from the expansion tank and re-
install the radiator cap. Do an internal leak test
if no external leak has been observed.

2. Check functionality of the radiator cap. The

radiator cap must relieve pressure at 103 kPa
(15 psi), and allow air in the system when vac-
uum is between 7 to 12 kPa (1.0 to 1.7 psi).
Remove and re-install the radiator cap to relieve
pressure. Pressurize the overflow tube to mea-
sure the opening pressure of the vacuum valve.
Pressurize the tank side of the radiator cap to
measure the relief pressure of the cap.
• If the relief pressure is too low, it will lead to
coolant loss through the radiator cap and a low-
ered boiling point of the coolant, which will re-
duce cooling capability.
• If the cooling system pressure is too high, it can
result in gasket failures with the water pump,
cylinder liners, and the cylinder head.
• A failed vacuum valve causes a slow build up
of pressure, which promotes corrosion in the
water pump and at the cylinder liners.

INTERNAL LEAK TEST

Coolant Leak Into the Engine Oil Sump 1. OVERFLOW TUBE
2. RADIATOR CAP
1. Take an oil sample from the bottom of the oil 3. PRESSURE TESTER
4. EXPANSION TANK
pan. It is important to include any aqueous sub-
stances that are in the sample taken. Figure 10. Radiator and Expansion Tank
Pressure Test
2. Have the sample examined in a laboratory and
repair the engine if coolant is present in the oil
sample.
• Coolant contamination is identified from ab-
normal levels of an corrosion inhibitor in the
coolant, that leaks into the oil.

13
Engine Cooling System Checks 700 SRM 1530

Combustion Leak clockwise direction. Verify with a stopped engine,

that manually rotating the fan clockwise involves
Obtain a commercially available combustion leak resistance. If not OK, the fan motor can have a
test kit to check if combustion gases have leaked into defect.
the cooling system. Note that test kits that react on
the presence of sulphur may not provide good results 3. Start engine. Observe immediate fan rotation
when sulphur level in diesel fuel is low. during starting. Run the cold engine at high idle
(+/ 1200 rpm). Pull connector from pump so-
Follow the manufacturer’s instructions when doing lenoid. Observe that fan speed immediately in-
the test. Repair the engine if exhaust gases are leak- creases. If not OK, the pump can have a defect.
ing into the cooling system.
4. Pull the connector from the pump solenoid. Start
If no combustion leak test kit is available, perform the engine, measure engine and fan speeds and
following steps to establish a combustion gas leak. compare with the values below in Table 2.

If fan speeds are acceptable, reinstall the connec-

WARNING
tor on the pump solenoid and check the hydraulic
During engine operation, stay clear of the fan, control system.
pulleys, and drive belts. Contact with these
parts can cause serious injury. If fan speeds are not acceptable, connect a pres-
sure gauge and a flow gauge. Measure at least
CAUTION the fan speeds at an engine speed of 1600 rpm
and 900 rpm.
If a combustion leak is present, pressure may
build up quickly and exceed the maximum al- Check functionality of the pump if oil flow is be-
lowable pressure. Immediately relieve cooling low the normal value.
system pressure if pressure reaches 140 kPa
(20 psi) during this test. Check functionality of the motor if oil flow is
above the normal value, and oil pressure is be-
1. Attach a pressure tester to the expansion tank. low the normal value.
Observe the pressure gauge, while your assistant
starts the engine. If pressure builds up quickly, BRAKE COOLING SYSTEM CHECKS
there is a serious combustion leak. Immediately
relieve the pressure from the cooling system and 1. Make sure the truck has passed the Fan Drive
stop the engine. Repair the engine if pressure System Checks.
builds up quickly
2. Make sure the service brakes operate correctly.
2. If there is a slow pressure build up, apply 103 kPa Verify absence of residual pressure when the
(15 psi) air pressure to the cooling system. Make brakes are released. Verify that both brake
sure coolant temperature is 80°C (175°F) or assemblies have equal braking performance.
lower. Observe the pressure gauge, while your Verify that operator releases brake pedal com-
assistant starts the engine and accelerates the pletely when no braking is required.
engine three times rapidly to 2000 rpm, followed
by 1 minute of idling. Stop the engine. Repair 3. Verify correct operation of the thermostatic by-
the engine if pressure in the cooling system has pass at the Filter Head. Measure that cooling
raised while revving the engine. core supply line remains cold until oil at the fil-
ter head has reached 65°C (149°F). Measure that
FAN DRIVE SYSTEM CHECKS there is no temperature difference between the
two OUT-ports on the filter head, when oil sup-
1. Check presence of fault codes. Look up any dis- ply temperature is above 80°C (176°F). Replace
played code in the relevant fault code guide and the filter head if the thermostatic bypass does not
use the provided information to rectify the fault. function correctly.

2. Check fan motor. Verify with a stopped engine

the virtually free rotation of the fan in the anti-

14
700 SRM 1530 Engine Cooling System Checks

4. Verify cooling effect of the cooling core. Mea- exceeds 20 kPa (2.9 psi). Establish that the
sure the temperature difference between cooler 140 kPa (20.3 psi) relief valve in the brake
in and cooler out connections. The value mea- manifold closes. Remove the hose from port R.
sured should at least reach the value shown in Replace the brake manifold if oil escapes from
Table 3. Clean or replace the cooler if the mea- port R at engine idle speed. Measure the tem-
sured temperature difference is less than stated. perature difference between ports TBL and TBR
at the brake manifold. Investigate oil flow re-
5. Verify oil supply to the brake assemblies. Mea- sistance of the brake assembly with the highest
sure flow resistance of the brake return filter. temperature.
Replace brake return filter if return pressure

Table 2. Engine/Fan Speed

Engine Speed (RPM) Fan Speed (RPM) Pump Pressure MPa Oil Flow liter/min
( psi) ( 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)
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)

Table 3. Core Temperature Difference

Core Tempera- Charge Engine Hydraulic Transmission

ture 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 150°C (302°F) 9°C (48°F) 17°C (62.6°F) 18°C (64.4°F)

15
Cooling System Repairs 700 SRM 1530

Cooling System Repairs

DRAIN THE ENGINE COOLING SYSTEM FLUSHING THE ENGINE COOLING
SYSTEM
WARNING
DO NOT remove the radiator cap from the ex- WARNING
pansion tank when the engine is hot. When DO NOT remove the radiator cap from the ex-
the radiator cap is removed, the pressure is re- pansion tank when the engine is hot. When
leased from the system. If the system is hot, the the radiator cap is removed, the pressure is re-
steam and boiling coolant can cause burns. leased from the system. If the system is hot, the
steam and boiling coolant can cause burns.
CAUTION
Disposal of lubricants and fluids must meet lo- CAUTION
cal environmental regulations. Disposal of lubricants and fluids must meet lo-
cal environmental regulations.
1. Turn the heater knob for the cabin in the full heat
position. 1. Let coolant cool to 40°C (104°F).
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 capacity

of 40 liter (9 gal).

4. Remove the radiator return hose from the water

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 radia-
tor 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 speci-
fication as mentioned in the section Coolant.

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

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

4. Install the radiator cap on the expansion tank.

Turn the heater knob for the cabin in the full hot
position. Start and run the engine until the ther-
mostat opens (top radiator hose will be warm). 1. COOLANT DRAIN VALVE
2. RADIATOR RETURN HOSE
5. Stop the engine and add coolant to the expansion 3. RADIATOR SUPPLY HOSE
tank as necessary. Coolant capacity is 40 liter
(10.5 gal). Figure 11. Engine Coolant Drain Valve

16
700 SRM 1530 Cooling System Repairs

2. Remove the radiator cap from the expansion

tank. CAUTION
Maximum recommended time with any type of
NOTE: Use a drain pan to catch the coolant capacity cleaner is 3 hours. Any prolonged usage may
of 35 liter (9 gal). cause damage to system elastomers and cor-
rode system soft metals.
3. Open the coolant drain valve at the left side of
the engine and drain the cooling system. See Fig- 2. Refill the cooling system with cleaner and follow
ure 11. the manufacturer’s instructions.
4. Close the coolant drain valve at the left side of 3. Flush the system twice before refilling with
the engine. See Figure 11. coolant. See Flushing the Engine Cooling Sys-
tem for the procedures.
CAUTION
Disposal of lubricants and fluids must meet lo-
cal environmental regulations.

5. Fill the radiator core and expansion tank with

clean water.

6. Install the radiator cap on the expansion tank.

7. Run the engine until the top radiator hose is hot.

8. Stop the engine and let the engine cool to room

temperature.

9. Remove the radiator cap from the expansion

tank.

10. Open the coolant drain valve and drain the water
from the radiator core. See Figure 12.

11. If the water is contaminated, investigate the

cause of the contamination and take appropriate
action.

CLEAN THE ENGINE COOLING SYSTEM 1. RADIATOR DRAIN VALVE

1. Flush the cooling system. See Flushing the En- Figure 12. Radiator Drain Valve
gine Cooling System and Refill the Engine Cool-
ing System for the procedures.

17
Cooling System Repairs 700 SRM 1530

FAN AND FAN MOTOR COOLING ASSEMBLY

Remove Remove
1. Remove the grid and the cover above the radiator. 1. Loosen the four bolts that hold the cooler screen
to the frame. Lift and remove the screen from the
2. Remove and plug the hoses connecting with the bolts.
fan motor. Plug the ports on the fan motor.
2. Remove the three bolts that connect the formed
3. Attach a lifting device to the frame that holds the plate between cooler assembly and separator
fan and the fan motor. plate between engine and cooler area.
4. Remove the four M10 bolts that retain the frame 3. Drain the engine cooling system.
to the core assembly and lift the fan assembly.
Lead the frame ends past the radiator hoses. Put 4. Remove the cover and the grid above the radiator.
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 pull 7. Remove and plug the hoses for charge air cooling,
the pulley from the motor shaft. Retain the key. engine coolant, hydraulic and transmission oil.
Put caps on the radiator fittings.
7. Remove the two M12 bolts that retain the motor
to the frame. 8. Connect a lifting device to the lifting eyes on the
cooler assembly.
Replace
9. Remove the nuts and washers from the four iso-
1. Install the motor on the frame. Tighten the two lators at the cooler assembly brackets.
bolts.
10. Lift and guide the cooler assembly from the iso-
2. Position the key in the motor shaft and slide the lators. The cooler assembly will tend to position
fan pulley on the shaft. Install the locking nut itself horizontally.
and torque to 45 N•m (33 lbf ft).
11. Lower the cooler assembly on a pallet. Remove
3. Install the fan on the pulley and tighten the 12 the pallet from under the truck.
nuts.
Disassemble
4. Attach a lifting device to the frame that holds the
fan and fan motor. 1. Remove the two side plates from the cooler as-
sembly by removing the attaching bolts: 2 times
5. Lift the assembly and position on the cooler as- 3 bolts at the suction side, 5 bolts at each of the
sembly. Insert the four M10 bolts. assembly sides, and 2 times 2 bolts at the fan
side.
6. Make sure there is even play between fan and
shroud. Tighten the four bolts. 2. Remove and replace the individual cores as nec-
essary.
7. Remove the plugs and install the hoses on the
motor. Assemble
8. Replace the cover and the grid above the radiator. 1. Put the cores and the two side plates into the
correct position.

2. Insert and tighten the bolts that retain the cores

to the side plates. Tighten to 20 N•m (14.7 lbf ft).

18
700 SRM 1530 Cooling System Repairs

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 from
2. Connect a lifting device to the lifting eyes on the the cores.
cooler assembly.
5. Remove the hoses from the cores for transmission
3. Lift and guide the cooler assembly on the isola- and hydraulic system. Plug the hoses and the
tors. Position the lower brackets on the lower iso- fittings of the cores.
lators first.
6. Remove two bolts at each side of the transmission
4. Install the washers and nuts and tighten. 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 Mo- 8. Loosen the two upper bolts that hold the frame
tor Replace. 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 necessary. 9. Remove the six bolts that retain the hydraulic
Start the engine and check for leaks. Stop the core to the side plates. Tilt the frame of the fan
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 radiator.
fasten the four bolts that retain the frame for the
11. De-aerate the engine cooling system fan assembly.

3. Slide the transmission core into position and

COOLER CORE REPLACEMENT FOR
tighten the two bolts at each side.
TRANSMISSION AND HYDRAULIC
SYSTEM 4. Remove the plugs and connect the hoses to the
core fittings.
It is possible to replace the transmission core and
hydraulic oil core without first removing the fan and 5. Install the 6 bolts that retain the formed plate to
the cooler assembly. the transmission core.

Remove 6. Install the 3 bolts that connect the formed plate

between cooler assembly and separator plate.
1. Loosen the four bolts that hold the cooler screen
to the frame. Lift and remove the screen from the 7. Replace the radiator screen at the steer wheel
bolts. area. Tighten the bolts that retain the screen to
the frame.
2. Remove the 3 bolts that connect the formed plate
between cooler assembly and separator plate be-
tween engine and cooler area.

19
Troubleshooting 700 SRM 1530

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Coolant leaks. There is a leak in the radiator. Pressure test radiator and expansion
tank. If leak cannot be repaired, re-
place radiator. See External Leak
Test. For radiator replacement, see
Cooling Assembly.

There is a leak in a radiator hose or Pressure test radiator and expansion

coolant hose. tank. Replace leaking hose. See Ex-
ternal Leak Test.

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

Water pump leaks. Install new water pump.

Thermostat housing leaks. Inspect thermostat housing for dam-

age. Replace, if necessary. Remove
the housing and check the thermo-
stat housing gasket for damage. Re-
place, before reinstalling. Check for
proper installation of thermostat and
O-ring. See thermostat and engine
cooling systems components .

Cylinder head gasket is damaged. Install new head gasket.

Cylinder head is cracked. Install new cylinder head.

Engine block is cracked. Install new cylinder block.

20
700 SRM 1530 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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

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

tor and clean the radiator with high
pressure air.

The radiator is dirty. Drain and clean radiator. Clean ra-

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

The thermostat is wrong heat range Check heat range. Install new ther-
or does not operate correctly. mostat.

The cooling system has restrictions. Drain and back-flush engine and ra-
diator. Refill with clean coolant.

The water pump is worn or damaged. Install new water pump.

The exhaust system has restrictions. Check exhaust system. Remove re-
strictions.

Fan is not running. Check the fan and mounting to the

fan motor. Replace if required.

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 1900 SRM 1476.

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

Cylinder head is damaged. Install new cylinder head.

21
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 TECHNICAL PUBLICATIONS

700 SRM 1530 8/12 (5/12)(1/12)(9/11) Printed in U.S.A.