Hyster H40FT, H50FT, H60FT, H70FT (L177, F001, F187) Service & Repair Manual

LPG FUEL SYSTEM MAZDA 2.0L AND 2.2L ENGINES S30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT (S40-70FT, S55FTS ) [F187]; H2.0-3.5FT (H40-70FT) [L177] PART NO. 1580507 900 SRM 1125

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand, use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte- nance section. • Keep the unit clean and the working area clean and orderly. • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. • Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual: WARNING Indicates a condition that can cause immediate death or injury! CAUTION Indicates a condition that can cause property damage!

LPG Fuel System Table of Contents TABLE OF CONTENTS General ............................................................................................................................................................... 1 Hoses Replacement ............................................................................................................................................ 1 LPG Tank Replacement ..................................................................................................................................... 1 Remove ........................................................................................................................................................... 1 Install ............................................................................................................................................................. 1 Fuel Filter........................................................................................................................................................... 3 Remove ........................................................................................................................................................... 3 Clean and Inspect .......................................................................................................................................... 4 Install ............................................................................................................................................................. 5 Relief Valve Replacement .................................................................................................................................. 6 Remove and Install ........................................................................................................................................ 6 Carburetor Repair .............................................................................................................................................. 6 Remove ........................................................................................................................................................... 6 Disassemble ................................................................................................................................................... 6 Clean .............................................................................................................................................................. 8 Assemble ........................................................................................................................................................ 8 Install ............................................................................................................................................................. 8 Fuel Injector Repair ........................................................................................................................................... 9 Remove ........................................................................................................................................................... 9 Clean and Inspect .......................................................................................................................................... 9 Install ............................................................................................................................................................. 9 Governor Repair ................................................................................................................................................. 9 Remove ........................................................................................................................................................... 9 Install ............................................................................................................................................................. 9 Regulator Repair ................................................................................................................................................ 10 Remove ........................................................................................................................................................... 10 Install ............................................................................................................................................................. 11 Control System................................................................................................................................................... 11 Engine Control Unit (ECU)........................................................................................................................... 11 Remove ....................................................................................................................................................... 11 Install ......................................................................................................................................................... 11 Engine Coolant Temperature (ECT) Sensor................................................................................................. 12 Remove ....................................................................................................................................................... 12 Install ......................................................................................................................................................... 12 Camshaft Position (CMP) Sensor ................................................................................................................. 12 Voltage Check ............................................................................................................................................ 12 Intake Air Temperature (IAT) Sensor .......................................................................................................... 13 Remove ....................................................................................................................................................... 13 Install ......................................................................................................................................................... 13 Manifold Absolute Pressure (MAP) Sensor .................................................................................................. 14 Remove ....................................................................................................................................................... 14 Install ......................................................................................................................................................... 14 Oxygen Sensor ............................................................................................................................................... 14 Remove ....................................................................................................................................................... 14 Install ......................................................................................................................................................... 14 Throttle Position (TP) Sensor ....................................................................................................................... 15 Remove ....................................................................................................................................................... 15 Install ......................................................................................................................................................... 15 ©2005 HYSTER COMPANY i

Table of Contents LPG Fuel System TABLE OF CONTENTS (Continued) This section is for the following models: S30FT, S35FT, S40FTS [E010]; H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001]; S2.0-3.5FT (S40-70FT, S55FTS ) [F187]; H2.0-3.5FT (H40-70FT) [L177] ii

900 SRM 1125 LPG Tank Replacement General This section has the repair procedures for the parts of the LPG fuel system used on the Mazda 2.0 liter and 2.2 liter engines. Hoses Replacement The hoses installed on LPG systems are specially made. Hoses that are made for use with hydraulic oil will be damaged by LPG. When replacing the LPG hoses, be sure to use only HYSTER APPROVED LPG hoses. When replacing the hose to the quick-disconnect fitting, make sure that it is the same length as the hose it replaces. A hose that is the wrong length allows the tank to be installed in an incorrect position. LPG Tank Replacement REMOVE WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system. LPG fuel systems can be discon- nected indoors only if the lift truck is at least 8 m (26 ft) from any open flame, motor vehicles, electrical equipment, or ignition source. Close the shutoff valve on the LPG tank before any part of the engine fuel system is discon- nected. Run the engine until the fuel in the system is used and the engine stops. If the engine will not run, close the shutoff valve on the LPG tank. Loosen the fitting on the supply hose from the LPG tank where it enters the filter unit. Permit the pressure in the fuel system to decrease slowly. Fuel leav- ing the fitting removes heat. Use a cloth to protect your hands from the cold fitting. NOTE: The LPG tank bracket used on this line of trucks to mount the LPG tank onto the counter- weight comes in two styles. One style of bracket swings out to the side of the truck and the other swings out to the side and drops down (EZXchange™ bracket). See Figure 1. 1. LPG tanks can be removed and replaced indoors only if the lift truck is at least 8 m (26 ft) from any flame or ignition source. Move the lift truck to an the area where LPG tanks are changed. 2. Turn the shutoff valve clockwise until the valve is completely closed. 3. Run the engine until it stops. If truck is equipped with a key switch, turn the key switch to the OFF position. If truck is equipped with a Power ON/OFF button, press the Power ON/OFF button to turn engine off. 4. Disconnect the quick-disconnect fitting on the LPG tank. See Figure 1. 5. Push in the bracket release pin, grab the bracket handle, and swing the tank and bracket out to the side of the lift truck. If your truck is equipped with a EZXchange bracket, drop the tank down to the side of the truck for ease of removal. See Figure 2. 6. Unlatch the tank strap and remove the LPG tank from the bracket. INSTALL NOTE: The LPG bracket must be in the swing-out position to install the LPG tank. If your lift truck has the EZXchange bracket, position the bracket in the drop-down position. WARNING When closing the LPG tank strap, do not wrap your fingers around the strap handle. The strap can close quickly and with enough force to cause injury to the fingers and hand. 1. Place the LPG tank into the bracket. Secure the tank strap around the tank and close the strap. 1

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Hyster H40FT, H50FT, H60FT, H70FT (L177, F001, F187) Service & Repair Manual

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