Hyster E010 S30ft S35ft S40fts Forklift Service Manual

GASOLINE FUEL SYSTEM MAZDA 2.0L AND 2.2L 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. 1580509

900 SRM 1127

Gasoline Fuel System

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Abbreviations .....................................................................................................................................................

Engine Tune-up..................................................................................................................................................

Engine Tune-Up Preparation........................................................................................................................

Idle Speed Adjustment ..................................................................................................................................

Idle-Up Speed Check .....................................................................................................................................

Intake-Air System..............................................................................................................................................

Intake-Air System Manifold Vacuum Check................................................................................................

Throttle Body .................................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Electronic Governor.......................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Intake-Air Control (IAC) Valve .....................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Intake Manifold .............................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Fuel System........................................................................................................................................................

Before Repair Procedure ...............................................................................................................................

Fuel Line Safety Procedure ......................................................................................................................

After Repair Procedure..................................................................................................................................

Fuel Hose, Install ......................................................................................................................................

Fuel Leakage Check ..................................................................................................................................

Fuel Line Pressure Check .............................................................................................................................

Fuel Injector...................................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Pressure Regulator ........................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Exhaust System .................................................................................................................................................

Exhaust System, Inspect...............................................................................................................................

Three-Way Catalytic (TWC) Converter ........................................................................................................

Remove and Install ...................................................................................................................................

Exhaust Manifold ..........................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Positive Crankcase Ventilation (PCV) Valve................................................................................................

Remove.......................................................................................................................................................

Inspect........................................................................................................................................................

Install .........................................................................................................................................................

Control System...................................................................................................................................................

Engine Control Unit (ECU)...........................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Intake Air Temperature (IAT) Sensor ..........................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Š2005 HYSTER COMPANY

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Table of Contents

Gasoline Fuel System

TABLE OF CONTENTS (Continued) Mass Air Flow (MAF) Sensor ........................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Throttle Position (TP) Sensor .......................................................................................................................

TP Sensor, Adjust ......................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Engine Coolant Temperature (ECT) Sensor.................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Camshaft Position (CMP) Sensor .................................................................................................................

Voltage Check ............................................................................................................................................

Oxygen Sensor ...............................................................................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Manifold Absolute Pressure (MAP)/Boost Sensor........................................................................................

Remove.......................................................................................................................................................

Install .........................................................................................................................................................

Technical Data....................................................................................................................................................

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]

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900 SRM 1127

Engine Tune-up

General This section has the repair procedures for the engine control unit (ECU) controlling the idle, fuel, spark,

and timing for the Mazda 2.0L and 2.2L gasoline engines.

Abbreviations AAS - air adjusting screw.

IAT Sensor - intake air temperature sensor.

CMP Sensor - camshaft position sensor.

MAF Sensor - mass air flow sensor.

ECT Sensor - engine coolant temperature sensor.

MAP Sensor - manifold absolute pressure sensor.

ECU - engine control unit.

PCV Valve - positive crankcase ventilation valve.

GCU - governor control unit.

TP Sensor - throttle position sensor.

IAC Valve - idle air control valve.

TWC Converter - three-way catalytic converter.

Engine Tune-up ENGINE TUNE-UP PREPARATION 1. Warm up the engine to normal operating temperature.

2. Turn off all electrical loads.

3. Verify that the steering wheel is at straight ahead position.

3. Verify that the idle speed is within the specification. If not as specified, adjust the idle speed by turning the air adjustment screw (AAS) of throttle body. See Figure 2.

Specification: 775 to 825 (800 Âą25) rpm 4. Remove the jumper wire from ECU test port connector.

4. Connect a tachometer.

IDLE-UP SPEED CHECK

IDLE SPEED ADJUSTMENT

1. Perform Engine Tune-Up Preparation.

1. Perform Engine Tune-Up Preparation.

WARNING Fuel line spills and leakage are dangerous.

Fuel can ignite and cause serious injuries or death and damage. Always perform the following procedure with the engine stopped.

CAUTION Only use a jumper wire with a momentary switch located within the wire to prevent arcing.

2. Verify that the idle speed is normal. See Idle Speed Adjustment.

3. Verify that the idle-up speed is within the specification. Load the engine at tilt relief, hoist relief, and steer relief while checking the engine speed at each condition. If not as specified with all load conditions, inspect the IAC valve. If not as specified with some load conditions, inspect the sensors (MAP/Boost, TP sensor, CMP sensor), harnesses, and connectors.

Specification: 900 to 1100 (1000 Âą100) rpm

2. Install a jumper wire across the engine control unit (ECU) test port connector terminals. See Figure 1.

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Engine Tune-up

900 SRM 1127

1. FUEL PUMP TEST CONNECTOR 2. ECU TEST PORT 3. 10 AMP FUSE, FUEL PUMP

4. FUEL PUMP RELAY 5. GCU INTERFACE 6. ALTERNATOR RELAY

Figure 1. Relays and Test Connectors

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900 SRM 1127

Intake-Air System

1. THROTTLE POSITION (TP) SENSOR 2. THROTTLE BODY

3. AIR ADJUSTING SCREW (AAS) Figure 2. Throttle Body

Intake-Air System NOTE: Always use new O-rings, seals, and gaskets when servicing the fuel and exhaust systems.

INTAKE-AIR SYSTEM MANIFOLD VACUUM CHECK

c. Vacuum leaks (installation areas of throttle body, electronic governor, fuel injector, IAC valve, PCV valve, intake manifold).

5. After measuring the intake manifold vacuum, install the intake manifold blind cap.

1. Verify that the intake-air system related parts and hoses are securely installed.

2. Remove the intake manifold blind cap and install the vacuum gauge. See Figure 3.

3. Warm up the engine.

4. Measure the intake manifold vacuum while idling (no load) using the vacuum gauge. If not within the specification, perform the following inspection: Specification: -60.0 kPa (-17.8 inHg) or more a. Accelerator cable free play. b. Compression pressure.

NOTE: If any vacuum leaks exist, the change in engine speed can be made apparent by spraying the penetrant lubricating spray on the applicable part.

1. VACUUM GAUGE Figure 3. Intake Manifold Vacuum Check

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Intake-Air System

900 SRM 1127

THROTTLE BODY

9. Fill the radiator with coolant.

For the following procedures, refer to Figure 4.

ELECTRONIC GOVERNOR

Remove

Remove

1. Drain the coolant from the radiator.

For the following procedures, refer to Figure 4.

2. Disconnect the air-intake hose from the throttle body.

1. Remove the throttle body. See Throttle Body, Remove.

3. Disconnect the wiring harness connector from the TP sensor connector.

2. Disconnect the wiring harness connector from the electronic governor sensor connector.

4. Tag and disconnect the coolant hoses from the throttle body.

3. Slide the electronic governor from the threaded studs and remove the electronic governor.

5. Disconnect the throttle cable.

4. Remove the gasket and discard.

6. Remove the two bolts from the bottom of the throttle body.

Install

7. Remove the two nuts from the top of the throttle body.

8. Slide the throttle body from the threaded studs and remove the throttle body.

9. Remove the gasket and discard.

For the following procedures, refer to Figure 4.

1. Verify that the mounting surface of the electronic governor and the intake manifold are clean and free of debris.

2. Install a new gasket.

Install

3. Slide the electronic governor onto the threaded studs.

1. Verify that the mounting surface of the throttle body and the electronic governor are clean and free of debris.

4. Install the throttle body. See Throttle Body, Install.

2. Install a new gasket.

3. Slide the throttle body onto the threaded studs.

INTAKE-AIR CONTROL (IAC) VALVE Remove

4. Install the two nuts and two bolts and tighten.

Tighten the two nuts to 22 to 30 N•m (16 to 22 lbf ft). Tighten the two bolts to 19 to 25 N•m (14 to 18 lbf ft).

For the following procedures, refer to Figure 4.

5. Connect the throttle cable.

3. Disconnect the electrical connector from the IAC valve connector.

6. Connect the coolant hoses.

7. Connect the wiring harness connector to the TP sensor connector.

8. Connect the air-intake hose.

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1. Drain the coolant from the radiator.

2. Tag and disconnect the the coolant hoses.

4. Remove the two nuts and capscrew securing the IAC valve.

5. Remove the IAC valve and gasket.

900 SRM 1127

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2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

THROTTLE BODY GASKET ELECTRONIC GOVERNOR GASKET THROTTLE BRACKET CAPSCREW BRACKET CAPSCREWS MAP/BOOST SENSOR NUT FUEL PRESSURE REGULATOR BRACKET CAPSCREWS CAPSCREW WASHER CAPSCREW BRACKET GASKET COOLANT HOSE CLAMP

Intake-Air System

21. CAPSCREW 22. COOLANT HOSE (TO ENGINE COOLANT HOSE ON RIGHT SIDE OF CYLINDER BLOCK) 23. CLAMP 24. IDLE AIR CONTROL (IAC) VALVE 25. NUT 26. GASKET 27. FUEL INJECTOR AND FUEL RAIL ASSEMBLY 28. PCV HOSE 29. CLAMP 30. INTAKE MANIFOLD 31. THREADED STUD 32. COOLANT HOSE (TO THERMOSTAT OUTLET HOUSING) 33. CLAMP 34. COOLANT HOSE (TO ENGINE COOLANT HOSE ON RIGHT SIDE OF CLYINDER BLOCK) 35. THROTTLE POSITION (TP) SENSOR 36. BOLT 37. NUT Figure 4. Intake-Air System

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Intake-Air System

Install For the following procedures, refer to Figure 4.

1. Verify that the mounting surfaces of the intake manifold and the IAC valve are clean and free from dirt or debris.

2. Install a new gasket.

3. Place the IAC valve in position and secure with the two nuts and capscrew.

4. Torque the two nuts to 8.9 to 12.7 N•m (79 to 112 lbf in). Torque the capscrew to 7.9 to 10.7 N•m (69.5 to 95.4 lbf in).

5. Connect the electrical connector to the IAC valve connector.

6. Connect the coolant hoses to the IAC valve.

7. Fill the radiator with coolant.

900 SRM 1127 9. Remove the MAP/boost sensor. See Manifold Absolute Pressure (MAP)/Boost Sensor, Remove.

10. Remove the capscrews retaining the rear bracket (12) to the intake manifold and the cylinder head.

Remove the bracket.

11. Remove the capscrews retaining the lower support bracket (17) to the intake manifold and remove the bracket.

12. Remove the nut and the capscrews retaining the intake manifold to the cylinder head.

13. Remove the intake manifold and gasket.

14. Remove the capscrew retaining the throttle bracket to the intake manifold and remove bracket.

15. Remove the fuel pressure regulator. See Pressure Regulator, Remove.

INTAKE MANIFOLD

16. Remove the fuel injectors and the fuel rail. See Fuel Injector, Remove.

Remove

Install

For the following procedures, refer to Figure 4.

For the following procedures, refer to Figure 4.

1. Drain the coolant from the radiator.

1. Verify that the mounting surfaces of the intake manifold and the cylinder head are clean and free from dirt or debris.

2. Disconnect the fuel line from the fuel rail. See Fuel System, Before Repair Procedure.

3. Remove the throttle body. See Throttle Body, Remove.

4. Remove the electronic governor. See Electronic Governor, Remove.

5. Remove the capscrews retaining the front bracket (7) to the intake manifold and remove the bracket.

6. Remove the IAC valve. See Intake-Air Control (IAC) Valve, Remove.

7. Tag and disconnect the vacuum hoses on the intake manifold.

8. Remove the ECT sensors. See Engine Coolant Temperature (ECT) Sensor, Remove.

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2. Install the fuel injectors and the fuel rail. See Fuel Injector, Install.

3. Install the fuel pressure regulator. See Pressure Regulator, Install.

4. Place the throttle bracket in position and install capscrews. Tighten capscrews to 7.9 to 10.7 N•m (69.5 to 95.4 lbf in).

5. Place a new gasket in position on the cylinder head.

6. Place the intake manifold in position on the cylinder head.

7. Install the nut and capscrews to retain the intake manifold to the cylinder head. Tighten the nut to 22 to 30 N•m (16 to 22 lbf ft). Tighten the capscrews to 19 to 25 N•m (14 to 18 lbf ft).

900 SRM 1127

Fuel System

8. Place the lower support bracket (17) in position and install the capscrews. Tighten the capscrew to the intake manifold to 19 to 25 N•m (14 to 18 lbf ft). Tighten the remaining capscrew to 38 to 51 N•m (28 to 38 lbf ft).

13. Install the IAC valve. See Intake-Air Control (IAC) Valve, Install.

14. Place the front bracket (7) in position and install the capscrews. Tighten the capscrews to 19 to 25 N•m (14 to 18 lbf ft).

9. Place the rear bracket in position and install the capscrews. Tighten the capscrews to 19 to 25 N•m (14 to 18 lbf ft).

15. Install the electronic governor. See Electronic Governor, Install.

10. Install the MAP/boost sensor. See Manifold Absolute Pressure (MAP)/Boost Sensor, Install.

16. Install the throttle body. See Throttle Body, Install.

11. Install the ECT sensors. See Engine Coolant Temperature (ECT) Sensor, Install.

17. Connect the fuel line to the fuel rail. See Fuel System, After Repair Procedure.

12. Connect the vacuum hoses to the intake manifold.

18. Fill the radiator with coolant.

Fuel System NOTE: Always use new O-rings, seals, and gaskets when servicing the fuel and exhaust systems.

3. Start the engine. After the engine stalls, crank the engine several times.

BEFORE REPAIR PROCEDURE

4. Turn OFF ignition.

Fuel Line Safety Procedure

5. Connect the fuel pump relay.

WARNING

AFTER REPAIR PROCEDURE

Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

Fuel Hose, Install

Fuel line spills and leakage are dangerous.

Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following procedure:

Fuel line spills and leakage are dangerous.

Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe the following procedure and the Fuel Leakage Check procedure.

NOTE: Fuel in the fuel system is under high pressure also when the engine is not running.

1. Replace damaged or deformed fuel hoses, fuel lines, and hose clamps.

1. Remove the fuel-filler cap and release the pressure in the fuel tank.

2. When installing the fuel hose on the fuel line, fit the hose onto the line over 25 mm (0.98 in.).

When the line has a stopper, fit the hose until it contacts the stopper. See Figure 5.

2. Disconnect the fuel pump relay. See Figure 1.

WARNING

7

Fuel System

900 SRM 1127

Fuel Leakage Check WARNING Fuel line spills and leakage are dangerous.

Fuel can ignite and cause serious injuries or death and damage. Always perform the following procedure with the engine stopped.

CAUTION Only use a jumper wire with a momentary switch located within the wire to prevent arcing.

1. Install a jumper wire across the fuel pump test connector terminals. See Figure 1.

1. FUEL LINES 2. STOPPER 3. FUEL HOSE Figure 5. Fuel Hose Installation NOTE: Do not use a clamp larger than the recommended size for the hose outside diameter.

3. Install a hose clamp over the fuel hose within the clamp installation range as shown, avoiding the original clamp position. Tighten the clamp screw to 2.45 to 2.77 N•m (22 to 25 lbf in). See Figure 6.

2. Turn the ignition ON to operate the fuel pump.

3. Pressurize the system this way for at least 5 minutes to be sure of no leakage. If there is fuel leakage, inspect the fuel hoses and fuel pipe sealing surface for damage. Replace as needed.

4. After repair, assemble the system and repeat Step 1 through Step 3.

FUEL LINE PRESSURE CHECK WARNING Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death.

Fuel can also irritate skin and eyes. Always perform the following procedure with the engine stopped.

1. Complete the Before Repair Procedure.

2. Disconnect the negative battery cable.

3. Connect a fuel pressure gauge between the fuel filter and the fuel rail. See Figure 7.

4. Connect the negative battery cable.

1. AVOID ORIGINAL CLAMP POSITION 2. CLAMP INSTALLATION RANGE Figure 6. Clamp Installation

8

5. Install a jumper wire across the fuel pump test connector terminals. See Figure 1.

900 SRM 1127

Fuel System 4. Disconnect the wiring harness from each fuel injector.

5. Disconnect the fuel lines from the fuel rail.

6. Remove the two capscrews retaining the fuel rail to the intake manifold.

7. Remove the fuel rail and fuel injectors.

8. Remove the fuel rail insulator.

9. Remove the fuel injector insulator.

10. Remove the fuel injectors.

11. Remove and discard O-rings.

Install 1. FUEL PRESSURE GAUGE Figure 7. Fuel Pressure Gauge 6. Measure the fuel line pressure. If less than the specification, inspect the fuel pump for fuel line leakage. If it exceeds the specification, inspect the pressure regulator and fuel line for clogging.

Specification: 260 to 310 kPa (38 to 45 psi)

1. Apply a small amount of engine oil to the new O-rings and install them into the fuel rail.

2. Verify that the O-rings and the fuel injector sealing surfaces are free of foreign material.

3. Install the fuel injectors in the fuel rail with light twisting motion so that the O-rings will not be folded.

7. Turn the ignition OFF to stop the fuel pump.

4. Install the fuel injector insulator.

8. Measure the fuel hold pressure after 5 minutes.

If not within the specification, inspect the fuel line for clogging or leakage.

Specification: More than 140 kPa (20 psi)

5. Install the fuel rail insulator.

9. Disconnect the jumper wire.

10. Disconnect the fuel pressure gauge.

11. Complete the After Repair Procedure.

FUEL INJECTOR Remove 1. Complete the Before Repair Procedure.

6. Install the fuel rail and fuel injectors onto the intake manifold. Install the two capscrews and tighten to 19 to 25 N•m (14 to 18 lbf ft).

7. Connect the wiring harness for each fuel injector.

8. Connect the vacuum hose to the pressure regulator.

9. Connect the fuel lines to the fuel rail.

10. Connect the negative battery cable.

11. Complete the After Repair Procedure.

2. Disconnect the negative battery cable.

3. Disconnect the vacuum hose from the pressure regulator. See Figure 8.

9

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