Hyster F001 (H30FT H35FT H40FTS) Forklift Service Repair Manual

Hyster F001 (H30FT H35FT H40FTS) Forklift

LPG FUEL SYSTEM MAZDA 2.0L AND 2.2L 2007 EMISSION COMPLIANT ENGINES S30FT, S35FT, S40FTS [E010]; H30FT, H35FT, H40FTS [F001]; S2.0-3.5FT (S40-70FT, S55FTS ) [F187]; H40-70FT [L177]

PART NO. 1653958

900 SRM 1326

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 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 ...............................................................................................................................................................

LPG Tank Replacement.....................................................................................................................................

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

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

Fuel Filter Unit Repair......................................................................................................................................

Fuel Filter Element .......................................................................................................................................

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

Clean/Inspect .............................................................................................................................................

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

Fuel Filter Housing .......................................................................................................................................

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

Disassemble ...............................................................................................................................................

Assemble ....................................................................................................................................................

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

Electronic Throttle Body Repair .......................................................................................................................

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

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

Electronic Pressure Regulator (EPR) Repair ...................................................................................................

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

Disassemble ...................................................................................................................................................

Assemble ........................................................................................................................................................

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

LPG Shutoff Valve Assembly.............................................................................................................................

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

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

Fuel Mixer Repair ..............................................................................................................................................

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

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

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

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

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

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

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

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

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

CAM Angle Sensor.........................................................................................................................................

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

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

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

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

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

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

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

Fuel Temperature Sensor..............................................................................................................................

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

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

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

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

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

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

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

©2007 HYSTER COMPANY

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Table of Contents

LPG Fuel System

TABLE OF CONTENTS (Continued) Three-Way Catalytic (TWC) Converter ........................................................................................................

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

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

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

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

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

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

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

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

This section is for the following models: S30FT, S35FT, S40FTS [E010]; H30FT, H35FT, H40FTS [F001]; S2.0-3.5FT (S40-70FT, S55FTS ) [F187]; H40-70FT [L177]

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900 SRM 1326

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 2007 emission compliant engines.

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 disconnected 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 disconnected. 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 leaving 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 counterweight 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.

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LPG Tank Replacement

900 SRM 1326

A. SWING-OUT LPG BRACKET

B. SWING-OUT AND DROP-DOWN LPG BRACKET (EZXCHANGE)

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LPG TANK TANK STRAP QUICK DISCONNECT FITTING HYDROSTATIC RELIEF VALVE MANIFOLD BLOCK ALIGNMENT PIN

STOP PIN BRACKET HANDLE BRACKET PIVOT GAS SPRING (DROP-DOWN BRACKET ONLY) BRACKET RELEASE PIN (BUTTON)

Figure 1. LPG Tank and Bracket

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900 SRM 1326

LPG Tank Replacement

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.

2. Pull the stop pin (see Figure 1) and swing the LPG tank bracket into the resting position on the counterweight. Be sure that the bracket locks into position.

3. If disconnected, connect the hose to the LPG fuel filter. See Figure 2.

4. Connect the quick-disconnect fitting on the LPG tank. See Figure 1.

5. Turn the fuel valve counterclockwise to open the fuel valve.

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QUICK-DISCONNECT CONNECTION HOSE ASSEMBLY CAPSCREWS LPG TANK HOSE ASSEMBLY TO LPG FUEL FILTER LPG FUEL FILTER CONNECTION HOSE ASSEMBLY TO LPG REGULATOR LPG FUEL FILTER LOW PRESSURE SWITCH Figure 2. LPG Tank Hose Connections

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.

6. Inspect the fuel system for leaks when the fuel valve is open. There are four methods used to inspect the fuel system for leaks: a. Sound - Listen for sound of LPG escaping from a tank fitting or hose connection. b. Smell - LPG has a very distinctive odor. If you smell LPG, DO NOT start the engine. c. Soapy Water - This method is used in conjunction with Step b above. If the odor of LPG is present, but escaping fuel cannot be heard, apply soapy water to the fittings and observe for bubbles. d. Frost - If the amount of LPG escaping is sufficient, frost may appear on the fittings.

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Fuel Filter Unit Repair

900 SRM 1326

Fuel Filter Unit Repair FUEL FILTER ELEMENT Remove WARNING LPG can cause an explosion. Do not permit any sparks or open flames in the work area.

1. Close fuel valve on tank. Run engine until it runs out of fuel and stops. Try to start engine 2 to 3 times until it no longer starts.

2. Disconnect negative battery cable.

3. Install fuel filter housing top section onto fuel filter housing bottom section.

4. Install bolt and new seal washer. Tighten bolt to 13 N•m (115 lbf in).

NOTE: Opening the fuel valve too quickly can cause the internal excess flow valve to close, restricting the flow of fuel. If this happens, close the fuel valve, wait a few seconds, and then slowly open the fuel valve again. This will reset the excess flow valve.

5. Slowly open the fuel valve on tank.

6. Connect the negative battery cable.

WARNING A small amount of fuel may still be present in the fuel line. Use gloves to prevent burns and wear eye protection. If liquid fuel continues to flow from the connections when loosened, check to make sure the manual valve is fully closed.

7. Turn the key to the ON position and back to the OFF position to pressurize the fuel system.

Check for leaks.

8. Check for leaks at connections by using soapy solution or electron leak detector. If leaks are detected, make proper repairs.

3. Remove the bolt and seal washer from the fuel filter housing top section. Discard seal washer.

See Figure 3.

4. Remove fuel filter housing top section from fuel filter housing bottom section.

5. Remove and discard housing O-ring.

6. Remove and discard fuel filter and fuel filter O-ring.

Clean/Inspect 1. Clean and inspect the fuel filter housing top section for contamination or damage. If damaged, replace the housing.

2. Clean and inspect the fuel filter housing bottom section for contamination or damage. If damaged, replace the housing.

Install 1. Install the new fuel filter and fuel filter O-ring.

See Figure 3.

2. Install new housing O-ring.

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BOLT* SEAL WASHER FUEL FILTER HOUSING TOP SECTION* FUEL FILTER FUEL FILTER O-RING HOUSING O-RING FUEL FILTER HOUSING BOTTOM SECTION* LOW PRESSURE SWITCH

*NOT SERVICED SEPARATELY Figure 3. Fuel Filter Removal/Installation

900 SRM 1326

Fuel Filter Unit Repair

FUEL FILTER HOUSING Remove WARNING LPG can cause an explosion. Do not permit any sparks or open flames in the work area.

1. Close fuel valve on tank. Run engine until it runs out of fuel and stops. Try to start engine 2 to 3 times until it no longer starts.

2. Disconnect negative battery cable.

WARNING A small amount of fuel may still be present in the fuel line. Use gloves to prevent burns and wear eye protection. If liquid fuel continues to flow from the connections when loosened, check to make sure the manual valve is fully closed.

3. Slowly loosen and disconnect inlet and outlet fittings.

4. Disconnect low pressure switch from engine wire harness. See Figure 6.

5. Remove the capscrews and nuts retaining the fuel filter assembly mounting bracket to the frame. See Figure 4.

6. Remove the socket head capscrews and fuel filter housing from the mounting bracket. Remove fuel filter assembly. See Figure 5.

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FRAME CAPSCREW NUT FUEL FILTER ASSEMBLY LOW PRESSURE SWITCH MOUNTING BRACKET Figure 4. Fuel Filter Assembly Removal/ Installation

5

Fuel Filter Unit Repair

900 SRM 1326 2. Apply pipe thread sealant (Hyster Part No. 0246108) on the threads of the low pressure switch fitting. Install the low pressure switch fitting onto the low pressure switch adapter.

3. Apply pipe thread sealant (Hyster Part No. 0246108) on the threads of the low pressure switch. Install the low pressure switch onto the low pressure switch fitting.

1. FUEL FILTER ASSEMBLY 2. MOUNTING BRACKET 3. SOCKET HEAD CAPSCREWS Figure 5. Fuel Filter Assembly and Mounting Bracket

Disassemble 1. Remove the fuel filter. See Fuel Filter Element, Remove.

2. Remove the low pressure switch from the low pressure switch fitting. See Figure 6.

3. Remove the inlet fitting from the fuel filter housing bottom section.

4. Remove the low pressure switch fitting from the low pressure switch adapter.

5. Remove the outlet fitting from the outlet adapter fitting.

Assemble CAUTION Do not use Teflon tape on any fuel fitting. Use a liquid pipe thread sealant when installing fittings.

1. Apply pipe thread sealant (Hyster Part No. 0246108) to the threads of the outlet fitting and install the outlet fitting and O-ring.

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BOLT* SEAL WASHER FUEL FILTER HOUSING TOP SECTION* FUEL FILTER HOUSING O-RING FUEL FILTER O-RING INLET FITTING* LOW PRESSURE SWITCH LOW PRESSURE SWITCH FITTING* LOW PRESSURE SWITCH ADAPTER* O-RING* FUEL FILTER HOUSING BOTTOM SECTION* OUTLET ADAPTER FITTING* OUTLET FITTING*

*NOT SERVICED SEPARATELY Figure 6. Fuel Filter Assembly

900 SRM 1326

Electronic Throttle Body Repair

4. Apply pipe thread sealant (Hyster Part No. 0246108) on the threads of the inlet fitting and install the inlet fitting.

5. Install the fuel filter. See Fuel Filter Element, Install.

Install

5. Connect the inlet and outlet fuel lines.

NOTE: Opening the fuel valve too quickly can cause the internal excess flow valve to close, restricting the flow of fuel. If this happens, close the fuel valve, wait a few seconds, and then slowly open the fuel valve again. This will reset the excess flow valve.

6. Slowly open the fuel valve on tank.

1. Place the fuel filter assembly in position on the mounting bracket.

2. Install the socket head capscrews to attach the fuel filter housing to the mounting bracket.

Tighten socket head capscrews to 5 N•m (44 lbf in).

3. Place the fuel filter assembly mounting bracket in position on the frame and install the capscrews and nuts to retain the bracket to the frame.

7. Connect the negative battery cable.

8. Turn the key to the ON position and back to the OFF position to pressurize the fuel system.

Check for leaks.

9. Check for leaks at connections by using soapy solution or electron leak detector. If leaks are detected, make proper repairs.

4. Connect engine wire harness to the low pressure switch.

Electronic Throttle Body Repair REMOVE WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected 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 disconnected. 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 leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting.

2. 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.

3. Disconnect the negative battery cable.

4. Remove the MAP sensor. See Manifold Absolute Pressure (MAP) Sensor, Remove.

5. Disconnect the electrical connector from the IAT sensor.

6. Disconnect the electrical connector from the electronic throttle body.

7. Remove the fuel mixer. See Fuel Mixer Repair, Remove.

8. Remove the screws to the cover of the air box. See Figure 7.

9. Remove the cover of the air box and the O-ring.

1. Turn the shutoff valve clockwise until the valve is completely closed.

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Electronic Throttle Body Repair

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SCREW COVER AIR BOX ELECTRONIC THROTTLE BODY INTAKE MANIFOLD SOCKET HEAD SCREW O-RING Figure 7. Air Box Removal/Installation

10. Remove the socket head screws retaining the air box to the throttle body and the intake manifold.

Remove the air box.

11. Remove the O-ring and sleeve from the electronic throttle body. See Figure 8.

12. Remove the electronic throttle body and gasket.

Discard old gasket.

900 SRM 1326

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O-RING SLEEVE ELECTRONIC THROTTLE BODY GASKET INTAKE MANIFOLD Figure 8. Electronic Throttle Body Removal/Installation

INSTALL 1. Clean the mating surfaces of the intake manifold and the electronic throttle body.

2. Place a new gasket in position on the intake manifold.

3. Place the electronic throttle body in position on the new gasket and intake manifold.

4. Place the sleeve and a new O-ring on the electronic throttle body.

5. Place the air box in position on the electronic throttle body and the mounting bracket. Install the socket head screws to retain the air box and

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900 SRM 1326

Electronic Pressure Regulator (EPR) Repair

electronic throttle body to the intake manifold but do not tighten.

6. Install the fuel mixer. See Fuel Mixer Repair, Install.

7. Tighten the socket head screws that retain the air box and electronic throttle body to the intake manifold to 12 N•m (106 lbf in).

8. Place a new O-ring in position on the air box.

9. Place the cover in position on the air box and install the retaining screws.

10. Connect the electrical connector to the electronic throttle body.

11. Connect the electrical connector to the IAT sensor.

12. Install the MAP sensor. See Manifold Absolute Pressure (MAP) Sensor, Install.

13. Connect the negative battery cable.

14. Slowly open the fuel valve on tank.

15. If truck is equipped with a key switch, turn the key switch to the ON position and back to the OFF position to pressurize the fuel system. If truck is equipped with a Power ON/OFF button, press the Power ON/OFF button to ON and back OFF again to pressurize the system. Check for leaks.

16. Check for leaks at connections by using soapy solution or electron leak detector. If leaks are detected, make proper repairs.

Electronic Pressure Regulator (EPR) Repair REMOVE WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected 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 disconnected. 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 leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting.

1. Turn the shutoff valve clockwise until the valve is completely closed.

2. 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.

3. Disconnect the negative battery cable.

4. Disconnect the electrical connector to the LPG shutoff valve.

5. Disconnect the electrical connector to the fuel temperature sensor.

6. Disconnect the electrical connector from the actuator of the EPR assembly.

7. Slowly disconnect the fuel inlet line from the LPG shutoff valve.

8. Put drain pan under drain valve for radiator.

Open drain valve so that coolant drains into pan.

9. Tag and disconnect the inlet and outlet coolant hoses from EPR. Cap coolant hoses. See Figure 9.

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Electronic Pressure Regulator (EPR) Repair

900 SRM 1326 3. Remove the retaining pin from the fuel temperature sensor and remove sensor. If necessary, remove and discard O-rings.

4. Remove retaining pin from the fuel outlet fitting and remove fitting. If necessary, remove and discard O-rings.

5. If necessary, remove balance line fitting from EPR assembly.

6. Remove both 90 degree fittings and LPG shutoff valve as an assembly. See LPG Shutoff Valve Assembly, Remove.

NOTE: Be sure to identify the type of screw and its location during each stage of disassembly to ensure proper placement during reassembly.

1. COOLANT OUTLET HOSE 2. EPR ASSEMBLY 3. COOLANT INLET HOSE

7. Remove the six screws that retain the regulator to the actuator. See Figure 12.

Figure 9. EPR Coolant Hoses 10. Disconnect the fuel outlet line from the EPR assembly. See Figure 10.

11. Disconnect balance line from EPR assembly.

12. Remove the nuts retaining the EPR assembly to the mounting bracket and remove the EPR. See Figure 11.

DISASSEMBLE 1. Remove the vibration mounts from the bottom of the EPR assembly. See Figure 11.

2. Remove the retaining pins from the coolant inlet and outlet fittings and remove fittings. If necessary, remove and discard O-rings.

1. FUEL OUTLET LINE 2. EPR ASSEMBLY Figure 10. Fuel Outlet Line

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LPG SHUTOFF VALVE 90 DEGREE FITTING EPR ASSEMBLY PLUG O-RINGS O-RINGS COOLANT INLET FITTING FUEL TEMPERATURE SENSOR

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VIBRATION MOUNTS NUTS MOUNTING BRACKET RETAINING PINS FUEL OUTLET FITTING COOLANT OUTLET FITTING BALANCE LINE FITTING 90 DEGREE FITTING

900 SRM 1326

Electronic Pressure Regulator (EPR) Repair

Figure 11. EPR Assembly Removal/Installation

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Electronic Pressure Regulator (EPR) Repair

900 SRM 1326 13. Inspect lever and fulcrum pin for excessive wear.

If the pin diameter is reduced at any point or if the holes in the lever are irregular (oblong), the EPR assembly is not repairable and must be replaced.

14. Turn the regulator over and remove the screws from the face cover of the regulator and remove cover.

15. Remove the primary diaphragm.

16. Remove the secondary body cover plate.

17. Remove the retaining clip from the primary valve pin.

18. Remove the primary valve pin and spring from the secondary body cover plate.

19. Remove the secondary body gasket.

1. EPR REGULATOR (SERVICEABLE) 2. EPR ACTUATOR (NOT SERVICEABLE) 3. SCREW Figure 12. EPR Assembly Disassemble/Assemble

CAUTION Use care when removing the regulator from the actuator to prevent damage to the secondary lever of the regulator and the diaphragm of the actuator. Neither part is serviceable and if damaged, the EPR assembly must be replaced.

NOTE: The lever from the primary valve slides into a slot of the secondary diaphragm, requiring the regulator to be moved sideways to free the tab from the diaphragm.

CAUTION Use only safety solvents for cleaning of the regulator and its components. Solvents such as carburetor cleaners and brake cleaners may damage gaskets, seals, O-rings, diaphragms, or other non-metal components.

20. Inspect the regulator body and cover plates for debris, deposits, heavy ends, and damage. Clean components using a safety solvent. Inspect for damaged or cracked components. If damaged or cracked components are found, replace the regulator.

ASSEMBLE

8. Gently pull the regulator away from the actuator.

If necessary, tap around the edge of the face plate with the handle of a plastic screwdriver to break the regulator free. Remove and discard clamp plate seal.

1. Place the new primary valve pin into the cover plate orifice.

9. Place regulator face down and remove the retaining screw holding the secondary lever.

3. Place a new secondary body gasket in position in position on the secondary body cover plate, ensuring that the small hole in the gasket is aligned with the small hole in the secondary body cover.

10. Remove the secondary lever, fulcrum pin, and secondary spring. See Figure 13.

11. Remove the secondary seat from the secondary lever.

12. Remove the secondary valve jet from the regulator body.

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2. Holding the valve pin in place, turn the body cover plate over. Place the valve pin spring over the valve pin and install retaining clip.

4. Place the secondary body plate cover and gasket in position on the front of the regulator body, ensuring that the holes in the gasket are aligned with all screw holes.

900 SRM 1326

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Electronic Pressure Regulator (EPR) Repair

SCREW FACE COVER PRIMARY DIAPHRAGM RETAINING CLIP PRIMARY SPRING PRIMARY VALVE PIN PRIMARY TEST PORT PLUG SECONDARY BODY COVER PLATE SECONDARY BODY GASKET

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REGULATOR BODY SECONDARY VALVE JET SECONDARY SEAT SECONDARY SPRING SECONDARY LEVER SCREW FULCRUM PIN CLAMP PLATE SEAL

Figure 13. EPR Disassemble/Assemble 5. Position new primary diaphragm on the face of the body cover using the screw holes for proper alignment.

6. Place the regulator face over the diaphragm and hand thread all seven screws through the face plate and body cover into the regulator body.

Tighten screws to 4.5 N•m (40 lbf in) in a crisscross pattern.

7. Install a new secondary seat on the secondary lever.

8. Install the secondary valve jet into the LPG regulator.

9. Place the secondary spring in position in the back of the regulator body.

10. Position the secondary lever and fulcrum pin assembly on top of the secondary spring. Push

down, compressing the spring until the fulcrum pin can be slid into place.

11. Install the screw to hold the lever and tighten screw to 4.5 N•m (40 lbf in).

12. Verify the secondary lever height by placing a straight edge over the mating surface (rim) of the regulator body. The distance between the rim of the regulator (as determined by a straight edge) and lever should be 0.794 mm (0.031 in.).

If the measurement does not meet the specification, the EPR cannot be repaired and must be replaced.

13. Place the regulator above the actuator, noting the position of the lever tab and slot on the secondary diaphragm. Carefully slide the lever tab into the slot of the secondary diaphragm and align the

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Electronic Pressure Regulator (EPR) Repair regulator to the actuator. Place the regulator on top the actuator, aligning the screw holes.

14. Insert the six screws through the actuator and into the regulator. Tighten screws to 4.5 N•m (40 lbf in).

WARNING DO NOT use Teflon tape to seal any LPG fittings.

15. Clean shutoff valve fitting and apply pipe thread sealant (Hyster Part No. 0246108) to the threads of the fitting and install the assembly on the EPR assembly. See LPG Shutoff Valve Assembly, Install.

16. Clean balance line fitting and apply pipe thread sealant (Hyster Part No. 0246108) to the threads of the fitting and install the fitting on the EPR assembly.

17. Lubricate new O-rings using a lubricant compatible with LPG and install O-rings on the fuel outlet fitting.

18. Insert fuel outlet fitting into the EPR assembly and install the retaining pin.

19. Lubricate new O-rings using a lubricant compatible with LPG and install O-rings on the fuel temperature sensor.

20. Insert fuel temperature sensor into the EPR assembly and install the retaining pin.

21. Lubricate new O-rings using a lubricant compatible with LPG and install O-rings on the coolant inlet and outlet fittings.

22. Insert coolant inlet and outlet fittings into the EPR assembly and install the retaining pins.

23. Install the vibration mounts on the bottom of the EPR assembly and tighten the vibration mounts until they are tight against the EPR assembly.

INSTALL 1. Place the EPR assembly in position on the mounting bracket.

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900 SRM 1326 2. Install the retaining nuts on the vibration mounts to secure the EPR assembly to the mounting bracket. Tighten the retaining nuts to 19 to 24 N•m (14 to 18 lbf ft).

3. Connect the balance line to the balance line fitting on the EPR assembly.

4. Connect the fuel outlet line to the EPR assembly.

5. Connect the coolant inlet and outlet hoses to the coolant inlet and outlet fittings on the EPR assembly.

6. Connect the fuel inlet line to the LPG shutoff valve.

7. Connect the electrical connect to the actuator of the EPR assembly.

8. Connect the electrical connector to the fuel temperature sensor.

9. Connect the electrical connector to the LPG shutoff valve.

10. Connect the negative battery cable.

11. Fill the cooling system. Refer to the section Periodic Maintenance for your lift truck.

12. Bleed the air from the regulator by removing the radiator cap and disconnecting the coolant outlet hose until coolant flows from the regulator. Connect the coolant outlet hose and check the coolant level. Refill the cooling system as needed as described in the section Periodic Maintenance for your lift truck. Install radiator cap.

13. Slowly open the fuel valve on tank.

14. If truck is equipped with a key switch, turn the key switch to the ON position and back to the OFF position to pressurize the fuel system. If truck is equipped with a Power ON/OFF button, press the Power ON/OFF button to ON and back OFF again to pressurize the system. Check for leaks.

15. Check for leaks at connections by using soapy solution or electron leak detector. If leaks are detected, make proper repairs.

900 SRM 1326

LPG Shutoff Valve Assembly

LPG Shutoff Valve Assembly REMOVE WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected 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 disconnected. 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 leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting.

8. Remove the 90 degree fitting that connects the LPG shutoff valve to the EPR from the LPG shutoff valve. See Figure 16.

9. Clean the threads of the 90 degree fittings.

INSTALL 1. Apply pipe thread sealant (Hyster Part No. 0246108) to the threads of the LPG shutoff valve.

2. Install the 90 degree fitting that connects the LPG shutoff valve to the EPR into the LPG shutoff valve and torque until tight, keeping the alignment of the fitting as shown in Figure 17.

1. Turn the shutoff valve clockwise until the valve is completely closed.

2. 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.

3. Disconnect the negative battery cable.

4. Disconnect the electrical connector to the LPG shutoff valve.

5. Slowly disconnect the fuel inlet line from the LPG shutoff valve.

6. Remove the 90 degree fuel inlet fitting from the LPG shutoff valve assembly. See Figure 14.

7. Remove the LPG shutoff valve and the 90 degree fitting connecting it to the EPR as an assembly.

See Figure 15.

1. 90 DEGREE FUEL INLET FITTING 2. LPG SHUTOFF VALVE ASSEMBLY 3. EPR Figure 14. 90 Degree Fuel Inlet Fitting Removal

15

LPG Shutoff Valve Assembly

900 SRM 1326

1. LPG SHUTOFF VALVE 2. 90 DEGREE FITTING, LPG SHUTOFF VALVE TO EPR Figure 16. LPG Shutoff Valve Disassembly/ Assembly

1. LPG SHUTOFF VALVE ASSEMBLY 2. EPR 3. 90 DEGREE FITTING Figure 15. LPG Shutoff Valve Assembly Removal/Installation 3. Apply pipe thread sealant (Hyster Part No. 0246108) to the threads of the 90 degree that connects the LPG shutoff valve to the EPR. 4. Install the LPG shutoff valve as an assembly on the EPR and torque until tight.

1. 90 DEGREE FITTING, LPG SHUTOFF VALVE TO EPR 2. LPG SHUTOFF VALVE Figure 17. LPG Shutoff Valve to EPR Fitting Alignment

16

900 SRM 1326

Fuel Mixer Repair

5. Apply pipe thread sealant (Hyster Part No. 0246108) to the threads of the 90 degree fuel inlet fitting.

6. Install the 90 degree fitting into the LPG shutoff valve and torque until tight, keeping the alignment of the fitting as shown in Figure 18.

7. Connect the electrical connector to the LPG shutoff valve.

8. Connect the fuel inlet to the LPG shutoff valve.

9. Connect the negative battery cable.

10. Slowly open the fuel valve on tank.

11. If truck is equipped with a key switch, turn the key switch to the ON position and back to the OFF position to pressurize the fuel system. If truck is equipped with a Power ON/OFF button, press the Power ON/OFF button to ON and back OFF again to pressurize the system. Check for leaks.

12. Check for leaks at connections by using soapy solution or electron leak detector. If leaks are detected, make proper repairs.

Figure 18. LPG Shutoff Valve Fuel Inlet Fitting Alignment

Fuel Mixer Repair REMOVE WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected 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 disconnected. 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 leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting.

1. Turn the shutoff valve clockwise until the valve is completely closed.

2. 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.

3. Disconnect the negative battery cable.

4. Disconnect the air intake hose from the fuel mixer.

5. Disconnect the balance line from the fuel mixer.

See Figure 19.

17

Fuel Mixer Repair

900 SRM 1326

1. FUEL MIXER 2. BALANCE LINE 3. FUEL LINE Figure 19. Balance Line and Fuel Line 6. Disconnect the fuel line from the fuel mixer.

7. Remove the four capscrews retaining the fuel mixer to the air box and mounting bracket. See Figure 20.

1.

2.

3.

4.

FUEL MIXER AIR BOX CAPSCREWS MOUNTING BRACKET Figure 20. Fuel Mixer Mounting Capscrews

8. Remove the fuel mixer and gasket. Discard old gasket. See Figure 21.

2. Insert fuel fitting into the fuel mixer and install the retaining pin.

9. If necessary, remove the 90 degree balance line fitting. See Figure 22.

10. Remove the fuel line fitting retaining pin and remove fuel line fitting.

3. Clean balance line fitting and apply pipe thread sealant (Hyster Part No. 0246108) to the threads of the fitting and install the fitting on the fuel mixer.

11. Remove O-rings from fuel line fitting and discard.

4. Clean the mating surfaces of the fuel mixer and air box.

INSTALL 1. Lubricate new O-rings using a lubricant compatible with LPG and install O-rings on the fuel fitting.

18

5. Place a new gasket in position on the air box.

900 SRM 1326

Fuel Mixer Repair 10. Connect the negative battery cable.

1.

2.

3.

4.

5.

FUEL MIXER 90 DEGREE BALANCE LINE FITTING RETAINING PIN O-RINGS FUEL INLET FITTING Figure 22. Fuel Mixer

11. Slowly open the fuel valve on tank.

1. FUEL MIXER 2. GASKET 3. AIR BOX Figure 21. Fuel Mixer Mounting Capscrews 6. Place the fuel mixer in position on the gasket and air box. Install the four capscrews to retain the fuel mixer to the air box and mounting bracket.

Tighten capscrews to 9 N•m (80 lbf in).

7. Connect the fuel line to the fuel mixer.

12. If truck is equipped with a key switch, turn the key switch to the ON position and back to the OFF position to pressurize the fuel system. If truck is equipped with a Power ON/OFF button, press the Power ON/OFF button to ON and back OFF again to pressurize the system. Check for leaks.

13. Check for leaks at connections by using soapy solution or electron leak detector. If leaks are detected, make proper repairs.

8. Connect the balance line to the fuel mixer.

9. Connect the air intake hose to the fuel mixer.

19

Control System

900 SRM 1326

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

ENGINE CONTROL UNIT (ECU) Remove

3. Remove the capscrews retaining the ECU to the mounting bracket and remove the ECU. See Figure 24.

4. If necessary, remove the capscrews retaining the mounting bracket to the engine and remove the mounting bracket.

1. Disconnect the negative battery cable.

2. Disconnect the wire harness connector from the ECU. See Figure 23.

1. ECU

2. WIRE HARNESS CONNECTOR Figure 23. ECU and Wire Harness Connector

20

900 SRM 1326

Control System

1. MOUNTING BRACKET 2. CAPSCREWS 3. ECU

4. CAPSCREWS 5. ENGINE Figure 24. ECU Removal/Installation

Install 1. If removed, place the ECU mounting bracket in position on the side of the engine and install the capscrews to secure the mounting bracket.

Tighten the capscrews to 47.5 to 54 N•m (35 to 40 lbf ft). See Figure 24.

ECU to the mounting bracket. Tighten the capscrews to 9.5 to 12.2 N•m (84 to 108 lbf in).

3. Connect the wire harness connector to the ECU. See Figure 23.

4. Connect the negative battery cable.

2. Place the ECU in position on the mounting bracket and install the capscrews to retain the

21

Control System

900 SRM 1326

ENGINE COOLANT TEMPERATURE (ECT) SENSOR Remove

Install 1. Apply Loctite® 567 to the threads of the ECT sensor.

1. Drain the engine coolant from the radiator before removing the ECT sensor. Refer to the section Cooling System 700 SRM 1123.

2. Install the ECT sensor and the new packing.

Tighten the ECT sensor to 7.9 to 11.7 N•m (70 to 104 lbf in).

2. Disconnect the ECT sensor connector.

3. Connect the ECT sensor connector.

3. Remove the ECT sensor and packing from the intake manifold. See Figure 25.

4. Refill the radiator with engine coolant after installing the ECT sensor.

1. PACKING (COPPER WASHER) 2. ECT SENSOR

3. WIRING CONNECTOR 4. INTAKE MANIFOLD Figure 25. ECT Sensor

22

900 SRM 1326

Control System

CAM ANGLE SENSOR

2007 Emission Compliant Engines 2200 SRM 1327.

Voltage Check

3. Connect the CAM angle sensor 4-pin connector.

WARNING Turning the ignition switch to the ON position with the fuel injector connector still connected will actuate the fuel injector. Disconnect the fuel injector connector.

WARNING Turning the ignition switch to the ON position with the ignition coil electrical connectors still connected will generate sparks, which can cause electrical shock. Disconnect all the ignition coil electrical connectors from the ignition coils before turning the ignition switch to the ON position when performing the following voltage check.

1. Verify that the ignition is OFF.

4. Tag and disconnect all the ignition coil electrical connectors.

5. Turn the ignition ON. 6. Measure the voltage between terminal A and terminal D. See Figure 26.

7. Rotate the CAM angle sensor drive by hand and verify the output signal. If not as specified, inspect the related wiring harnesses for open or short. If wiring harnesses are okay, replace the CAM angle sensor.

Specification: 1 pulse (5 V)/rev.

8. Install the CAM angle sensor and set engine timing. See the section Electrical System, Mazda 2.0L and 2.2L, 2007 Emission Compliant Engines 2200 SRM 1327.

2. Remove the CAM angle sensor. See the section Electrical System, Mazda 2.0L and 2.2L,

1. CAM ANGLE SENSOR 2. CAM ANGLE SENSOR CONNECTOR (ON CAM ANGLE SENSOR) 3. 4-PIN ELECTRICAL CONNECTOR Figure 26. CAM Angle Sensor Voltage Check

23

Control System

900 SRM 1326

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Remove 1. Disconnect the wiring harness connector from the MAP sensor connector. See Figure 27.

2. Disconnect the vacuum hose from the MAP sensor. See Figure 28.

3. Remove the retaining screws from the MAP sensor and remove the MAP sensor. See Figure 28.

1. RETAINING SCREWS 2. MAP SENSOR 3. VACUUM HOSE Figure 28. MAP Sensor Removal/Installation

INTAKE AIR TEMPERATURE (IAT) SENSOR Remove 1. Disconnect the wiring harness connector from the sensor connector.

1. MAP SENSOR 2. ELECTRICAL CONNECTOR

2. Remove the sensor and aluminum seal washer.

See Figure 29.

Figure 27. MAP Sensor Electrical Connector

Install Install 1. Place the MAP sensor in position and install the retaining screws.

2. Connect the vacuum hose to the MAP sensor.

3. Connect the wiring harness connector to the MAP sensor connector.

24

1. Install the IAT sensor and new aluminum seal washer. Tighten the IAT sensor to 7.9 to 11.7 N•m (70 to 104 lbf in).

2. Connect the wiring harness connector to the sensor connector.

900 SRM 1326

Control System ON/OFF button, press the Power ON/OFF button to turn engine off.

3. Disconnect the negative battery cable.

4. Disconnect the electrical connector to the fuel temperature sensor.

5. Remove the retaining pin from the fuel temperature sensor and remove sensor. See Figure 30.

1. IAT SENSOR 2. ALUMINUM SEAL WASHER 3. AIR BOX Figure 29. IAT Sensor

FUEL TEMPERATURE SENSOR Remove WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected 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 disconnected. 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 leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting.

1.

2.

3.

4.

FUEL TEMPERATURE SENSOR O-RINGS RETAINING PIN EPR ASSEMBLY Figure 30. Fuel Temperature Sensor Removal/Installation

Install 1. Lubricate new O-rings using a lubricant compatible with LPG and install O-rings on the new fuel temperature sensor.

1. Turn the shutoff valve clockwise until the valve is completely closed.

2. Insert fuel temperature sensor into the EPR assembly and install the retaining pin.

2. 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

3. Connect the electrical connector to the fuel temperature sensor.

4. Connect the negative battery cable.

25

Control System

900 SRM 1326

5. Slowly open the fuel valve on tank.

6. If truck is equipped with a key switch, turn the key switch to the ON position and back to the OFF position to pressurize the fuel system. If truck is equipped with a Power ON/OFF button, press the Power ON/OFF button to ON and back OFF again to pressurize the system. Check for leaks.

7. Check for leaks at connections by using soapy solution or electron leak detector. If leaks are detected, make proper repairs.

catalytic oxygen sensor and a post-catalytic oxygen sensor.

Remove 1. Disconnect the oxygen sensor electrical connector.

2. Remove oxygen sensor from the exhaust pipe.

See Figure 31.

Install

OXYGEN SENSOR

1. Coat the oxygen sensor sparingly with an antiseize compound. Install the oxygen sensor and tighten to 39 N•m (29 lbf ft).

If the lift truck is equipped with a catalytic convertor, there will be two oxygen sensors. There will be a pre-

2. Connect the oxygen sensor electrical connector.

1. MUFFLER 2. POST-CATALYTIC CONVERTER OXYGEN SENSOR 3. PRE-CATALYTIC CONVERTER OXYGEN SENSOR

4. EXHAUST PIPE 5. EXHAUST PIPE 6. CATALYTIC CONVERTER

Figure 31. Oxygen Sensors

26

900 SRM 1326

Exhaust System

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

EXHAUST SYSTEM, INSPECT Start the engine and inspect the exhaust system component for exhaust gas leakage. If leakage is found, repair or replace components as necessary.

THREE-WAY CATALYTIC (TWC) CONVERTER Remove and Install

2. Remove the three capscrews retaining the exhaust manifold insulator and remove the insulator. See Figure 32.

3. Remove the four nuts retaining the exhaust pipe to the exhaust manifold.

4. Remove the six nuts and washers retaining the exhaust manifold to the cylinder head.

5. Remove the exhaust manifold and gaskets.

6. Discard all of the old gaskets.

Install WARNING When the engine and exhaust system are hot, they can cause severe burns. Turn off the engine and wait until they are cool before removing the exhaust system.

1. Refer to the section Frame 100 SRM 1120 for the removal and installation of the TWC.

EXHAUST MANIFOLD Remove WARNING When the engine and exhaust system are hot, they can cause severe burns. Turn OFF the engine and wait until cool before removing the exhaust system.

1. Disconnect the negative battery cable.

1. Place the new gaskets in position on the cylinder head and the exhaust manifold.

2. Place the exhaust manifold in position on the cylinder head and secure with the six nuts and washers.

3. Tighten the six nuts evenly to 19 to 25 N•m (14 to 18 lbf ft).

4. Verify the position of the new exhaust manifold gasket to exhaust pipe is correct.

5. Connect the exhaust pipe to the exhaust manifold and secure with the four nuts and tighten evenly.

6. Place the exhaust manifold insulator in position and secure with the three capscrews. Tighten the capscrews to 19 to 25 N•m (14 to 18 lbf ft).

7. Connect the negative battery cable.

27

Exhaust System

900 SRM 1326

A. TO INTAKE MANIFOLD 1.

2.

3.

4.

5.

6.

7.

8.

9.

VALVE COVER CYLINDER HEAD CAPSCREWS EXHAUST MANIFOLD INSULATOR CAPSCREW WASHER NUT OXYGEN SENSOR NUT

10.

11.

12.

13.

14.

15.

EXHAUST PIPE GASKET EXHAUST MANIFOLD GASKET GROMMET POSITIVE CRANKCASE VENTILATION (PCV) VALVE 16. CLAMP 17. VACUUM HOSE Figure 32. Exhaust System

28

900 SRM 1326

POSITIVE CRANKCASE VENTILATION (PCV) VALVE

Exhaust System Table 1. PCV Valve Specifications Condition

Airflow

Remove

Air applied from port A

Yes

1. Slide the clamp back on the vacuum hose connected to the PCV valve. See Figure 32.

Air applied from port B

No

2. Disconnect the vacuum hose.

3. Remove the PCV valve.

Inspect 1. Blow air through the PCV valve and verify that air flows as specified. See Table 1 and Figure 33.

2. If not as specified, replace the PCV valve.

Install 1. Install the PCV valve into the grommet in the valve cover.

2. Connect the vacuum hose.

Figure 33. PCV Valve

3. Slide the clamp into position.

29

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

30

TECHNICAL PUBLICATIONS 900 SRM 1326

3/07 (12/06) Printed in U.S.A.