Hyster F001 Operating instructions

Hyster F001 (H30FT H35FT H40FTS) Forklift

LPG FUEL SYSTEM
MAZDA 2.0L AND2.2L
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 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
LPG Tank Replacement..................................................................................................................................... 1
Remove ........................................................................................................................................................... 1
Install ............................................................................................................................................................. 3
Fuel Filter Unit Repair...................................................................................................................................... 4
Fuel Filter Element ....................................................................................................................................... 4
Remove....................................................................................................................................................... 4
Clean/Inspect............................................................................................................................................. 4
Install......................................................................................................................................................... 4
Fuel Filter Housing ....................................................................................................................................... 5
Remove....................................................................................................................................................... 5
Disassemble............................................................................................................................................... 6
Assemble.................................................................................................................................................... 6
Install......................................................................................................................................................... 7
Electronic Throttle Body Repair ....................................................................................................................... 7
Remove ........................................................................................................................................................... 7
Install ............................................................................................................................................................. 8
Electronic Pressure Regulator (EPR) Repair ................................................................................................... 9
Remove ........................................................................................................................................................... 9
Disassemble ................................................................................................................................................... 10
Assemble ........................................................................................................................................................ 12
Install ............................................................................................................................................................. 14
LPG Shutoff Valve Assembly............................................................................................................................. 15
Remove ........................................................................................................................................................... 15
Install ............................................................................................................................................................. 15
Fuel Mixer Repair.............................................................................................................................................. 17
Remove ........................................................................................................................................................... 17
Install ............................................................................................................................................................. 18
Control System................................................................................................................................................... 20
Engine Control Unit (ECU)........................................................................................................................... 20
Remove....................................................................................................................................................... 20
Install......................................................................................................................................................... 21
Engine Coolant Temperature (ECT) Sensor................................................................................................. 22
Remove....................................................................................................................................................... 22
Install......................................................................................................................................................... 22
CAM Angle Sensor......................................................................................................................................... 23
Voltage Check ............................................................................................................................................ 23
Manifold Absolute Pressure (MAP) Sensor.................................................................................................. 24
Remove....................................................................................................................................................... 24
Install......................................................................................................................................................... 24
Intake Air Temperature (IAT) Sensor .......................................................................................................... 24
Remove....................................................................................................................................................... 24
Install......................................................................................................................................................... 24
Fuel Temperature Sensor.............................................................................................................................. 25
Remove....................................................................................................................................................... 25
Install......................................................................................................................................................... 25
Oxygen Sensor ............................................................................................................................................... 26
Remove....................................................................................................................................................... 26
Install......................................................................................................................................................... 26
Exhaust System ................................................................................................................................................. 27
Exhaust System, Inspect............................................................................................................................... 27
©2007 HYSTER COMPANY i

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Table of Contents LPG Fuel System
TABLE OF CONTENTS (Continued)
Three-Way Catalytic (TWC) Converter ........................................................................................................ 27
Remove and Install ................................................................................................................................... 27
Exhaust Manifold .......................................................................................................................................... 27
Remove....................................................................................................................................................... 27
Install......................................................................................................................................................... 27
Positive Crankcase Ventilation (PCV) Valve................................................................................................ 29
Remove....................................................................................................................................................... 29
Inspect........................................................................................................................................................ 29
Install......................................................................................................................................................... 29
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]
ii

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 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 sys-
tem 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 but-
tontoturnengineoff.
4. Disconnect the quick-disconnect fitting on the
LPGtank.SeeFigure1.
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.
1

LPG Tank Replacement 900 SRM 1326
A. SWING-OUT LPG BRACKET B. SWING-OUT AND DROP-DOWN LPG BRACKET
(EZXCHANGE)
1. LPG TANK
2. TANK STRAP
3. QUICK DISCONNECT FITTING
4. HYDROSTATIC RELIEF VALVE
5. MANIFOLD BLOCK
6. ALIGNMENT PIN
7. STOP PIN
8. BRACKET HANDLE
9. BRACKET PIVOT
10. GAS SPRING (DROP-DOWN BRACKET ONLY)
11. BRACKET RELEASE PIN (BUTTON)
Figure 1. LPG Tank and Bracket
2

900 SRM 1326 LPG Tank Replacement
1. QUICK-DISCONNECT CONNECTION
2. HOSE ASSEMBLY
3. CAPSCREWS
4. LPG TANK
5. HOSE ASSEMBLY TO LPG FUEL FILTER
6. LPG FUEL FILTER CONNECTION
7. HOSE ASSEMBLY TO LPG REGULATOR
8. LPG FUEL FILTER
9. 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.
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 injurytothefingersandhand.
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.
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 con-
junction 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 suf-
ficient, frost may appear on the fittings.
3

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 openflamesintheworkarea.
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 itnolongerstarts.
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. Remove the bolt and seal washer from the fuel
filter housing top section. Discard seal washer.
SeeFigure3.
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 sec-
tion for contamination or damage. If damaged,
replace the housing.
2. Clean and inspect the fuel filter housing bottom
section for contamination or damage. If dam-
aged, replace the housing.
Install
1. Install the new fuel filter and fuel filter O-ring.
SeeFigure3.
2. Install new housing O-ring.
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.
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.
1. BOLT*
2. SEAL WASHER
3. FUEL FILTER HOUSING TOP SECTION*
4. FUEL FILTER
5. FUEL FILTER O-RING
6. HOUSING O-RING
7. FUEL FILTER HOUSING BOTTOM SECTION*
8. LOW PRESSURE SWITCH
*NOT SERVICED SEPARATELY
Figure 3. Fuel Filter Removal/Installation
4

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 fit-
tings.
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. SeeFigure4.
6. Remove the socket head capscrews and fuel filter
housing from the mounting bracket. Remove fuel
filter assembly. See Figure 5.
1. FRAME
2. CAPSCREW
3. NUT
4. FUEL FILTER ASSEMBLY
5. LOW PRESSURE SWITCH
6. MOUNTING BRACKET
Figure 4. Fuel Filter Assembly Removal/
Installation
5

Fuel Filter Unit Repair 900 SRM 1326
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 hous-
ing 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 fit-
tings.
1. Apply pipe thread sealant (Hyster Part No.
0246108) to the threads of the outlet fitting and
install the outlet fitting and O-ring.
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. BOLT*
2. SEAL WASHER
3. FUEL FILTER HOUSING TOP SECTION*
4. FUEL FILTER
5. HOUSING O-RING
6. FUEL FILTER O-RING
7. INLET FITTING*
8. LOW PRESSURE SWITCH
9. LOW PRESSURE SWITCH FITTING*
10. LOW PRESSURE SWITCH ADAPTER*
11. O-RING*
12. FUEL FILTER HOUSING BOTTOM SECTION*
13. OUTLET ADAPTER FITTING*
14. OUTLET FITTING*
*NOT SERVICED SEPARATELY
Figure 6. Fuel Filter Assembly
6

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
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.
4. Connect engine wire harness to the low pressure
switch.
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.
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.
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 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 sys-
tem 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.
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 but-
tontoturnengineoff.
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 elec-
tronic throttle body.
7. Remove the fuel mixer. See Fuel Mixer Repair,
Remove.
8. Removethescrewstothecoveroftheairbox.See
Figure 7.
9. Remove the cover of the air box and the O-ring.
7

Electronic Throttle Body Repair 900 SRM 1326
1. SCREW
2. COVER
3. AIR BOX
4. ELECTRONIC THROTTLE BODY
5. INTAKE MANIFOLD
6. SOCKET HEAD SCREW
7. 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.
1. O-RING
2. SLEEVE
3. ELECTRONIC THROTTLE BODY
4. GASKET
5. 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 man-
ifold.
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 elec-
tronic 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
8

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. Placethecoverinpositionontheairboxand
install the retaining screws.
10. Connect the electrical connector to the electronic
throttle body.
11. Connect the electrical connector to the IAT sen-
sor.
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 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 sys-
tem 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.
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 but-
tontoturnengineoff.
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 ac-
tuator 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.
9

Electronic Pressure Regulator (EPR) Repair 900 SRM 1326
1. COOLANT OUTLET HOSE
2. EPR ASSEMBLY
3. COOLANT INLET HOSE
Figure 9. EPR Coolant Hoses
10. Disconnect the fuel outlet line from the EPR as-
sembly. 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 neces-
sary, remove and discard O-rings.
3. Remove the retaining pin from the fuel tempera-
ture sensor and remove sensor. If necessary, re-
move and discard O-rings.
4. Remove retaining pin from the fuel outlet fitting
and remove fitting. If necessary, remove and dis-
card O-rings.
5. If necessary, remove balance line fitting from
EPR assembly.
6. Remove both 90 degree fittings and LPG shutoff
valveasanassembly. SeeLPGShutoffValve
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.
7. Remove the six screws that retain the regulator
totheactuator.SeeFigure12.
1. FUEL OUTLET LINE
2. EPR ASSEMBLY
Figure 10. Fuel Outlet Line
Legend for Figure 11
1. LPG SHUTOFF VALVE
2. 90 DEGREE FITTING
3. EPR ASSEMBLY
4. PLUG
5. O-RINGS
6. O-RINGS
7. COOLANT INLET FITTING
8. FUEL TEMPERATURE SENSOR
9. VIBRATION MOUNTS
10. NUTS
11. MOUNTING BRACKET
12. RETAINING PINS
13. FUEL OUTLET FITTING
14. COOLANT OUTLET FITTING
15. BALANCE LINE FITTING
16. 90 DEGREE FITTING
10

900 SRM 1326 Electronic Pressure Regulator (EPR) Repair
Figure 11. EPR Assembly Removal/Installation
11

Electronic Pressure Regulator (EPR) Repair 900 SRM 1326
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 reg-
ulator to be moved sideways to free the tab from the
diaphragm.
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.
9. Place regulator face down and remove the retain-
ing screw holding the secondary lever.
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 regula-
tor body.
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.
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 regu-
lator.
ASSEMBLE
1. Place the new primary valve pin into the cover
plate orifice.
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.
3. Place a new secondary body gasket in position in
position on the secondary body cover plate, en-
suring that the small hole in the gasket is aligned
with the small hole in the secondary body cover.
4. Place the secondary body plate cover and gasket
in position on the front of the regulator body, en-
suring that the holes in the gasket are aligned
with all screw holes.
12

900 SRM 1326 Electronic Pressure Regulator (EPR) Repair
1. SCREW
2. FACE COVER
3. PRIMARY DIAPHRAGM
4. RETAINING CLIP
5. PRIMARY SPRING
6. PRIMARY VALVE PIN
7. PRIMARY TEST PORT PLUG
8. SECONDARY BODY COVER PLATE
9. SECONDARY BODY GASKET
10. REGULATOR BODY
11. SECONDARY VALVE JET
12. SECONDARY SEAT
13. SECONDARY SPRING
14. SECONDARY LEVER
15. SCREW
16. FULCRUM PIN
17. 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 criss-
cross pattern.
7. Install a new secondary seat on the secondary
lever.
8. Install the secondary valve jet into the LPG reg-
ulator.
9. Place the secondary spring in position in the back
of the regulator body.
10. Position the secondary lever and fulcrum pin as-
semblyontopofthesecondaryspring. 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 specifica-
tion, the EPR cannot be repaired and must be re-
placed.
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
13

Electronic Pressure Regulator (EPR) Repair 900 SRM 1326
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 fit-
tings.
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, In-
stall.
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 compat-
ible with LPG and install O-rings on the fuel out-
let fitting.
18. Insert fuel outlet fitting into the EPR assembly
and install the retaining pin.
19. Lubricate new O-rings using a lubricant compat-
ible with LPG and install O-rings on the fuel tem-
perature sensor.
20. Insert fuel temperature sensor into the EPR as-
sembly and install the retaining pin.
21. Lubricate new O-rings using a lubricant compat-
ible 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. PlacetheEPRassemblyinpositiononthe
mounting bracket.
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 fit-
ting 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 as-
sembly.
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 tem-
perature sensor.
9. Connect the electrical connector to the LPG shut-
off valve.
10. Connect the negative battery cable.
11. Fill the cooling system. Refer to the section Pe-
riodic Maintenance foryourlifttruck.
12. Bleed the air from the regulator by removing the
radiator cap and disconnecting the coolant outlet
hose until coolant flows from the regulator. Con-
nect the coolant outlet hose and check the coolant
level. Refill the cooling system as needed as de-
scribed 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.
14