Hyster F001 Service & Repair Manual
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Hyster F001 Service & Repair Manual

Hyster F001 Service & Repair Manual

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Hyster F001 (H30FT H35FT H40FTS) Forklift

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  • Page 1 Hyster F001 (H30FT H35FT H40FTS) Forklift...
  • Page 2 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...
  • Page 3 • 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.

  • Page 4: Table Of Contents

    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...
  • Page 5 Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...
  • Page 6 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]...

  • Page 7: General

    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 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.
  • Page 8 LPG Tank Replacement 900 SRM 1326 A. SWING-OUT LPG BRACKET B. SWING-OUT AND DROP-DOWN LPG BRACKET (EZXCHANGE) 1. LPG TANK 7. STOP PIN 2. TANK STRAP 8. BRACKET HANDLE 3. QUICK DISCONNECT FITTING 9. BRACKET PIVOT 4. HYDROSTATIC RELIEF VALVE 10.

  • Page 9: Install

    900 SRM 1326 LPG Tank Replacement WARNING When closing the LPG tank strap, do not wrap your fingers around the strap handle. 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.

  • Page 10: Fuel Filter Unit Repair

    Fuel Filter Unit Repair 900 SRM 1326 Fuel Filter Unit Repair FUEL FILTER ELEMENT 3. Install fuel filter housing top section onto fuel filter housing bottom section. Remove 4. Install bolt and new seal washer. Tighten bolt to 13 N•m (115 lbf in). WARNING LPG can cause an explosion.

  • Page 11: Fuel Filter Housing

    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.

  • Page 12: Disassemble

    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.

  • Page 13: Install

    900 SRM 1326 Electronic Throttle Body Repair 4. Apply pipe thread sealant (Hyster Part No. 5. Connect the inlet and outlet fuel lines. 0246108) on the threads of the inlet fitting and NOTE: Opening the fuel valve too quickly can cause install the inlet fitting.
  • Page 14 Electronic Throttle Body Repair 900 SRM 1326 1. O-RING 2. SLEEVE 3. ELECTRONIC THROTTLE BODY 4. GASKET 5. INTAKE MANIFOLD 1. SCREW 2. COVER Figure 8. Electronic Throttle Body 3. AIR BOX Removal/Installation 4. ELECTRONIC THROTTLE BODY 5. INTAKE MANIFOLD INSTALL 6.

  • Page 15: Remove

    900 SRM 1326 Electronic Pressure Regulator (EPR) Repair electronic throttle body to the intake manifold 12. Install the MAP sensor. See Manifold Absolute but do not tighten. Pressure (MAP) Sensor, Install. 6. Install the fuel mixer. See Fuel Mixer Repair, 13.

  • Page 16: Remove

    Electronic Pressure Regulator (EPR) Repair 900 SRM 1326 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.
  • Page 17 900 SRM 1326 Electronic Pressure Regulator (EPR) Repair Figure 11. EPR Assembly Removal/Installation...

  • Page 18: Assemble

    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.
  • Page 19 900 SRM 1326 Electronic Pressure Regulator (EPR) Repair 1. SCREW 10. REGULATOR BODY 2. FACE COVER 11. SECONDARY VALVE JET 3. PRIMARY DIAPHRAGM 12. SECONDARY SEAT 4. RETAINING CLIP 13. SECONDARY SPRING 5. PRIMARY SPRING 14. SECONDARY LEVER 6. PRIMARY VALVE PIN 15.

  • Page 20: Install

    EPR as- 15. Clean shutoff valve fitting and apply pipe thread sembly. sealant (Hyster Part No. 0246108) to the threads of the fitting and install the assembly on the EPR 6. Connect the fuel inlet line to the LPG shutoff valve.

  • Page 21: Lpg Shutoff Valve Assembly

    8 m (26 ft) from any open flame, motor vehicles, 1. Apply pipe thread sealant (Hyster Part No. electrical equipment, or ignition source. 0246108) to the threads of the LPG shutoff valve.
  • Page 22 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. 1. 90 DEGREE FITTING, LPG SHUTOFF VALVE TO 4.

  • Page 23: Remove

    900 SRM 1326 Fuel Mixer Repair 5. Apply pipe thread sealant (Hyster Part No. 7. Connect the electrical connector to the LPG shut- 0246108) to the threads of the 90 degree fuel off valve. inlet fitting. 8. Connect the fuel inlet to the LPG shutoff valve.
  • Page 24 3. Clean balance line fitting and apply pipe thread fitting. See Figure 22. sealant (Hyster Part No. 0246108) to the threads of the fitting and install the fitting on the fuel 10. Remove the fuel line fitting retaining pin and re- mixer.
  • Page 25 900 SRM 1326 Fuel Mixer Repair 10. Connect the negative battery cable. 1. FUEL MIXER 2. 90 DEGREE BALANCE LINE FITTING 3. RETAINING PIN 4. O-RINGS 5. FUEL INLET FITTING Figure 22. Fuel Mixer 11. Slowly open the fuel valve on tank. 1.

  • Page 26: Remove

    Control System 900 SRM 1326 Control System NOTE: Always use new O-rings, seals, and gaskets 3. Remove the capscrews retaining the ECU to the when servicing the fuel and exhaust systems. mounting bracket and remove the ECU. See Fig- ure 24. ENGINE CONTROL UNIT (ECU) 4.
  • Page 27 900 SRM 1326 Control System 1. MOUNTING BRACKET 4. CAPSCREWS 2. CAPSCREWS 5. ENGINE 3. ECU Figure 24. ECU Removal/Installation Install ECU to the mounting bracket. Tighten the cap- screws to 9.5 to 12.2 N•m (84 to 108 lbf in). 1.

  • Page 28: Remove

    Control System 900 SRM 1326 ENGINE COOLANT TEMPERATURE (ECT) Install SENSOR ® 1. Apply Loctite 567 to the threads of the ECT sen- sor. Remove 2. Install the ECT sensor and the new packing. 1. Drain the engine coolant from the radiator before Tighten the ECT sensor to 7.9 to 11.7 N•m (70 removing the ECT sensor.
  • Page 29 900 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 4. Tag and disconnect all the ignition coil electrical connectors. Turning the ignition switch to the ON position with the fuel injector connector still connected 5.

  • Page 30: Remove

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

  • Page 31: Remove

    900 SRM 1326 Control System ON/OFF button, press the Power ON/OFF but- ton 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 tempera- ture sensor and remove sensor.

  • Page 32: Remove

    Control System 900 SRM 1326 5. Slowly open the fuel valve on tank. catalytic oxygen sensor and a post-catalytic oxygen sensor. 6. If truck is equipped with a key switch, turn the key switch to the ON position and back to the Remove OFF position to pressurize the fuel system.

  • Page 33: Remove

    900 SRM 1326 Exhaust System Exhaust System NOTE: Always use new O-rings, seals, and gaskets 2. Remove the three capscrews retaining the ex- when servicing the fuel and exhaust systems. haust manifold insulator and remove the insu- lator. See Figure 32. EXHAUST SYSTEM, INSPECT 3.
  • Page 34 Exhaust System 900 SRM 1326 A. TO INTAKE MANIFOLD 1. VALVE COVER 10. EXHAUST PIPE 2. CYLINDER HEAD 11. GASKET 3. CAPSCREWS 12. EXHAUST MANIFOLD 4. EXHAUST MANIFOLD INSULATOR 13. GASKET 5. CAPSCREW 14. GROMMET 6. WASHER 15. POSITIVE CRANKCASE VENTILATION (PCV) 7.
  • Page 35 900 SRM 1326 Exhaust System POSITIVE CRANKCASE VENTILATION Table 1. PCV Valve Specifications (PCV) VALVE Condition Airflow Remove Air applied from port A 1. Slide the clamp back on the vacuum hose con- Air applied from port B nected to the PCV valve. See Figure 32. 2.
  • Page 36 NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________...
  • Page 38 TECHNICAL PUBLICATIONS 900 SRM 1326 3/07 (12/06) Printed in U.S.A.

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