INTRODUCTION

GENERAL static relief valve, fuel filter and fuel valve unit, vapor-
This section has the description, operation and the repair izer, carburetor, solenoid valve, fuel pressure sensor and
procedures for the parts of the LPG fuel system used on indicator lamp, and a governor. The LPG arrangement
the MAZDA M4–2.0G engine. for the S/H1.50–1.75XM, S/H2.00XMS
(S/H25–35XM, H40XMS) units is shown FIGURE 1.
DESCRIPTION AND OPERATION. The LPG arrangement for the S/H2.00–3.20XM
The LPG fuel system has a fuel tank and valve, hydro- (S/H40–65XM) units is shown FIGURE 2.

1. LPG TANK
2. SHUT–OFF VALVE
3. RELIEF VALVE
4. FUEL VALVE/FILTER
5. LIQUID LPG HOSE
6. LPG VAPOR HOSE
7. VAPORIZER
8. COOLING SYSTEM HOSES
9. VACUUM LINE
10. PRESSURE SWITCH 2
11. LPG CARBURETOR

11
3
9
5

6 10

FIGURE 1. LPG SYSTEM, S/H1.50–1.75XM, S/H2.00XMS (S/H25–35XM, H40XMS)

1
 1
13
12
2
11 15

10 14

9
4

1. LPG TANK
2. SHUT–OFF VALVE
3. RELIEF VALVE
4. FUEL VALVE/FILTER
8 5. LIQUID LPG HOSE
5 6. LPG VAPOR HOSE
7. VAPORIZER
8. COOLING SYSTEM HOSES
9. GOVERNOR
6 10. BALANCE LINE
11. SOLENOID VALVE
12. CHECK VALVE
7 13. IDLE CONTROL ACTUATOR
14. LPG CARBURETOR
15. VACUUM LINE

FIGURE 2. LPG SYSTEM, S/H2.00–3.20XM (S/H40–65XM)

Fuel Tank (See FIGURE 3.) of the outlet tube inside the tank is near the lower surface
The fuel tank is the reservoir for the LPG system. The of the tank. The other end of the tube is fastened to the
fuel tank keeps the fuel in the liquid condition. The pres- outlet port. A shut–off valve is connected to the outlet
sure of the fuel is 1.7 MPa (240 psi) when the tank is full port of the tank. The shut–off valve can prevent fuel
at an temperature of 27°C (80°F). The tank has a pres- from leaving the tank when the outlet line is discon-
sure relief valve that is set at 3.4 MPa (480 psi). The inlet nected. A quick disconnect fitting is installed for easy
tube for the pressure relief valve is in the vapor area at tank removal. The tank has a guard for the valves and fit-
the top of the tank. tings. The guard has a hole for the alignment dowel on
The tank has a fuel gauge that measures the percentage the mount. The tank is fastened to the lift truck by metal
of fuel that is in the tank. A liquid level valve near the straps with latches. A fuel pressure sensor in the line
pressure relief valve is used to indicate the maximum from the tank energizes an indicator light on the instru-
liquid level that is permitted. The tank is filled until liq- ment panel when the tank is nearly empty and the fuel
uid fuel and flows from the liquid level valve. One end pressure decreases.

2
 seat. Liquid LPG then flows through the fuel valve to the
vaporizer.

1
8 8
5
1

2
4

3 7

4
6 3 5 6 7 8 9

1. SHUT–OFF VALVE 5. LIQUID LEVEL

2. QUICK DISCON- INDICATOR 1
NECT FITTING 6. RELIEF VALVE 10
3. FUEL GAUGE 7. ALIGNMENT
4. PLUG PIN
8. TANK RELIEF 17
VALVE
NOTE: Some LPG tanks have an auxiliary fill
fitting instead of a plug for Item 4.
11
FIGURE 3. LPG TANK

16

Fuel Filter and Fuel Valve Unit

(See FIGURE 4.) 12
A fuel line connects the fuel tank to the fuel filter. The
fuel filter prevents dirt from entering the vaporizer and
has a fuel valve that is operated by engine vacuum. The
fuel valve prevents fuel from entering the vaporizer un- 15 13
less the engine is being started or is running. The fuel 1. DIAPHRAGM 10. FILTER ELEMENT
valve has a leaf spring that holds a polyurethane pad 2. FULCRUM AND SCREEN
against the seat. A diaphragm is used to open the fuel 3. VACUUM INLET 11. FUEL INLET
4. O–RING 12. LEAF SPRING
valve. Air pressure pushes on the vent side of the dia- 5. WASHER 13. GASKET
phragm. The other side of the diaphragm has inlet mani- 6. PIN 14. BODY
fold vacuum and a lever and plunger that open the fuel 7. FUEL OUTLET 15. DIAPHRAGM COVER
valve. When the engine starts, the air pressure on the 8. VALVE PAD 16. AIR INLET
9. FILTER COVER 17. LEVER
lever side of the diaphragm decreases. Then the air pres-
sure on the vent side of the diaphragm moves the dia- FIGURE 4. FUEL FILTER AND FUEL VALVE
phragm, lever and pin to move the valve pad from the

3
Vaporizer (See FIGURE 5. and FIGURE 6.)
1
The function of the vaporizer is to change the liquid fuel
to a vapor (gas) and to control the pressure of the vapor. 2
The LPG fuel changes from a liquid to a vapor inside the
expansion chamber. A liquid needs heat to change to a 2
gas. Heat is removed from the vaporizer when the pres-
sure of the liquid LPG is quickly decreased in the expan-
sion chamber. The vaporizer must to be heated by the
engine coolant to replace the heat that is lost to the fuel.
Coolant passages in the vaporizer prevent the vaporizer
from being too cold to operate.
The vaporizer also controls the pressure of the gas that
goes to the carburetor. The pressure reducer valve keeps
the pressure of the gas in the expansion chamber at 38 5
mm (1.5 in) of water. When gas is required at the carbu- 4
3
retor, there is a vacuum in the vapor chamber. The vac-
uum opens the vapor valve and permits the gas to flow to 1. FUEL INLET
the carburetor. 2. COOLANT PORTS
3. BUTTON FOR LOW PRESSURE VALVE
Liquid fuel enters the vaporizer inlet from the filter unit. 4. FUEL OUTLET
The pressure reducer valve has a polyurethane pad and a 5. BALANCE LINE PORT
seat. When the pad is against the seat, the liquid fuel can- FIGURE 5. VAPORIZER
not enter the expansion chamber.

1 9
9 6
2

7
3
10

4
6

5 5
6. EXPANSION CHAMBER
1. VAPOR CHAMBER 7. COOLANT PASSAGE
2. COVER 8. DIAPHRAGM FOR PRESSURE
3. DIAPHRAGM FOR VAPOR VALVE REDUCER VALVE
4. VAPOR VALVE LEVER 9. PRESSURE REDUCER VALVE
5. VAPOR VALVE 10. OUTLET

FIGURE 6. INSIDE THE VAPORIZER

4
When the liquid fuel enters through the pressure reducer to flow from the vacuum chamber above the diaphragm
valve, the pressure of the fuel pushes on the diaphragm. to the inside of the air tube. There is clearance between
The diaphragm immediately moves and closes the the air measuring plate and the fuel metering valve. The
valve. Because only a very low pressure is needed to clearance permits air to flow through holes in the dia-
close the valve, the fuel pressure in the expansion cham- phragm if there is an explosion in the inlet manifold.
ber is very low. The sudden decrease in pressure causes
the fuel to change from a liquid to a vapor. This change
of condition takes heat from the surfaces of the expan-
sion chamber. Warm coolant flows next to the surfaces 1
2
of the chamber to replace the heat.

The LPG vapor is kept in the expansion chamber by the

vapor valve. When the engine starts, the gas in the vapor
chamber leaves the vapor chamber to flow through the
carburetor. The pressure on the vapor diaphragm then
decreases. Air pressure on the other side of the vapor
diaphragm pushes on the diaphragm and opens the va-
por valve. The gas flows from the expansion chamber to
7 6
the vapor chamber and then to the solenoid valve and
carburetor. The pressure in the expansion chamber de- 5 3
creases and again the pressure reducer valve opens to re-
peat the operation. When the carburetor throttle is 4
closed, the vacuum in the vapor chamber decreases and
the vapor valve closes. The pressure in the vapor cham-
1. DIAPHRAGM
ber stays at 10.3 kPa (1.5 psi). 2. AIR INLET
3. FUEL METERING VALVE
A balance line connects the air pressure side of the vapor 4. FUEL PASSAGE
diaphragm to an air inlet port at the carburetor. If the air 5. IDLE AIR ORIFICE
6. POWER VALVE
filter has a restriction, the pressure decreases in the car- 7. IDLE MIXTURE SCREW
buretor and in the vapor chamber of the vaporizer. When
FIGURE 7. INSIDE THE CARBURETOR
a balance line is not installed, this decrease can cause the
diaphragm to move and open the vapor valve. When a
balance tube is connected, the restriction causes an
When the engine starts, the air in the air tube and in the
equal decrease on both sides of the diaphragm. The bal-
vacuum chamber flows to the engine. Air pressure on
ance line prevents an increase in the fuel mixture in the
the outside of the air tube pushes the diaphragm against
carburetor. A button in the housing can be used to manu- the metering spring and moves the valves from their
ally open the vapor valve. LPG vapor then flows to the seats. Air then flows from the outside of the air tube to
carburetor for starting the engine. the inside of the tube. At the same time, the fuel valve is
lifted from its seat. The fuel pressure moves the LPG va-
Carburetor por from the fuel tube to mix with the air flowing
(See FIGURE 7. through FIGURE 10.) through the air tube. Because the air measuring valve
causes a restriction, the pressure in the inside of the tube
The carburetor has only two moving parts. There is a is always less than the outside of the tube. The difference
throttle plate and a diaphragm with the air measuring in pressure changes when the amount of air flowing
and fuel metering valves. A fuel tube in the center of the through the air tube changes. The diaphragm and valve
air passage is the seat for the fuel metering valve. The move according to the air flow. The amount of fuel that
seat for the air measuring valve is a tube that is around can flow through the fuel valve is controlled by the
the fuel tube. Four small passages in the valve permit air amount of air flowing into the air tube.

5
 FIGURE 10. DIAPHRAGM AND FUEL VALVE
ASSEMBLY

When the throttle plate is fully open at high engine

FUEL FLOW speeds, the fuel metering valve is at the top of its travel.
AIR FLOW See FIGURE 9. The carburetor has an adjustable valve
that controls the amount of LPG vapor that goes to the
FIGURE 8. AIR AND FUEL FLOW AT IDLE fuel metering valve. The restriction in fuel flow by this
valve is small when the fuel flow is low. When more fuel
flows through the valve, the valve becomes an orifice.
Adjusting the valve opening changes the mixture of fuel
and air when the engine is operated at high speed with a
load.
Solenoid Valve (See FIGURE 2.)
The solenoid valve is installed at the fuel inlet of the car-
buretor. The valve opens to let fuel to the carburetor
when the key switch is ON. When the key switch is
OFF, the valve closes and fuel cannot flow to the carbu-
retor.
Idle Control Actuator (See FIGURE 2.)
NOTE: Only the H2.00–3.20XM (H40–65XM) units
use the idle control actuator.
The idle control actuator is a vacuum controlled device
FUEL FLOW that increases idle speed when there is a load on the en-
AIR FLOW gine. The idle control actuator is mounted on the carbu-
VACUUM retor and acts directly on the throttle linkage. The vacu-
um line is connected to the governor and senses man-
FIGURE 9. AIR FUEL FLOW AT HIGH SPEED ifold vacuum. A check valve in the vacuum line keeps
the vacuum at the actuator.
When the throttle plate is near the closed position, the
pressure difference decreases. The metering spring During normal operation, vacuum holds the actuator rod
pushes the valves toward their seats. Flow through the away from the throttle linkage. When the engine is at
fuel valve decreases. An air screw for idle permits ad- idle speed and the throttle is depressed, manifold vacu-
justment of the mixture of the air fuel at low engine um decreases. The decrease in vacuum lets the actuator
speed. rod extend and increase the idle speed.

6
 Governor (See FIGURE 11.)
1 2
The governor is installed between the carburetor and the
intake manifold. The governor helps control the maxi-
mum speed of the engine.

3
1. SECONDARY ADJUSTMENT SCREW
2. ADJUSTMENT SPRING
3. MAIN ADJUSTMENT WHEEL
4. LOCK SCREW AND WASHERS
FIGURE 11. GOVERNOR

REPAIRS
REPLACEMENT OF THE HOSES fuel leak creates an explosion and fire hazard. Do not
attempt to start the engine if there is a leak in the
The hoses installed on LPG systems are special. Hoses
LPG fuel system.
that are made for use with hydraulic oil are damaged by
LPG. When replacing the LPG hoses, make sure to use LPG tanks are heavy. The weight of an LPG tank can
only HYSTER Approved LPG hose. Make sure to use exceed the maximum recommended weight for safe
the correct size of hose. When replacing the hose to the lifting by an individual. Get assistance when lifting
quick disconnect fitting, make sure that it is the same or lowering an LPG tank. Use correct lifting proce-
length as the hose it replaces. A hose that is the wrong dures.
length permits the tank to be installed in a position that is
not correct. Do not store LPG tanks near heat or an open flame.
For complete instructions on the storage of LPG fu-
LPG TANK els, refer to ANSI/NFPA 58 & 505.
Removal (See FIGURE 12.)
WARNING
WARNING Do not use any LPG tank that is damaged. Damaged
Before disconnecting any part of the LPG fuel sys- tanks must be removed from service.
tem, close the shut–off valve on the fuel tank. Run
the engine until the fuel lines are empty and the en- 1. Move the lift truck to the area where tanks are
gine stops. If the engine will not run, close the shut– changed.
off valve on the fuel tank and release the fuel slowly 2. Turn the shut–off valve clockwise until the valve is
in a non–hazardous area. completely closed.
LPG can cause an explosion even when the tanks are 3. Run the engine until it stops, then turn the key to the
empty. When replacing the tanks, do not weld, cause OFF position.
sparks or permit flammable material on or near the
4. Disconnect the quick disconnect fitting.
tanks. Do not change tanks when the engine is run-
ning. Tanks must be filled by authorized personnel. WARNING
Follow all the safety rules. Do not remove any parts
LPG is very cold. Always wear gloves to protect your
from the tank. Use a cloth to protect your hands from
hands from the cold fittings. Do not permit LPG to
cold metal.
contact the skin.
Frost on the surface of the tank, the valves or fittings
and the odor of LPG fuel indicates a leak. Inspect the 5. Release the tank latch and remove the tank from the
LPG system and repair a leak immediately. An LPG bracket.

7
 5. Inspect the fuel system for leaks when the shut–off
8 valve is open. Frost on the surface of the tank, valves or
5
1 fittings or a strong odor of LPG fuel indicates a leak.

WARNING
2
4 The shut–off valve on the tank must be closed when
the truck is not being used.
3 7
HYDROSTATIC RELIEF VALVE
Removal and Installation
6
WARNING
LPG can cause an explosion. Do not cause sparks or
5. LIQUID LEVEL permit flammable material near the LPG system.
1. SHUT–OFF VALVE
2. QUICK DISCON- INDICATOR Close the fuel valve on the tank. Disconnect the nega-
NECT FITTING 6. RELIEF VALVE tive battery cable to prevent sparks.
3. FUEL GAUGE 7. ALIGNMENT
4. PLUG PIN 1. Close the shut–off valve on the tank.
8. TANK RELIEF
VALVE 2. Slowly loosen the hose fitting for the relief valve. Let
the fuel drain from the fitting before removing the relief
NOTE: Some LPG tanks have an auxiliary fill
valve.
fitting instead of a plug for Item 4.
FIGURE 12. LPG TANK WARNING
LPG is flammable. Make sure there are no sparks or
flames in the area when the fuel lines are drained.

Installation (See FIGURE 12.) 3. The valve cannot be repaired. If the valve is damaged,
install a new valve. After installation, open the shut–off
1. Before the tank is installed on the lift truck, check the valve slowly and inspect the system for leaks.
operation of the fuel gauge. Look at the fuel gauge and
FILTER UNIT
move the tank. The needle of the gauge must move when
the fuel moves. If the needle does not move, a new tank NOTE: Use a liquid thread sealant on all fittings with
must be installed. threads at the filter unit.
Replacement Of The Fuel Filter Element
WARNING (See FIGURE 13.)
Make sure the alignment pin extends through the 1. Close the shut–off valve on the tank. Slowly loosen
correct hole in the rim of the LPG tank. The hose or the hose fitting to the filter. Let the fuel drain from the
fittings can be damaged if the LPG tank is not fitting before disassembling the filter unit.
installed in the correct position. A damaged hose or
fitting can release LPG fuel and cause an explosion WARNING
and fire hazard. LPG is flammable. Make sure there are no sparks or
flames in the area when the fuel lines are drained.
2. Install the LPG tank in its bracket so that the align- 2. Remove the ten screws and the filter cover. Replace
ment pin is in the correct hole in the bracket. Close the the filter element.
latches.
3. Install the cover and gasket. Tighten the screws for the
3. Connect the quick disconnect fitting to the shut–off cover. Tighten the hose fitting.
valve on the tank. Use your hand to tighten the fitting.
2. Remove the ten screws from the filter cover. Remove
4. Turn the shut–off valve counter clockwise to open the the filter and screen. Remove the six screws from the
valve. diaphragm cover. Remove the covers and gaskets.

8
Replacement of the Diaphragm and Fuel LPG drain from the lines. Remove the vacuum hose and
Valve (See FIGURE 13.) the mount capscrews.
3. Remove the diaphragm. Remove the filter and screen.
1. Close the shut–off valve on the tank. Slowly discon- Remove the screw for the leaf spring. Remove the valve
nect the fittings for the inlet and outlet hoses and let the pad. Pull the pin from its bore.

2 8
9

10
1

1
11

4
12

3 1

13
5

14

1. SCREW 6. WASHER
2. DIAPHRAGM COVER 7. BODY 11. SCREEN
3. DIAPHRAGM 8. O–RING 12. FILTER
4. FULCRUM 9. PIN 13. GASKET
5. LEVER 10. VALVE PAD 14. FILTER COVER

FIGURE 13. FUEL VALVE AND FUEL FILTER

9
4. Remove the fitting from the fuel outlet port. Remove 3. Disconnect the coolant fittings to the vaporizer. Re-
the washer and O–ring through the outlet port. move the balance line from the vaporizer. Remove the
capscrews at the mount for the vaporizer.
5. Install a new O–ring in its bore. Align the washer with
the O–ring and install the pin through the washer and O–
Disassembly
ring.
1. Remove the seven screws that hold the high pressure
6. Install the valve pad with the side with the polyure-
cover and plate to the vaporizer body. Remove the cover
thane pad toward the bore. Install the leaf spring, lock
and pressure reducer diaphragm. Remove the pin and
washer and screw.
spring from the plate.
7. Install the screen and filter element. Put the gasket on
2. Remove the plate and gasket. Remove the pressure
the body and install the filter cover and the ten screws
reducer valve.
and lock washers.
8. Replace the diaphragm. Install the diaphragm so that 3. Remove the six screws that hold the cover for the va-
the large plate is toward the valve. Install the cover and por chamber to the vaporizer. Remove the cover. Move
tighten the six screws and lock washers. the diaphragm toward the inlet port to release it from the
lever.
9. Install the capscrews for the mount. Connect the vac-
uum line. Connect the lines for the tank and the vapor- 4. Remove the screw that holds the lever pin. Cut the
izer. wire that holds the vapor valve pad to the lever. Remove
the pad.
10. Open the shut–off valve on the tank and check for
leaks in the line to the filter unit. Start the engine and in- Cleaning
spect for leaks on the outlet side of the filter unit.
WARNING
VAPORIZER (See FIGURE 14.)
Cleaning solvents can be flammable and toxic, and
Removal can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
WARNING manufacturer.
LPG can cause an explosion. Do not permit any
Wash all parts of the assembly, except the diaphragms in
sparks or flames in the work area.
solvent. Use compressed air to dry the parts. Do not use
1. Close the shut–off valve on the tank. Run the engine compressed air on the diaphragms.
until it stops. Slowly disconnect the fitting from the fil-
ter unit on the vaporizer. Disconnect the hose to the car- Inspection
buretor.
Make sure the vaporizer housing does not have cracks or
2. Put a drain pan under the drain valve for the radiator. damage. Inspect the threads for damage. The dia-
Open the drain valve so that the coolant drains in the phragms, valve pads, and gaskets are included in the re-
pan. pair kit.

10
 1
2

11

12

1
4
7 6
5
8 13
14
15
6 9

16 1

10

11. GASKET
1. SCREW 6. SPRING 12. PLATE
2. COVER FOR VAPOR VALVE 7. VAPOR VALVE PAD 13. PLUG
DIAPHRAGM 8. PIN 14. ACTUATING PIN
3. VAPOR VALVE DIAPHRAGM 9. HOUSING 15. DIAPHRAGM FOR PRESSURE
4. VAPOR VALVE LEVER 10. PAD FOR PRESSURE REDUCER VALVE
5. PIVOT PIN REDUCER VALVE 16. COVER

FIGURE 14. PARTS OF THE VAPORIZER

11
Assembly (See FIGURE 15.) Installation
NOTE: Use a liquid thread sealant on all fittings with
Follow the procedures shown in FIGURE 15. Always threads at the vaporizer.
use a HYSTER Approved repair kit when assembling Install the mount capscrews. Connect all the lines to the
the vaporizer. fittings. Fill the radiator with coolant. Check for leaks.

STEP 1:
Install the pad for the pressure reducer valve. STEP 3:
Make sure the polyurethane surface is against Install the actuating pin and spring.
the seat.

STEP 2:
Install a new gasket. Install the plate with pin STEP 4:
guide over the pressure reducer valve. Install a new diaphragm.

FIGURE 15. ASSEMBLY OF THE VAPORIZER (1 OF 3)

12
 STEP 7:
Put the valve spring in position on the housing.
STEP 5: Install the cover. Tighten the screws. Put the lever assembly over the spring. Install
the screw so that the head of the screw is
holding the pivot pin.

STEP 6:
Remove the vapor valve pad from the valve
lever. Install a new valve pad in the lever. Leave
the pad loose enough against the lever so that STEP 8:
the pad can tilt for alignment against the seat. Tighten the screw. Make sure the lever moves
Bend and cut the pin shown. freely.

FIGURE 15. ASSEMBLY OF THE VAPORIZER (2 OF 3)

13
 STEP 9:
Slide the lever into the slot in the diaphragm STEP 10:
bracket. Install the diaphragm. Install the cover and tighten the screws.

FIGURE 15. ASSEMBLY OF THE VAPORIZER (3 OF 3)

CARBURETOR

Removal

1. Remove the hose from the air cleaner at the carburetor

inlet. Disconnect the wires to the solenoid valve. Re-
move the fuel inlet hose at the solenoid valve. Remove
the hose to the idle control actuator. Remove the fuel fil-
ter hose and vaporizer hose.

2. Disconnect the throttle cable at the carburetor. Re-

move the carburetor from the governor.

Disassembly
(See FIGURE 16. and FIGURE 17.)

NOTE: Disassemble the throttle body and throttle shaft

assembly only if the gaskets or seals must be replaced.
1
1. Remove the four screws from the diaphragm cover. 3
Remove the cover and metering spring. 2
4
1. THROTTLE BODY
2. Remove the metering valve assembly from the carbu- 2. CARBURETOR BODY
retor body. Remove the four screws from the diaphragm 3. POWER VALVE
back–up plate and disassemble the valve. The valve as- 4. IDLE MIXTURE SCREW
sembly includes a fuel metering valve, air measuring
plate, diaphragm and back–up plate. FIGURE 16. THROTTLE BODY REMOVAL

3. Remove the solenoid valve and the idle control actua- 4. Disconnect the throttle springs from the attachment
tor. Remove the idle mixture screw and spring. plate. Remove the four screws that connect the throttle

14
body to the carburetor body. Remove the throttle body Cleaning
and attachment plate.
WARNING
5. Remove the two screws that connect the throttle plate Cleaning solvents can be flammable and toxic, and
to the throttle shaft and remove the throttle plate. Re- can cause skin irritation. When using cleaning sol-
move the retainer, spring guides and springs from the vents, always follow the recommendations of the
throttle shaft. Remove the throttle shaft from the throttle manufacturer.
body.
Make sure all the carburetor parts are clean before as-
6. Remove the seal retainers and seals from the throttle sembly. Wash all the parts, except the diaphragm, in sol-
body. If necessary remove the bearings from the throttle vent. Make sure the air passages in the metering valve
body. are clean.

1. COVER
2. SPRING
3. MIXTURE VALVE ASSEMBLY
4. CARBURETOR BODY
5. IDLE MIXTURE SCREW 2
6. IDLE CONTROL LEVER AND
ADJUSTER ASSEMBLY 1

16

18 19
3
16
17

16

15 14
13
12 5
11
8
10 7
9
11. SEAL
6 12. RETAINER
13. BEARING
14. THROTTLE BODY
15. SPRINGS
7. THROTTLE LEVER 16. GASKETS
8. IDLE SPEED SCREW 17. ATTACHMENT PLATE
9. THROTTLE SHAFT 18. ADAPTER PLATE
10. THROTTLE PLATE 19. POSITION MARK

FIGURE 17. PARTS OF THE CARBURETOR, S/H2.00–3.20XM (S/H40–65XM)

15
 1. COVER
2. SPRING
3. MIXTURE VALVE ASSEMBLY
4. CARBURETOR BODY
5. IDLE MIXTURE SCREW 1
6. THROTTLE LEVER
7. IDLE SPEED SCREW 14
8. THROTTLE SHAFT 2
15

13 14

18 3
11
10 12

9
7
6 8

16
5

17

9. THROTTLE PLATE 14. GASKETS

10. SEAL 15. ATTACHMENT PLATE
11. RETAINER 16. GASKET
12. BEARING 17. ADAPTER
13. THROTTLE BODY 18. POSITION MARK

FIGURE 18. PARTS OF THE CARBURETOR, S/H1.50–1.75XM, S/H2.00XMS (S/H25–35XM, H40XMS)

Assembly (See FIGURE 16. and FIGURE 17.) 3. Assemble the the metering valve, air measuring plate,
diaphragm and back–up plate. Align the position mark
1. Install new bearings as needed in the throttle body.
on the metering valve of the mixture valve assembly
Install new seals in the throttle body. Install the seal re-
with the fuel inlet, and install the mixture valve assem-
tainers and the throttle shaft. Install the throttle plate to
bly in the carburetor. Install the metering spring and
the throttle shaft using lock washers with the screws.
cover. Make sure the spring is in the correct position be-
Install the spring guides, springs and retainer on the
fore installing the cover.
throttle shaft.

2. Install the throttle body and attachment plate with

new gaskets to the carburetor body. Connect the springs Installation (See FIGURE 2.)
to the attachment plate. Install the idle mixture spring
and screw. Install the idle control actuator and solenoid NOTE: Use a liquid thread sealant on all fittings with
valve. threads at the carburetor.

16
1. Install a new gasket on the governor. Install the carbu- 1. Disconnect the hose from the air cleaner to the carbu-
retor on the governor. Install the idle control actuator on retor inlet. Remove the fuel inlet hose. Disconnect the
the bracket. wires at the solenoid valve. Remove the solenoid valve.

2. Install the balance line and the fuel hose. Install the 2. Use a liquid thread sealant and install the solenoid
vacuum hose and check valve for the idle control actua- valve on the carburetor. Connect the wires and fuel hose.
tor. The GRAY side of the check valve must be toward Connect the hose to the air cleaner. Turn the key switch
the idle control actuator. ON and OFF to check the operation of the solenoid
valve. Start the engine and check for leaks.
3. Connect the throttle linkage. Connect the wires at the
solenoid valve. GOVERNOR
Remove and install the governor as described in the pro-
4. Connect the hose to the air cleaner.
cedures for the CARBURETOR. When the governor is
5. Check and adjust the carburetor, throttle linkage and removed or replaced, adjust the governor and throttle
idle control actuator as described in CHECKS AND linkage as described in CHECKS AND ADJUST-
ADJUSTMENTS. MENTS.

NOTE: The vacuum hoses installed on the carburetor

SOLENOID VALVE (See FIGURE 2.)
and governor are made of special high–temperature ma-
The solenoid valve cannot be repaired. If the solenoid terial. If any of the hoses are replaced, make sure the cor-
valve does not operate it must be replaced. rect hoses are installed.

CHECKS AND ADJUSTMENTS

CHECK THE VAPORIZER
WARNING
LPG can cause an explosion. Do not permit any Pressure Reducer Valve
sparks or open flames in work area.
1. Connect a pressure gauge that can measure with accu-
CHECK THE FILTER UNIT racy a pressure below 35 kPa (5 psi) to the test port of the
1. Make sure there is fuel in the tank and that the tank vaporizer. The gauge must indicate 10.5 kPa (1.5 psi)
valve is open. when the engine is at idle. If the gauge indicates a pres-
sure greater than 10.5 kPa (1.5 psi), the pressure reducer
2. Check the operation of the fuel valve/filter. Loosen valve is damaged.
the fitting for the liquid LPG hose where it enters the
vaporizer. Check for a leak. A leak will be indicated by Vapor Valve
frost on the fitting. If there is frost at the fitting, repair or
replace the fuel valve/filter. 1. Run the engine until it is warm.

3. If there is no frost at the fitting, disconnect the vacuum 2. To check for leaks, stop the engine and disconnect the
line at the fuel valve/filter. Connect a hand operated hose from the fuel inlet port at the carburetor. Put the end
vacuum pump to the fitting on the fuel valve/filter. Ap- of the hose just below the surface of water in a container.
ply just enough vacuum to permit fuel to escape from the If bubbles are seen, the vapor valve is damaged or is
fitting loosened in step 1. dirty.
4. If frost does not appear at the fitting loosened in step 1
3. To check the vapor diaphragm, remove the inlet hose
when a vacuum is applied to the fitting for the vacuum
to the vaporizer. Remove the inlet hose at the carburetor.
line, repair or replace the fuel valve/filter.
Put the end of the hose below the surface of the water in a
5. If frost appears at the fitting loosened in step 1 when a container. Remove the balance line from the carburetor
vacuum is applied to the fitting for the vacuum line, and apply air pressure to the line. If bubbles continue to
check the vacuum hose for restrictions. be seen in the water, the diaphragm is damaged.

17
ADJUST THE CARBURETOR
CAUTION
Idle Mixture (See FIGURE 19.)
The adjustment of the throttle cable must be correct
1. When the engine is not running, turn the idle mixture or the cable can break during operation. The accel-
screw clockwise until it stops. In this position, the idle erator pedal or the MONOTROL pedal must reach
mixture screw prevents air from entering the air tube the pedal stop (floor plate) by the time the throttle
through the idle air port. plate in the carburetor is fully open.
2. Turn the idle mixture screw four turns counterclock-
wise. Power Mixture Adjustment (See FIGURE 19.)
3. Start the engine and run until warm. Adjust the mix- The power mixture valve controls the flow of fuel to the
ture screw clockwise (up to 2 full turns) as needed until carburetor when the engine is running near full load. Set
the idle is smooth. Turning the screw clockwise in- the power mixture valve on the center notch. This set-
creases the ratio of fuel to air. ting will be correct for most conditions. If further adjust-
ment is needed, the engine speed must not be permitted
Idle Adjustments (See FIGURE 19.)
to increase to the governor limit.
NOTE: Only the H2.00–3.20XM (H40–65XM) units
use the idle control actuator.

1. The engine must be at the normal operating tempera-

ture. Connect a tachometer to the engine.

2. Turn the idle speed screw until the idle speed of the 5
engine is 725 ± 25 rpm.

3. Turn the idle mixture screw (2) 4 1/2 ± 1/2 turns from 4
the full IN position. Check and adjust the idle speed as
1
necessary.
3
4. Check the idle control adjustment as follows:

a. Adjust the idle speed and mixture as described

above.

b. Put the transmission in NEUTRAL and discon-

nect the vacuum hose from the idle control actua-
tor (4). Put a plug in the vacuum hose. Adjust the
engine idle speed to 1400 ± 50 rpm with the idle
control screw (3).
2
c. Install the vacuum hose and clamp to the idle con-
trol actuator (4). 1
6
d. Check the idle speed. If the idle speed is higher
than specifications, make the adjustment at the
idle control screw (3).
1. IDLE SPEED SCREW
2. IDLE MIXTURE SCREW
5. Check that the engine runs at its governed speed when
3. IDLE CONTROL SCREW
the accelerator pedal or the MONOTROL pedal reaches 4. IDLE CONTROL ACTUATOR
the floor plate. If necessary, adjust the throttle cable at 5. VACUUM HOSE CONNECTION
the bracket on the engine. Loosen the lock nuts and 6. POWER VALVE ADJUSTER
move the cable as necessary. Check that the maximum
FIGURE 19. LPG CARBURETOR
engine speed is 2600 to 2700 rpm.

18
 2. Make sure the tachometer will work with the ignition
CAUTION system.
During this test the mast must be fully extended.
Make sure there is enough overhead clearance in the 3. Make sure the air filter is clean and connected to the
building or do the test outdoors. carburetor.

Adjustments
1. Operate the lift truck until the engine, transmission
and hydraulic system are at normal operating tempera- With the engine at operating temperature, adjust the
tures. Apply the parking brake. governor as follows:
1. Remove the lock wire from the governor lock screw.
2. Install an exhaust gas analyzer in the exhaust pipe.
Loosen the governor lock screw. Apply the parking
Connect a tachometer to the engine. Start the engine and
brake.
fully extend the mast. Pull back on the LIFT lever to put
a load on the engine. Fully depress the accelerator pedal 2. With no load on the engine, run the engine at full open
and turn the power mixture valve until the reading on the throttle to obtain maximum engine speed. To adjust the
exhaust gas analyzer is 0.5 to 1.0% CO (carbon monox- maximum no load speed, hold the secondary adjustment
ide) maximum. If an exhaust analyzer is not available screw and turn the main adjustment wheel. Turn the
adjust the power mixture valve until the highest engine main adjusting screw clockwise to increase engine
speed is reached. speed and counterclockwise to decrease engine speed.
Set the maximum engine speed to 2600 to 2700 rpm.
GOVERNOR (See FIGURE 20.) 3. Tighten the lock screw for the governor.
The governor does not normally need adjustment. If ad-
4. Run the engine with the throttle fully open, then pull
justment is necessary, do not turn the adjustment screws
on the Tilt lever to load the engine. The governor setting
more than 1/4 turn at a time. If the adjustment screws are
is correct when the engine runs smoothly (without speed
turned more than this the governor can be difficult to ad-
changes), and the difference in speed between the load
just.
and no load conditions is within the limits of the specifi-
cations.
Checks
5. If the engine speed changes, loosen the lock screw and
Before making any adjustments to the governor, check turn the secondary adjustment screw 1/4 turn clockwise.
the following: Set the maximum no load engine speed by turning the
main adjustment wheel counterclockwise. Repeat this
1. Make sure the mechanical, electrical and fuel systems
procedure until the engine speed is steady.
are operating correctly.
6. If the engine speed difference between the load and no
load conditions is greater than specified, turn the main
1
adjustment wheel 1/4 turn clockwise. Set the maximum
no load engine speed by turning the secondary adjust-
ment screw counterclockwise. Repeat this procedure
until the engine runs correctly.
7. When the governor adjustment is correct, tighten the
lock screw and install wire between the lock screw and
2 the secondary adjustment screw.
3
ADJUST THE THROTTLE LINKAGE,
1. MAIN ADJUSTMENT WHEEL S/H2.00–3.20XM (S/H40–65XM)
2. SECONDARY ADJUSTMENT SCREW (See FIGURE 21. and FIGURE 22.)
3. LOCK SCREW
NOTE: Each time the throttle system is disassembled, it
FIGURE 20. GOVERNOR ADJUSTMENT is important to adjust the throttle cables.

19
1. Adjust the idle speed as described in Idle Adjust-
ments. MONOTROL PEDAL
SHOWN
2. Make sure the throttle linkage at the pedal assembly is
in the correct position.
1
3. Push the Monotrol or throttle pedal until it stops
against the floor plate. Adjust the throttle cable so that
the pedal stops on the floor plate just as the throttle plate 4 9 8
reaches the wide open position. Use the nuts at the pedal 2 8
end of the cable housing to change the adjustment of the
cable.

9 4
6 5
4
3

11707
7 9
1. PEDAL PAD 8
7 8
2. LINK
3. CRANK 6
4. PEDAL FRAME
5. FORWARD SOLENOID (BLACK WIRE) 5
1 6. BATTERY (RED WIRE)
7. REVERSE SOLENOID (YELLOW WIRE)
3 8. CORRECT HOLES FOR THE LINKAGE
H2.00–3.20XM (H40–65XM)
9. CORRECT HOLES FOR THE LINKAGE
2 S2.00–3.20XM (S40–65XM)
FIGURE 22. THROTTLE ARRANGEMENT,
S/H2.00–3.20XM (S/H40–65XM)
1. PIN 5. NUT
2. COTTER PIN 6. LOCK WASHER
3. THROTTLE CABLE 7. PEDAL LINKAGE
4. ROD END ASSEMBLY ADJUST THE THROTTLE LINKAGE,
S/H1.50–1.75XM, S/H2.00XMS
FIGURE 21. THROTTLE CABLE (S/H25–35XM, H40XMS) (See FIGURE 23.)
ARRANGEMENT
NOTE: Each time the throttle linkage is disassembled,
4. Adjust the pedal return stop (see FIGURE 22.) so that it is important to adjust the throttle cable.
there is no tension on the throttle cable at the idle posi-
tion. Do the following to check this adjustment: 1. Connect the throttle cable at the pedal. Tighten the
jam nut at the pedal bracket (7).
a. Run the engine at idle speed. Make sure the rod
on the idle control actuator is retracted and the 2. Adjust the idle speed of the engine. The idle adjust-
throttle linkage is against the idle speed screw. ment screw on the carburetor controls the idle speed.
The correct idle speed is 725 ± 25 rpm.
b. When the pedal return stop is in the correct posi-
tion, tighten the capscrew that holds the stop to 3. Adjust the pedal height to 41.3 mm (1.63 in) using the
the bracket. pedal stop (4).

20
 MONOTROL PEDAL SHOWN
1. PEDAL PAD
2 2. PEDAL FRAME
3. LINK
1 4. PEDAL STOP
5. CRANK
6. PEDAL HEIGHT
7. PEDAL BRACKET
6 A 8. THROTTLE CABLE
C
7
8

5 LINKAGE CONNECTIONS
A = All Units
B= Gasoline/LPG Units
C B C = Diesel Units
B
12822

FIGURE 23. THROTTLE ARRANGEMENT, S/H1.50–1.75XM, S/H2.00XMS (S/H25–35XM, H40XMS)

4. Connect the cable at the carburetor. Adjust the length CHECK THE MONOTROL PEDAL
of the cable housing so that the cable is not loose. With (See FIGURE 22.)
the engine running at the correct idle speed, change the Slowly move the Monotrol pedal pad from Forward to
position of the cable housing with the nuts at the bracket. Reverse and Reverse to Forward. There must be some
movement of the pedal pad before the pedal frame
moves and the throttle opens.

TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
The engine will not start easi- Low coolant level. Check coolant level at radiator and
ly. The vaporizer is freezing. coolant recovery reservoir. Fill to cor-
rect level.
Water hoses have a restriction or are Make sure there is adequate water
too small. flow to vaporizer. Install larger hoses.
Air lock in coolant line to the vaporizer. Remove air from coolant line.
Belt for water pump is loose or broken. Adjust tension. Install new drive belt.
Hose from vaporizer to carburetor has Find and repair leak. Install new hose.
a leak.
Thermostat is not operating correctly. Install new thermostat.
Idle mixture screw is not adjusted cor- Adjust idle mixture screw.
rectly.
Fuel valve in carburetor is damaged. Install new fuel valve. Overhaul carbu-
retor. Install new carburetor.

21
 TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
The engine will not start easi- Solenoid valve is disconnected or Connect wire to solenoid. Install new
ly. The vaporizer is freezing. does not operate correctly. solenoid valve.
Air filter is dirty. Check air restriction indicator. Clean
or install new filter element.
Balance line is disconnected. Connect balance line.
Accelerating too soon after engine is Allow longer warm–up time before
started. starting operation.
Engine does not idle smoothly Idle mixture screw is not adjusted cor- Adjust idle mixture screw.
rectly.
Diaphragm in carburetor is damaged. Install new diaphragm or carburetor.
Air leak between carburetor and gov- Fix air leak.
ernor or between governor and intake
manifold.
PCV system has a restriction. Remove restriction. Install new PCV
valve.
Air leak at throttle shaft. Repair or install new carburetor.
Hose from vaporizer to carburetor is Install new hose.
damaged.
Balance line is disconnected. Connect balance line.
Pressure reducer diaphragm has a Install new diaphragm.
hole.
Low pressure valve in vaporizer is Install new low pressure valve or new
damaged. vaporizer.
Idle speed is too low. Adjust idle speed.
Idle speed screw is loose. Tighten screw and adjust idle speed.
Water in fuel. Check fuel supply and tank filling pro-
cedure. Clean system.
Fuel tank is installed in the wrong Install fuel tank in correct position.
position.
Fuel valve on the tank is in the wrong Install fuel valve in the correct port.
port.
Idle control actuator is not adjusted Connect vacuum hose. Adjust the idle
correctly or the vacuum hose is dis- control actuator.
connected.
Engine idle speed is too high. Idle mixture screw is not adjusted cor- Adjust idle mixture screw.
rectly.
Idle speed screw is loose. Tighten screw and adjust idle speed.
Idle control actuator is not adjusted Connect vacuum hose. Adjust the idle
correctly or the vacuum hose is dis- control actuator.
connected.

22
 TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Engine does not run smoothly. The governor is damaged. Install new governor.
Low pressure diaphragm or valve in Repair or install new vaporizer.
vaporizer is damaged.
Wrong or damaged fuel valve in car- Repair or install new carburetor.
buretor.
PCV system has a restriction. Remove restriction. Install new PCV
valve.
Air leaks in the intake manifold. Repair leaks.
Balance line has a restriction. Remove restriction.

Loss of power. Air filter is dirty. Check air restriction indicator. Clean
or install new filter element.
PCV system has a restriction. Remove restriction. Install new PCV
valve.
Governor is damaged. Install new governor.
Power mixture valve is not adjusted Adjust power mixture valve.
correctly.
Hose from vaporizer to carburetor has Repair leak or install new hose.
leaks.
Diaphragm in carburetor is damaged. Install new diaphragm.
Wrong type of fuel. Clear system of wrong fuel. Fill tank
with correct fuel..
Hose from vaporizer to carburetor has Remove restriction or install new or
a restriction or is too small. larger hose.
Vaporizer is damaged. Repair or install new vaporizer.

Engine stops running. Valve on fuel tank is closed. Open fuel valve at the tank.
Fuel tank is empty. Install tank that has fuel.
Hose from fuel tank is too close to the Locate hose away from excessive
exhaust pipe. heat. Install new hose.
Vacuum line to filter unit is discon- Connect vacuum line.
nected.
Filter unit is damaged. Install new filter unit.
Vaporizer is damaged. Repair or install new vaporizer.
Carburetor is damaged. Install new carburetor.
Hose to carburetor is damaged. Install new hose.
Idle speed is too low. Adjust idle speed.
Water in the fuel. Check fuel supply and tank filling pro-
cedure. Clean system.
Fuel filter is dirty. Clean fuel filter.
Governor is damaged. Repair or install new governor.
Air leak at the intake manifold. Repair leak.
Solenoid valve is disconnected or Connect wire to solenoid. install new
does not operate correctly. solenoid valve.

23