AI00007

09/28/07

See Models Below

TO: DEALER PRINCIPALS, BRANCH MANAGERS, SERVICE MANAGERS, PARTS

MANAGERS and TRAINERS

SUBJECT: Air Filtration – Dirt Ingestion

MODELS AFFECTED: All Fortis Products

DESCRIPTION:
Hyster Company has recently completed an extensive Engineering review of Cummins and
Yanmar engine dusting complaints. We focused on the Cummins and Yanmar diesels because
diesels (compression ignited engines) are much more susceptible to dust contamination than
gasoline or LP (spark ignited engines). This investigation determined that improper servicing of
the air filtration system in the field is most likely the cause of these failures. Parts-Service Gram
AI00005R1 was issued previously to provide information relative to that issue. This Parts-
Service Gram is being issued to assist you when you receive complaints and when your
technicians are servicing these engines. If your customers service their own engines, please
provide a copy of this Parts-Service Gram to them.

When a complaint is received, have the technician start off by looking at the air filter housing
cap. You can generally tell right away if the element is correctly installed or not. A correctly
installed element will allow the cap to seat completely while a misinstalled element will hold the
cap off the housing slightly.

The following pictures are of the air filter housing cap being held off by misinstalled elements
and a correctly installed cap. You may need to enlarge them to see the gap clearly.

No
Gap Gap

Once you know what to look for, this gap is easily identified.
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Next, inspect for air leaks.

Be sure to know and follow all of the Cautions and Warnings in the Operating Manual and
Periodic Maintenance Guide and Service and Repair Manual when working on or inspecting the
truck.

Start the truck and listen for air being sucked into the air intake system around hose connection.
You can use a small rubber hose (¼” dia., about 3 feet long of black neoprene vacuum hose) as
a stethoscope. Place one end next to your ear and move the other about the hose connections
at the exit end of the filter housing and at the intake on the engine manifold. Also check the
engine manifold joints, as best as you can get to them. Listen for vacuum leaks, any place that
may be sucking unfiltered air into the engine. We recommend that you do this at idle and then at
full rpm. The rational is that there may be a leak at low vacuum that you don’t get at high
vacuum or vice versa.

Shut the engine off and remove the air filter cap and the air filter element. Inspect the “X” on the
inside of the cap and the ‘fingers’ between the “X” on the top of the element for damage.

The fingers on top of the elements are supposed to interfere with the “X” on the inside of the cap
if the element is misinstalled and prevent the cap from fully seating. The cap not seating
completely is an indication to the technician/operator that the element is not correctly installed
and to re-install the element correctly. Any damage to the “X” in the cap indicates that the
current element, or a previous element, has been misinstalled.

Next remove the element and look inside of the filter element and down through the housing into
the clean air hose. Any dirt found past the seal, on the inside of the element or on the inside of
the clean air hose, indicates that this engine may be in the process of being dusted. Here are
two pictures of elements for comparison.

Dirt is visible inside of the element. No dirt has passed the seal.

One item to note: Just because there is dirt on the inside of the element does not necessarily
mean that the element was misinstalled. Diesel engines ‘breathe’ or pulse, particularly at idle.
Once dirt gets into the air intake system, by any means, this pulsing action tends to blow it all
over all the surfaces. That’s what causes this even coating of dirt. If a pinhole or small leak
exists, you would still see this even coating of dirt but, you would also see a heavier stream of
dirt emanating from the leak and fanning out toward the engine in the direction of air flow.
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If there is no dirt on the inside of the air filter element or on the inside of the clean air hose, you
are done. This is a good system that has not been breached and is operating as expected. This
engine is not in danger of being dusted.

If there is dirt on the inside of the air filter element, or on the inside of the clean air hose, then
you must to find the source of the leak.

Clean out the inside of the air filter housing. Be very careful to not push dirt into the clean air
hose. You will probably need to use a dry rag first to get out the majority of the loose dirt and
then use a damp rag to get the rest. Pay particular attention the twist lock lugs in the bottom of
the housing. These need to be inspected next and you will need to get them clean for a good
inspection. Please refer to Donaldson’s installation instructions attached for your convenience as
well

The twist to lock lugs on the filter element fit below the lugs in the housing, so there should be no
wear on top of the lugs in the housing. If there is wear on top of the lugs in the housing, this will
indicate that an element has been misinstalled in the past.

Below is a picture of brand new non damaged lugs.

Below is a picture of damaged lugs

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The picture below has the damaged lugs blown up for clarity. Notice the flat spots that have
been worn on the tops of the nubs. This wear is caused by a misinstalled filter element. The
element lugs were on top of these housing lugs, instead of being underneath them. That is what
caused this wear.

The wear is sometimes difficult to see with the naked eye. You need to get the lugs clean and
you need to take good, clear pictures of them that you can blow up and maintain the clarity for
evaluation.

Wear on top of the housing lugs indicates that a filter element has been misinstalled at some
time in the past. This engine has been dusted.

It is recommended that you impress upon the technicians and the customers operators or
service personnel how important it is to get the element installed correctly by twist locking the
element into place. The cap will help indicate whether the element is installed correctly. If the
cap doesn’t go on easily and fit completely down against the housing, the element is
misinstalled. The element installation should be checked and verified before the cap is installed
again.
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The air filter housing should NOT be opened periodically to check the element. See below.

If a truck is equipped with the premium monitoring option, the air filter housing should not be
opened unless the indicator light goes on, indicating its time to change the element, or the
required number of hours have passed and the truck has reached the recommended time for a
filter change. Each time the air filter housing is opened and the element removed, you risk
getting dirt into the clean air hose. Do not open the filter housing unless you are ready to
change the element.

"Be sure to use only genuine Hyster elements. We have found off-brand elements in the
field and those elements have not had the correct alignment between the bottom locking
tabs and the cross in the top. These off-brand elements could allow for the cap to be fully
seated and the element to not be correctly installed."

In dirty/dusty applications, if the truck is not equipped with the premium monitoring option, the air
filter housing should not be opened unless the required number of hours has passed and the truck
has reached the recommended time for a filter change. For diesel trucks without the premium
monitoring option, there is an optional Manual Restriction Indicator kit which contains a secondary
element (inner liner). Note! Use of the secondary element in a truck equipped with gas or LPG
engine will void the UL label on the truck.

These Manual Indicator kits have been used many years and they are part numbers 1670585 for
models F001 (H30-40FTS) and L177 (H40-70FT) with the Yanmar engines and 1680586 for models
N005 (H80-120FT), D024 (S135-155FT) and H006 (H135-155FT) with the Cummins engines. This
will provide the service technician/customer’s operators/service personnel with a visible indicator of
when to change the filter if it has not yet reached the recommend change interval. See these kits on
the following page.
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For use with all engines w/o the Premium Monitoring Option except the pre 2007 Mazda LPG
emissions engines with balance line connections. Kits are used for diesel engines only. Gas and
LPG engines only require the fitting (#2) and restrictor indicator (#3).

Kit contains –
Item 1
Secondary Liner *
2
Item 2
90 Degree Fitting -
0016151

Item 3
3
Restrictor Indicator –
165991

* Use for diesel engines

only
1

For use with pre 2007 Mazda LPG emissions engines with balance line connections - w/o the
Premium Monitoring Option

2
3
4

Item 2
90 Degree Fitting -
0016151

Item 3
Restrictor Indicator –
165991

Item 4
Special Fitting - 141259
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The following instructions will accompany the kit.

The use of this kit or the premium monitoring option are excellent ways to monitor the condition
of the air filter element.

Warranty Reimbursement

This Parts-Service Gram is for information purposes only and will not be considered for warranty
reimbursement unless a failure occurs within the warranty period that is not attributable to
incorrectly installing the air cleaner cap.

We reserve the right to change the design of our products without incurring an obligation to modify previously manufactured products.