LPG FUEL SYSTEM (IMPCO CA 50, CA 100) HYSTER PART NO. 899772 900 SRM 15,SAFETY PRECAUTIONS MAINTENANCE AND REPAIR ‘© When lifting parts or assemblies, make sure that all slings, chains or cables are correctly fastened and that the load being lifted is balanced. Make sure that the crane, cables and chains have the capacity to support the weight of the load. * Donot lift heavy parts by hand. Use a lifting mechanism. © Wear safety glasses. * DISCONNECT THE BATTERY CONNECTOR before doing any ‘maintenance or repair on electric lift trucks. Disconnect the battery ground ‘cable on internal combustion lift trucks. ‘© Always use correct blocks to prevent the unit from rolling or falling. See “How To Put The Lift Truck On Blocks” in the OPERATING MANUAL or the PERIODIC MAINTENANCE section. ‘* Keep the unit and working area clean and in order. ‘© 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 that all nuts, bolts, snap rings and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE sign to the controls of the unit when ‘making repairs or if the unit needs repairs. ‘* Make sure you follow the DANGER, WARNING and CAUTION notes in the instructions. © Gasoline, Liquid Petroleum Gas (LPG), and Diesel are flammable fuels. Make sure that you 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 has ventilation.CONTENTS ‘THE LPG FUEL SYSTEM(MPCO CA 50, CA 100) .. GENERAL. DESCRIPTION .. Fuel Tank Fuel Filter and Fuel Valve Unit . . Vaporizer ‘The IMPCO CA 100 Carbureto IMPCO CA 50 Carburetor ‘The Governor (GM Engines Only) .... Governor With Electronic Controller .. REPAIRS LPG TANK .. Removal Installation REPLACE THE HOSES HYDROSTATIC RELIEF VALVE Removal and Installation FILTER UNIT .... Replacement Of The Fuel Filter Element Replacement of the Diaphragm and Fuel Valve . VAPORIZER ...... Removal Disassembly Cleaning Inspection Assembly Installation ween CARBURETOR (IMPCO CA 100) . Removal .. Disassembly Cleaning .. Assembly .. Installation CARBURETOR (IMPCO CA 50) Removal .. Disassembly @HYSTER COMPANY 1993 ee rueenene 10 10 10 u ul u ul 12 12 13 13 13 13 13, 13, 15 15 7 7 7 7 7 17 19 19 19Cleaning .... Inspection Assembly (See FIGURE 26.) . CHECKS AND ADJUSTMENTS . CHECK THE FILTER UNIT CHECK THE VAPORIZER . Pressure Reducer Valve ‘Vapor Valve ..... ADJUST THE CARBURETOR Idle Mixture . Idle Speed ..... ADJUST THE GOVERNOR (GM Engines Only) .. Checks Main Adjust Secondary Adjusting Screw . AISAN Governor .. Adjustments, AISAN Governor. TROUBLESHOOTING ........- This section is for the following models: $20-30A, S/H1.25-1.75XL (S/H25-35XL), $30-50C, S40-SOF, $2.00-3.00XL ($40-60XL), $30-120E, $125-150A, H20-30E, 30-60, 130-60), H2.00-3.00XL (H40-60XL) H60-80C, H60-110E, HI10-150F, P40-50A, P60-80A, KE ©HYSTER COMPANY 1993 20 20 20 2 21 2 2 a a a ERBBRERBTHE LPG FUEL SYSTEM (IMPCO CA 50, CA 100) GENERAL DESCRIPTION ‘The LPG fuel system has a fuel tank, hydrostatic relief valve, a filter with a fuel valve, a vaporizer, a carburetor This section has the description and the repair proce- and a governor. dures for the LPG fuel system installed on the 4 and 6 cylinder engines FUEL TANK CARBURETOR BALANCE LINE GOVERNOR . FUEL VALVE ON TANK HYDROSTATIC RELIEF VALVE . TO COOLING SYSTEM VAPORIZER, FILTER UNIT VACUUM LINE FIGURE 1. LPG FUEL SYSTEMZZ HGH-PRESSURE LIQUID FUEL LOW-PRESSURE VAPORIZED FUEL VACUUM FUEL TANK . HYDROSTATIC RELIEF VALVE |. FILTER UNIT (WITH FUEL VALVE) |. ENGINE COOLING SYSTEM 3. VAPORIZER CARBURETOR GOVERNOR . INTAKE MANIFOLD FOR THE ENGINE VACUUM ADVANCE LINE FOR DISTRIBUTOR FIGURE 2. LPG SYSTEM SCHEMATIC Fuel Tank (See FIGURE 3.) ‘The fuel tank is the reservoir for the LPG system, The fuel tank keeps the fuel in the liquid condition. The pres- sure of the fue is 1.7 MPa (240 psi) when the tank is full at an temperature of 27°C (80°F). The tank has a pres- sure relief valve thatis set 3.4 MPa (480 psi). The inlet tube for the pressure relief valve is in the vapor area at the top of the tank. ‘The tank has a fuel gauge that measures the percentage of fuel that is in the tank. A liquid level valve near the pressure relief valve is used to indicate the maximum liquid level that is permitted, The tank is filled until lig uid fuel and flows from the liquid level valve. One end of the outlet tube inside the tank is near the lower surface, of the tank. ‘The other end of the tube is fastened to the: outlet port. A shut-off valve is connected to the outlet port of the tank. ‘The shut-off valve can prevent fuel from leaving the tank when the outlet line is discon- nected. A quick disconnect fitting is installed for easy tank removal. The tank has a guard for the valves and fit- tings. The guard has a hole for the alignment dowel on the mount. The tanks fastened to the lift truck by metal straps with latches. A fuel pressure sensor in the line from the tank energizes an indicator light on the instru- ment panel when the tank is nearly empty and the fuel pressure decreases. LIQUID LEVEL 1. SHUT-OFF VALVE ano INDICATOR 2. QUICK Dis RECTENTING RELIEF VALVE 3. FUEL GAUGE ALIGNMENT 4. PLUG. PIN TANK RELIEF VALVE ‘Some LPG tanks have an auxiliary fill fitting instead of a plug for Item 4. FIGURE 3. LPG TANK NOTE:DIAPHRAGM FULCRUM VACUUM INLET O-RING |. WASHER, 5. PIN 1. BODY FILTER ELEMENT AND SCREEN FUEL INLET LEAF SPRING GASKET FUEL OUTLET VALVE PAD AIR INLET FILTER COVER LEVER FIGURE 4, FUEL FILTER AND FUEL VALVE DIAPHRAGM COVER Fuel Filter and Fuel Valve Unit (See FIGURE 4.) AA 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- less the engine is being started or is running. The fuel valve has a leaf spring that holds a polyurethane pad against the seat. A diaphragm is used to open the fuel valve. Air pressure pushes on the vent side of the dia- phragm, The other side of the diaphragm has inlet mani- fold vacuum and a lever and plunger that open the fuel valve, When the engine starts, the air pressure on the lever side of the diaphragm decreases. Then the air pres- sure on the vent side of the diaphragm moves the dia- phragm, lever and pin to move the valve pad from the seat. Liquid LPG then lows through the fuel valve tothe vaporizer. Vaporizer (See FIGURE 5. and FIGURE 6.) ‘The function ofthe vaporizer isto change the liquid fuel toa vapor (gas) and to control the pressure of the vapor. ‘The LPG fuel changes from aliquid toa vapor inside the expansion chamber. A liquid needs heat to change to a £888, Heat is removed from the vaporizer when the pres- sure ofthe 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 mum (1.5 in) of water. When gas is required at the carbu- ‘etor, there is a vacuum in the vapor chamber. The vac- ‘uum opens the vapor valve and permits the gas to flow to the carburetor. Liquid fuel enters the vaporizer inlet from the filter unit. ‘The pressure reducer valve has apolyurethane pad and a seat. When the pad is against the seat, the liquid fuel can- ‘not enter the expansion chamber, ‘When the liquid fuel enters through the pressure reducer valve, the pressure of the fuel pushes on the diaphragm. The diaphragm immediately moves and closes the valve, Because only a very low pressure is needed to ‘close the valve, the fuel pressure in the expansion cham- beris 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 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 the vapor chamber and then to the solenoid valve and carburetor. The pressure in the expansion chamber de- creases and again the pressure reducer valve opens tore- peat the operation. When the carburetor throttle is closed, the vecuum in the vapor chamber decreases and the vapor valve closes. The pressure in the vapor cham- ber stays at 10.3 kPa (1.5 psi). A balance line connects the air pressure side of the vapor diaphragm to an air inlet port atthe carburetor. If the air filter has a restriction, the pressure decreases in the car- buretor and in the vapor chamber of the vaporizer. When balance lineis notinstalled, this decrease can cause the diaphragm to move and open the vapor valve, When & balance tube is connected, the restriction causes an equal decrease on both sides of the diaphragm. The bal- ance line prevents an increase in the fuel mixture in the carburetor. A button in the housing can be used tomanu- 1. VAPOR CHAMBER 2. COVER 3. DIAPHRAGM FOR VAPOR VALVE 4. VAPOR VALVE LEVER 5. VAPOR VALVE ally open the vapor valve. LPG vapor then flows to the carburetor for starting the engine. 1. FUEL INLET 2. COOLANT PORTS 3. BUTTON FOR LOW PRESSURE VALVE 4. FUEL OUTLET 5. BALANCE LINE PORT FIGURE 5. VAPORIZER 6. EXPANSION CHAMBER 7. COOLANT PASSAGE 8. DIAPHRAGM FOR PRESSURE REDUCER VALVE, 9. PRESSURE REDUCER VALVE 10. OUTLET FIGURE 6. INSIDE THE VAPORIZERThe IMPCO CA 100 Carburetor (See FIGURE 7.) ‘The IMPCO CA 100 carburetor has only two moving parts, There is a throttle plate and a diaphragm with the air measuring and fuel metering valves. A fuel tube in the center of the air passageis the seat for the fuel meter- ing valve. The seat for the air measuring valve is a tube that is around the fuel tube. Four small passages in the valve permit air to flow from the vacuum chamber above the diaphragm to the inside ofthe air tube. There isclearance between the air measuring plate and the fuel ‘metering valve. The clearance permits air to go through holes in the diaphragm if there is an explosion in the in- Jet manifold, 1. FUEL INLE 2. BALANCE LINE 3. THROTTLE BODY 4. IDLE SPEED SCREW FIGURE 7. IMPCO CA 100 1. FUEL METERING VALVE 2. VACUUM PASSAGE. 3. AIR INLET 4. THROTTLE LEVER 5. POWER VALVE 6. IDLE MIXTURE SCREW 7. FUEL INLET 8. AIR MEASURING VALVE 9. METERING SPRING 10. AIR TUBE 11. DIAPHRAGM 12. VACUUM CHAMBER 13. FUEL TUBE 14. IDLE MIXTURE PORT 15. THROTTLE PLATE 16. BALANCE TUBE PORT FIGURE 8. PARTS OF THE CARBURETORAIR MEASURING AND FUEL METERING VALVE . FUEL METERING VALVE AIR MEASURING PLATE DIAPHRAGM . PLATE . SCREW (4) CONTACT SURFACE FOR AIR TUBE AIR DIRECTION VANE. FUEL METERING CONE VACUUM PASSAGES PRESSURE RELIEF HOLES FOR EXPLOSIONS IN INTAKE MANIFOLD FIGURE9. AIR MEASURING AND FUEL METERING VALVE ‘When the engine starts, the air in the air tube and in the vacuum chamber flows to the engine. Air pressure on the outside of the air tube pushes the diaphragm against the metering spring and moves the valves from their seats. Air then flows from the outside of the air tube to the inside of the tube, Atthe same time, the fuel valve is lifted from its seat. The fuel pressure moves the LPG va- por from the fuel tube to mix with the air flowing through the air tube. Because the air measuring valve causes arestrction, the pressure in the inside ofthe tube is always less than on the outside of the tube. The diffe ence in pressure changes when the amount of air lowing through the air tube changes. The diaphragm and valve move according to the air flow. The amount of fuel that can flow through the fuel valve is controlled by the amount of air flowing into the air tube. ‘When the throttle plate is near the closed position, the pressure difference decreases. The metering spring pushes the valves toward their seats. Flow through the fuel valve decreases. An air screw for idle permits ad- Jjustment of the mixture of the air and fuel at low engine speed. When the throttle plate is fully open at high engine speeds, the valves are at the top of their travel. The car~ buretor has an adjustable valve that controls the amount of LPG vapor that goes to the 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 en- gine is operated at high speed with a load. FIGURE 10. NORMAL OPERATION OF THE CA 100 CARBURETOR,<=" AR —e FueL FIGURE 11. AIR AND FUEL FLOW AT IDLE (CA 100 CARBURETOR) IMPCO CA 50 Carburetor (See FIGURE 12. Through FIGURE 14.) ‘The air and fuel valves of the Impco CA 50 carburetor are part of a piston assembly. A plate with a check valve holds the metering spring for the piston. The throttle body has the throttle plate and a valve for the ar for idl. ‘The body of the carburetor has the bore for the piston and the seats for the fuel valve and air valve. The adjusters for the fuel power valve and the idle air mixtures are also in the carburetor body. Whenair enters the carburetor it pushes downon the pis- ton. Because the air valve part ofthe piston is a restic- tion to the air flow, there is less air pressure under the piston, The check valve in the plate permits air to leave the vacuum chamber and flow past the throttle. Airpres- sure above the piston compresses the metering spring and moves the air valve and fuel valve from their seats. This action permits fuel to mix with the air that is flow- ing through the air valve. The engine RPM and throttle opening cause the piston to move the correct distance from the seats. If the engine speed or throttle opening changes, the piston will move to a different position. ‘The fuel will flow in the correct ratio for the air that flows by the throttle, FUEL VALVE . BALANCE PORT |. POLYURETHANE ‘SEAT PISTON ASSEMBLY FIBER SEAL RING ‘SPRING THROTTLE PLATE SPRING IDLE VALVE PLATE |. AIR VALVE, IDLE AIR SCREW 13. POWER FUEL, VALVE FIGURE 12. PARTS OF THE CA 50 CARBURETOR atidle, the idle circuit in the carbure- tor is used. Atidle, the vacuum is high in the inlet mani- fold, but only a small amount of air flows past the throt- e plate, An idle air screw isin the body to permit an ad- ditional amount of air to mix with the air and fuel mix- ture during idle. The piston is pushed down just enough to open the fuel valve. The idle air screw adjusts the amount of air entering the mixture chamber. If more air passes through the idle circuit, less ai flows through the air valve. The piston then closes the fuel valve a small amount. Anidle valve permits air from the idle air screw to enter the mixture chamber only during idle. The idle valve prevents air flow through the idle circuit when the en- gine is being started. This action causes more fuel to flow for easier starting. When the throttle is opened, the idle valve closes the passage from the idle air screw. A passage is drilled from below the throttle to the idle valve. When the throttle is closed, the vacuum in the in-let manifold pulls the plunger against the spring and opens the valve, ‘The power valve permits the mixture to be adjusted dur- ing full power conditions. The power valve is a variable restriction tothe fuel flow. During light loads the power valve cannot change the mixture because the opening is too large. Y YS 1. FUEL CHAMBER 2. VACUUM CHAMBER 3. MIXTURE CHAMBER 4. TO INTAKE MANIFOLD 5. IDLE AIR CHAMBER FIGURE 13. CARBURETOR CHAMBERS ‘The Governor (GM Engines Only) NOTE: Lift trucks beginning with serial codes C177 and C187 have an governor with an electronic control- ler, See FIGURE 17. and FIGURE 18. NOTE: See THE MAZDA M4-121G ENGINE, 600 SRM 6 for information on the governor for this engi ‘The governor prevents the engine speed from increasing above the RPM specification. A higher speed can cause damage to the hydraulic pumps. The governor is in- stalled between the carburetor and the inlet manifold. ‘The governor has a throttle plate that is connected to a leaf spring and to a vacuum diaphragm. The leaf spring keeps the throttle plate open until the engine speed has increased to near the specification. The vacuum dia- phragm is used for part throttle operation. The shaft of the throttle plate is not in the center of the plate so that increased air flow closes the throttle plate. AR CARBURETOR 1. THROTTLE PLATE 2. DIAPHRAGM HOUSING 3. VACUUM PASSAGE 4, TO DISTRIBUTOR 5. TO CARBURETOR FIGURE 15. GOVERNOR, GM ENGINES. (EARLY PRODUCTION) ‘When the air and fuel mixture hits the throttle plate of the governor, the plate moves toward the closed position‘When the force of the mixture flow is equal tothe spring force, the throttle plate stops closing. The position of the throttle plate changes when the flow of the mixture changes. This movement permits the engine to stay at the RPM limit during changing load conditions. ‘The governor is carefully calibrated at the factory and adjustments not normally needed. If adjustment is nec- essary, see the procedure in the Checks and Adjust- ments, FIGURE 16, AIR INLET TO THE GOVERNOR DIAPHRAGM (EARLY PRODUCTION) ‘The governors on some of the engines have vacuum transfer ports for the distributor and carburetor. These governors have a valve that permits the vacuum control of the distributor to adjust the spark timing according to the load. Vacuum hose is used to connect the distributor and carburetor to the governor. A hose connects the ‘chamber for the diaphragm to the air inlet for the carbu- retor on some models. Governor With Electronic Controller (See FIGURE 17. and FIGURE 18.) ‘The governor is installed between the carburetor and the intake manifold. The solenoid valve is installed to the body of the governor. The governor controller is on the cowl in the operator’s compartment. Vacuum lines con- nect the diaphragm of the governor to the solenoid valve and the throttle body of the governor. The governor con- troller iselectrically connected to the solenoid valve and the ignition distributor. TO SOLENOID VALVE AND MANIFOLD VACUUM . DIAPHRAGM DIAPHRAGM ROD VACUUM CHAMBER . GOVERNOR LEVER, GOVERNOR SPRING FIGURE 17. GOVERNOR, GM ENGINES, LATER PRODUCTION ‘The operation of the governor is controlled by an elec- tronic controller. Manifold vacuum provides the force to actuate the governor while the controller regulates this force. The governor has two throttle plates that are con- nected to a diaphragm. Linkage from the diaphragm closes the throttle plates. A spring inthe governor opens the throttle plates. ‘The electronic controller is connected to the distributor and controls the operation of the solenoid valve. The so- lenoid valve controls the vacuum atthe diaphragm inthe ‘governor, When the solenoid valve is not energized, itis ‘open and manifold vacuum does not affect the governor. During operation, the electronic controller receives en- ‘gine speed (rpm) signals from the distributor. The con- twoller compares these signals with an internal reference in the circuit for the controller. When the engine speed signal is more than the internal reference, current flows tothe solenoid valve. The solenoid valve closes, causing ‘manifold vacuum to operate the diaphragm. When actu- ated, the diaphragm works against the governor spring to close the throttle plates and decrease engine speed. The solenoid valve opens and closes as necessary to keep the engine speed within the governor limits,nnn ENGINE GROUND GOVERNOR CONTROLLER ENGINE HARNESS DIAPHRAGM, GOVERNOR MANIFOLD VACUUM TO GOVERNOR GOVERNOR (UNDER CARBURETOR) LPG CARBURETOR SOLENOID VALVE AIR FILTER AND VENT VACUUM HOSE SPECIAL TEE FITTING FIGURE 18. GOVERNOR CIRCUIT, GM ENGINES: REPAIRS LPG TANK Removal (See FIGURE 19.) A WARNING Before disconnecting any part of the LPG fuel sys- tem, close the shut-off valve on the fuel tank. Run the engine until the fuel lines are empty and the en- gine stops. If the engine will not run, close the shut- off valve on the fuel tank and release the fuel slowly in a non-hazardous area. LPG can cause an explosion even when the tanks are empty. When replacing the tanks, do not weld, cause sparks or permit flammable material on or near the tanks. Do not change tanks when the engine is run- ning, Tanks must be filled by authorized personnel. Follow all thesafety rules. Do not remove any parts from the tank. Usea cloth to protect your hands from cold metal. Frost on the surface of the tank, the valves or fittings and the odor of LPG fuel indicates a leak. Inspect the 10 LPG system and repair a leak immediately. An LPG fuel leak creates an explosion and fire hazard, Do not attempt to start the engine if there is a leak in the LPG fuel system, LPG tanksare heavy. The weight of an LPG tank can umn recommended weight for safe ice when lifting ng an LPG tank. Use correct lifting proce- Do not store LPG tanks near heat or an open flame. For complete instructions on the storage of LPG fu- els, refer to ANSI/NFPA 58 & 505. A warning Do not use any LPG tank that is damaged. Damaged tanks must be removed from service. 1, Move the lift truck to the area where tanks are changed.2. Turn the shut-off valve clockwise until the valve is completely closed. 3, Run the engine until it stops, then turn the key to the OFF position. 4, Disconnect the quick disconnect fitting. & warNinG LPG is very cold. Always wear gloves to protect your hands from the cold fittings. Do not permit LPG to contact the skin. 5. Release the tank latch and remove the tank from the bracket LIQUID LEVEL, 1. SHUT-OFF VALVE Roleron 2. QUICK DISCON- NECT FITTING RELIEF VALVE 3. FUEL GAUGE ALIGNMENT 4PI PIN tus 8. TANK RELIEF VALVE ‘Some LPG tanks have an auxiliary fill fitting instead of a plug for Item 4. FIGURE 19. LPG TANK NOTE: Installation (See FIGURE 19.) |, Before the tank is installed on the lift truck, check the ‘operation of the fuel gauge. Look at the fuel gauge and move the tank. The needle of the gauge must move when the fuel moves. Ifthe needle does not move, a new tank ‘must be installed. A warnine Make sure the alignment pin extends through the correct hole in the rim of the LPG tank. The hose or fittings can be damaged if the LPG tank is not installed in the correct position. A damaged hose or fitting can release LPG fuel and cause an explosion and fire hazard. 2. Install the LPG tank in its bracket so that the align- ‘ment pin is inthe correct hole in the bracket. Close the latches, 3. Connect the quick disconnect fitting to the shut-off valve on the tank. Use your hand to tighten the fitting 4, Tum the shut-off valve counter clockwise to open the valve, 5. Inspect the fuel system for leaks when the shut-off valve is open. Frost on the surface ofthe tank, valves or fittings or a strong odor of LPG fuel indicates a leak. A WaRNING ‘The shut-off valve on the tank must be closed when. the truck is not being used. REPLACE THE HOSES ‘The hoses installed on LPG systems are special. Hoses that are made for use with hydraulic oil are damaged by LPG. When replacing the LPG hoses, make sure to use only HYSTER Approved LPG hose. Make sure to use the correct size of hose. When replacing the hose to the ‘quick disconnect fitting, make sure that it is the same length as the hose it replaces. A longer hose permits the tank to be installed in a position that is not correct. Ifa fuel hose has a restriction, itis coldest around the restric- tion, HYDROSTATIC RELIEF VALVE Removal and Installation A WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system. Close the fuel valve on the tank. Disconnect the nega- tive battery cable to prevent sparks. 1. Close the shut-off valve on the tank. 2. Slowly loosen the hose fitting for the relief valve. Let the fuel drain from the fitting before removing the relief, valve, 3. The valve cannot be repaired. Ifthe valveis damaged, install anew valve, After installation, open the shut-off valve slowly and inspect the system for leaks.WASHER 2. DIAPHRAGM COVER, BODY 3. DIAPHRAGM |. O-RING 4. FULCRUM PIN 5. LEVER VALVE PAD 11, SCREEN 12. FILTER, 13. GASKET 14, FILTER COVER FIGURE 20, FUEL VALVE AND FUEL FILTER FILTER UNIT NOTE: Use liquid thread sealant on all fitings with threads at the filter unit, Replacement Of The Fuel Filter Element (See FIGURE 20.) 1. Close the shut-off valve on the tank. Slowly loosen the hose fitting to the filter. Let the fuel drain from the fitting before disassembling the filter unit. 2 A warning LPG is Nammable, Make sure there are no sparks or flames in the area when the fuel lines are drained. 2, Remove the ten screws and the filter cover. Replace the filter element, 3. Install the cover and gasket. Tighten the screws forthe cover. Tighten the hose fiting,Replacement of the Diaphragm and Fuel Valve (See FIGURE 20.) 1. Close the shut-off valve on the tank. Slowly discon- nect the fittings for the inlet and outlet hoses and let the LPG drain from the lines. Remove the vacuum hose and the mount capscrews. 2, Remove the ten screws from the filter cover. Remove, the filter and screen. Remove the six screws from the diaphragm cover. Remove the covers and gaskets. 3, Remove the diaphragm. Remove the filter and screen. Remove the screw for the leaf spring. Remove the valve pad. Pull the pin from its bore. 4, Remove the fitting from the fuel outlet port. Remove the washer and O-ring through the outlet port. 5. Install a new O-ring inits bore. Align the washer with the O-ring and install the pin through the washer and O- ring, 6. Install the valve pad with the side with the polyure- thane pad toward the bore. Install the leaf spring, lock washer and screw. 7. Install the screen and filter element. Put the gasket on the body and install the filter cover and the ten screws. and lock washers. 8, Replace the diaphragm. Install the diaphragm so that the large plate is toward the valve. Install the cover and tighten the six screws and lock washers. 9. Install the capscrews for the mount. Connect the vac- ‘uum line, Connect the lines for the tank and the vapor- izer, 10. Open the shut-off valve on the tank and check for leaks in the line to the filter unit. Stat the engine and in- spect for leaks on the outlet side of the filter unit. VAPORIZER (See FIGURE 21.) Removal & WARNING LPG can cause an explosion. Do not permit any sparks or open flames in the work area, 1. Close the shut-off valve on the tank. Run the engine until it stops. Slowly disconnect the fitting from the fil- ter unit on the vaporizer. Disconnect the hose to the car- buretor. 2. Puta drain pan under the drain valve for the radiator. (Open the drain valve so that the coolant drains in the pan. 3, Disconnect the coolant fittings to the vaporizer. Re- ‘move the balance line from the vaporizer. Remove the ‘capscrews at the mount for the vaporizer, Disassembly 1, Remove the seven screws that hold the high pressure cover and plate to the vaporizer body. Remove the cover and pressure reducer diaphragm. Remove the pin and spring from the plate. 2. Remove the plate and gasket. Remove the pressure reducer valve. 3. Remove the six screws that hold the cover for the va- por chamber to the vaporizer. Remove the cover. Move the diaphragm toward the inlet portto release it from the lever. 4. Remove the screw that holds the lever pin. Cut the wire that holds the vapor valve pad tothe lever. Remove the pad. Cleaning A warning Cleaning solvents can be flammable and toxic, and can cause skin irritation. When using cleaning sol- vents, always follow the recommendations of the manufacturer, ‘Wash all parts of the assembly, except the diaphragms in solvent. Use compressed air to dry the parts. Do not use compressed air on the diaphragms. Inspection ‘Make sure the vaporizer housing does not have cracks or damage. Inspect the threads for damage. The dia- phragms, valve pads, and gaskets are included in the re- pair kit. 1BGASKET ‘SCREW SPRING PLATE COVER FOR VAPOR VALVE VAPOR VALVE PAD PLUG DIAPHRAGM . PIN ‘ACTUATING PIN VAPOR VALVE DIAPHRAGM . HOUSING DIAPHRAGM FOR PRESSURE. VAPOR VALVE LEVER PAD FOR PRESSURE REDUCER VALVE ;. PIVOT PIN REDUCER VALVE COVER FIGURE 21. PARTS OF THE VAPORIZER “Assembly (See FIGURE 22.) Installation NOTE: Use a liquid thread sealant on all fittings with Follow the procedures shown in FIGURE 22. 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. Install the pad for the pressure reducer valve. STEP3: Make sure the polyurethane surface is against 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 22. ASSEMBLY OF THE VAPORIZER (1 OF 2)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 the pad can tt for alignment against the seat. Bend and cut the pin ': Put the valve spring in position on the housing. Put the lever assembly over the ‘spring. Install the screw so that the head of the screw is holding the pivot pin. the lever into the slot in the agm bracket. Install the diaphragm. STEP 10: Install the cover and tighten the screws. FIGURE 22. ASSEMBLY OF THE VAPORIZER (2 OF 2)CARBURETOR (IMPCO CA 100) Removal 1, Remove the hose from the air cleaner to the carburetor inlet. Disconnect the hose, if one is installed, from the governor to the inlet, Remove the balance line from the carburetor. Remove the fuel inlet hose and vacuum hose. 2. Remove the linkage to the carburetor from the ‘Monotrol or accelerator pedal. Remove the nuts from the studs on the governor. Remove the carburetor, Disassembly Disassemble the carburetor. Use FIGURE 24. as arefer- ence, Cleaning ‘Wash all the parts, except the diaphragm, in solvent. Use compressed airto ry al the parts except the diaphragm. Make sure the air passages in the metering valve are clean. Assembly Assemble the carburetor, See FIGURE 23. Installation Install a new gasket on the governor. Install the carbure- tor, lock washers and nuts. Connect the linkage to the Monotrol or accelerator pedal. Install the balance line, the fuel hose, and the hose to the air cleaner. Bex CIE, ‘STEP 1. Install the throttle body as shown. Always use new gaskets. STEP 2. Assemble the valve as shown, then install the carburetor body. STEPS. Install the spring and cover. Tighten the screws for the cover. Make sure that the spring is in the correct, Position. FIGURE 23. ASSEMBLE THE CA 100 CARBURETOR "7. CARBURETOR BODY . SCREW (4) 15, 16. 17. 18. 19, 20. 21 22, 23. 24, 25, 26. 27. 18 FILTER GOVERNOR GASKET ‘SOLENOID VALVE VACUUM HOSE SPACER COVER SPRING VALVE AND DIAPHRAGM ‘SCREW BACKUP PLATE. RING, AIR VALVE AIR VALVE SCREW SPRING IDLE ADJUSTMENT SCREW ASSEMBLY GASKET THROTTLE SB SPACER, PLATE CLAMP ‘SPECIAL FITTING ‘SOLENOID VALVE BRACKET GASKET ‘SCREW (4) FITTING VENTURI THROTTLE SHAFT 28. BEARING (2) 32. IDLE CONTROL SCREW PIN 29. SEAL (2) 33. SCREW THROTTLE PLATE 30. STOPLEVER 34, THROTTLE LEVER ‘CLAMP, SCREW (2) 31. SPRING 35. RETAINER WASHER FIGURE 24. PARTS OF THE CA 100 CARBURETOR AND GOVERNOR SRES2SSS‘SCREW (4) AIR INLET GASKET SPRING IDLE AIR SCREW CARBURETOR BODY PISTON 8. SEAL RING 9. SPRING 11. GASKET 13. SPRING 10. CHECK VALVE PLATE 12. IDLE VALVE PLUNGER 14, THROTTLE BODY 15, THROTTLE SHAFT 16. THROTTLE PLATE 17. SEAL 18. IDLE SPEED SCREW 19, THROTTLE LEVER 20. GASKET FIGURE 25. PARTS OF THE CA 50 CARBURETOR. CARBURETOR (IMPCO CA 50) Removal 1, Remove the hose from the air cleaner to the carburetor inlet. Remove the balance line from the carburetor. Re- ‘move the fuel inlet hose and vacuum hose. 2. Remove the linkage to the carburetor from the ‘Monotrol or accelerator pedal. Remove the carburetor from the intake manifold, Disassembly (See FIGURE 25.) 1 Remove the four screws that hold the throttle body to the carburetor body. Separate the throttle body from the carburetor body. Do not permit the plunger and spring for the idle valve to release quickly. The check valve plate also has spring pressure on it. 2. Removethe check valve plate and spring. Remove the piston assembly. Remove the seal ring from the piston, 93, Remove the gasket, plunger and spring from the throt- tle body. To inspector replace the seals, the throttle shaft assembly mast be disassembled, Cleaning Clean the carburetor with solvent, Do notuse any carbu- retor cleanes that will damage the polyurethane seals. Inspection 1. Inspect the throttle seals for wear or damage. 2, Make sure the piston assembly moves freely in the body. Look for scratches on the piston or carburetor body. 3. Check the polyurethane seat for damage. Replace the piston assembly if the seat is hard or damaged. 4, Inspect the check valve for damage. ‘Assembly (See FIGURE 26.) 1. Install the fiber seal ring inthe piston, Start one end of the ring in the groove and move the ring around the pis ton. Be careful so that the ring does not break. 2. Install the piston assembly in the carburetor body. Tilt the piston assembly a small amount so that one end of theringisinthe bore, Use tool witha pointto compress the ring into the bore. 3. Install the spring and plate for the check valve. The check valve must be in the correct position on the throt- We body. 4. Install the idle valve spring and plunger in the throttle body. ‘5. Install the throttle body to the carburetor body. Make sure the idle valve stays in position. Ifthe linkage arms ‘were removed, install them on the throttle shaft Installation Install a new gasket on the intake manifold. Insiall the carburetor, lock washers and nuts. Connect the linkage to the Monotrol or accelerator pedal. Install the balance line, the fuel hose, and the hose to the air cleaner. STEP 3. Install the idle valve. FIGURE 26. ASSEMBLE THE CARBURETOR 20CHECKS AND ADJUSTMENTS. & WARNING LPG can cause an explosion. Do not permit any sparks or open flames in work area. CHECK THE FILTER UNIT 1. Check for leaks inthe fuel valve by disconnecting the fuel inlet hose atthe vaporizer. Putthe end of the hose in a container of water. There must be no bubbles in the water, If there are bubbles in the water, install a new valve pad in the filter unit, 2. If there are no bubbles in the water, remove the pri- mary wire to the distributor or cause a short circuit in coil secondary wire. & WARNING Do not remove the coil secondary wire to cause an ‘open circuit. A spark can cause an explosion. ‘Tum the key switch momentarily to the “START” posi- tion to cause a vacuum in the inlet manifold. Bubbles must appear in the container of water, 3. IF there are no bubbles seen instep B, check the vac- ‘uum hose for arestriction. Ifthere is vacuum tothe filter unit, inspect the diaphragm for holes or cracks. Make sure the tank has fuel and that the tank valve is open. CHECK THE VAPORIZER Pressure Reducer Valve 1. Connect a pressure gauge that can measure with accu- racy apressure below 35 kPa (5 psi) tothe test port ofthe vaporizer. The gauge must indicate 10.4 kPa (1.5 psi) when the engine is at idle. Ifthe gauge indicates a pres- sure greater than 10.4 kPa (1.5 psi), the pressure reducer valve has a problem. 2. Stop the engine. The gauge must not indicate an in- crease in pressure. Ifthe pressure increases when the en- ine is stopped, the pressure reducer valve has a prob- Jem. Vapor Valve 1, Run the engine until itis warm. 2. To check for leaks, stop the engine and disconnect the hose from the fuel inlet port at the carburetor. Put the end of the hose just below the surface of water ina container. If bubbles are seen, the vapor valve has a problem or is, diy. 3. To check the vapor diaphragm, remove the inlet hose tothe vaporizer. Remove the inlet hose at the carburetor. Putthe end of the hose below the surface ofthe water in a container. Remove the balance line from the carburetor and apply air pressure to the line. If bubbles continue to be seen in the water, the diaphragm has a problem. ADJUST THE CARBURETOR (See FIGURE 27.) Idle Mixture 1, When the engine is not running, turn the idle mixture screw clockwise until it stops. In this position, the idle ‘mixture screw prevents air from entering the air tube through the idle air port 2. Turn the idle mixture screw 3-!/p turns counterclock- wise, Start the engine, Adjust the screw as needed until the idle is smooth. Turning the screw counterclockwise increases the ratio of air to fuel. 3, Stop the engine, Restart the engine. Ifthe engine does not start easily, turn the idle mixture screw clockwise ‘one half turn and restart the engine. Continue this proce- dure until the engine starts easily. Idle Speed ‘Turn the idle speed serew until the idle speed of the en- gine is within the specification. Power Mixture ‘The power mixture valve controls the flow of fuel tothe carburetor when the engine is running at near full capac- ity, Set the power mixture valve one notch rich from center. This setting will be satisfactory for most condi- tions. If further adjustment is required proceed as fol- ows: When adjusting the power mixture valve the en- ‘gine RPM must not be permitted to increase to the gov- emnor limit. 21. POWER MIXTURE 2. IDLE MIXTURE 3. IDLE SPEED FIGURE 27. ADJUST THE CARBURETOR 1. Units with manual transmissions: . Connect a tachometer to the engine. Apply the parking brake. Start the engine, Push on the ac~ celerator pedal until the throttle plate is fully open. Pull backward on the Tilt lever until the pump reaches relief pressure. b. If the engine speed increases to the governor limit, release the accelerator pedal a small amount until engine speed decreases. Turn the power mixture valve until the highest engine speed is reached. 2. Units with powershift transmission: a. Applythe brake and block the wheels so the truck cannot move. b. Connect a tachometer to the engine. Start the en- gine. Engage the transmission. Fully depress the accelerator pedal and turn the power mixture valve until the highest engine speed is reached. 2 ADJUST THE GOVERNOR (GM Engines Only) Checks, Before making any adjustments to the governor, check the following: |. Make sure the mechanical, electrical and fuel systems are operating correctly. 2. Use a tachometer that is accurate, Make sure it will ‘work with the ignition system. 3. Make sure the air filter element is clean, Make sure the air filter is connected to the engine. Main Adjusting Screw (See FIGURE 28.) |. Make sure the engine is operating correctly and is at operating temperature. 2. Connect a tachometer to the engine, Make surethe ta- chometer gives an accurate indication of the engine speed. 3. Remove the seal from the main adjusting screw. Turn the main adjusting screw clockwise if the engire runs Jess than the governed rev/min, Turn the main adjusting screw counterclockwise if the engine runs greater than the governed rev/min, 1. MAIN ADJUSTING SCREW 2. SECONDARY ADJUSTING SCREW FIGURE 28, ADJUST THE GOVERNOR: Secondary Adjusting Screw (See FIGURE 28.) 1. Ifthe governor control operates too quickly, the en- gine speed will not stay constant at the governed rpm. ‘The engine speed will increase and decrease. Turn thesecondary adjusting screw clockwise '4 of a turn at a time. Turn the main adjusting screw one full turn coun- terclockwise each time you turn the secondary adjusting screw '/g of a turn, 2. Ifthe governor control operates too slowly, there will bea large variation between the load and no load engine speeds. Turn the secondary adjusting screw counter- clockwise '/, turn at a time, Turn the main adjusting screw one full turn clockwise each time you turn the sec- ondary adjusting screw '/s of a turn. When the adjustments are complete, install the follow- ing parts: © brass lock washer (part number 181764) © plug (part number 181765) Make sure the tab of the lock washer engages the slot of the adjusting screw. If these parts are not installed, the governor will not stay in adjustment and there can be a Jeak in the intake system. AISAN Governor (See FIGURE 29.) An alternate AISAN governor is installed on some lift, trucks. ‘This governor does not normally need adjust- ‘ment. If adjustment is necessary, service personnel must use !/4 rotations or less at atime of the adjusting screws. If the adjusting screws are moved outside of the control limits, this governor can be difficult to calibrate 1. MAIN ADJUSTMENT SCREW 2. SECONDARY ADJUSTMENT SCREW = sccas 3. LOCK SCREW FIGURE 29. AISAN GOVERNOR Adjustments, AISAN Governor 1. With the engine at operating temperature, adjust the ‘maximum engine rpm as follows: a. Remove the lock screw from the main adjustment screw. , Hold the secondary adjustment screw and turn the main adjustment screw. Turn the main adjust- ment screw clockwise to increase engine rpm and counterclockwise to decrease engine rpm. Set the ‘maximum engine speed as specified for the unit . Install the lock serew in the closest hole, then check engine rpm again. 4. Run the engine with the throttle fully open, then ppull on the Tilt lever to load the engine. If the en- gine runs smooth and does not surge, install lock wire between the screws. 2. Ifthe engine does not run smooth (governor surges), turn the secondary adjustment screw !/, turn clockwise. ‘Tum the main adjustment screw counterclockwise to adjust the maximum (no load) engine rpm, Repeat this procedure until engine rpm is stable, Install the lock wire when adjustments are complete. 3. Ifoperation of the governor is not correct, itcan cause too great a difference in engine rpm, between load and ‘no load conditions. When this condition exists, turn the ‘main adjustment screw '/, turn clockwise. Then turn the secondary adjustment screw counterclockwise to adjust enginerpm withno load. Repeat this procedure until the engine runs correctly. Install lock wire when adjust- ments are complete, 23TROUBLESHOOTING Problem Possible Cause Correcting Action ‘The vaporizer is freezing. Engine idle speed is too high. "The engine will not start easily. [1 Tow coolant level Water hoses have a restriction or are too smi Air lock in coolant line to the vapor- izer. Belt for water pump is loose or bro- ken. 5. Hose from vaporizer to carburetor has a leak. ‘Thermostat is not operating cor- rectly Ignition system does not function correctly. Starter is damaged. 3. Idle mixture screw is not adjusted correctly. 1. Fuel valve in carburetor is dam- aged. '10.Solenoid valve is disconnected or does not operate correctly. 11. Air fiter is dirty 12.Balance line is disconnected. 13.Accelerating too soon after engine is started. Idle mixture screw is not adjusted correctly Idle speed screw is loose. - Check coolant level at radiator and coolant recovery reservoir. Fill to correct level ‘Make sure there is adequate water flow to vaporizer. Install larger hoses. Remove air from coolant line. Adjust tension. Install new drive bett. Find and repair leak. Install new hose. Install new thermostat. ‘See troubleshooting chart "Electri- cal System: Dual Fuer", Adjust idle mixture screw. Install new fuel valve. Overhaul carburetor. Install new carburetor. 10.Connect wire to solenoid. Install new solenoid valve. 11. Check air restriction indicator. Clean or install new fitter element. 12. Connect balance line. 13.Allow longer warm-up time before starting operation. 1. Adjust ile mixture screw. Tighten screw and adjust idle speed. 24 }3. Idle control actuator is not ad- 13. Connect vacuum hose. Adjust the justed correctly or the vacuum idle control actuator. hose is disconnected. Engine does not run smoothly. |7. The govemoris damaged, T._ Install new governor. 12. Low pressure diaphragm or valve |2. Repair or install new vaporizer. in vaporizer is damaged. }3. Wrong or damaged fuel valve in |3. Repair or install new carburetor. carburetor. 4, PCV system has restriction. |4. Remove restriction. Install new PCV valve. 5. Air leaks in the intake manifold. |. Repair leaks. ]6. Balance line has a restriction. 16. Remove restriction.TROUBLESHOOTING Possible Cause Correcting Action Engine does not idle smoothly | 1. idle mixture screw is not adjusted correctly. 2. Diaphragm in carburetor is dam- aged. 3. Air leak between carburetor and ‘governor or between governor and intake manifold. }4. PCV system has a restriction. 5. Air leak at throttle shaft. 16. Hose from vaporizer to carburetor is damaged. 7. Balance line is disconnected. 18. Pressure reducer diaphragm has a hole. 19. Low pressure valve in vaporizer is damaged. 10. Idle speed is too low. 11, Idle speed screw is loose. 12. Water in fuel. 13, Fuol tanks installed in the wrong position. 14, Fuel valve on the tanks in the ‘wrong port. 15. Idle control actuator is not ad- justed correctly or the vacuum, hose is disconnected. 7. Adjust idle mixture screw. 2. Install new diaphragm or carboure- tor. 13. Fix air leak. '4, Remove restriction. Install new PCV valve, 5. Repair or install new carburetor. }6. Install new hose. 7. Connect balance line. 8. Install new diaphragm. 9, Install new low pressure valve or new vaporizer. 10. Adjust idle speed. 11, Tighten sorew and adjust idle speed. 12. Check fuel supply and tank filing procedure. Clean system. 19, Inetall fuel tank in correct position, 14. Install fuel valve in the correct port 15. Connect vacuum hose. Adjust the idle control actuator. Loss of power. 1. Air filter is dirty, 2. PCV system has a restriction. 3. Governor is damaged. 4. Power mixture valve is not ad- justed correctly. 15. Hose from vaporizer to carburetor has leaks. }6. Diaphragm in carburetor is dam- aged. ‘7. Wrong type of fuel. 8. Hose from vaporizer o carburetor 1. Check air restriction indicator, Clean or install new fiter element. }2. Remove restriction. Install new PCV valve, }3. install new governor. }4. Adjust power mixture valve. 15. Repair leak or install new hose. ‘6. Install new diaphragm. 7. Clear system of wrong fuel. Fill tank with correct fuel 8. Remove restriction or install new restriction or is too small 9. Ree is damaged. or larger hose. 9. Repair or install new vaporizer.TROUBLESHOOTING Problem Possible Cause I Correcting Action Engine stops running. 7. Valve on fuel tank is dosed. 2. Fuel tank is empty. 3. Hose from fuel tank is too close to the exhaust pipe. 4, Vacuum line to filter unit is discon- nected. 5. Filter unit is damaged, [6. Vaporizer is damaged. 7. Carburetor is damaged. 18. Hose to carburetor is damaged. }9. Idle speed is too low. ). Water in the fuel 11. Fuel filter is dirty. 12. Govemor is damaged. 18. Air leak at the intake manifold. 14. Solenoid valve is disconnected or does not operate correctly. ‘Open fuel valve at the tank. Install tank that has fuel, Locate hose away from excessive heat. Install new hose. Connect vacuum line, Install new fter unit Repair or install new vaporizer. Install new carburetor. Install new hose. Adjust idle speed. Check fuel supply and tank fling procedure. Clean system. Clean fuel fier. Repair or install new governor. Repair leak. Connect wire to solenoid. install new solenoid valve.“THE QUALITY KEEPERS” HYSTER APPROVED PARTSHyster Easy Language Program HYSTER tecunicar pusuications 900 SRM 15 9/93 (2/85) (5/84) (10/82) (11/61) (7/81) Litho in U.S.A.