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LPG FUEL SYSTEM,

KUBOTA 3.8L SI
ENGINE
S4.0-5.5FT, S5.5FTS (S80-120FT,
S80-100FTBCS, S120FTS, S120FTPRS) [J004];
H4.0FT5, H4.0-4.5FT6, H4.5FTS5, H5.0-5.5FT
(H80-120FT) [U005]

PART NO. 4129471 0900 SRM 1905

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SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 HeavyManuals.com
Table of Contents

TABLE OF CONTENTS

General .....................................................................................................................................................................1
LPG Tank and Bracket Replacement .....................................................................................................................1
Remove LPG Tank .............................................................................................................................................. 1
Install LPG Tank ................................................................................................................................................ 3
Remove LPG Bracket ..........................................................................................................................................4
Install LPG Bracket ............................................................................................................................................6
Remove LPG Tank Bracket Alignment Pin .......................................................................................................6
Install LPG Tank Bracket Alignment Pin .........................................................................................................7
LPG Fuel Filter Unit Repair .................................................................................................................................. 8
LPG Fuel Filter Element ....................................................................................................................................8
Remove/Disassemble ...................................................................................................................................... 8
Clean/Inspect .................................................................................................................................................. 8
Assemble/Install ............................................................................................................................................. 9
Fuel Filter Housing .............................................................................................................................................9
Remove ............................................................................................................................................................ 9
Disassemble .................................................................................................................................................. 10
Clean and Inspect ......................................................................................................................................... 11
Assemble ....................................................................................................................................................... 11
Install ............................................................................................................................................................ 12
Electronic Throttle Body Repair ...........................................................................................................................12
Remove .............................................................................................................................................................. 12
Install .................................................................................................................................................................13
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair ................................................... 15
Remove .............................................................................................................................................................. 15
Install .................................................................................................................................................................16
Control System ...................................................................................................................................................... 17
Engine Control Unit (ECU) .............................................................................................................................. 17
Remove .......................................................................................................................................................... 17
Install ............................................................................................................................................................ 17
LPG Low Level Sensor ......................................................................................................................................18
Remove .......................................................................................................................................................... 18
Install ............................................................................................................................................................ 18
Exhaust System .....................................................................................................................................................19
Counterweight Exhaust ....................................................................................................................................19
Remove and Disassemble ............................................................................................................................. 19
Inspect ........................................................................................................................................................... 20
Assemble and Install .................................................................................................................................... 21
Exhaust Manifold ..............................................................................................................................................21
Remove .......................................................................................................................................................... 21
Install ............................................................................................................................................................ 21
Oxygen (HEGO) Sensor .................................................................................................................................... 22
Remove .......................................................................................................................................................... 22
Install ............................................................................................................................................................ 22

This section is for the following models:

S4.0-5.5FT, S5.5FTS (S80-120FT, S80-100FTBCS, S120FTS, S120FTPRS) [J004];

H4.0FT5, H4.0-4.5FT6, H4.5FTS5, H5.0-5.5FT (H80-120FT) [U005]

©2015 HYSTER COMPANY i

 HeavyManuals.com

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
 HeavyManuals.com
0900 SRM 1905 General

General

This section contains repair procedures for the parts of the LPG fuel system used on lift trucks equipped
with a Kubota 3.8L SI engine. For more information not covered in this manual and related to the
maintenance and repair of the Kubota 3.8L SI LPG engine, see one of the following Service Manuals:

See Kubota 3.8L LPG SI Engine 0600SRM1893 for service and repair procedures of the Kubota 3.8L SI
LPG engine.

See Electrical System 2200SRM1901 for service and repair procedures to electrical system and electrical
components of the Kubota 3.8L SI LPG engine.

See Periodic Maintenance 8000SRM1902 for procedures to maintain the Kubota 3.8L SI LPG engine.

LPG Tank and Bracket Replacement

REMOVE LPG TANK
WARNING
LPG can cause an explosion. DO NOT cause
sparks or permit flammable material near the LPG
system. LPG fuel systems can be disconnected
indoors only if the lift truck is at least 8 m (26 ft)
from any open flame, motor vehicles, electrical
equipment, or ignition source.
LPG is heavier than air. LPG can stay in low pla-
ces and cause an explosion when a spark occurs.
DO NOT overfill the LPG tank. Liquid is expelled
from the vent valve when the bottle has reached
the 80 percent full point. At this point, the bottle
filling operation must be halted. Filling the bottle
to 80 percent allows the appropriate expansion
volume within the bottle. The tank relief valve is
installed in the tank to allow for pressure relief if
the bottle is overfilled or if exposed to high tem-
peratures.
Close the shutoff valve on the LPG tank before
any part of the engine fuel system is disconnec-
ted. Run the engine until the fuel in the system is
used and the engine stops.
If the engine will not run, close the shutoff valve
on the LPG tank.
Loosen the fitting on the supply hose from the
LPG tank where it enters the filter unit. Permit the
pressure in the fuel system to decrease slowly.
Fuel leaving the fitting removes heat. Use a cloth
to protect your hands from the cold fitting.
NOTE: The LPG tank bracket used on this line of
trucks to mount the LPG tank onto the counter-
weight comes in two styles. One style of bracket
swings out to the side of the truck and the other
swings out to the side and drops down (EZXchange
bracket). See Figure 1.
1. LPG tanks can be removed and replaced in-
doors only if the lift truck is at least 8 m (26 ft)
from any flame or ignition source. Move the lift
truck to an the area where LPG tanks are
changed.
2. Turn the shutoff valve clockwise until the valve
is completely closed.
3. Run the engine until it stops. If truck is equip-
ped with a key switch, turn the key switch to
the OFF position. If truck is equipped with a
Power ON/OFF button, press the Power
ON/OFF button to turn engine off.
4. Disconnect the quick-disconnect fitting on the
LPG tank. See Figure 1.

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LPG Tank and Bracket Replacement 0900 SRM 1905

5. Pull up the bracket release lever, grab the
bracket handle, and swing the tank and bracket
out to the side of the lift truck. If your truck is
equipped with a EZXchange bracket, drop the
tank down to the side of the truck for ease of re-
moval. See Figure 1.
6. Unlatch the tank strap or straps, if lift truck is
equipped with optional dual steel straps, and
remove the LPG tank from the bracket. See
Figure 2.

A. SWING-OUT LPG BRACKET B. SWING-OUT AND DROP-DOWN LPG BRACKET

(EZXCHANGE)
1. LPG TANK 7. STOP PIN
2. TANK STRAP 8. BRACKET HANDLE
3. QUICK DISCONNECT FITTING 9. BRACKET PIVOT
4. HYDROSTATIC RELIEF VALVE 10. GAS SPRING (DROP-DOWN BRACKET ONLY)
5. MANIFOLD BLOCK 11. BRACKET RELEASE LEVER
6. ALIGNMENT PIN

Figure 1. LPG Tank and Bracket

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0900 SRM 1905 LPG Tank and Bracket Replacement

INSTALL LPG TANK
WARNING
When closing the LPG tank strap, DO NOT wrap
your fingers around the strap handle. The strap
can close quickly and with enough force to cause
injury to the fingers and hand.
NOTE: The LPG bracket must be in the swing-out
position to install the LPG tank. If your lift truck
has the EZXchange bracket, position the bracket in
the drop-down position. See Figure 1.
1. Place the LPG tank into the bracket. Secure the
tank strap or straps, if lift truck is equipped
with optional dual steel straps, around the tank
and close the strap or straps. See Figure 2.
2. Pull the stop pin (see Figure 1 or Figure 2) and
swing the LPG tank bracket into the resting po-
sition on the counterweight. Be sure that the
bracket locks into position.
3. Connect the hose to the LPG fuel filter. See Fig-
ure 3.

A. SWING-OUT LPG TANK BRACKET B. SWING-OUT AND DROP-DOWN LPG BRACKET

(EZXCHANGE BRACKET)
1. DUAL STEEL TANK STRAP 7. BRACKET RELEASE LEVER
2. MANIFOLD BLOCK 8. GAS SPRING
3. ALIGNMENT PIN 9. BRACKET DATA PLATE
4. STOP PIN 10. HYDROSTATIC RELIEF VALVE
5. BRACKET PIVOT 11. TANK FOOTREST PLATE
6. BRACKET HANDLE

Figure 2. LPG Tank Bracket with Dual Steel Straps

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LPG Tank and Bracket Replacement
4. Connect the quick-disconnect fitting on the
LPG tank. See Figure 1.
5. Turn the fuel valve counterclockwise to open
the fuel valve.
6. Inspect the fuel system for leaks when the fuel
valve is open. There are four methods used to
inspect the fuel system for leaks:
a. Sound - Listen for sound of LPG escaping
from a tank fitting or hose connection.
b. Smell - LPG has a very distinctive odor. If
you smell LPG, DO NOT start the engine.
c. Soapy Water - This method is used in con-
junction with Step b above. If the odor of
LPG is present, but escaping fuel cannot be
heard, apply soapy water to the fittings and
observe for bubbles.
d. Frost - If the amount of LPG escaping is suf-
ficient, frost may appear on the fittings.
REMOVE LPG BRACKET
NOTE: The LPG tank must be removed from the
lift truck before removing the LPG bracket. See sec-
tion Remove LPG Tank .
1. Disconnect the hose from the LPG fuel filter
and remove hose through hole in counter-
weight. See Figure 3.
Figure 3. LPG Tank Hose Connections
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0900 SRM 1905
Legend for Figure 3
1. HOSE ASSEMBLY TO LPG REGULATOR
2. BRACKET
3. LPG LOW LEVEL SENSOR
4. LPG FUEL FILTER
5. HOSE ASSEMBLY TO LPG FUEL FILTER
6. CAPSCREW
7. FITTING
8. LPG FUEL FILTER CONNECTION
WARNING
When removing the capscrews and shims, if
equipped, for the LPG tank bracket, only remove
the capscrew and shim (4, illustration A and 5, il-
lustration B in Figure 4) with the LPG bracket in
the swing-out or extended position. The LPG tank
bracket is heavy and difficult to handle if all the
capscrews are removed with the bracket in the
swing-out position. Personal injury and damage
to the lift truck can result if the bracket is re-
moved and handled while in the swing-out or ex-
tended position.
2. Pull up the bracket release lever, grab bracket
handle, and swing LPG tank bracket out to side
of lift truck. See Figure 1.
3. If lift truck is equipped with a swing-out LPG
tank bracket with either a steel or fabric strap
or a swing-out and drop-down LPG tank
bracket with optional dual steel straps, remove
capscrew and shim, if equipped (4, Figure 4).
If lift truck is equipped with a swing-out and
drop-down LPG tank bracket with either a steel
or fabric strap, remove capscrew (5, Figure 4).
4. Pull bracket stop pin and swing LPG tank
bracket back into the resting position on coun-
terweight. Be sure that the LPG tank bracket
latch clicks shut and locks. See Figure 4.
5. If lift truck is equipped with a swing-out LPG
tank bracket with either a steel or fabric strap
or a swing-out and drop-down LPG tank
bracket with optional dual steel straps, remove
the two other capscrews and shims, if equipped
(1, Figure 4).
If lift truck is equipped with a swing-out and
drop-down LPG tank bracket with either a steel
or fabric strap, remove the two other capscrews
(3, Figure 4).
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0900 SRM 1905 LPG Tank and Bracket Replacement

6. Remove LPG tank bracket from counterweight.

NOTE: THE REMOVAL AND INSTALLATION PROCEDURES ARE THE SAME FOR ALL STYLES OF LPG
TANK BRACKETS COVERED IN THIS MANUAL.

NOTE: ONLY THE SWING-OUT OPTION AND THE SWING-OUT AND DROP-DOWN WITH OPTIONAL DUAL
STEEL STRAPS LPG TANK BRACKETS MAY BE EQUIPPED WITH OPTIONAL SHIMS.

A. LPG TANK BRACKET WITH STEEL STRAP - SWING-OUT OPTION SHOWN.

B. LPG TANK BRACKET WITH STEEL STRAP, SWING-OUT AND DROP-DOWN OPTION (EZ-XCHANGE)
SHOWN.
1. CAPSCREW AND SHIM - REMOVE WITH BRACKET IN RESTING POSITION ON COUNTERWEIGHT
2. COUNTERWEIGHT
3. CAPSCREW - REMOVE WITH BRACKET IN RESTING POSITION ON COUNTERWEIGHT
4. CAPSCREW AND SHIM - REMOVE WITH BRACKET IN SWING-OUT (EXTENDED) POSITION
5. CAPSCREW - REMOVE WITH BRACKET IN SWING-OUT (EXTENDED) POSITION
6. LPG TANK BRACKET LATCH
7. BASE PLATE

Figure 4. LPG Tank Bracket Remove/Install

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LPG Tank and Bracket Replacement 0900 SRM 1905

INSTALL LPG BRACKET strap, the alignment pin will have a weldment off-
set plate. If the LPG tank has a steel strap or op-
1. Place the LPG tank bracket onto counter- tional dual steel straps, the alignment pin will not
weight. Be sure to align the holes on counter- have a weldment offset plate. See Figure 5.
weight with holes on LPG tank bracket. Insert
hose assembly to LPG fuel filter (see Figure 3)
through the hole in counterweight.

2. If lift truck is equipped with a swing-out LPG

tank bracket with either a steel or fabric strap
or a swing-out and drop-down LPG tank
bracket with optional dual steel straps, install
two capscrews and shims, if equipped or re-
quired (1, Figure 4) and LPG bracket onto coun-
terweight. Tighten capscrews to
38 N•m (28 lbf ft).

If lift truck is equipped with a swing-out and

drop-down LPG tank bracket with either a steel
or fabric strap, install two capscrews (3, Fig-
ure 4). Tighten capscrews to 38 N•m (28 lbf ft).

3. Pull LPG tank bracket release lever up and pull

bracket handle to swing the bracket out to the
side of the lift truck.

4. If lift truck is equipped with a swing-out LPG

tank bracket with either a steel or fabric strap
or a swing-out and drop-down LPG tank
bracket with optional dual steel straps, install
capscrew and shim, if equipped or required (4,
Figure 4). Tighten capscrew to
38 N•m (28 lbf ft).

If lift truck is equipped with a swing-out and

drop-down LPG tank bracket with either a steel
or fabric strap, install capscrew (5, Figure 4).
Tighten capscrews to 38 N•m (28 lbf ft)
A. ALIGNMENT PIN - LPG TANK WITH STEEL
5. Install LPG tank. See section Install LPG STRAP. SWING-OUT LPG BRACKET SHOWN
B. ALIGNMENT PIN - LPG TANK WITH FABRIC
Tank . STRAP. SWING-OUT AND DROP-DOWN LPG
BRACKET (EZXCHANGE BRACKET) SHOWN.
REMOVE LPG TANK BRACKET
ALIGNMENT PIN 1. ALIGNMENT PIN
2. PIN WELDMENT OFFSET PLATE
The LPG tank alignment pin can be replaced if it
Figure 5. LPG Tank Alignment Pin Types
becomes damaged or worn. There are two types of
alignment pins used. If the LPG tank has a fabric

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0900 SRM 1905 LPG Tank and Bracket Replacement

1. Remove the LPG tank from LPG tank bracket.

See Remove LPG Tank for procedures.

2. Remove the LPG tank bracket from lift truck.

See Remove LPG Bracket for procedures.

3. Remove alignment pin from LPG tank bracket.

a. If LPG tank is equipped with a fabric strap,

remove flange button head capscrew, hard-
ened washer, curved washer, spacer (if
equipped), hardened washer, and two pins
from alignment pin and weldment offset
plate. Remove alignment pin and weldment
offset plate from LPG tank bracket. See Fig-
ure 6.

b. If LPG tank is equipped with a steel strap or

optional dual steel straps, remove flange but-
ton head capscrew, hardened washer, curved
washer, spacer (if equipped), and hardened
washer from alignment pin. Remove align-
ment pin from LPG tank bracket. See Fig-
ure 6.

INSTALL LPG TANK BRACKET

ALIGNMENT PIN
1. Install new LPG tank alignment pin.

a. If LPG tank is equipped with a steel strap,

insert new alignment pin in slot on LPG
tank bracket. Place hardened washer, curved
washer, spacer (if equipped), and hardened NOTE: PARTS OF THE LPG TANK BRACKET
washer on flanged button head capscrew. In- OMITTED FOR CLARITY.
stall flanged button head capscrew and hard- A. LPG TANK WITH STEEL STRAP. SWING-OUT
ware into bottom of alignment pin. Tighten LPG BRACKET SHOWN.
flanged button head capscrew to secure B. LPG TANK WITH FABRIC STRAP. SWING-OUT
alignment pin to LPG tank bracket. See Fig- AND DROP-DOWN LPG BRACKET (EZX-
ure 6. CHANGE BRACKET) SHOWN.
1. FLANGE BUTTON HEAD CAPSCREW
b. If LPG tank is equipped with fabric strap, in- 2. HARDENED WASHER
sert new alignment pin and weldment offset 3. CURVED WASHER
plate in slot on LPG tank bracket. Place 4. SPACER*
hardened washer, curved washer, spacer (if 5. PIN
required), and hardened washer on flanged 6. ALIGNMENT PIN
7. WELDMENT OFFSET PLATE
button head capscrew. Install flanged button 8. SLOT
head capscrew and hardware into hole in
weldment offset plate. Tighten flanged but- *IF EQUIPPED.
ton head capscrew to secure alignment pin
and weldment offset plate to LPG tank Figure 6. LPG Tank Alignment Pin Removal
bracket. See Figure 6.

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LPG Tank and Bracket Replacement 0900 SRM 1905

2. After LPG tank alignment pin has been instal-

led, measure the distance between the hard-
ened washers. The distance should not exceed 2
±1 mm (0.08 ±0.04 in.). Add or remove spacers
between the hardened washer and curved
washer, as needed to achieve the correct dis-
tance. See Figure 6 and Figure 7.

3. Install LPG tank bracket onto lift truck. See In-

stall LPG Bracket for procedures.

4. Install LPG tank onto LPG tank bracket. See

Install LPG Tank for procedures.

1. HARDENED WASHER
2. SPACER
3. CURVED WASHER
4. ALIGNMENT PIN

Figure 7. LPG Tank Alignment Pin Measurement

LPG Fuel Filter Unit Repair

LPG FUEL FILTER ELEMENT 4. Remove bolt and seal washer from fuel filter
housing top section. Discard seal washer. See
Remove/Disassemble Figure 8.

5. Remove fuel filter housing top section from fuel

WARNING
LPG can cause an explosion. DO NOT permit any
sparks or open flames in the work area.
1. Close fuel valve on tank. Run engine until it
runs out of fuel and stops. Try to start engine
two to three times until it no longer starts.
filter housing bottom section. See Figure 8.
6. Remove and discard housing O-ring. See Fig-
ure 8.
7. Remove and discard fuel filter element and fuel
filter O-ring. See Figure 8.

2. Raise the hood and remove left rear panel for
access to the LPG fuel filter assembly. See
Frame 0100SRM1891 for procedures.
3. Disconnect the negative battery cable.
Clean/Inspect
1. Clean and inspect fuel filter housing top section
for contamination or damage. If damaged, re-
place the housing. See Parts Manual.

2. Clean and inspect fuel filter housing bottom

WARNING section for contamination or damage. If dam-
A small amount of fuel may still be present in the aged, replace the housing. See Parts Manual.
fuel line. Use gloves to prevent burns and wear
eye protection. If liquid fuel continues to flow
from the connections when loosened, check to
make sure the manual valve is fully closed.

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0900 SRM 1905 LPG Fuel Filter Unit Repair

7. Slowly open the fuel valve on tank.

8. If lift truck is equipped with a key switch, turn

the key to the ON position and back to the OFF
position to pressurize the fuel system. If lift
truck is equipped with a Power ON/OFF but-
ton, press the Power ON/OFF button ON and
then press it OFF to pressurize the fuel sys-
tem.

9. Check for leaks at connections by using a soapy

solution or electron leak detector. If leaks are
detected, make proper repairs.

FUEL FILTER HOUSING

Remove

WARNING
1. BOLT* LPG can cause an explosion. DO NOT permit any
2. SEAL WASHER sparks or open flames in the work area.
3. FUEL FILTER HOUSING TOP SECTION*
4. FUEL FILTER ELEMENT 1. Close fuel valve on tank. Run engine until it
5. FUEL FILTER O-RING runs out of fuel and stops. Try to start engine
6. HOUSING O-RING
7. FUEL FILTER HOUSING BOTTOM SECTION* two to three times until it no longer starts.
8. LPG LOW LEVEL SENSOR
2. Open hood and remove left rear panel for access
*NOT SERVICED SEPARATELY to fuel filter assembly. For procedures see the
Figure 8. Fuel Filter Element Removal/Installation Frame manual for your lift truck model.

3. Disconnect negative battery cable.

Assemble/Install
1. Install new fuel filter element and fuel filter O-
ring. See Figure 8.
2. Install new housing O-ring. See Figure 8.
3. Install fuel filter housing top section onto fuel
filter housing bottom section. See Figure 8.
4. Install bolt and new seal washer. Tighten bolt
to 13 N•m (115 lbf in).
5. Connect negative battery cable.
6. Install left rear panel onto lift truck frame and
close the hood. For procedures see the Frame
manual for your lift truck model.
WARNING
A small amount of fuel may still be present in the
fuel line. Use gloves to prevent burns and wear
eye protection. If liquid fuel continues to flow
from the connections when loosened, check to
make sure the manual valve is fully closed.
4. Slowly loosen and disconnect tube assembly
from LPG fuel filter assembly (1, Figure 9).
5. If lift truck is equipped with optional LPG low
level sensor, disconnect hose from LPG low
level sensor (2, Figure 9). Disconnect LPG low
level sensor from engine wire harness (3 and 4,
Figure 9).

NOTE: Opening the fuel valve too quickly can 6. Remove two capscrews and fuel filter assembly
cause the internal excess flow valve to close, re- from mounting bracket. See Figure 10.
stricting the flow of fuel. If this happens, close fuel
valve, wait a few seconds, and then slowly open fuel
valve again. This will reset the excess flow valve.

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LPG Fuel Filter Unit Repair 0900 SRM 1905

Disassemble b. Remove LPG low level sensor adapter fitting

and O-Ring from LPG fuel filter housing bot-
1. Remove fuel filter element. See LPG Fuel Filter tom section.
Element, Remove/Disassemble and Figure 8.
c. Remove inlet fitting from LPG fuel filter
2. If lift truck is equipped with optional LPG housing bottom section. See Figure 11.
low level sensor:
d. Remove adapter fitting plug, outlet adapter
a. Remove LPG low level sensor from LPG low fitting, and O-Ring from LPG fuel filter hous-
level sensor adapter fitting. Remove outlet ing bottom section. See Figure 11.
adapter fitting from LPG low level sensor.
See Figure 11.

1. FUEL FILTER HOSE ASSEMBLY 5. LPG LOW LEVEL SENSOR

2. HOSE TO LPG LOW LEVEL SENSOR 6. FITTING
3. LPG LOW LEVEL SENSOR CONNECTOR 7. FUEL FILTER ASSEMBLY
4. ENGINE WIRE HARNESS

Figure 9. Fuel Filter Assembly Hoses, Fittings, and Electrical Connections

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0900 SRM 1905 LPG Fuel Filter Unit Repair

Install plug onto outlet adapter fitting.

c. Apply pipe thread sealant (Hyster Part No.

0246108) on the threads of inlet fitting. In-
stall inlet fitting onto LPG fuel filter housing
bottom section. See Figure 11.

d. Apply pipe thread sealant (Hyster Part No.

0246108) on the threads of outlet adapter fit-
ting and LPG low level sensor adapter fit-
ting. Install both fittings onto the LPG low
level sensor. Install new O-Ring onto LPG
low level sensor adapter fitting. Install LPG
low level sensor onto LPG fuel filter housing
bottom section. See Figure 11.

2. Install fuel filter element. See LPG Fuel Filter

Element, Assemble/Install for procedures.

1. CAPSCREWS
2. MOUNTING BRACKET
3. LPG FUEL FILTER ASSEMBLY
4. LOW LPG PRESSURE SENSOR

Figure 10. Fuel Filter Assembly Removal/

Installation From Mounting Bracket

Clean and Inspect

Clean and inspect fittings and adapters for damage

to bores or threads. If damaged, replace with new
fitting or adapter. See Parts Manual for replace-
ment parts.

Assemble

CAUTION 1. LPG LOW LEVEL SENSOR

DO NOT use Teflon tape on any fuel fitting. Use a
liquid pipe thread sealant when installing fittings.
1. If lift truck is equipped with optional LPG
low level sensor:
a. Apply pipe thread sealant (Hyster Part No.
0246108) on the threads of outlet adapter fit-
ting. Install new O-Ring and outlet adapter
fitting onto LPG fuel filter housing bottom
section. See Figure 11.
b. Apply pipe thread sealant (Hyster Part No.
0246108) on the threads of adapter fitting
plug.
2. OUTLET ADAPTER FITTING*
3. LPG LOW LEVEL SENSOR ADAPTER FITTING*
4. O-RING
5. LPG FUEL FILTER HOUSING TOP SECTION*
6. LPG FUEL FILTER HOUSING BOTTOM SEC-
TION*
7. INLET FITTING*
8. ADAPTER FITTING PLUG*
*NOT SERVICED SEPARATELY
Figure 11. Fuel Filter Assembly With Optional LPG
Low Level Sensor, Adapters and Fittings

11

LPG Fuel Filter Unit Repair
Install
1. Place fuel filter assembly in position on mount-
ing bracket. See Figure 10.
2. Install two capscrews to attach fuel filter hous-
ing to mounting bracket. Tighten capscrews to
5 N•m (44 lbf in). See Figure 10.
3. If lift truck is equipped with optional LPG low
level sensor, connect engine wire harness to
LPG low level sensor (3 and 4, Figure 9). Con-
nect hose to LPG low level sensor (2, Figure 9).
4. Connect tube assembly to LPG fuel filter as-
sembly (1, Figure 9).
NOTE: Opening the fuel valve too quickly can
cause the internal excess flow valve to close, re-
stricting the flow of fuel. If this happens, close the
fuel valve, wait a few seconds, and then slowly open
the fuel valve again. This will reset the excess flow
valve.
Electronic Throttle Body Repair
REMOVE
WARNING
LPG can cause an explosion. DO NOT cause
sparks or permit flammable material near the LPG
system. LPG fuel systems can be disconnected
indoors only if the lift truck is at least 8 m (26 ft)
from any open flame, motor vehicles, electrical
equipment, or ignition source.
Close the shutoff valve on the LPG tank before
any part of the engine fuel system is disconnec-
ted. Run the engine until the fuel in the system is
used and the engine stops.
If the engine will not run, close the shutoff valve
on the LPG tank. Loosen the fitting on the supply
hose from the LPG tank where it enters the filter
unit. Permit the pressure in the fuel system to de-
crease slowly. Fuel leaving the fitting removes
heat. Use a cloth to protect your hands from the
cold fitting.
1. Turn shutoff valve clockwise until valve is com-
pletely closed.
12
HeavyManuals.com
0900 SRM 1905
5. Slowly open the fuel valve on tank.
6. Connect the negative battery cable.
7. Install left rear panel and close the hood. See
Frame 0100SRM1891 for procedures.
8. If lift truck is equipped with a key switch, turn
the key to the ON position and back to the OFF
position to pressurize the fuel system. If lift
truck is equipped with a Power ON/OFF but-
ton, press the Power ON/OFF button ON and
then press it OFF to pressurize the fuel sys-
tem.
9. Check for leaks at connections by using soapy
solution or electron leak detector. If leaks are
detected, make proper repairs.
2. Run engine until it stops. If truck is equipped
with a key switch, turn the key switch to the
OFF position. If truck is equipped with a Power
ON/OFF button, press the Power ON/OFF but-
ton to turn engine off.
3. Raise hood for access to the electronic throttle
body. For procedures see the Frame manual
for your lift truck model.
4. Disconnect negative battery cable.
5. Disconnect fuel vapor hose from Direct Elec-
tronic Pressure Regulator (DEPR). See Fig-
ure 12.
6. Disconnect the electrical connector from the
DEPR. See Figure 12.
7. Disconnect the electrical connector from the
electronic throttle body. See Figure 12.
8. Remove fuel mixer and DEPR from adapter.
See LPG Fuel Mixer With Direct Electronic
Pressure Regulator (DEPR) Repair for proce-
dures.
 HeavyManuals.com
0900 SRM 1905 Electronic Throttle Body Repair

9. Remove four capscrews (5, Figure 13) from
adapter. Remove adapter from electronic throt-
tle body. Remove and discard O-Ring from
adapter. See Figure 13.
10. Remove O-Ring and spacer from electronic
throttle body. See Figure 12.
11. Remove electronic throttle body from intake
manifold. Remove gasket from throttle body.
Discard old gasket. See Figure 13.
INSTALL
1. Clean mating surfaces of the intake manifold
and electronic throttle body.
12. Slowly open the fuel valve on tank.
13. If truck is equipped with a key switch, turn key
switch to ON position and back to OFF position
to pressurize the fuel system. If truck is equip-
ped with a Power ON/OFF button, press Power
ON/OFF button to ON and back OFF again to
pressurize the system.
14. Check for leaks at connections by using soapy
solution or electron leak detector. If leaks are
detected, make proper repairs.

2. Place a new gasket in position on the intake

manifold.

3. Place electronic throttle body in position on new

gasket and intake manifold. See Figure 12.

4. Place spacer and new O-Ring on electronic

throttle body.

5. Place adapter on electronic throttle body. In-

stall adapter to electronic throttle body with
four capscrews (5, Figure 12) Tighten cap-
screws to 7 to 9 N•m (62 to 80 lbf in).

6. Install fuel mixer and DEPR to adapter. See

LPG Fuel Mixer With Direct Electronic Pres-
sure Regulator (DEPR) Repair for procedures.

7. Connect the electrical connector to the elec-

tronic throttle body. See Figure 12.
8. Connect the electrical connector to the DEPR.
See Figure 12.
9. Connect fuel vapor hose to DEPR. See Fig-
ure 12.
1. DIRECT ELECTRONIC PRESSURE REGULA-
TOR ELECTRICAL CONNECTOR (DEPR)
2. ELECTRONIC THROTTLE BODY CONNECTOR
3. LPG FUEL MIXER
4. ELECTRONIC THROTTLE BODY
5. FUEL VAPOR HOSE

10. Connect negative battery cable. Figure 12. Electronic Throttle Body Connections

11. Close the hood. For procedures see the Frame

manual for your lift truck model.

13
 HeavyManuals.com
Electronic Throttle Body Repair 0900 SRM 1905

1. CAPSCREW 6. ADAPTER
2. LPG FUEL MIXER 7. O-RING
3. DIRECT ELECTRONIC PRESSURE REGULA- 8. SPACER
TOR 9. ELECTRONIC THROTTLE BODY
4. SEAL 10. GASKET
5. CAPSCREW 11. INTAKE MANIFOLD

Figure 13. Electronic Throttle Body Remove/Install

14
 HeavyManuals.com
0900 SRM 1905 LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair

LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR)

Repair
REMOVE 6. Disconnect electrical connector from DEPR. See
Figure 14.
WARNING
LPG can cause an explosion. DO NOT cause
sparks or permit flammable material near the LPG
system. LPG fuel systems can be disconnected
indoors only if the lift truck is at least 8 m (26 ft)
from any open flame, motor vehicles, electrical
equipment, or ignition source.

Close the shutoff valve on the LPG tank before

any part of the engine fuel system is disconnec-
ted. Run the engine until the fuel in the system is
used and the engine stops.

If the engine will not run, close the shutoff valve

on the LPG tank. Loosen the fitting on the supply
hose from the LPG tank where it enters the filter
unit. Permit the pressure in the fuel system to de-
crease slowly. Fuel leaving the fitting removes
1. FUEL VAPOR HOSE
heat. Use a cloth to protect your hands from the 2. DEPR ELECTRICAL CONNECTOR
cold fitting. 3. DEPR
4. LPG FUEL MIXER
1. Turn shutoff valve clockwise until valve is com-
pletely closed. Figure 14. LPG Fuel Mixer and DEPR Location and
Connections
2. Run engine until it stops. If truck is equipped
with a key switch, turn the key switch to the
OFF position. If truck is equipped with a Power 7. Remove four bolts (1, Figure 15) and LPG fuel
ON/OFF button, press the Power ON/OFF but- mixer and DEPR from throttle body adapter.
ton to turn engine off. See Figure 13.
3. Open the hood for access to LPG fuel mixer and 8. Remove four bolts (6, Figure 15) and DEPR
DEPR. For procedures see the Frame manual from side of LPG fuel mixer. Remove and dis-
for your lift truck model. card seals.
4. Disconnect negative battery cable. 9. Remove four screws (8, Figure 15) and flange
from DEPR. Remove and discard seal from
NOTE: Tag electrical connectors prior to discon-
flange.
necting to aid in reconnecting.
10. If necessary, remove two plugs from LPG fuel
5. Disconnect fuel vapor hose from DEPR flange.
mixer. See Figure 15.
See Figure 14.

15
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LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 0900 SRM 1905

INSTALL 7. Connect negative battery cable.

1. If removed, install two plugs in LPG fuel mixer. 8. Close the hood. For procedures see the Frame
See Figure 15. manual for your lift truck model.

2. Install new seal, four screws (8, Figure 15) and
flange onto DEPR.
3. Install DEPR, four bolts, and new seals onto
side of LPG fuel mixer. Tighten bolts to 3 to
4 N•m (27 to 35 lbf in).
4. Install LPG fuel mixer and DEPR to throttle
body adapter using four bolts (1, Figure 15).
Tighten bolts to 7 to 9 N•m (62 to 80 lbf in).
See Figure 13 and Figure 15.
5. Connect electrical connector to DEPR. See Fig-
ure 14.
9. Slowly open shutoff valve on tank.
10. If truck is equipped with a key switch, turn key
switch to ON position and back to OFF position
to pressurize fuel system.
If lift truck is equipped with Power ON/OFF
button, press Power ON/OFF button to ON and
back to OFF again to pressurize fuel system.
Check for leaks.
11. Check for leaks at connections by using soapy
solution or electron leak detector. If leaks are
detected, make proper repairs.

6. Connect fuel vapor hose to DEPR flange. See

Figure 14.

1. BOLT 6. BOLT
2. PLUG 7. FLANGE (FUEL VAPOR HOSE CONNECT
3. FUEL MIXER HERE)
4. SEAL 8. SCREW
5. DIRECT ELECTRONIC PRESSURE REGULA- 9. DEPR ELECTRICAL CONNECTOR
TOR

Figure 15. LPG Fuel Mixer and DEPR Remove/Install

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0900 SRM 1905 LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair

Control System
NOTE: Always use new O-rings, seals, and gaskets
when servicing fuel and exhaust systems.
ENGINE CONTROL UNIT (ECU)
Remove
1. Disconnect negative battery cable.
2. Open the hood for access to the ECU. For proce-
dures see the Frame manual for your lift truck
model.
3. Disconnect wire harness and ECU connector
from ECU. See Figure 16.
4. Remove four capscrews and ECU from ECU
mounting bracket. See Figure 17.
5. If necessary, remove one capscrew and ECU
mounting bracket from intake manifold. See
Figure 17.
Install
1. If removed, install ECU mounting bracket and
one capscrew to intake manifold. Tighten cap-
screw to 47 to 54 N•m (35 to 40 lbf ft). See Fig-
ure 17.
2. Install Engine Control Unit (ECU) and four
capscrews onto ECU mounting bracket. Tighten
capscrews to 5 to 8 N•m (44 to 71 lbf in). See
Figure 17.
3. Connect wire harness and ECU connector to
ECU. See Figure 16.

NOTE: PARTS OF ENGINE REMOVED FOR

NOTE: PARTS OF ENGINE REMOVED FOR CLARITY.
CLARITY.
1. CAPSCREW (ECU)
1. WIRE HARNESS 2. ECU
2. ECU CONNECTOR 3. CAPSCREW (MOUNTING BRACKET)
3. ECU 4. ECU MOUNTING BRACKET
4. INTAKE MANIFOLD 5. CUSHION
6. CUSHION SPACER
Figure 16. ECU and Wire Harness Connector
Figure 17. ECU Removal/Installation

17

Control System
4. Close the hood. For procedures see the Frame
manual for your lift truck model.
5. Connect negative battery cable.
LPG LOW LEVEL SENSOR
NOTE: The LPG low level sensor is an optional fea-
ture.
Remove
WARNING
LPG can cause an explosion. DO NOT cause
sparks or permit flammable material near the LPG
system. LPG fuel systems can be disconnected
indoors only if the lift truck is at least 8 m (26 ft)
from any open flame, motor vehicles, electrical
equipment, or ignition source.
Close the shutoff valve on the LPG tank before
any part of the engine fuel system is disconnec-
ted. Run the engine until the fuel in the system is
used and the engine stops.
If the engine will not run, close the shutoff valve
on the LPG tank. Loosen the fitting on the supply
hose from the LPG tank where it enters the filter
unit. Permit the pressure in the fuel system to de-
crease slowly. Fuel leaving the fitting removes
heat. Use a cloth to protect your hands from the
cold fitting.
1. Close shutoff valve on LPG tank. Run engine
until it runs out of fuel and stops. Try to start
engine two to three times until it no longer
starts.
2. Disconnect the battery.
3. Remove left rear panel for access to LPG low
level sensor. For procedures see the Frame
manual for your lift truck model.
4. Disconnect engine wire harness from LPG low
level sensor connector. See Figure 18.
5. Disconnect outlet hose from outlet fitting. Re-
move outlet fitting from LPG low level sensor.
See and Figure 18
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HeavyManuals.com
0900 SRM 1905
WARNING
A small amount of fuel may still be present in the
fuel line. Use gloves to prevent burns and wear
eye protection. If liquid fuel continues to flow
from the connections when loosened, check to
make sure the manual valve is fully closed.
6. Slowly loosen and remove LPG low level sensor
from LPG low level sensor adapter fitting. See
Figure 18.
Install
CAUTION
DO NOT use Teflon tape on any fuel fittings. Use a
liquid pipe thread sealant when installing fittings.
NOTE: Install LPG low level sensor with UP arrow
pointing upwards. See Figure 18.
1. Apply pipe thread sealant, Hyster Part No.
0246108, onto LPG low level sensor adapter fit-
ting. Install LPG low level sensor onto LPG low
level sensor adapter fitting See Figure 18.
2. Apply pipe thread sealant, Hyster Part No.
0246108, onto threads of outlet fitting. Install
outlet fitting into LPG low level sensor. Con-
nect outlet hose to outlet fitting. See Figure 18.
3. Connect engine wire harness to LPG low level
sensor connector.
NOTE: Opening the fuel valve too quickly can
cause the internal excess flow valve to close, re-
stricting the flow of fuel. If this happens, close the
fuel valve, wait a few seconds, and then slowly open
the fuel valve again. This will reset the excess flow
valve.
4. Slowly open fuel valve on tank.
5. Install left rear panel to lift truck. For proce-
dures see the Frame manual for your lift truck
model.
6. Connect the battery.
 HeavyManuals.com
0900 SRM 1905 Control System

7. If truck is equipped with a key switch, turn key

switch to ON position and back to OFF position
to pressurize the fuel system. If truck is equip-
ped with a Power ON/OFF button, press Power
ON/OFF button to ON and back OFF again to
pressurize the system.

8. Check for leaks at connections by using soap

and water solution or electron leak detector. If
leaks are detected, make proper repairs.

1. LPG LOW LEVEL SENSOR

2. LPG LOW LEVEL SENSOR CONNECTOR
3. OUTLET ADAPTER FITTING
4. LPG FUEL FILTER ASSEMBLY
5. LPG LOW LEVEL SENSOR ADAPTER FITTING
6. LPG FUEL FILTER AND LOW LEVEL SENSOR
BRACKET

Figure 18. LPG Low Level Sensor Remove/Install

Exhaust System
COUNTERWEIGHT EXHAUST
NOTE: Remove counterweight before removing
muffler and other components of exhaust system.
See Frame 0100SRM1891 for procedures.
1. Disconnect oxygen (HEGO) sensors from wiring
harness. Remove sensors.
2. Loosen clamp; remove exhaust pipe (12, Fig-
ure 19) and clamp from muffler.

In a counterweight exhaust system, the muffler is
installed inside the cavity of the counterweight
with a short exhaust pipe that sends exhaust gas-
ses out of the lift truck through a grille in the coun-
terweight.
Remove and Disassemble
3. Remove two nuts, muffler to catalytic converter
exhaust pipe (1, Figure 19) and gaskets from
muffler. Discard gasket.
4. Remove two capscrews, two lock nuts, and four
exhaust isolators from muffler and frame. Re-
move muffler from lift truck. See Figure 19.

5. Remove two nuts, two lockwashers, muffler to

WARNING
Exhaust system components are hot to touch. Be
sure exhaust system components are cool before
starting disassembly, or personal injury may oc-
cur.
catalytic converter exhaust pipe (1, Figure 19),
and gaskets from catalytic converter. Discard
gasket.

19
 HeavyManuals.com
Exhaust System 0900 SRM 1905

NOTE: Note position and orientation of catalytic
converter prior to removal to aid in installation.
6. Remove two nuts, bracket, gasket, and catalytic
converter from exhaust header pipe (10, Fig-
ure 19). Discard gasket. Remove catalytic con-
verter from lift truck.
7. Remove four locknuts, exhaust header pipe (10,
Figure 19), and plate gasket from exhaust
manifold.
Inspect
Inspect the following items in the exhaust system:
• Exhaust pipes for damage, corrosion, and
rust. Replace as needed.
• If equipped, inspect all exhaust wraps for
wear, proper fit, contamination with oil or
antifreeze, gaps in coverage, and failed fas-
teners. Replace as needed.
• If replacing an exhaust pipe section that has
a wrap, also replace the wrap. DO NOT re-
use wraps if they have been removed for
service operation.
• Catalytic converter and muffler for damage,
corrosion and rust. Replace as needed.
• After installation, start engine and inspect
exhaust system components for exhaust
leakage. If leakage is found, repair or replace
components as necessary.

1. MUFFLER TO CATALYTIC CONVERTER EX- 8. EXHAUST ISOLATOR

HAUST PIPE 9. LOCKNUT
2. NUT 10. EXHAUST HEADER PIPE
3. LOCKWASHER 11. BRACKET
4. GASKET 12. EXHAUST TAIL PIPE
5. MUFFLER 13. OXYGEN SENSOR
6. CATALYTIC CONVERTER 14. CLAMP
7. CAPSCREW
Figure 19. Counterweight Exhaust System

20
 HeavyManuals.com
0900 SRM 1905 Exhaust System

Assemble and Install
1. Install plate gasket, exhaust header pipe (10,
Figure 19), and four locknuts on exhaust mani-
fold. Tighten locknuts to 39 N•m (29 lbf ft).
NOTE: Install catalytic converter so that stamped
serial number is visible from rear of lift truck.
2. Place catalytic converter in position as noted
during removal. Install new gasket, catalytic
converter, bracket, and two nuts onto exhaust
header pipe (10, Figure 19).
3. Install new gaskets, muffler to catalytic con-
verter exhaust pipe (1, Figure 19), two lock-
washers, and two nuts onto catalytic converter.
4. Place muffler into lift truck. Install four ex-
haust isolators, two capscrews, bracket and two
locknuts onto muffler and frame. See Figure 19.
Tighten locknuts to 22 N•m (195 lbf in).
2. Remove four locknuts and exhaust header pipe
(10,Figure 19) from bottom of exhaust manifold.
Remove plate gasket from exhaust header pipe.
3. Remove six flange bolts, heat shield, eight
flange nuts, exhaust manifold, and gasket from
engine. Discard gaskets. See Figure 20.
Install
1. Install new gasket, exhaust manifold, eight
flange nuts, shield and six flange bolts onto en-
gine. See Figure 20.
2. Install plate gasket, exhaust header pipe (10,
Figure 19), and four locknuts onto exhaust
manifold.
3. Connect negative battery cable.

5. Install new gaskets, catalytic converter exhaust

pipe (1, Figure 19), and two nuts onto muffler.

6. Install exhaust pipe (12, Figure 19) and clamp

onto muffler. Tighten clamp.

7. Install oxygen (HEGO) sensors. Connect sen-

sors to wiring harness.

8. Install counterweight. See Frame

0100SRM1891 for procedures.

EXHAUST MANIFOLD
Remove 1. STUD
2. GASKET
3. EXHAUST MANIFOLD
WARNING 4. FLANGE NUT
5. FLANGE BOLT
Exhaust system components are hot, they can 6. SHIELD
cause sever burns. Turn OFF the engine and wait
until it cools before removing exhaust system Figure 20. Exhaust Manifold
components.

1. Disconnect negative battery cable.

21

Exhaust System
OXYGEN (HEGO) SENSOR
Remove
CAUTION
The HEGO sensor is sensitive to silicone based
products and can become contaminated. Avoid
using silicone sealers or air or fuel hoses treated
with a silicone based lubricant.
NOTE: Heated Exhaust Gas Oxygen (HEGO) sen-
sors are mounted in the exhaust system. For lift
truck models with a catalytic converter, there is
one before and one after the catalytic converter. For
lift truck models without a catalytic converter the
one HEGO sensor is mounted to the muffler.
1. Disconnect negative battery cable.
NOTE: Tag electrical connectors prior to removal
to aid in installation.
22
HeavyManuals.com
0900 SRM 1905
2. Disconnect oxygen (HEGO) sensor connectors
from wiring harness.
NOTE: Note placement of sensor prior to removal
to aid in installation.
3. Remove oxygen (HEGO) sensors from catalytic
converter or exhaust pipe. See Figure 19.
Install
1. Install oxygen (HEGO) sensors onto catalytic
converter or exhaust pipe as noted during re-
moval. See Figure 19.
2. Connect HEGO sensor connectors to wiring
harness connectors as tagged during removal.
3. Connect negative battery cable.
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0900 SRM 1905 3/15