ENGINE FUEL

(EF)

-H1S/H20-II/H2S ENGINE-

CONTENTS

SERVICE DATA AND SPECIFICATIONS " EF- 2

FUEL PUMP EF- 2
CARBURETOR EF- 2
GOVERNOR EF- 2
TROUBLE DIAGNOSES AND CORRECTIONS EF- 3
CARBURETOR EF- 3
AUTO.CHOKE MECHANISM EF- 4
GOVERNOR EF- 5
FUEL PUMP EF- 6
OPERATING TEST EF- 6
INSPECTION EF- 6
CARBURETOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. EF- 7
INSPECTION AND ADJUSTMENT EF- 8
MAJOR SERVICE OPERATION EF-10
GOVERNOR EF-11
DISASSEMB L Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. EF-12
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. EF-12
ASS EM B L Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. E F-12
ADJUSTMENT EF-13
 SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS

FUEL PUMP
Fuel pump capacity
mQ (US fl OZ, Imp fl oz)/minute More than 1AOO (47.3,49.3)
at 1,000 rpm

Fuel pump pressure 16.7 - 23.5 (0.167 - 0.235,

kPa (bar, kg/em' , psi) 0.17 - 0.24, 2.4 .3.4)

CARBURETOR
Engine H15 H2O-II H25

Carburetor model 210030-051 210030-061 210030-071

Choke type Automatic Automatic Automatic

Inlet diameter mm (in) 63 (2.48) 63 (2.48) 63 (2.48)

Outlet diameter mm (in) 30 (1.18) 30 (1.18) 30 (1.18)

Venturi diameter mm (in)

Large 22 (0.87) 24 (0.94) 26 (1.02)
Small (inner dia. - outer dia.) 12 - 16.5 (0.472 - 0.650) 12 -16.5 (0.472 - 0.650) 12 - 16.5 (0.472 - 0.650)

Main jet #104 #114 #120

Main air bleed #80 #60 #60

Slow jet #44 #48 #54

Slow air bleed #80/#150 #80/#140 #80/#150

Float level adjustment mm (in)

Top float position "H1" 5.6 (0.220) 5.6 (0.220) 5.6 (0.220)
Bottom float position "H2" 42 (1.65) 42 (1.65) 42 (1.65)

GOVERNOR
Type Pneumatic

Speed control system By controlling mixture amount

Operation of control mechanism By suction negative pressure

Max. engine speed under no load

rpm
H15 3,100 - 3,300
H20-II 3,100 . 3,300
H25 2,800 - 3,000

Max. engine speed under load

rpm
H15 2,500 . 2,900
H20-II 2,600 - 3,000
H25 2,300 - 2,600

No. of allowable hunting

3 times (Max.)
repetitions

EF-2
 TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS

CARBURETOR There are various causes of engine tern is faulty. Therefore, whenever the
malfunctions. It sometimes happens engine has problems, electrical system
In the following table, the symp-
toms and causes of carburetor prob- that a carburetor which has no fault must be checked first before making
lems and remedies for them are listed seems apparently to have some prob- carburetor adjustment.
lems, when in fact the electrical sys-
to facilitate quick repairs.

Condition Probable cause Corrective action

Overflow Float level improper. Adjust or repair float system parts.

Float damaged. Replace.
Dirt accumulated on needle valve of float. Clean ball valve.
Fuel pump pressure too high. Repair or replace pump.
Needle valve seat improper. Repair or replace.

Excessive fuel Fuel overflow. See above item.

consumption Main jet or slow jet size too large. Replace with the sp'ecified one.
Main air bleed clogged. Clean.
Mainjet or slow jet damaged. Replace,
Choke valve does not fully open. Adjust.
Ou tlet valve seat of accelerator pump im- Lap.
proper.
Idle adjustment incorrect. Adjust.

Power shortage Main jet clogged or damaged. Clean or replace.

Throttle valve does not open fully. Adjust.
Choke valve does not open fully. Adjust.
Fuel filter clogged. Replace.
Malfunctioning fuel pump. Repair or replace.
Air cleaner clogged. Clean or replace.

Improper idling Idle adjustment incorrect. Adjust.

Slow jet clogged. Clean.
Slow jet tightened improperly. Correct.
Throttle valve does not close. Adjust.
Throttle valve shaft worn. Replace.
Manifold/carburetor tightening improper. Correct.
Packing between manifold/carburetor faulty. Replace gasket.
Fuel overflow. See above item.

Engine hesitation Main jet or slow jet clogged. Clean.

By-pass hole, idle passage clogged. Clean tube.
Emulsion tube clogged. Clean.
Idling adjustment incorrect. Correct adjustment.
Accelerator pump operating improperly. Clean or adjust.

EF-3
 TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Engine does not Fuel overflow. See above item.

start. No fuel fed to engine. Check pump, fuel pipe and needle valve.
Idle adjustment incorrect. Adjust.
Fast idle adjustment incorrect. Adjust.
Choke valve operating improperly. Adjust.

AUTO-CHOKE MECHANISM

Condition Probable cause Corrective action

Engine does not start. Seized plunger. Replace.

Choke valve is stuck to open Seized choke valve. Replace.
and throttle valve, to close.
Engine starts but operates Thermostatic coil improperly Adjust.
poorly or at a low speed. adjusted.

Fast idle earn improperly adjusted. Adjust.

Thermowax deteriorated. Replace.

Choke valve opens and throttle
PTC heater circuit broken. Replace.
valve does not close.
Engine speed does not
Auto-choke linkage deformed. Replace.
decrease during warm-up.
(Auto earn fails to drop.) Choke valve seized. Replace.
Choke valve does not open. Thermostatic coil heater circuit
Replace.
broken .
..

Engine operates poorly or Fast idle earn drop-time improperly

Cam drops too fast. Adjust.
engine stalls. adjusted.

INSPECTION AND MAINTENANCE PROCEDURES

Engine does not start/engine starts Engine operates poorly

but operates poorly or at a low speed. or stalls.

Visually check full auto-choke mechanism.

Check for broken circuits using circuit tester.

Replace carburetor upper Check thermowax and PTC

body assembly. heater.

Check auto-choke mechanism

for operation.

EF-4
 TROUBLE DIAGNOSES AND CORRECTIONS

GOVERNOR chart as a guide. completely, then gradually open car-

1. Track down problem, referring to buretor's throttle valve.
When an engine problem occurs,
descriptions listed in the chart. 4. If engine speed gradually increases
first determine whether or not it is
2. Remove earn chamber's cover and in response to movement of throttle
due to faulty governor or engine
check condition of earn band. valve, governor is malfunctioning.
using following information and
3. If earn band is in good order, 5. If engine speed does not increase,
Trouble Diagnoses and Corrections
start engine, open governor valve engine itself is malfunctioning.

Condition Probable cause Corrective action

Insufficient engine Broken earn rope. Replace.

performance Broken or fatigued spring.

Lift truck speed too Improper adjustment of earn spring. Adjust.

slow (but lifting speed Sticking of stabilizer piston. Replace governor assembly.
is good, or hunting is
accompanied).

Lift truck speed too Incorrect adjustment of earn spring. Adjust.

slow (Lifting speed Fatigued earn spring. Replace earn-rope kit.
too slow).

Lifting speed too slow Improper adjustment of earn spring. Adjust.

(lift truck speed is
good).

Too high lift truck Incorrect adjustment of earn spring. Adjust.

speed. Sticking of stabilizer piston. Replace governor assembly.
Sticking of governor valve shaft. Replace governor assembly.

Excessive repetition Improper adjustment of earn spring. Adjust.

of hunting (should be Sticking of stabilizer piston. Replace governor assembly.
within three times,
or within 9 seconds). Sticking of governor valve shaft. Replace governor assembly.

EF-5
 FUEL PUMP

FUEL PUMP

3. Connect a suitable pressure gauge

to the opening of T-connector, and
fasten the hose between carburetor
and T-connector securely with a clip.
4. Start and run the engine at
various speeds.
S. The pressure gauge indicates fuel
pressure in the line. The gauge reading
should be within the specified value.
Fuel pressure:
16.7 - 23.5 kPa
Spring---e

Element-tj j' (0.167 - 0.235 bar,

0.17 - 0.24 kg/cm2,
2.4 - 3.4 psi)

GaSket-CO
INSPECTION

J
Valveretainer
V' 1. Flush pump by immersing it in a
Diaphragm fuel bath and operating rocker arm
Diaphragmspring FEF062 a number of times.
2. Drain fuel from fuel pump.
Then block off the inlet port and
operate rocker arm. If the rocker
arm operates, the fuel pump seat is
A WARNING:
OPERATING
FUEL PRESSURE
TEST
TEST
malfunctioning. Replace fuel pump.
a. Be sure to turn ignition switch 3. Remove your finger from the inlet
"off" . 1. Disconnect fuel hose between car- port and listen for a suction sound
b. Before starting to work on any part buretor and fuel pump. which will confirm that a sufficient
of fuel system, disconnect battery 2. Connect a rubber hose to each suction was produced.
ground cable from battery. open end of a T-connector, and con- 4. Block off outlet port and once
c. Arcs, sparks, flames and lit ciga- nect this connector-hose assembly again operate the rocker arm. After
rettes should be kept away from between carburetor and fuel pump. air pressure has been built up, confirm
any part of fuel system. that the pressure remains for two or
Locate this T-connector as close to
three more seconds.
carburetor as possible.
When disconnecting fuel hoses, use S. Put a finger over the outlet port
a container to receive fuel remaining and again build up pressure in the
in fuel hoses. pump. Then submerse the pump in a
fuel bath and check for air leaks.

EF-6
 CARBURETOR

CARBURETOR
A WARNING:
a. Be sure to turn ignition switch
"off" .
b. Before starting to work on any part
of fuel system, disconnect battery
ground cable from battery.
c. Arcs, sparks, flames and lit ciga-
rettes should be kept away from
any part of fuel system.

Choke valve
Accelerating pump

Push rod

Cam drop-
time adjusting
screw
Pu sh rod lever

Bimetal case

FICD

Idle adjusting
screw

FET064

EF-7
 CARBURETOR

Slow air bleed jet

Acceleration weight

Float valve

Check valve

Float --

/
Main jet--I

Throttle valve J/
Slow port / /

Idle port~
FEF055

INSPECTION AND Top float position "H 1" Bottom float position "H2"
ADJUSTMENT Turn down float and check float posi. Check float position "H2" when float
IDLE RPM AND MIXTURE RATIO tion "HI". is fully raised.
Top float position "H1": Bottom float position "H2":
Refer to Checking and Adjusting of
idle rpm and mixture ratio in section 42 mm (1.65 in)
5.6 mm (0.220 in)
ET.

FUEL LEVEL
Fuel level is factory.adjusted and H2
needs no adjustment.
Adjust only when overhauling or
replacing inner parts. .
Use the following procedure. ..~. ~I 1110
, 0 I

FEF057 H2 = 42 mm (1.65 in)

If out of specification, adjust it by If out of specification, adjust it by

bending float hanger. bending float stopper.

EF-8
 CARBURETOR

JET AND AIR BLEED DASH POT FUEL CUT SOLENOID VALVE
1. Idle speed of engine and mixture If engine does not stop when igni-
CAUTION: must be well tuned and engine suffi- tion switch is turned off, this indicates
a. Be sure to use a screwdriver of ciently warm. that a striking (closed) solenoid valve
proper size. 2. Turn throttle lever by hand, and is shutting off supply of fuel to engine.
b. Be careful not to scratch or score read engine speed when dash pot If harness is in guod condition, replace
jet and air bleed. just touches throttle lever. solenoid valve as a unit.
c. To clean jet and air bleed, use
Dash pot touch speed: (iJ Tightening torque:
solvent and compressed air.
1,450 - 1,550 rpm 18 - 22 N.m
(1.8 - 2.2 kg.m, 13 - 16 ft-Ib)
3. If out of specification, adjust it
1. Remove choke chamber from by turning dash pot adjusting screw
center body and check jets and air After replacement, start engine and
after loosening lock nut.
bleeds for stamped number., looseness check to be sure that fuel is not leak-
and clogging. ing, and that fuel cut solenoid is in
If any abnormality is found, correct. good condition.
2. Check power jet for looseness
and clogging.
3. Remove main jet cap from lower
portion of float chamber and check AUTO-CHOKE MECHANISM
main jet.
Functional check

ACCELERATOR PUMP • Visually check auto-choke mecha-

nism for bent linkage, etc.
When accelerator pump is operated
• Before starting engine, depress ac-
by opening throttle lever by hand with
4. Tighten lock nut and make sure celerator pedal one time.
engine stopped, remove air horn and
that engine speed drops smoothly • After starting engine, make sure
check pump injector located at pri- engine speed automatically de-
from 2,000 to 1,000 rpm in approxi-
mary port if it injects fuel smoothly creases to specified idle rpm.
mately three seconds.
without delay.

--------
Ambient temperature
below 20°C (68°F)
Choke valve

Fully closed
Throttle valve

Fast idle position

Cam lever and fast idle carn

Differs with ambient temperature:

During engine starts
(1 st or 2nd ratchet position)
During warm-up
(3rd or 4th ratchet position)

After warm-up Fully open Idle position Clearance exists.

EF-9
 CARBURETOR

THERMOSTATIC COIL THERMOWAX MAJOR SERVICE

• Ensure PTC heater becomes hot OPERATION
Removal
when engine starts. (simple check The perfectly adjusted carburetor de-
• Scribe alignment mark on thermo-
method) livers the proper fuel and air ratios
static coil case if not clear.
• Remove three screws, then thermo- • Using circuit tester, check PTC at all speeds for the particular engine
heater for continuity. Continuity for which it was designed. The car-
static coil case.
must exist. buretor should be maintained in its
Inspection original condition and will continue to
CAM LEVER deliver the proper ratios.
• Start engine and touch thermo- To maintain accurate carburetion of
Inspection
static coil case. It should be hot. passages and discharge holes, extreme
(simple check method) Ensure clearance does not exist be- care must be taken in cleaning.
• Using circuit tester, check thermo- tween fast idle carn anq cam lever Use only carburetor solvent and com-
static coil for continuity. Con- when choke valve is closed by hand. pressed air to clean all passages and
tinuity must exist. discharge holes. Never use wire or
Adjustment other pointed instrument to clean or
Installation carburetor calibration will be affected.
Adjust cam drop time adjustment
While aligning alignment mark, install screw until choke valve is closed
thermostatic coil case. completely.

EF-10
 GOVERNOR

GOVERNOR

Governor body

Hot water pipe

/ Air pipe (To carburetor)

.-- -~ Air pipe (To distributor)

Ri''''~:
--- ~ Valve stock

i
"'.~~r16<:::::s~,: '21

",~1! ~lio
/ bearing ~
C.m T.p" pi,

r
" ~ Cam adjusting plate

Screw ~ ~haft
Governor
0. ~ J/ Wire rope assembly

t.,,, .p<:
~
~
Ignition advance an~le
switching valv~~.

s",. ~
~G

~
~

p,", ~
Cam spring Chamber cover
gasket
Chamber cover
Screw (3)

FEF150

EF-11
 GOVERNOR

DISASSEMBL Y assembly which requires precise 5. Remove adjusting screw.

adjustment of cam and cam plate. 6. Drive tapered pin out of camshaft
Do not attempt to disassemble gover-
from the lower end; then remove
nor unless necessary, especially cam
tapered pin.

Governor body
o

o9t
/ r~AI
r:J ~/t::)
-\~ , Inner

_ bearing
Governor Taper pin
~ ~ @,haftcamflamadjusting
....; " - "-~ ~ ~ /late

, ",
/~
~'Ad;'";''' oc"w is,,~~~ .
~~
: Wirerope
assembly
SEF2648

\~),~~-AdjUstinghandle
,}V < sA;;;(~'
cre~.
(!
7. Remove earn, earn spring and
Gum cap -~ e wire rope assembly from camshaft
Cam spring 12'~ f Screw as a unit. Be careful not to deform
Chamber cover ~ earn spring.
gasket Chamber cover
When it is necessary to further dis-
assemble it, record number of spring's
FEF151 active turns, screwed-in state of spring
ends.

I. Remove seal and gum cap. 8. Remove earn spring and wire
rope assembly.

Do not attempt to disassemble cam

and cam adjusting plate unless neces-
sary, since it requires precise adjust-
ment during re-installation.

INSPECTION
Carefully check governor and other
parts for signs of wear, cracks or
sticking; if any part is found damaged,
FEF 152
replace entire governor assembly
3. Remove stopper screw.
- not only damaged parts.
4. Remove adjusting handle.
2. Paint alignment marks across To facilitate adjustments during re-
ASSEMBLY
adjusting handle, adjusting screw and installation, use alignment marks as a
body. Then, remove cover from earn guide to record number of rotations To assemble, reverse disassembly pro-
chamber. required to remove adjusting handle. cedure.

EF-12
 GOVERNOR

ADJUSTMENT valve under a condition where mast as-

sembly is tilted fully backward with
hydraulic control lever.
(2) Adjust engine speed by adjusting
Adjusting handle ~ Screw screw so that engine speed is within
Wire rope assembly
Gum cap
I
~Vacuum hose allowable range (HI5: 2,500 to 2,900
rpm, H20-II: 2,600 to 3,000 rpm,

-~?r~ I~~ carburetor

H25: 2,300 to 2,600 rpm).
adjust maximum engine speed under
no-load.
Also

SealJ
[
'J ]Jf distributor
3. Check for hunting
Term "Hunting" means sudden fluc-
tuation of engine speed attended with
. '-Cam
Cam spring Taper pm vibration. Be sure to check engine
Cam adjusting plate for hunting when maximum engine
/
Screw speed under no-load as well as rated
output has been adjusted.
(I) Stop hydraulic mechanism, place
FEF154
gear in neutral, and idle engine.
(2) Suddenly toe in accelerator
• Turn adjusting handle. This changes pedal under this condition, and make
Stopper screw
amount of spring tension. Because certain that hunting ceases after re-
of this, maximum speed (rpm) peating three times or less, or within
under no-load can be adjusted 9 seconds.
without changing output character- If hunting repeats more than three
istics of governor as often. Turn times, or within 9 seconds, proceed as
adjusting screw. This changes both follows:
earn spring's tension and rate Gum cap (a) Turn adjusting screw of a revo-
accordingly. In other words, output lution counterclockwise, and every
characteristics change along with a time begin with adjustment of max-
change in maximum speed under FE F 155 imum engine speed under no-load
no-load. as described in paragraph "I" above.
• Output characteristics change con- FINAL ADJUSTMENT (b) If hunting still remains ume-
siderably when relative position of moved, it may be eliminated by adjust-
Before proceeding to final adjust-
earn and earn adjusting plate is ing earn. But this should be avoided as
ment, completely adjust engine opera-
changed. (Do not attempt to adjust far as possible because it is very
tion with respect to such points as
relative position unless necessary, valve clearance, advance angle of igni- delicate and is liable to affect engine
because it greatly influences output. tion, distributor air gap, revolution performance.
characteristics. ) during idling, etc. (c) Shift earn set screw in direction
I. Adjusting maximum engine speed of arrow mark shown in figure below
Before adjusting the adjusting handle,
under no-load and secure earn. By doing so, hunting
loosen stopper screw by rotating
(l) Shift transmission gears into may be remedied easily.
it counterclockwise approximately 1
to 2 turns. neutral so that engine will bear no-
Governor cannot be properly adjust- load, then fully open throttle valve of
ed due to adjusting handle deforma- carburetor.
tion. (2) Under this condition. bring en-
Tighten stopper screw by turning it gine speed within allowable range
clockwise until it just contacts the
adjusting handle; then turn
clockwise an additional 1/4 to 1/2
turn.
it
(H15 and H20-II: 3,100 to 3,300 rpm,
H25: 2,800 to 3,000 rpm) by turning
adjusting handle.
Turn adjusting handle clockwise to
t
Affix seal to cover both stopper increase, or counterclockwise to de-
screw and gum cap. crease engine speed. FE047

2. Adjusting maximum engine speed

under load (d) After adjustment, begin once
(l) Shift transmission gears into more with adjustment of maximum
neutral. Fully open carburetor throttle no-load speed as described above.

EF-13
 -
BULLfTIN
1'lW)11 NISSAN MOTOR Co.. LTD.
Engine Fuel
Industrial Machinery Division
Overseas Sales Department
Tokyo, Japan FEF 94.JOl
APPLIED MODEL J01 and J02 series equipped with gasoline engine

LPG SYSTEM

SERVICE INFORMATION:
An LPG (Liquefied Petroleum Gas) system has been adopted as optional equipment for all territories
except the U.S.A. and Canada. This LPG system permits the use of gasoline, and the fuel can be easily
changed by selecting the LPG-Gasoline switch on the instrument panel.

Connector

I
I
I
Fuse
block +
To intake LPG
manifold cylinder

Carburetor
1
2
3
'LPG-Gasoline
select switch

Solenoid valve (Gasoline)

Ignition
switch FEF166

Along with the adoption of this system, the repair and maintenance procedures for the LPG system
have been introduced in this bulletin.

The information in this bulletin should not be' interpreted as the basis for claims unless so designated.
Whenever you order spare parts, refer to the Spare Parts Bulletin, not to this Technical Bulletin.

Issue date: June 30, 1994 (01)

Printed in Japan -1- Publication No. TB4E-F.01GGO
 LPG (Liquefied Petroleum Gas) SYSTEM
VAPORIZER are all necessary for the efficient com- Cooling water from the radiator
bustion of liquid fuel discharged under circulates in the water passage to
DESCRIPTION high pressure from the LPG cylinder. prevent the vaporizer from freezing
It supplies vaporized fuel to the carbu- due to the latent heat that is produced
The vaporizer performs three func-
retor. by the vaporization of the fuel.
tions, (pressure reduction, fuel vapori-
zation and pressure regulation), which

Pressure balance port

Pressure adjusting screw
Primary cover
Primary diaphragm
Primary chamber (VaporiZing)~
Water drain valve~
Pressure test port plug
Secondary valve seat
Primary valve seat

Radiator water

Vacuum
(To intake
-manifold)

Idling adjusting scre

Secondary
Idling adjusting screw spring chamber (Controlling)
Secondary valv Secondary valve ~
lever
Secondary cover acuum lock diaP.hragm spring
Secondary valve lever spring Balance lever Secondary diaphragm-

Balance spring

-2-
STRUCTURE AND OPERATION pressure of the fuel that flows out of to achieve an economical fuel con-
the LPG cylinder, to approx. 29 kPa sumption rate and the maximum
Primary chamber
(0.29 bar, 0.3 kg/cm2, 4 psi), in order power output.
This reduces the considerably high

•
To secondary chamber
1
2
3
4
5
6
Primary
Primary
Primary
Primary
Primary
Hook
valve
valve sea t
cham ber
diaphragm
diaphragm spring
•
7 Primary valve lever

Fuel that is discharged from the As fuel continues to flow and the kPa (0.29 bar, 0.3 kg/cm2, 4 psi) the
LPG cylinder under approx. 226 kPa primary chamber pressure goes higher diaphragm spring @ tension will be
(2.26 bar, 2.3 kg/cm2, 33 psi) of than 29 kPa (0.29 bar, 0.3 kg/cm2, 4 higher than the fuel pressure, so the
pressure [cylinder temperature: 200e psi) the primary diaphragm @ over- primary diaphragm @ is pushed
(68°F)] is delivered to the vaporizer's comes the diaphragm's spring @ ten- down. This causes the hook @ to
fuel inlet through the LPG solenoid sion and is raised. This causes the hook push the primary valve lever (j) down,
valve. @ (which is attached to the dia- which, in turn opens the primary valve
From the solenoid valve, fuel is phragm) to move the primary valve CD in order to admit more fuel. In this
delivered to the primary chamber CID lever (j) up, which closes the primary manner, the pressure of the primary
through the clearance between the valve CD in order to terminate the chamber is maintained at a constant
primary valve CD and the valve seat flow of fuel. 29 kPa (0.29 bar, 0.3 kg/cm2, 4 psi)
@, in order to reduce the fuel pres- As fuel is consumed and the prima- approx.
sure. ry chamber pressure drops below 29

-3-
Secondary chamber pressure to almost atmospheric levels volume of air that flows into the
in order to prevent any fuel overflow carburetor.
This reduces the vaporized fuel
into the carburetor, regardless of the

8 Secondary valve
9 Secondary valve seat
10 Secondary chamber
11 Secondary diaphragm
12 Secondary diaphragm spring

Gas
outlet

13 Secondary valve lever

14 Vacuum lock-off diaphragm
15 Vacuum lock-off chamber
16 Vacuum lock diaphragm spring
17 Balance lever
18 Balance spring

Fuel which is regulated to a pres- Vacuum lock-off mechanism REMOVAL AND INSTALLATION
sure of approx. 29 kPa (0.29 bar, 0.3 When the engine starts, the vacuum 1. Completely close the LPG outlet
kgJcm2, 4 psi) is delivered to the lock diaphragm @ will be pulled and shut-off valves.
secondary chamber @ through the toward the vacuum lock-off chamber 2. Run the engine until all of the
clearance between the secondary valve @ so that the vacuum lock-off dia- fuel in the fuel line is consumed.
@ and the valve seat @ and is phragm spring Q~) inactivates the 3. Completely drain the engine cool-
reduced in pressure to the equivalent secondary valve lever @. As this ant.
of the atmospheric pressure. happens, the tension of the balance 4. Disconnect the water hoses from
While the engine is operating, the spring @, which is installed to the vaporizer.
secondary diaphragm (jJ) is raised by balance lever @, overcomes the ten- 5. Disconnect the vaporizer con-
the vacuum that is produced in the sion of the secondary valve lever spring nectors (hose to adapter and pipe from
intake manifold, while it simultaneous- @, keeping the secondary valve @ the LPG solenoid valve), and the
ly lifts the secondary valve lever @ up, raised slightly off its seat @. This vacuum hose.
which, in turn is moved together with allows LPG gas to flow from the 6. Remove the bolts securing the
the secondary diaphragm (jJ). This primary chamber to the secondary vaporizer to the bracket, and remove
causes the secondary valve @ to open chamber so that the engine is ready for the vaporizer.
and allows the fuel to flow. starting. 7. Install'ltion is in the reverse order
When the engine is stopped, The vacuum lock diaphragm is pull- of removal.
vacuum is not produced. The second- ed toward the vacuum lock-off cham-
ary diaphragm (jJ) is then moved down C!J : LPG pipe flare nut
ber while the engine is running. As a 18 - 26 N.m
by the reaction of the diaphragm result. the secondary valve lever is
spring @, causing the secondary valve (1.8 - 2.7 kg-m,
operated regardless of the position of 13 - 20 ft-Ibl
@ to close and terminate the flow of the vacuum lock diaphragm.
fuel. Water hose clamp
0.34 - 0.83 N.m
(3.5 . 8.5 kg-em,
3.0.7.4 in.lbl
Hose to adapter clamp
0.53.1.14 N.m
(5.4 . 11.6 kg.cm,
4.7 - 10.1 in-Ibl

-4-
 DISASSEMBLY. ASSEMBLY AND After all parts have been assembled. there is no fuel leakage.
INSPECTION check all connections to ensure that

t----Idle adjusting screw

@
c:

Secondary valve
lever assembly
Pressure test
port plug ~
LPG outlet connector~ ~

Secondary cover
LPG inlet connector ~ '-', 1
Secondary diaphragm
Primary diaphragm

Body

FEF167

Primary chamber 5. Check all disassembled parts or lever.

1. Remove the screws securing the units and remove dust, impurities, etc. • Direct air [approximately 392 kPa
primary cover and detach the cover. with dry compressed air. (3.9 bar. 4 kg/cm2• 57 psi))
2. Remove the primary diaphragm 6. Scrape off any sulphur or tar that through the vaporizer inlet while
spring. has come into contact with parts or pulling the end of the lever upward
3. Carefully remove the primary dia- units. to properly seat the primary valve.
phragm in the direction opposite to 7. Assembly is in the reverse order of Check the primary valve to see if it
the LPG inlet port. disassembly. shows any sign of leakage. If it
4. Remove the primary valve lever • Make sure that the diaphragm does. replace it with a new one .
assembly. tongue is properly engaged with the

-5-
• Adjust the primary lever with tioned asshown in the figure below. PRESSURE INSPECTION
a suitable tool so that it is posi- Check the primary chamber pres-
sure as follows:
1. Disconnect the pressure test port
plug from the primary chamber, and
connect a pressure gauge, using a
suitable connector.
2. Start the engine and check the
primary chamber pressure.
Specified pressure:
23.5 - 33.3 kPa
(0.235 - 0.333 bar,
0.24 . 0.34 kg/cm2 ,
3.4 - 4.8 psi)

3. If the measured pressure is not

within the specified range, adjust it by
turning the pressure adjusting screw.
When refitting the plug, apply an
adhesive agent to the plug to ensure
airtightness.

IDLE ADJUSTMENT
1. Turn the carburetor's throttle ad-
Secondary chamber • Make sure that the secondary dia- justing screw and adjust the vaporizer's
1. Remove the secondary cover. phragm is properly engaged with idle adjusting screw so that the engine
2. Remove the secondary diaphragm. the secondary valve lever. runs stable at its highest speed within
Be careful not to damage it. • Direct air [approximately 392 kPa the specified idling speed.
3. Remove both the secondary valve (3.9 bar, 4 kg/cm2, 57 psi)) 2. Turn the carburetor's throttle ad-
lever assembly and the spring. through the fuel inlet of the prima- justing screw so that the engine runs in
4. Remove the vacuum lock dia- ry chamber to determine if leakage the specified idling range.
phragm and spring. is present. If leakage is found, 3. Repeat steps 1 and 2 above until
5. Check all disassembled parts for replace the secondary valve lever the engine runs smoothly at an idling
abnormalities. assembly. speed within the specified range.
6. Assembly is in the reverse order of • Set the secondary lever at the
Specified idling speed:
disassembly. specified position as shown in the
650 - 700 rpm
figure below.
Ignition timing (B.T.D.C.):
H15 3°_5°
H20-II & H25 5° - 7°

Main adjusting screw setting:

Tighten adjusting screw fully, then
back off 2 rotations.

REMOVAL OF IMPURITIES
LPG contains non-flammable ma-
terials (such as tar, etc.). If left un-
heeded, non-flammable materials pro-
gressively accumulate in the vaporizer
and may cause the fuel system to
become inoperative. For this reason,
impurities should be periodically
drained off through the drain valve
3.0 - 4.0 mm
(0.118 - 0.157 in) while the engine is hot and before such
materials solidify.

-6-
AIR DUCT

FEF168

LPG-GASOLINE SELECT SWITCH

(L P G.G P L.TREIBGAS)

Lock nut (G A S.ESSENCE.BENZIN)

Waterproof cap

FE F169

Fit se Iec t switch so t h at green wire

is positioned on the top.

-7-
INSPECTION Cil : Flare nut
18-26N.m
(1.8 - 2.7 kg-m.
~nWire 13 - 20 ft-Ibl
UP (LPG)

OFF--
r 2
FILTER
Oean the filter every 600 hours of
operation or 3 months (whichever
\
DOWN (GAS)
3
~ire
comes first). Replace it every 2,400
hours of operation or 12 months
~Wire (whichever comes first). Further, in
dusty operating conditions, carry out
maintenance as often as possible.

GASOLINE SOLENOID VALVE

Removal and installation
1. Disconnect battery ground cable.
2. Disconnect the solenoid harness
connector.
3. Disconnect the gasoline hoses.
FEF170 4. Remove the solenoid valve from
the bracket.
5. Installation is in the reverse order
of removal.
LPG SOLENOID VALVE AND FILTER

CD Cover
@ Solenoid
@ Guide
G) a-ring
CID Plunger
@ Body
(J) Connector
@ Filter
@ O-ring
@ Cover
([j) Plunger spring

LPG SOLENOID VALVE

Removal and installation 5. Disconnect the solenoid harness
1. Completely close the LPG outlet connector.
and shut-off valves. 6. Remove the solenoid valve from
2. Run the engine until all of the the mounting bracket of LPG solenoid
fuel in the fuel line is consumed. valve.
3. Disconnect battery ground cable. 7. Installation is in the reverse order
4. Disconnect the LPG pipe. of removal.

-8-
PERIODIC MAINTENANCE SCHEDULE
MAINTENANCE OPERATION MAINTENANCE INTERVAL
Periodic maintenance should be performed Months I 2 3 4 5 6 7 8 9 10 11 12
after specified intervals have elapsed in Hundreds 2 4 6 8 10 12 14 16 18 20 22 24
months or hours, whichever comes fIrst. of hours

LPG FUEL SYSTEM

1. Piping or pipe connector portion for gas leakage I I I I I I I I I I I I
2. Tar in vaporizer D D D D D D D D D D D D
3. Piping or pipe connector portion for damage I I I I I I I I I I I I
4. Mounting bracket of LPG cylinder for looseness or damage I I I I I I I I I I I I
5. Piping or pipe connector portion for gas leakage (1)
6. LPG filter C C C R

NOTE: (1) At time of LPG cylinder replacement, inspect pipe connectors for gas leakage with soapy water.
Abbreviations: I = Inspect. Correct or replace if necessary.
D = Drain C = Clean R = Replace

WIRING DIAGRAM

LPG-GASOLI NE
SELECT SWITCH LPG SOLENOID
LPG VALVE

BR~ ~R
: {]lP--j
1
2
3
OFF GAS LPG
J
J

IGNITION
SWITCH
0
GAS

?IND ...J

OFF ON ST
1 J
2 .J
:::::rrn
GY
B/Y DJJ 1m 3
4

'"
>- ,
ID Q
~
'"
W;J
BR
~
IDA
""
>-
IDID

lMJ
ID

~
ID'

[iJ FUSIBLE
LINK
GASOLINE
SOLENOID
VALVE

m1
ID

~
BR
ENGINE -=- -=-
BODY BODY
FUSE BLOCK
IGNI TI ON
RELAY ~BATTERY GROUND
GROUND GROUND
-=- F EF171

-9-
lie,., NISSAN MOTOR CO., LTD.
Industrial Machinery Division
Tokyo, Japan

BULLfTIH FEF 99-J01

Engine Fuel

APPLIED MODEL : TD27 engine model for J01/J02 series

ENGINE FUEL
SERVICE INFORMATION:
The injection pump used in the diesel engine model available in North America has been changed to meet
U.S.A. exhaust gas controls (EPA regulations).
The EPA certification label is located on the upper surface of the engine rocker cover.

LOCATION

IMPORTAIT EIGIIE IIFORMATIOI

IISSAI DIESEL MOTOR CO.,LTD.

ENGINE PAMILY: XNDXL02.7THA

BIGISE MODEL : TD27

DISPLACEMEIT : 163 CIDI2.663L)

ADVERTISED BP: 55BP/2300RPN
SAE JI995IGROSS)
PUEL RATE AT ADV.BP:
45mm3/st.
VALVE LASH IS'EXB:O.014IN.
(BOT)
INITIAL IHJ.TIMIHG:
5 DEG.BTDC

TBIS EIGIIE IS CERTIFIED TO

OPERATE OR DIESEL PUEL.

THIS ERG I.! CORrORKS TO

1998MODEL YEAR U.S EPA
RIGULATIORS LARGE HONROAD
COMPRESSIOI-IGIITIOH IIGIII.

EFT0023

The information in this bulletin should not be interpreted as the basis for claims unless so designated.
Whenever you order spare parts, refer to the Spare Parts Bulletin. not to this Technical Bulletin.

Issue date: March IS, 1999(01)

Publication No. TB99E-1l2EUO
Printed in Japan
-1-
MODIFICATION NOTICE:
Full load screw and maximum speed screw are sealed with the tamper resistant cap. Full load and full (maxi-
mum) speed cannot be adjusted.

Full load tamper resistant cap

Full (Maximum) speed tamper resistant cap

EFT0024

SERVICE DATA FOR INJECTION PUMP

NOTE:
The injection pump adjustment should be carried out at ZEXEL service station.

Part number 16700-0K701

Maximum speed 2,700 + 50 rpm Under no load
Full load fuel 45 + 3 mm /st-cyl
3 (On engine) Engine speed : 2,300 rpm

-2-
II CLASS 1,4,5SERVICE BULLETINII
NlSSAN Forklift Corporation. North'America
~
240 North Prospect Street; Marengo~]L 60152
FORKLIFT
8B97-015
POLICY
Date: June 3. 1997

To: All Dealer Principals, Parts and Service Managers

From: Customer Satisfaction Warranty Department

Subject: L.P.G. Conversion / D.L. Rated

When converting a gasoline powered Nissan Forklift to L.P.G., and requesting a U.L. Rating
change from Gasoline to L.P .G. please be advised of the following:

• Only L.P.G. Kits listed on L.P. Gas "Listed By Report Form" (Form #PSM-l13) are
eligible for D.L. Rating Change (Dual Fuel Kits are not eligible) .

• Only approved L.P.G. Conversion Kits purchased through NFC's Parts Department are
eligible for the V.L. Rating Change.

• L.P .G. Conversion Kits purchased locally or somewhere other than NFC's Parts
Department ARE NOT eligible for a V.L. Rating Change.

Please insure the appropriate people within your organization are aware of this important
information.

Sincerely.
Nissan Forklift Corporation

Customer Satisfaction Warranty Department

Phone Number: (815) 568-0061 Fax Number: (815) 568-0187

 II CLASS 1,4,5SERVICE BULLETINII
~
NISSAN Forklift Corporation, North'America
240 North Prospect Street; Mareng~! 1L 60152
FORKLIFT
SB98-038
POLICY
SERVICE ADVISORY

Date: January 12, 1998

To: All Dealer Principals and Service Managers

From: Customer Satisfaction Department

Subject: UL Rating on LP Kits

Affected Products: All JO1IJ02 Models

Please be advised that the current LP Kits for the JO1 and J02 Series trucks purchased from NFC
parts are not UL compliant at this time. This means that any JO1 or J02 truck that is converted to
LP in the field is not UL rated. Our engineering group is working on obtaining the UL approval
and it should be available soon.

All trucks that are built as LP trucks in Marengo .!m UL listed. However, please be advised that
any modifications to the trucks could affect the UL rating.

Please contact the NFC Customer Satisfaction Department if you have any questions.

Sincerely,
Nissan Forklift Corporation

Customer Satisfaction Department

The information provided inthis

bulletin is notto be construed as a

... J~ basis for any claimsagainstNFCNA,

unless otherwise stated.

Phone Number: (815) 568-0061 Fax Number: (815) 568-0187

 II CLASS 1,4,5 SERVICE BULLETINII
NISSAN Forklift Corporation. North America
~
240 North Prospect Street; Marengo, IL 60152
FORKLIFT
SB 98-057
MECHANICAL
Date: July 11, 1998

To: All Dealer Principals and Service Managers

From: Customer Satisfaction Department

Subject: UL Rating on LP Kits

Models: All JO1IJ02 Models

In our continuing effort toward product improvement. we are please to announce that the
current LPG Conversion Kits for JO1 and J02 Series trucks purchased from NFC's Parts
Department are now UL Approved.

Please be aadvised that all LPG Conversion Kits for JO1IJ02 models purchased prior to April
24, 1998 are not UL approved. refer to our Service Bulletin SB 98-038 Policy dated January
12, 1998.

NOTE: As a reminder. NFC requires that any unit that is converted in the field. needs to have
a "L.P. GAS Listed by Report Form", completed and sent to the CSD Warranty Department

Please contact the NFC Customer Satisfaction Department if you have any questions.

Please add these to your JOI/J02 Service Manual behind EM Section.

Sincerely,
Nissan Forklift Corporation

Customer Satisfaction Department

.... JI The intonnalion provided in lhis

buUelin is not 10 be construed as a
basis for any claims againsl NFCN A.
unless otherwise staled.

Phone Number: (815) 568-0061 Fax Number: (815) 568-0187

 II ClASS 1,4,5 SERVICE BULLETIN II
/ NISSAN Forklift Corporation, North' America
~
240 North Prospect Street; Marengo,IL 60152
FORKLIFT
SB99.069
POLICY
Date: April 21,1999

To: Dealer Principals, Parts and Service Managers

From: Customer Satisfaction Department

Subject: Optional 43# LPG Tanks on Optimum Model Units

It has recently come to our attention that the use of 43# LPG Tanks on certain Optimum
Model units is no longer recommended or will require relocation of the LPG Tank mounting
brackets. This is due to the variation in tank construction by different LPG tank manufactur-
ers, which could allow the tank to overhang the counterweight of the truck and cause a
potential hazard. The effected models are the Optimum, cushion 4000 # (JC40) and Opti-
mum, pneumatic 6000 # (JP60) units. Also, please be aware that certain LPG Field Conver-
sion Kits will also be effected by this change.

Units Currently in the Field

• JC40 units will require this option removed
• JP60 units will require tank bracket relocation

Detailed information will be provided, in the very near future, to affected Dealers regarding
corrective measures on subject units currently within their servicing APR. Please contact the
Customer Satisfaction Service Department at 815-568-0061 should any questions arise.

Please insert a copy of this bulletin into your JO 1IJ02 Service Manual behind Tab Labeled
LPG.

Sincerely,

Nissan Forklift Corporation, North America

Customer Satisfaction Department

Phone Number: (815) 568-0061 Fax Number: (815) 568-0187

 ......... .-]OlIJ02.LPG.SYSXEM

SERVICE DATA AND SPECIFICATIONS

LPG
INSPECTION AND ADJUSTMENT

I~I
Valve clearance Intake
"" H20. II H25

(Hotl mm Iinl 0.38 10.0151

Exhaust

Fan belt deflection mmlinl 11.1310.43.0.511

Applied pushing force

98110.221
N Ikg.lbl

Engine oil capacity

2 (US Qt. Imp QtI
With oil filter 3.8 (4. 3.3181

Without oil filter 3.5 (3.3/4. 3.1181

Engine compression pressure

kPa Ibar, kgf/cm2, psil/rpm
Standard 1.275112.75.13.0.18511300 1.226112.26.12.5.178)/300 1.275112.75.13.0.185)/300

Minimum 1.079110.79.11.0.15611300 1.030 (10.30.10.5.14911300 1,079110.79.11.0.15611300

Spark plug
Type BP4ES. BPR4ES

Gap mmlinl 0.8 • 0.9 10.031 • 0.035)

Distributor
Air gap nwn linl 0.35 • 0.45 10.0138 • 0.0177)

High tension cable resistance n Less than 30.000

Ignition timing idle speed

8.T.D.C. degree/rpm 10° @ 650-700 12° @ 650-700 8°@650-700

Max. engine speed under no load

3.100.3.300 2.800 • 3.000
rpm

Max. engine speed under load

2,500.2.900 2.600 • 3.000 2,300 • 2,600
rpm

TIGHTEN ING TORQUE

Unit: N'm Ikgf.m. fl-Ibl

Cylinder head bolt 74.8317.5.8.5. 54 • 611

Manifold nut 16.1911.6.1.9.12.141

Oil pan drain plug 20.3912.0.4.0.14.291

Spark plug 18.2411.8.2.4.13.171

LPG -1 9/97
J011J02 LPG SYSTEM.
•
LIQUEFIED PETROLEUM GAS
(LPG)
LPG, also known as Liquefied Petroleum Gas or Propane, is a gas that is heavier than air. It consists
of eight parts of hydrogen and three parts of carbon.

LPG is produced as a by-product of oil and natural gas refming.

When LPG burns it forms:

Carbon Dioxide
Carbon Monoxide
Nitrous Oxide
Hydrocarbons
Water

LPG, with correct fuel/air mixtures, burns clean with little or no carbon monoxide produced. How-
ever, with incorrect fuel/air mixtures, LPG can produce large amounts of carbon monoxide.

The main reasons for selecting LPG over conventional gasoline operation are:

Fewer harmful exhaust emissions, such as carbon monoxide.

Fewer contaminants produced to contaminate engine oil.

LPG is stored under pressure as a liquid. 272 gallons of gas will produce 1 gallon of liquid.

In it's liquid state, LPG will boil at -44 degrees Fahrenheit.

LPG ignites at between 957 degrees to 1090 degrees Fahrenheit. Gasoline will ignite at about 780
degrees Fahrenheit.

Because of the very low boiling point of LPG, high outside temperatures will cause the pressure in
storage containers to be very high. Fuel containers must be constructed of strong, high quality
materials to contain this high pressure.

LPG fuel containers are only filled to 80% of capacity to allow for expansion.

9/97 LPG -2
 1011102 LPG SYSTEM
•
CARBON MONOXIDE
WHAT SERVICE PERSONNEL SHOULD KNOW

OSHA REQUIREMENT

The CO level shall not exceed 50 PPM measured over an 8 hour period in the work environment.

How does parts per million (PPM) relate to percentage numbers?

On million parts per million equals one hundred percent of the engines exhaust gases.

10% CO = 100,000 PPM

1% CO = 10,000 PPM
.1% CO = 1,000 PPM
.01% CO = 100 PPM

For each one one-hundredth of one percent you will have 100PPM.

Example: .01 % x 1,000,000 PPM CO - 100 PPM CO.

With adequate ventilation and following the enclosed adjustment instructions, you should be able to
keep the carbon-monoxide level below the OSHA requirement.

WE STRONGLY RECOMMEND THE USE OF A

CARBON MONOXIDE ANALYZER

ALTERNATE FUEL SYSTEMS

Arlington Heights, II.., 60005-4771 (847) 437-2345 Fax (847) 437-2350

LPG -3 9/97
JOIIJ02 LeG SYSTEM
•

LPG ENGINE SPECIFICATIONS

MODEL IDLE MAX FULL TILT IDLERPM MAX CO AT MAX CO AT

AND RPM RPM BACK WITHFICD FULL TILT IDLERPM
ENGINE RELIEFRPM VACUUM BACK
LINE RELIEF
DETACHED RPM
& PLUGGED

ALL I01'S 3000 2400

KCPH01 650-700 -50 +100/-50 1000 0.80 0.20
H2O-II

KAH01 3200 2450

A-15 650-700 -50 +50/-50 1000 0.80 2.00

CPJ02
KCPH02
H2O-II

API02
KAPH02 3300 2650
H2O-II 650-700 -50 +100/-50 1000 0.80 0.20

KPH01
H2O-II

PI02
KPH02
H2O-II

CUI02
KCUH02
H25 3000 2450
700-750 -50 +50/-50 1100 0.80 0.20
UI02
KUH02
H25

ALWAYS TRY TO MAINTAIN HIGH END OF SPECIFICATION

TIMING SPECIFICATION FOR LPG MODELS (RECORD ON INSPECTION FORM)

Al (A15) = 10° + 1
ALL MODELS WI H25 = 8°+0,-2
ALL MODELS W1H20-II = 12° +2,-0

9/97 LPG -4
 1011102 LPG SYSTEM
•
RECOMMENDED SAFETY
MAINTENANCE PROCEDURE
Warning: All fuels used in internal combustion engines are flammable and should be treated
with caution. All cigarette smoking and open flames should be prohibited. Sparks should be
avoided. The fuel cylinder should be mounted so that it does not extend outside the truck and
should also be properly positioned by using the locating pin or key way.

The fuel valve should be turned off when the machine is not in service. Cast fittings should not be
used in the LP-GAS system. Use only Underwriters Laboratories or Factory Mutual listed LP-GAS
hose assemblies where pressure fuel lines are required. All pipe threaded fittings should be installed
using an approved sealing compound. Fuel lines should be supported by clamps to minimize
chafing and wear. The LP-GAS solenoid valve should be wired to an automatic shut off switch (oil
pressure or vacuum) to prevent leakage of gas in the event the ignition is on without the engine
. .
runmng.

Check the propane solenoid or vacuum shut off valve for leakage as follows:
1. Turn fuel cylinder valve off, start and run engine until it stops.
2. Install a 0 to 30 PSI pressure gauge per instruction A or B.
A. For propane systems with a single unit consisting of primary and secondary
regulators, install at the primary test port.
B. For propane systems consisting of two separate regulators, install between the
primary and secondary stages.
3. Turn cylinder fuel valve on. The pressure gauge should maintain a zero reading. If it does
not, the solenoid valve or vacuum shut off valve must be repaired or replaced.

An odor is added to LP-GAS to help detect leaks. If the gas odor is detected the fuel cylinder supply
valve and engine should be turned off. Remove all sources of ignition, and ventilate the area. Make
all of the necessary repairs before you turn the fuel supply on.

The complete LP-GAS system should be inspected periodically. Check all hoses for wear,
connections for leaks and all parts for damage.

NOTE: Fuel hoses have a limited life expectancy. They should be checked for cracking and drying
due to age. Hoses with visible signs of age should be replaced. Use only Underwriters Laboratories
or Factory Mutual listed LP-GAS parts for replacements.

NOTE: The above information is provided as a guide. Consult the National Fire Protection
Association pamphlet 58 for the safe storage and handling of liquefied petroleum gases.
Governmental safety regulations in your locality could vary. Check with the authority having
jurisdiction to be sure that you meet all of their requirements. Contact the manufacturer for detailed
service information.

SERVICE WORK SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY

ALTERNATE FUEL SYSTEMS

Arlington Heights, IL 60005-4771 (847) 437-2345 Fax (847) 437-2350

LPG -5 9/97
J011J02 LPG SYSTEM
•
IMPCO FUEL SYSTEM ADJUSTMENT INSTRUCTIONS

1. Be sure that water hoses, fuel hoses, and wires are properly fastened in place. They should
be clear of the exhaust system and sharp objects.
2. The fuel cylinder must be located within the outer limits of the machine.

Check for fuel system leaks

1. Pressurize the fuel system by opening the fuel cylinder hand valve slowly and continue as
follows:

A. Systems with vacuum operated shut off valves such as the Impco VFF30 must have
vacuum applied to the valve to allow fuel to pass through to the convertor (vaporizer-
regulator). This can be done by operating the engine cranking motor.

B. Systems with electrically operated shut off valves must have current to the valve before it
opens and allows fuel to pass through. A vacuum switch or oil pressure switch must be used
as an additional safety and wired in series with he electric solenoid. Acutating either of
these can be done with the cranking motor. It may take more cranking to actuate the oil
pressure switch.

2. Check all of the fuel connections for leaks with an approved leak check solution while the'
system is under LP GAS pressure of not less than 90 psi. All leaks must be replaced.

Before you make any fuel adjustments

1. The air cleaner should be installed.

2. Ignition timing must be checked and adjusted per the engine manufacturer's specifications.
Propane burns slower than gasoline. Retarded timing will reduce horsepower and increase
exhaust emissions. Most manufactures recommend advancing the timing 3 to 5 degrees.
This will increase lower end torque horsepower; however you may experience a loss of power
under extreme heavy load conditions. When machines are worked very hard, be careful not
to advance the timing beyond the manufactures recommendation. This would cause
unnecessary stress on the engine.

3. Converting engines to burn propane may cause the governed engine speed to change. To
maintain the trucks "No Load" and "Light Load" drivability, it may be necessary to reset the
governor to factory specifications. The engine and transmission must be at it's normal
operating temperature prior to making any adjustments.

Power Adjustment
Full power mixtures are controlled by the mixture adjustment at the fuel inlet of the mixer. The fuel
mixer casting is marked with an R & L indicating the full, rich and lean positions of the valve. This
adjustment will control the full load fuel mixture and must be made with the engine under full or
working load.

9/97 LPG -6
 .1011102 LPG SYSTEM
•
IMPCO FUEL SYSTEM ADJUSTMENT INSTRUCTIONS

Idle Adjustment
Turning the screw "IN" will make the fuel mixture richer and turning it "OUT" will make it lean.
This adjustment must be made at the manufactures recommended idle RPM.

We stronl:ly recommend that you use a carbon monoxide fuel analyzer to adjust the fuel
mixture.

Readings using carbon monoxide analyzer

Power Mixture - .5% +/- .25%

Idle Mixture - .5% TO .75%

Readings using air fuel ratio analyzer

Power Setting - 15.5 - 16 TO 1

Idel Setting - 14.5 TO 1

Note: When exhaust analyzers are not available, a tachometer may be used. Make fuel adjustments
to obtain maximum RPM reading. Then lean fuel mixture to lower readings 10-20 RPM.

Periodic Maintenance Schedule

Before delivery of your new forklift, your dealer provides a pre-delivery inspection and adjustment service specified by the factory and
designed to ensure satisfactory performance.

The following tables list the servicing required to keep your forklift operating at peak mechanical condition, and should be attended to as
indicated, preferably by an authorized NISSAN dealer.

Maintenance Operation Maintenance Interval

Periodic maintenance should be performed after specified Months 2 4 5 6 7 8 9 10 II 12
intervals have elapsed in months or hours, whichever comes first.
Hundreds 2 4 6 10 12 14 16 18 20 22 24
of hours

LPG Fuel System

I Check all pressure hoses and pipes for gas leakage with soap & I I
water or approved liquid.
2 Check all pressure hoses and pipes for wear, chafing, and
damage, properly secure,
3 Check mounting brackets for LPG cylinder, damage and proper
adjustment, tank locator pin.
4 Filter for LPG (VFF30) R R R R
5 Regal fittings (tank conneclor) for proper sealing. (see note one) I I I I

6 Test emissions. I I I I
Note: (I) At time of LPG cylinder replacement, inspect pipe connectors for gas leakage with soapy water.
Abbreviations: 1= Inspect. Correct or replace if necessary.
0= Drain. C= Clean. R= Replace.

ALTERNATE FUEL SYSTEMS

Arlington Heights, IL 60005-4771 (847) 437-2345 Fax (847) 437-2350

LPG -7 9/97
J011J02 LPG SYSTEM
•

9/97 LPG -8
 JOIIJQ.2 LPG SYSTEM
•
LPG INSTALLATION FOR
FORKLIFT TRUCKS

MODEL VFF30
FUEL LOCKIFILTER

.-....,
.... ;..
""."AU.
~ ~
\
I
I
r
I
I
I
I
I
I

I
I
I.
I

MODEL J CONVERTER MODEL CA55 CARBURETOR,

LPG-9 9~7
j011j02 LPCi SYSTEM

9/97
 J011J02 LPG SYSTEM

LPG Tank

1. Filler valve 5. Vapor withdrawal tube (if applicable)

2. Pressure relief valve 6. 80% Limiter tube
3. 80% Fill check valve 7. Fuel level float
4. Fuel gauge 8. Liquid withdrawal tube

l"'DEL FROIlI1JEL TAIOt

I"UEL TO IIODICL .I CORVICR1'1I:R

allM

VFF30 Fuel Lock/Filter

The IMPCO LPG carburetion system starts with the filter and the fuellockoff. The model used by
NIEC is the VFF30. The filter/fuellock is vacuum operated. When a slight vacuum is sensed (2"
W.C.), it opens and allows fuel from the tank to flow through a fuel filter and then to the converter.
Any time the engine stops, whether the ignition key is on or off, the fuel is shut off automatically.
Also, it filters and large particles of solid material out of the fuel before they reach the high pressure
side of the converter.

LPG -10 9/97

J011J02 LPG SYSTEM

FUEL FROM VFF30

- COOLANT IN OR OUT

- roEL TO CARBtIRETOR -

COOLANT I1'f OR OUT ----'"

Model J Converter

The IMPCO LPG converter is a combined two-stage regulator and vaporizer. It receives liquid fuel
at tank pressure from the filter/fuellock and then reduces that pressure in two stages to slightly less
than atmospheric pressure. When the engine is cranking or running, a partial vacuum is created in
the fuel line to the carburetor which opens the regulator permitting fuel to flow to the carburetor.

In the process of reducing the pressure from approximately 180 PSI in the tank to atmospheric
pressure, the liquid propane expands to become a vapor, causing refrigeration. To compensate for
this and to assist in vaporization, water from the engine cooling system circulates through a heat
exchanger in the converter. The regulator seals off fuel flow when the engine is stopped. The
IMPCO Model J converter is rated for engines up to 100RP.

JIANDl'OLD SIDE

FUEL FROIlIlODEL J
C01'fVERl&R -

AlRINTAKE

Model 50 Carburetor

The Model 50 carburetor is an air valve design utilizing a relatively constant pressure drop to draw
fuel into the carburetor from cranking up to full speed. This type design requires a "strong signal"
or vacuum to overcome the force applied by metering spring keeping the air valve closed. The
amount of vacuum required to open the valve during cranking is 6" W.e. This amount of vacuum
is also felt at the converter and filter/fuellock to allow fuel flow. With the engine stopped, fuel is
sealed off within the carburetor as well as in the converter and the fuel lock giving a triple seal for
safety.

9/97 LPG-ll
 1011102 LPG SYSTEM

LPG SPECIFICATIONS

Converter:

Secondary spring
Blue - 1 - 1/2 inches negative w.e.
Orange - 1/2 inch negative w.e.
Primary chamber pressure - 1/2 to 1- 1/2 PSI

Carburetor:

Fuel supply - 1/2 to 1 - 1/2 PSI (same as primary chamber of converter).

Air valve - requires 6" negative W.e. to raise from fuel port.

Carburetor Adjustment (Preliminary):

LeanJRich screw - screw in fully. Then, screw out 2 - 1/2 turns.

Power Valve - (See Drawing):

L R

Set pointer at one mark past center on lean side of scale.

Carburetor Adjustment (Final):

1. Install vacuum gauge into intake side of carburetor.

2. Warm engine to operating temperature.
3. Turn lean/rich screw out until engine speed becomes erratic and vacuum gauge fluctuates.
4. Turn lean/rich screw in until engine speed and vacuum gauge stabilize.

LPG -12 9/97

 i,'!fEM'
Regulator Operation Check

This method can be used with either air hose. Gauge should read 1h PSI. The pressure
pressure for bench tasting or LP-gas in field reading does not have to be exact as long as it
testing. All that is needed is a simple pressure remains constant.
testing gauge (such as the fuel pressure gauge 3. If the pressure holds, the primary seal is
illustrated here). sound.
4. Remove or shut off the incoming pressure
Testing Procedure source. If the gauge reading does not drop,
1. Attach the gauge to the primary test port of the secondary seat is not leaking.
the regulator. This procedure completely checks the. operation
2. Pressure the.regulator, and remove pressure of the regulator.

MODEL E CONVERTER

MODEL J CONVERTER
 Model J Repair Kit
Installation Instructions
1 RK-J kit contains all necessary parts to replace com-
ponents subject to deterioration. Installation of complete
kit should be necessary only at time of major overhaul or
when converter has been out of service for some time.
Gaskets and diaphragms deteriorate if converter is stored
after being used.

2 Start disassembly by removing secondary cover assembly

(AC1-34).Take out six S1-59 screws to loosen cover.

3 Break cover loose by tapping with plastic screwdriver

handle.

4 Remove secondary diaphragm assembly (A1-26).

Diaphragm assembly must be moved toward LP-gas inlet
to disengage diaphragm link from the lever assembly.

LPG-14
 MOdel J Repair Kit
Installation Instructions
5 Straight-on view showing lever still engaged in link slot.
Move diaphragm ahead to clear slot.

6 Cover and diaphragm assembly removed.

7 Remove S1-42 screw to disassembly secondary lever from

converter body.

8 Secondary lever assembly and spring (S2-35). Note

locating tabs for spring at each side of lever. These, plus
tab punched through top of lever, position spring correctly
and prevent it from slipping out from under the lever.
 .Vl1.1121SPG
Model J Repair Kit
Installation Instructions
9 Remove primary regulator cover (C1-33), Take out six
81-10 screws to loosen cover,

10 Cover and primary diaphragm assembly (AD1-22) removed,

Note triangular lever riveted to diaphragm, This lever is
supported on the upper side by a fulcrum cast in the
cover, The lever rocks over the fulcrum to depress prirnary
valve pin and spring, Pencil points to sensing port for
pressure regulation,

11 Primary valve pin (P1-14) and primary regulator spring

(82-36), Primary valve is operated by this pin moving
through a boss in the converter body cover plate (P2-26),
This isolates the diaphragm from contact with liquid
propane and prevents diaphragm stiffening due to
refrigeration,

12 Removai of cover plate and gasket (G1-85) shows serrated

vaporizing chamber in body and heat exchange labyrinth
which heats vaporized fuel.
 MddelJ Repair Kit
Installation Instructions
13 Pencil points to aluminum alloy backing of primary
regulator valve (84-16) in place in vaporizing chamber.

14 Remove gasket (G1-85) from converter body cover plate.

15 Viton seat is bonded to aluminum alloy backing of primary

regUlator valve.

16 With gasket (G1-85) in place and converter body cover

plate (P2-26)positioned, insert primary valve pin (P1-14) in
place through the primary regulator spring (82-36).
 01t.0!2/lJ'6-
Model J Repair Kit
Installation Instructions
17 Showing diaphragm assembly (AD1-22), primary regulator
cover (C1-33),and screws (S1-10).Diaphragm lever lifted
to show fulcrum cast in cover over which lever rocks to
operate primary valve pin.

18 With primary regulator cover, diaphragm assembly and

converter body cover plate in place, turn seven S1-10
screws in until they touch the cover, Then tighten screws
from one side to the other until all screws are solidly
tightened.

19 Note that primary regulator cover has cast-in lettering in-

dicating LPG inlet, water inlet and outlet and the primary
pressure check plug. Small orifice below lower leltering is
atmospheric vent to primary diaphragm.

20 Bend or straighten old secondary seat pin and remove old

seat (right). Replace with new secondary regulator seat
(84-17) and secondary seat pin (P1-8).
 Model J Repair Kit
Installa tion Instructions
21 Draw pin through secondary regulator lever assembly
(AD1-26).

22 Draw pin through with enough force to seal the head

against seat, but leave loose enough so seat can tilt for
alignment with the secondary jet.

23 Bend pin as shown to retain seat in place.

24 Clip off excess pin. Completed assembly should be as

illustrated.
----------- -- -- - .-

lOllJ02 LPG SYSTEM

-------------------------
Model J Repair Kit
Installation Instructions
25 S~condary blue spring (S2-35) in place on body. Secondary
regulator lever assembly ready for replacement, attaches
with S1-42 screw. An alternate orange spring (S2-38) is in-
stalled when converter is used with a CA300A mixer or
with another make of venturi carburetor. The orange
spring may be used with an IMPCOcarburetor when the
EC1 device is installed.

26 Shows how secondary spring is located and heid in place

bY tabs on underside of regulator lever.

21 Hold lever assembly with fulcrum pin in place in its

iocating groove, fasten in place by replacing S1-42 screw.

28 Tighten S1-42 screw solidly to retain lever assembly.

Secondary lever should be 1/32" below level of casting.
Use a straight edge or G2-2 gauge.

LPG -20 9/97

 J011J02 LPG SYSTEM ..
Model J Repair Kit
Installation Instructions
29 Secondary diaphragm assembly ready for reassembly.
Place diaphragm link slot over end of lever. Note, gap
from which link is punched should be located toward the
LP-gas inlet. Refer to pictures (4), (5) and (6) for proper
placement.

30 With diaphragm assembly in place, replace secondary

cover assembly using six S1-59 screws.

31 First, tighten screws in until they touch cover.

32 Then tighten solidly, alternating from side to side until all

screws are solidly seate'd.
Use only brass or plastic fittings in the water inlet and
outlet passages. Steel fittings will cause the casting to
deteriorate due to electrolysis.
NOTE: Check completed converter under pressure with
soap suds or testing solution to detect possible leaks.

-----------------------------------~==~
9/97 LPG -21
..
-
 TEM
VFF30 Repair Kit
Installation Instructions
1 Remove 10 screws from "Fuel In" Cover.

2 Remove cover and Gl-89 gasket.

3 Remove FHO filter and screen.

4 Remove Sl-12 screw holding valve spring.

LPG-.22 9197
 VFF30 Repair Kit
Installation Instructions
5 Remove valve spring.

6 Remove 84-18 valve seat.

7 Remove P1.15 valve operating pin.

8 With paper clip or wire, fashion a hook as shown.

9/97 LPG -23

 VFF30 Repair Kit
Installation Instructions
9 Cutaway shows assembly of valve spring, valve seat, valve
operating pin, seal retaining washer and "0" ring seal.
Note that removal of valve pin allows retaining washer to
be removed through the "Fuel Out" (1/4" N.P.T.) opening.

Note: Not in scale. Enlarged for clarity.

10 Insert hook in hole in W1-42 seal retaining washer and

remove.

11 Washer rSlmoved.

12 Same hook tool ready to remove "0" ring seal through

valve jet.
"I

JOlll()2 IJO SYSTEM ..

VFF30 Repair Kit
Installation Instructions
13 Insert tool through jet.

14 Pick out S3-42 "0" ring. Wash body, cover and jet area
clean as needed. (Use kerosene or equivalent petroleum
solvent. Do not Lise carburetor cleaner as it will attack
synthetic rub.ber seals).

15 RK-VFF30Kit Includes:
1 G1-89 •Gasket
1 F1-10 Filter
1 87-3 8creen
1 8D1-26 Diaphragm Assy.
2 81'59 Screws, 8-32 x 5/8"
2 S1-19 Screws, 12-24 x 5/8"
1 84-18 Seat (Vitor) Bonded to Aluminum)
1 S3-42 Seal, "0" Ring
1 PHS, Pin.Valve Operating

16 To reassemble valve parts, place new "0" ring seal on jet

as shown. "0" ring should be coated with silicone grease
or equivalent to prevent friction against valve pin .

.......... , .......... J, ....'1 ------------------""r"'--~-~--- ....

_... ll,~_'' ' '. __

9/97 LPG~25
 VFF30 Repair Kit
Installation Instructions
Using one of 81-19screws, press "0" ring down into its
17 recess. Rotate Screw head ina circular motion while
pressing down to ease "0" ring into position.

With "0" ring in place in its recess, use needle nose pliers
18 to hold W1-42 seal retainer washer.

Insert seal retainer washer in slot to hold "0" ring in

19 place.

20 Insertion of PH5 valve operating pin will retain washer

and "0" ring in place.

LPG-26 9/97
•

J011J02 LPG SYSTEM ...

VFF30 Repair Kit
Installation Instructions
21 Insert pin, lubricated with silicone grease, through hole in •
retainer washer and "0" ring. Again rotate head of pin ,
'gently in a circular motion to ease pin into place through
washer, "0" ring and body housing.

22 Shows P1-15 valve operating pin in place in valve jet.

23 Valve seat shown with aluminum side up ready to be

placed on jet.

24 Seat, viton (rubber) side down, in position on jet.

9/97 LPG -27

 VFF30 Repair Kit
Installation Instructions
25 S2-40 spring ready to be fastened in place.

26 Spring fastened in place by 81-12 screw (8-32 x 5/16"). In

tightening screw, hold tip of spring (over valve) centered
between the 3 guide fins as shown here to avoid friction.

27 With spring in place, lift it slightly to assure freedom of

travel.

28 Insert 87-3 screen in recess as shown.

LPG-28 9/97
 VFF30 Repair Kit
Installation Instructions
29 Insert F1-1O filter in recess over screen,

30 Plac<;! G1-89 gasket in place, Align with screw holes,

31 With 2 opposite screws in "Fuel In" cover, lower cover on

to gasket and start two screws in their threads,

32 After examining position of gasket through remaining open

holes to .insure correct alignment, insert remaining 8
screws in their openings,
 VFF30 Repair Kit
Installationl nstructions
33 Tighten screws, alternating from side to side on opposite
sides of the caVer until all screws are solidly .set

34 Fully loosen 6 screws on diaphragm cover side as shown.

35 Remove cover and diaphragm assy.

36 Clean parts as necessary. (See instructions in step 14 for

cleaning.) Check lever for free travel and check P1-11lever
control. pin to see thatit follows lever travel. Prepare to in-
stall new diaphragm assembly with plate marked "This
Side Down" toward the lever. This plate is steel, the upper
plate is aluminum.
 VFF30 Repair Kit
Installation Instructions
37 Turn diaphragm to position where Its screw hole pattern
matches holes in body. There is oi1ly one position In Which
the holes will line up.

38 Place cover in correct position.

39 Tighten screws alternately from side to side across cover

until all are solidly fastened. Pressurize the "Fuel In"
opening with air or fuel. Check fuel outlet and fuel Inlet
cover gasket for leaks with soap suds or testing solution.

s J

9/97 LPG -31

,'EM
Model CA50 Repair Kit
InstaUation Instructions
1 With carburetor removed from engine, remove 4 screws
(81-3) holding throttle body to mixer bowl.

2 With throttle body removed, note that gasket retains idle

cutoff piston in place (under finger tip).

3 Remove gasket. Idle cutoff piston and spring are released.

Do not lose either one.

4 Remove check valve plate and air valve spring. Lift air/gas
valve from mixer bowl.
 .iBM!
Model CA50 Repair Kit
Installation Instructions
5 Clean mixer bowl assembly in kerosene or equivalent
petroleum solvent. Do not use carburetor cleaner as it will
attack synthetic rubber seals.

6 RK-CA50 KIT INCLUDES:

1 AVH8 Air-Gas Valve Assy.
1 R1-23 Ring, Sealing
1 AP2-32 Plate, Check Valve
1 G1-92 Gasket, TB to Mixer
4 S1-3 Screw. 10-24 x 5/8"
1 P4-1 Piston, Idle cutoff
1 S2-44 Spring, ,Idle cutoff

7 Install sealing ring in piston groove. Install one end in

groove and coax the ring in spirally to avoid breaking or
creasing the ring.

8 Replace air/gas valve assembly in mixer bowl. Tilt valve

slightly to Insert one end of the split sealing ring irtto.the
cylinder of the bowl. Then, using pencil lead or similar
point. slide around circumference of sealing ring pressing
it in until ring and assembly drop Into the bowl.

\1. 6

9/97 LPG -33

Model CA50 Repair
Installation Instructions
9 Replace atrlvalve spring and check valve plate tn the
mixer bowl.

10 Shows mixer bowl assembled with check valve assembly

centered towards air horn. The idle cutoff piston and
spring are shown in place ready for assembly to the mixer
bowl.

11 Gasket in place retaining id.lecutoff piston in its recess

(under thumb).

12 Invert throttle body, holding gasket and idle cutoff piston in

place. Note cutout of gasket to clear check valve
assembly on plate.

LPG -34 J)197

 U'
Model CA50 Repair Kit
Installation Inst ructions
13 Lower throttle body gently onto mixer bowl making sure
idle cutoff pistondO/ilS not escape from its recess. With
throttle body flush on the mixer bowl, align the holes and
start the 4 screws.

14 Tighteh 4 screws.

15 With assembly completed, reach a forefinger ihto the car-

buretor air horn and lift air valve several times to check
free movement. Air valve should lift easily and return
slowly due to actiOh of check valve.

IFJL ..•... J
;1 Hi. JHI ..• t,,: -r-"

9/97 LPG-35
 J011/02 LPG SYSTeM
•
WARNING SWITCH ADJUSTMENT
SWING STYLE LPG TANK MOUNT (U.S. PRODUCED)
Opetatioll

The WARNING SWlTCHfunctipn is to energize or de~energize a. \V~ing light locat;ed in the truck
dashboard.

The purpose of the waminglight is toinfonnthe truck operator when the LPG Tank Swing Bracket
Assembly is in the LOCKED or UNLOCKED position.

WARNING LIGHT 'OFF" INDICATES LOCKED POSITION.

WARNING LIGHT "ON" INDICATES UNLOCKED POSITION.

WARNING SWITCH

LPG-36 9/97
J01IJ02 ..LPG.SYSTlM_ _ _
•
\VARNlNGSWITCH ADJUSTMENT
SWING STYLE LPG TANK MOUNT(U .S. PRODUCED)

Adjust11lents

L Ensurelatph pin is funyengaged and thatthe swing bracket assembly cannot move.

2. Loosen two (2) latch assembly mounting bolts.

3. Move latch assembly so thatswingroneractuatorisa.gainst the swing bracket assembly and

turns the WARNING LIGHT "OFF", Torque the mounting bolts 16-20 ftIlbs.

MQUNTtNGBOL.TSfZ)

L.ATCH ASSEMBL.Y

SWING BRACKET
ASSEMBL.Y

9/97 LPG-37
 JOIIJ02-LPOSYSTEM -
• •
W ARNING.SWITCH.ADJUSTMENT
SWING STYLE LPG TANK MOUNT (U.S. PRODUCED)

Adjustments (cont.)

4. Release latch and move swing bracket assembly rearw3J."d.. Check that the WARNlNG
LIGHT goes "ON" as the swing bracket assembly moves from LOCKED position.

5. Move swing bracket assembly to LOCKED position. Check that WARNING LIGHT goes
"OFF" as latch engages ..

6. Ifcheck procedure in items 4 & 5DO NOT give required results,repeatWARNING

SWITCH adjustments using items 1,2, & 3.

7. If check procedure in items 4 & 5 DO give required results, the WARNING SWITCH is
properly adjusted.

LPG ..38 9/97

/011/02 LPG SYSTEM
•

9/97
 .]01Ij02 LPG SYSTEM
•

BUMPERADIDSTMENT

Purpose an.d Operation

Thebllnlper isa STOP" ..to limit fotWardroovement of the swingbracketasseIIlblypast the lo.ck
II

p<:>s~tion
...The bumpe~ compresses (wbenswing bracket assembly is.closed) to elinrinate looseness. in
LOCKED. p(>$ition.

SWING BRACKET
ASSEMBLY

LOCKNUT

SWITCH HOUSfNG

Adjustment:
Note: This/:JIimpet adjustmentis not required unless factory bumpera4justmentis disturbed.

1. Move swing bracket assembly to UNLOCKED

position and loosen bumper locknut.

2. Rotate bumper clockwise against the

bumper bracket.

LPG-39 9/97
J011J02 LPG SYSTEM
•
BUMPER ADJUSTMENT

Purpose and Operation (cont.)

3. Move swing bracket assembly to LOCKED position and

rotate bumper counterclockwise until contact with
switch housing.

4. Move swing bracket assembly to UNLOCKED position and

rotate bumper counterclockwise to extend the distance
an additional (1-2mm) from the bumper bracket.

5. Torque locknut 9-11 ft/lbs.

6. Move swing bracket assembly to LOCKED position and check adjustment. Slight
compression of bumper and no looseness of swing bracket assembly indicates proper
adjustment.

9/97 LPG-40