Product Safety Report: LPG-Powered Lift Trucks
Product Safety Reports for LPG-Powered Industrial Lift Trucks presenting a risk of fire.
Summary
Product: Three brands of Liquefied Petroleum Gas (LPG) powered industrial lift trucks fitted with the IMPCO C-Series vaporiser manufactured by EControls BV installed as part of the trucks fuel system. Other LPG powered vehicles fitted with the IMPCO C-Series vaporiser as originally supplied or as a replacement part may also be affected.
Hazard: Although these trucks had operated for many years without issue a change in the composition of LPG fuel which has been distributed in some regions of Great Britain has resulted in a risk of fire in certain conditions due to the design of the IMPCO C-Series vaporisers. The products present a risk of fire because the particular design of the IMPCO C-Series vaporiser means a build-up of deposits caused by some LPG fuel can lead to sticking valves resulting in the fuel mixture supplied to the engine being too rich to be ignited. Repeated starting attempts can then result in a risk of fire.
Corrective action: The manufacturers have contacted owners and suppliers of affected lift trucks to warn them of the risks and provide guidance. A corrective action program was initiated to modify the LPG fuel systems of affected lift trucks to reduce the risk. The IMPCO C-Series (Part Number: MD-54231-001) is no longer fitted to new trucks produced by these manufacturers but is still available from spare parts suppliers. A modified design IMPCO C-Series vaporiser (Part Number: MD-54231-011) is now available and recommended for use as a replacement part.
Product information
| PSD Number | Brand Name | Model Numbers | Link to Product Image and PDF |
|---|---|---|---|
| 2305-0163 | Linde Material Handling | 391, 392, 393, 394 and 396 (serial numbers in attached PDF) | |
| 2306-0002 | STILL | RX70 Series (serial numbers in attached PDF) | |
| 2306-0003 | Jungheinrich | TFG 316s, TFG 320s, TFG 425s, TFG 430s, and TFG 435s (serial numbers in attached PDF) |
Hazard
Owners, users and other persons supplying, inspecting and maintaining these LPG powered vehicles are being alerted to the risk of fire when presented with a non-starting engine.
A build-up of deposits in fuel systems, in particular the vaporiser units, of some LPG powered vehicles has led to several fires. Deposits in vaporiser units, flow regulators and shut off valves are also causing trucks to fail to start, particularly from cold. The cause of these deposits appears to be related to variation in the composition of LPG fuel now available in some regions of Great Britain.
The models and serial numbers listed in the attached Product Safety Reports, manufactured by Linde Material Handling, STILL and Jungheinrich are known to have been fitted with the IMPCO C-Series vaporiser (Part Number: MD-54231-001) in their fuel systems, which are particularly affected.
Any other industrial lift truck or other LPG powered vehicle fitted with the IMPCO C-Series vaporisers (Part Number: MD-54231-001) manufactured by EControls Europe BV, either as originally supplied or as a replacement part, may also now be affected.
The particular design of the IMPCO C-Series vaporiser means that the build-up of fuel deposits can lead to sticking valves resulting in the fuel mixture supplied to the engine being too rich to be ignited. Repeated starting attempts can then result in the release of unburned LPG, which in extreme cases can be ignited setting fire to the vehicle and surrounding materials.
Corrective action
The manufacturers of the listed lift truck models have contacted owners and suppliers to warn them of the risks and provide guidance on how to reduce and mitigate risks.
The manufacturers listed above initiated voluntary corrective action programmes to modify the fuel systems of affected lift trucks to reduce the risk, prioritising users worse affected by vaporiser contamination issues. For details on the corrective action undertaken by each of the manufacturers, please access the Product Safety Reports linked above.
IMPCO C-Series vaporisers with the Part Number MD-54231-001 are no longer fitted as new by these manufacturers. A modified IMPCO C-Series vaporiser (Part Number: MD-54231-011) is now available and is recommended for use as a replacement part. Where heavy fuel deposits are experienced IMPCO recommend continued use of a secondary stage pressure switch of the type installed by manufacturers as part of their fuel system modification action programme.
Owners and users of any other LPG powered lift truck or vehicle fitted with a IMPCO C-Series vaporiser (Part Number MD-54231-001) as originally supplied or as a replacement part should contact the manufacturer or supplier for advice.
Owners and users of other makes and models of LPG-powered lift trucks and vehicles incorporating other vaporiser designs may also experience problems due to LPG fuel composition and should take note of the general advice given.
The Health and Safety Executive (HSE) has also issued a safety notice informing users and persons supplying, inspecting and maintaining LPG powered vehicles of the risk of fire in certain conditions and measures to take.
This can be accessed from:
LPG forklift truck fire risk - Safety Bulletin - HSE
Additional information
Notified by: Health and Safety Executive