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ep R Series Service Manual
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ep R Series Service Manual

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CPQD15/18N-RW21-Y
CPQD20/25/30/35N-RW22A-Y CPQD20/25/30/35N-RW22B-Y
SERVICE MANUAL
CPQD20/25/30/35N-RW22-Y
1.5-3.5T R Series of LPG Forklift
（USA IMPCO Combustion System）
（ITALY BRC Combustion System）
&
PARTS LIST
E - P E q u i p m e n t
2008.03
1st EDITION

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Summary of Contents for ep R Series

  • Page 1 CPQD15/18N-RW21-Y CPQD20/25/30/35N-RW22-Y CPQD20/25/30/35N-RW22A-Y CPQD20/25/30/35N-RW22B-Y 1.5-3.5T R Series of LPG Forklift （USA IMPCO Combustion System） （ITALY BRC Combustion System） SERVICE MANUAL & PARTS LIST E - P E q u i p m e n t 2008.03 1st EDITION...

  • Page 2: Foreword

    IMPCO single-fuel(USA) CPQD20/25/30/35N-RW22B-Y3 This series of LPG forklift is an advanced model of R series forklift. A set of LPG fuel system has been adopted，which makes it possible to take both petrol and LPG as fuel. This service manual is about structure，principle，performance and characteristic of LPG forklift and its fuel system ，...

  • Page 3: Table Of Contents

    Content FOREWORD..............................1 1 Parameter................................ 3 2 Operation.................................7 3. Fuel system parts catalog and maintenance manual..................8 4. Notice................................46...

  • Page 4: Parameter

    1 Parameter 1.5~1.8t R series LPG forklift specification CPQD15N-RW21-Y CPQD18N-RW21-Y Model USA IMPCO Dual-Fuel Single-Fuel Dual-Fuel Single-Fuel Combustion Combustion system (Y3) (Y3) system （Y2） （Y2） ITALY BRC Dual-Fuel Single-Fuel Dual-Fuel Single-Fuel configuration Combustion system (Y1) (Y1) （Y0） （Y0） Rated capacity Kg...
  • Page 5 2~3.5t R series LPG forklift specification CPQD20N –RW22-Y CPQD25N- RW22-Y CPQD30N –RW22-Y CPQD35N –RW22-Y Model IMPCO Dual-Fuel Dual-Fuel Single-Fuel Dual-Fuel Single-Fuel Dual-Fuel Single-Fuel Single-Fuel (Y3) Combusti (Y3) (Y3) (Y3) （Y2） （Y2） （Y2） （Y2） Combustion on system system ITALY configuration Dual-Fuel...
  • Page 6 Model CPQD20N-RW22A-Y CPQD25N-RW22A-Y CPQD30N-RW22A-Y CPQD35N-RW22A-Y Dual-Fuel Dual-Fuel Dual-Fuel Dual-Fuel IMPCO Single-Fuel Single-Fuel Single-Fuel Single-Fuel （Y2） （Y2） （Y2） （Y2） Combustion (Y3) (Y3) (Y3) (Y3) Combustion system system ITALY Dual-Fuel Dual-Fuel Dual-Fuel Dual-Fuel configuration Single-Fuel Single-Fuel Single-Fuel Single-Fuel （Y0） （Y0） （Y0） （Y0） Combustion (Y1) (Y1)
  • Page 7 Model CPQD20N-RW22B-Y CPQD25N-RW22B-Y CPQD30N-RW22B-Y CPQD35N-RW22B-Y Combustion Dual-Fuel Dual-Fuel Dual-Fuel Dual-Fuel Single-Fuel Single-Fuel Single-Fuel Single-Fuel system （Y2） （Y2） （Y2） （Y2） (Y3) (Y3) (Y3) (Y3) configuration Rated capacity 2000 2500 3000 3500 Load center mm Max lift height 3000 3000 3000 3000 Free lift height Max lift speed mm/s...

  • Page 8: Operation

    2 Operation LPG fuel system consists of LPG cylinder, petrol solenoid valve ， LPG solenoid valve with filter, LPG vaporizer， adapter， LPG-petrol select switch and level indication. passing through the combination valve, the high-pressured pipe, the filter，and the solenoid valve in sequence，enters the LPG vaporizer to vaporize， then mix with air in certain proportion in the adapter, and combust in the engine cylinder to drive the forklift truck to work 1.

  • Page 9: Fuel System Parts Catalog And Maintenance Manual

    a. Change from LPG to petrol: Switch the select switch from GAS position to PET position directly, then the engine use the petrol as fuel instead of LPG. b. Change from petrol to LPG Switch the select switch from the petrol position to the neutral position, when the petrol in the Carburetor nearly finished, and the engine speed decline, then select the switch to the LPG position swiftly, and the engine use the LPG as fuel.
  • Page 10 DK-02001 BULKHEAD FITTING DK-02002 HYDROSTATIC RELIEF VALVE 400PSI DK-02003 LOCKWASHER Star,7/8" DK-02004 NUT 7/8" DK-02005 BUCKHEAD OUTLET FITTING 3/8" SAE FLARE X 1/4"NPT X45° DK-02006 PLASTIC CAP DK-02007 BULKHEAD INLET FITTING 3/8" SAE FLARE X 1/4"NPT 6-12 installed together DK-03001 GASOLINE SOLENOID VALVE DK-03002 SOLENOID INLET FITTING 1/4"SAE FLARE X 1/4"NPT X 90°...
  • Page 11 DK-05003 CRANKCASE VENTILATION HOSE FITTING 1/2" HOSE X 1/8 NPT DK-05004 CRANKCASE VENTILATION HOSE 1/2" ID HOSE X 400mm DK-05005 VACUUM SIGNAL HOSE 1/4" ID HOSE X 60mm DK-05006 MIXER LPG INLET FITTING 5/8" ID HOSE X 3/8 NPT X 90° DK-05007 VACUUM FITTING 1/4"...
  • Page 12 DK-04016 WATER RETURN HOSE 10mm ID HOSE, 600mm DK-04017 WATER HOSE CLAMP 10-18mm DK-04018 REGULATOR LPG OUTLET FITTING 5/8" ID HOSE X 1/2" NPT X 90° DK-04019 LPG INLET HOSE 5/8" ID HOSE X 850mm DK-04020 CLAMP 14-27mm SK-04021 ASSY's BRACKET DK-04022 BOLT 1/4"-20 X 3/4"...
  • Page 13 3. Combustion system main parts illustration CONNECTION ITEM PART No NAME LINE BRACKET-FUEL DK-01001 HOSE HOLDER COUPLING-MALE TANK DK-01002 CONNECTION COUPLING-FEMALE TANK DK-01003 CONNECTION CONVERSION DK-01004 FITTING LPG HOSE ASSY DK-01005 BULKHEAD ITEM PART No NAME BULKHEAD DK-02001 FITTING HYDROSTATIC DK-02002 RELIEF VALVE DK-02003...
  • Page 14 CONVERSION DK-03004 FITTING DFK8634A DUAL-FUEL FILTERLOCK-REGULATOR ASSY ITEM PART No NAME ITEM PART No NAME THERMOSTATE WATER 31 DK-04015 DK-04002 AUXILIARY FUEL LINT OUTLET FITTING 32 DK-04016 DK-04003 FILTERLOCK INLET FITTING WATER RETURN HOSE 33 DK-04017 DK-04004 FILTERLOCK WATER HOSE CLAMP REGULATOR LPG OUTLET DK-04005 VACUUM FITTING...
  • Page 15 38 DK-04022 DK-04009 LPG SOLENOID VALVE BOLT LPGSOLENOIDVALVEOUELET DK-04010 39 DK-04023 FLATWASHER FITTING 40 DK-04024 DK-04011 REGULATOR INLET FITTING LOCKWASHER REGULATOR WATER INLET 41 DK-04025 DK-04012 REGULATOR FITTING REGULATORWATEROUTLET DK-04013 42 DK-04026 WATER SUPPLY HOSE FITTING DK-04014 THERMOSTATE DFK8634A DUAL-FUEL ITEM PART No NAME...
  • Page 16 K8634A SINGLE-FUEL FILTERLOCK-REGULATOR ASSY DK-04002 AUXILIARY FUEL LINT DK-04016 WATER RETURN HOSE DK-04003 FILTERLOCK INLET FITTING DK-04017 WATER HOSE CLAMP REGULATOR LPG OUTLET DK-04004 FILTERLOCK DK-04018 FITTING DK-04005 VACUUM FITTING DK-04019 LPG INLET HOSE DK-04006 FILTERLOCK OUTLET FITTING DK-04020 CLAMP SK-04007 TUBE ASSY DK-04021...
  • Page 17 K8634A SINGLE-FUEL ITEM PART No NAME CARBURETOR SK-05001 MIXER IDLE ADJUSTMENT SK-05002 SCREW MIXER LPG SK-05003 INLET FITTING VACUUM SK-05004 FITTING VACUUM DK-05005 SIGNAL HOSE SK-05006 GASKET THROTTLE LEVER SK-05007 BRACKET CONVERSION SK-05008 FLANGE RETURN SK-05009 SPRING SK-05010 DASHPOT CABLE SK-05011 BRACKET OTHERS...
  • Page 18 4. VFF30-2 Filterlock disassembly and assembly flow Do not use the TELFON screw thread instead of NPT type, where the fuel pass through. Use suds inspect all joints, fuel tank and covers. Using the correct bolt to ensure the safety of lock valve, longer bolt may lead to serious damage. G1-89 gasket AF1-10...
  • Page 19 Remove the cover and the gasket Remove the filter and screen Remove screw holding spring in p...
  • Page 20 Remove the valve spring Remove valve seat Remove valve operating pin...
  • Page 21 Using a bent paper clip or wire, fashion a hook as shown Cut way show the relationship of valve spring, valve seat, valve operating pin, seal retaining washer and O-ring. Note that removal of valve pin allows retaining washer to removed through the "Fuel out"(1/4"...
  • Page 22 !-Pull the retaining washer out of th body through the jet hole Using the same hook/wire, pull the o- ring seal through the hole in the body from which you removed the valve operating pin in step-7.wash body, cove and jet area as needed, using kerosene or equivalent petroleum solvent.
  • Page 23 Place the body with the filter side up, as shown. With the o-ring lip seal in the holder, groove visible and facing up, slide the holder into the body, look through the Fuel in port to check the position of seal, above the cavity of the seal recess(see cut way, step 10).
  • Page 24 Use needle nose pilers to insert seal retainer washer through the fuel in threaded port. Again refer to cut way drawing,step-10 Lubricate valve operating pin with silicone grease and insert in body as shown, so that pin passes through retainer washer and o-ring lip seal. Rotate pin showly to ease passage through washer and o-ring Place valve seat on top of head of...
  • Page 25 Add valve spring and secure with screw. Lift the spring slightly to confirm its freedom of movement. Insert screen and filter...
  • Page 26 Place gasket on body and align with screw holes Add filter cover and secure with screws, alternate side to another side. Remove diaphragm cover retaining screws.
  • Page 27 Cover and diaphragm are removed, clean parts as necessary, using only kerosene or equivalent petroleum solvent, Do NOT use carburetor cleaner Check valve operating lever for freedom of movement. Use silicone grease to coat the surface of the gasket. Which will contact the body.
  • Page 28 Add cover and secure with screws...
  • Page 29 5. COBRA-30177 Regulator disassembly and assembly flow The Rk-J kit contains all parts required for perodic service. In installation of complete kit should be required only at time of a major overhual of the converter, or the converter has been out of service for 30 days.
  • Page 30 Remove the secondary cover and secondary diaphragm as a unit.Note the seconday lever protruding through the metal tab slot of the secondary diaphragm. Slide the conver and diaphragm toward the gas inlet to free the lever from the slotted tab of the diaphragm.
  • Page 31 Turn the converter over. Remove the seven screws(S1-15265-005) and lift off the primary cover. Remove the primary diaphragm The triangular lever riveted to the diaphragm pivots on a fulcrum cast into the cover. The pivoting of the lever depresses the control gas flow. The pen points to the sensing port for pressure regulation Remove the primary valve pin...
  • Page 32 Remove the cover plate and the gasket Remove the gasket from the cover plate. Clean cover plate as needed to ensure a good seal with a new gasket The pen points to the aluminum alloy backing of the primary regulator valve in the vaporizing chamber.
  • Page 33 Remove the primay regulator valve. Note: remove oil and foreign deposit from all chambers and parts. Do not apply liquid cleaners to the diaphragms and neoprene faced valves. Inspect seat for wear or cuts. If the primary seat is worn or damaged, the regulator is not rebuildable and must be replaced Install new primary regulator valve...
  • Page 34 Place the cover plate and gasket on to the converter body and align the cover screw holes. Insert the primary valve pin the through the spring and into the cover plate. Insert the new primary valve pin through the previously removed spring and then into cover plate.
  • Page 35 Carefully place the primary cover over the diaphragm. hand-thread the screws through the cover and cover plate into the converter body. Tighten the screws to 37 in.lbs(4.18 N.m) minimum, using a crisscross pattern. Remove the old secondary seat and snap the new seat into the opening of the lever, Be sure the new seat snap-locks into place...
  • Page 36 Position the secondary spring in place on the body. Place the secondary lever assembly into place over the spring. Hold the lever assmebly with the fulcrum pin in place in its locating groove and fasten in place with screw(S1-17460-001) Tighten the screw to 32 in.lbs(3.62 N.m) minimum...
  • Page 37 The secondary lever should be 1/32" below the level of the body. Use a straight edge or tool G2-2 to measure. Gently bend the lever if necessary to obtain the correct height. Be careful not to apply excessive force to the secondary seat.
  • Page 38 Tighten the screws in a crisscross pattern to 29 in.lbs.(3.29 N.m) minmum. To complete the installation of the repair kit components.
  • Page 39 （二） 、BRC Combustion system There are two kinds of BRC conversion kit. 1)、LPG dual-fuel conversion kit 2)、LPG single-fuel conversion kit Manuals are divided into parts list, and main parts disassembly and assembly, refer to the contents. Content BRC Dual-fuel, single-fuel parts list LPG Solenoid valve maintenance BRC AT90 E Regulator adjustor maintenance Compared BRC single-fuel with dual-fuel, the difference is...
  • Page 40 BRC dual-fuel system BRC single-fuel system（No serial number 27,28,29,30）...
  • Page 41 PART No NAME REMARKS Q’ TY SERIES GB93-87 Washer 6 GB5783-86 Bolt M6×25 GB6170-86 Nut M6 BRC-01RD00403004 LPG vaporizer BRC AT90 E TERL2.5-102-G00 Brass seal ringφ6 TERL2.5-103-G00 Fasten pipe fittingφ6 GB1527-87 Out let brass pipeφ6×1 L=450 BRC-03EV00100001 （LPG）solenoid valve BRC ET98 GB6170-86 Nut M5 GB5783-86...
  • Page 42 PART No NAME Q’ TY REMARKS SERIES Low Working Pressure Hose JISK6347-25-G00 L=100 n16Dn25 BK25-G00 Clampφ25-40 JiaxingTaishan JiaxingTaishan PV-10-G00 Petrol solenoid valve PSV3.0 single-fuel none TERL2.5-5A-101B-G00 Single-fuel none Oil resistant rubber hose 5 × GB1054-89 Single-fuel none 3-2A BK8-G00 Clampφ8-12 Single-fuel none...
  • Page 43 2． ET98 solenoid maintenance Before overhauling the LPGET98 solenoid valve, be sure that the tank gas flow is interrupted by closing a cock or another solenoid valve. By dismounting the solenoid valve the LPG contained in the pipe between the tank interception element and the solenoid valve is liberated in the environment.
  • Page 44 The basin fixing nut must be tightened by a 18 Nm torque. If necessary disconnect the copper pipes from the solenoid valve and re-use them tightening them by a 16 Nm torque. 3．Instructions for the overhauling of BRC AT90E-AT90E Turbo reducer DISASSEMBLING Steps: 1 - Disassembly the II°stage back cover (5).
  • Page 45 2 - Remount the idle adjusting screw (36a). 3 - Mount the I°stage lever (14). 4 - Mount the diaphragm (10b) and the cover (7a) by securing it with the screws (4) ha- ving care to execute an intercrossed tightening with a torque wrench of 2,5 N°§m. 5 - Position the spring (9) and secure it through the washer (8).
  • Page 46 . Cylinder and its bracket assembly catalog list (IMPCO and BRC) 1．Cylinder bracket assembly PART No Q’ TY REMARTKS NAME SERIES No. Cylinder support N051-371100-000 1．5-1．8T base Cylinder support N171-371100-000 2-3．5T base N171-371001-000 GB894.1-86 Retainer ring 8 N171-371200-000 Bracket(top) N171-371300-000 Buckle N171-371002-000 N171-371400-000...

  • Page 47: Notice

    2 Cylinder assembly PART No NAME Q’ REMARKS SERIES CYSW314-35-2.2-G00 Cylinder 1．5-1．8T CYSW314-50-2.2-G00 Cylinder 2-3．5T GB1527-87 Liquid brass pipeφ8×1 L=270 TERL2.5-7-104-G00 Fasten pipe nut 8 Jiaxingtaishan TERL2.5-7-105-G00 Brass seal ring 8 Jiaxingtaishan TERL2.5-8-G00 Filling mouth Jiaxingtaishan GB93-87 Washer 8 GB5783-86 Bolt M8×20 GB6170-86 Nut M8...
  • Page 48 5． Shut off power and all valves after the truck is garaged 。 Keep good ventilation and extinguishing measure in the garage。 6． Never repair the LPG cylinder，valves or pipes at garages or parking lots，any smoke on the truck。 Notice: Details of other systems refer to OPERATION AND MAINTENANCE MANUAL and SERVICE MANUAL of 1-3.5t R series.
  • Page 49 List1 technique parameter of LPG special for vehicle Quality parameter Mixture of propane and Item component com position Trial propane for vehicle butane for vehicle According to 37.8 C vapour (indication) kPa 1430 ≤1430 GB/T6602 ） propane — ≥60 Butane and advanced ≤2.5 —...

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