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CPQD15/18N-RW21-Y CPQD20/25/30/35N-RW22-YCPQD20/25/30/35N-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 Equ i pmen t
2008.03 1st EDITION
1
FOREWORD
Thanks for your purchasing EP forklift.1.5-3.5T R Series LPG trucks use Japan Nissan gasoline engine. There are 4 types of combustion
system, respectively, BRC dual-fuel (Italy), BRC single-fuel (Italy), IMPCO dual-fuel(USA), and IMPCOsingle-fuel(USA), in this manual, they are distinguished by Y0, Y1,Y2,Y3. Details are shown in table below.
1.5-1.8T R Series LPG forkliftProduct Code Configuration Manuals CodeCPQD15/18N-RW21-Y BRC dual-fuel(Italy) CPQD15/18N-RW21-Y0
BRC single-fuel(Italy) CPQD15/18N-RW21-Y1IMPCO dual-fuel (USA) CPQD15/18N-RW21-Y2IMPCO single-fuel(USA) CPQD15/18N-RW21-Y3
2-3.5T R Series LPG forkliftProduct Code Configuration Manuals CodeCPQD20/25/30/35N-RW22-Y BRC dual-fuel(Italy) CPQD20/25/30/35N-RW22-Y0
BRC single-fuel(Italy) CPQD20/25/30/35N-RW22-Y1IMPCO dual-fuel (USA) CPQD20/25/30/35N-RW22-Y2IMPCO single-fuel(USA) CPQD20/25/30/35N-RW22-Y3
CPQD20/25/30/35N-RW22A-Y BRC dual-fuel(Italy) CPQD20/25/30/35N-RW22A-Y0BRC single-fuel(Italy) CPQD20/25/30/35N-RW22A-Y1IMPCO dual-fuel (USA) CPQD20/25/30/35N-RW22A-Y2IMPCO single-fuel(USA) CPQD20/25/30/35N-RW22A-Y3
CPQD20/25/30/35N-RW22B-Y BRC dual-fuel(Italy) CPQD20/25/30/35N-RW22B-Y0BRC single-fuel(Italy) CPQD20/25/30/35N-RW22B-Y1IMPCO dual-fuel (USA) CPQD20/25/30/35N-RW22B-Y2IMPCO 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 fuelsystem 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 LPGforklift and its fuel system， as well as its operation and maintenance, OPERATION ANDMAINTENANCE MANUAL and SERVICE MANUAL of 1-3.5t R series are also concerned. All thepersonnel in charge of operation，maintenance and management should read all these threemanuals completely.
Owing to continuous update and improvement，thereis maybe something different between the explanationsin this manual and the forklift in your hand.
○C 2008.03 1st EDITION E-P Equ i pmen t
.
2
Content
FOREWORD..................................................................................................................................................... 1
1 Parameter........................................................................................................................................................ 3
2 Operation.........................................................................................................................................................7
3. Fuel system parts catalog and maintenance manual......................................................................................8
4. Notice...........................................................................................................................................................46
3
1 Parameter
1.5~1.8t R series LPG forklift specification
Model CPQD15N-RW21-Y CPQD18N-RW21-YCombustionsystem
configuration
USA IMPCOCombustion system
Dual-Fuel（Y2）
Single-Fuel(Y3)
Dual-Fuel（Y2）
Single-Fuel(Y3)
ITALYBRCCombustion system
Dual-Fuel（Y0）
Single-Fuel(Y1)
Dual-Fuel（Y0）
Single-Fuel(Y1)
Rated capacity Kg 1500 1800
Load center mm 500 500
Max lift height mm 3000 3000
Free lift height mm 155 155
Max lift speed mm/s 500 500
Mast tilt range (F/R) 6°/12° 6°/12°
Max speed(Unload) Km/h 15 15
Min ground clearance mm 115 115
Turning radius (Out side) mm 1970 2000
Max gradeability % 20 20
Wheel base mm 1400 1400
Track（F/R）mm 890/900 890/900
Self weight Kg 2690 2880
Dimension
（L×W×T）（include forks）
3185×1080×2110 3222×1080×2110
Tires（F/R）6.5-10-10PR/2
5.00-8-8PR/2
6.5-10-10PR/2
5.00-8-8PR/2
Voltage V/Capacity Ah 12/60/20h 12/60/20h
Gasoline
Engine
Model NISSAN K21
Rated power/rpm 31.2 KW /2250rpm
Max torque/rpm 143.7Nm/1600 rpm
displacement cc 1980
4
2~3.5t R series LPG forklift specification
Model CPQD20N –RW22-Y CPQD25N- RW22-Y CPQD30N –RW22-Y CPQD35N –RW22-Y
Combustionsystem
configuration
USAIMPCOCombustion system
Dual-Fuel（Y2）
Single-Fuel (Y3)Dual-Fuel（Y2）
Single-Fuel(Y3)
Dual-Fuel（Y2）
Single-Fuel(Y3)
Dual-Fuel（Y2）
Single-Fuel(Y3)
ITALYBRC
Combustion system
Dual-Fuel（Y0）
Single-Fuel (Y1)Dual-Fuel（Y0）
Single-Fuel(Y1)
Dual-Fuel（Y0）
Single-Fuel(Y1)
Dual-Fuel（Y0）
Single-Fuel(Y1)
Rated capacity Kg 2000 2500 3000 3500
Load center mm 500 500 500 500Max lift height mm 3000 3000 3000 3000Free lift height mm 140 140 155 155Max lift speed mm/s 560 560 450 350Mast tilt range F/R 6°/12° 6°/12° 6°/12° 6°/12°Max speed(Unload)
Km/h22 21.5 19.5 19.5
Min ground clearancemm
105 105 130 130
Min Turning radius(Out side) mm
mm2175 2255 2375 2430
Gradeability (fullload) %
20 20 20 15
Wheel base mm 1650 1650 1760 1760trace（F/R）mm 965/970 965/970 1005/975 1005/975
Self weight Kg 3440 3765 4255 4755dimension（L×W×H）
（include forks） 3600×1155×2120 3675×1155×21203820×1225×
21503870×1225×
2150
tires（F/R）7.00-12-12PR6.00-9-10PR
7.00-12-12PR6.00-9-10PR
28×9-15-12PR/26.50-10-10PR/2
28×9-15-12PR/26.50-10-10PR/2
Battery Voltage V/Capacity Ah 12/60/20h
Gasolineengine
Model K25
Rated power/rpm 37.4KW /2300rpm
Max torque/rpm 176.5Nm/1600 rpm
Displacement cc 2472
5
Model CPQD20N-RW22A-Y CPQD25N-RW22A-Y CPQD30N-RW22A-Y CPQD35N-RW22A-Y
Combustionsystem
configuration
USAIMPCO
Combustionsystem
Dual-Fuel（Y2） Single-Fuel
(Y3)
Dual-Fuel（Y2） Single-Fuel
(Y3)
Dual-Fuel（Y2） Single-Fuel
(Y3)
Dual-Fuel（Y2） Single-Fuel
(Y3)
ITALYBRC
Combustionsystem
Dual-Fuel（Y0） Single-Fuel
(Y1)
Dual-Fuel（Y0） Single-Fuel
(Y1)
Dual-Fuel（Y0） Single-Fuel
(Y1)
Dual-Fuel（Y0） Single-Fuel
(Y1)
Rated capacity Kg 2000 2500 3000 3500
Load center mm 500 500 500 500Max lift height mm 3000 3000 3000 3000Free lift height mm 150 150 155 155Max lift speed mm/s 560 560 450 350
Mast tilt range F/R 6°/12° 6°/12° 6°/12° 6°/12°Max speed(Unload)
Km/h 19.5 19.5 19.5 19.5
Min ground clearancemm
105 105 130 130
Min turningradium(outside) mm 2175 2235 2375 2415
Gradeability(Full load) %
20 20 20 15
Wheel base mm 1650 1650 1760 1760
Trace（F/R）mm 965/970 965/970 1005/975 1005/975
Self weight Kg 3440 3765 4255 4555Dimension
（L×W×H）（include forks）
3600×1155×2120 3675×1155×21203820×1225×
21503870×1225×2150
Tires（F/R）7.00-12-12PR
6.00-9-10PR
7.00-12-12PR
6.00-9-10PR
28×9-15-12PR/2
6.50-10-10PR/2
28×9-15-12PR/2
6.50-10-10PR/2
Battery Voltage V/capacity Ah 12/60/20h
Gasoline
engine
Model K25
Rated power/rpm 37.4KW /2300rpm
Max torque/rpm 176.5Nm/1600 rpm
Displacement 2472
6
Model CPQD20N-RW22B-Y CPQD25N-RW22B-Y CPQD30N-RW22B-Y CPQD35N-RW22B-YCombustion
system
configuration
Dual-Fuel
（Y2）
Single-Fuel
(Y3)
Dual-Fuel
（Y2）
Single-Fuel
(Y3)
Dual-Fuel
（Y2）
Single-Fuel
(Y3)
Dual-Fuel
（Y2）
Single-Fuel
(Y3)
Rated capacity
Kg
2000 2500 3000 3500
Load center mm 500 500 500 500
Max lift height
mm3000 3000 3000 3000
Free lift height
mm150 150 155 155
Max lift speed
mm/s560 560 450 350
Mast tilt range
F/R
6°/12° 6°/12° 6°/12° 6°/12°
Maxspeed(Unload)
Km/h21 21 20 20
Ground
clearance mm105 105 130 130
Min turning
radium (outside)
mm
2175 2235 2375 2430
Gradeability
(full loade)%20 20 20 15
Wheel base
mm
1650 1650 1760 1760
Trace（F/R）mm 965/970 965/970 1005/975 1005/975
Self weight
Kg3440 3765 4255 4755
dimension（L×
W × H ）
（include forks）
3600×1155×2120 3675×1155×21203820×1225×
21503870×1225×
2150
tires（F/R）7.00-12-12PR
6.00-9-10PR
7.00-12-12PR
6.00-9-10PR
28×9-15-12PR/2
6.50-10-10PR/2
28×9-15-12PR/2
6.50-10-10PR/2
battery Voltage V/Capacity Ah 12/60/20h
Gasoline
engine
Model K25
Rated power/rpm 37.4KW /2300rpm
Max torque/rpm 176.5Nm/1600 rpm
Displacement cc 2472
7
2 OperationLPG fuel system consists of LPG cylinder, petrol solenoid valve，LPG solenoid valve with filter, LPGvaporizer，adapter，LPG-petrol select switch and level indication. passing through the combination valve, thehigh-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 forklifttruck to work
1. LPG filling & replacing
Replace the LPG cylinder when fuel in it is used up as following: shut off the outpouring valve，disconnect
the female body from the LPG cylinder，cover a dust cap on the valve tie-in （H2-63）, and get the LPG
cylinder away from the truck to a LPG filling station to refill the LPG. Fill LPG as following: Lay the LPG
cylinder flat, and set the charging limit valve upward(the level indication is exactly 60°to the horizontal
line), then screw off the dust cap on the charging valve，plug the filling connector, open the limit charging
valve to charge LPG till 80% rated volume of the container is full (the charging device is automatically
closed when 80% rated volume of the container is full)，take out the filling connector，screw down the dust
cap and the charging limit valve。Secondly，install the LPG cylinder to the truck by a certain angle (the
level indication is exactly 60°to the horizontal line)，connect the female body，open the outpouring valve，
check and eliminate it if there is any leak before starting the truck. Close the outpouring valve after every
task。
2. Operating the select switch
1．Switch to the GAS position，the fuel for the engine is LPG。
2．Switch to the PET position，the fuel for the engine is petrol。
3．Switch to the neutral position，neither is in use。
3. Starting up the engine
1．By petrol
Shut off LPG，switch on the petrol switch for several seconds，after petrol is flowing into the
floater room of the carburetor，turn the ignition key to start the motor-----the engine is started by petrol。
2．By LPG
a. Starting up when there is no petrol in the carburetor：If there is no petrol in the carburetor before
starting-up，you could start up the engine directly by LPG，that is，to shut off the petrol switch，but switch
on the LPG switch for several seconds，turn the ignition key to start the motor-----the engine is started by
LPG。
b. Starting up when there is petrol in the carburetor：It is some difficult to start up when there is
petrol in the carburetor，you should switch the select switch to the neutral position，start up the
engine by petrol。After petrol in the carburetor is used up and the engine is halted，switch on the
LPG switch，turn the ignition key to start the motor-----the engine is started.
4. Change fuel during the engine runs
8
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 LPGSwitch 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.
5. If there is LPG leak during operation，shut off the LPG switch and the outpouring valve at once，check
every part and all connection to see if there is leak or loose，and get rid of it in time。Fuel by petrol before
malfunction is removed。
6. Choose 90# petrol or LPG special for vehicle as fuel for the truck。Otherwise it may affect the ignition
veracity and decline the motive performance。
7. If there is 10 minutes halt，you should shut off the LPG switch and the outpouring valve.
8. It is suitable to keep water in the radiator in the range 700C~850C during operation.
3. Fuel system parts catalog and maintenance manual
Explanation: The structure of CPQD15~18N-RW21-Y,CPQD20~35N-RW22-Y,CPQD20-35N-RW22A-Y,CPQD20-35N-RW22B-Y LPG is the same as， CPQD15~18N-RW21（or CPQD15~18N-RW20）,CPQD20~35N-RW22（or CPQD20~35N-RW11）,CPQD20-35N-RW22A（or CPQD20-35N-RW11A）,CPQD20-35N-RW22B（or CPQD20-35N-RW11B）except the LPG fuel system.1. IMPCO Fuel system
There are two kinds of IMPCO changing device1)、LPG dual-fuel changing device-DFK8634A2)、LPG single-fuel changing device-K8634A
There are three sections in Impco parts catalog and maintenance manual, they are list, illustration anddismantle of main pars. For details, please see the reference content.content1． DFK8634A dual-fuel list2． K8634A single list3． Fuel system main parts’ illustration4． Main part VFF3-2 valve dismantle process.Main part COBRA-30177 Pressure reducer dismantle process
1. DFK8634A dual-fuel convert device listSerial Code Name Specification Quantity1 DK-01001BRACKET-FUEL HOSE HOLDER 12 DK-01002COUPLING-MALE TANK CONNECTION 1-1/4"F.ACME X 3/8" FNPT 1
1-2 Installed together
3 DK-01003COUPLING-FEMALE TANK CONNECTION 1/4" FNPT X 1-1/4"M.ACME 1
4 DK-01004CONVERSION FITTING 3/8" SAE FLARE X 1/4"NPT X45° 1
5 DK-01005 LPG HOSE ASSY 800mm 13-5 Installed together
9
6 DK-02001BULKHEAD FITTING 17 DK-02002HYDROSTATIC RELIEF VALVE 400PSI 18 DK-02003 LOCKWASHER Star,7/8" 19 DK-02004NUT 7/8" 1
10 DK-02005BUCKHEAD OUTLET FITTING 3/8" SAE FLARE X 1/4"NPT X45° 111 DK-02006PLASTIC CAP 1
12 DK-02007BULKHEAD INLET FITTING 3/8" SAE FLARE X 1/4"NPT 16-12 installed together
13 DK-03001GASOLINE SOLENOID VALVE 12V 1
14 DK-03002SOLENOID INLET FITTING 1/4"SAE FLARE X 1/4"NPT X 90° 115 DK-03003SOLENOID OUTLET FITTING 1/4"NPT X 1/8"NPT 116 DK-03004CONVERSION FITTING 1/8" FPTX 1/8BSP X 90 1
13-15 installed together
17 DK-04001Fuel change switch assemble 12V 118 DK-04002AUXILIARY FUEL LINT 1000mm X 2- 3/8 SAE FLARE FITTING119 DK-04003FILTERLOCK INLET FITTING 3/8" SAE FLARE X 1/4"NPT 120 DK-04004FILTERLOCK VFF30-2 121 DK-04005VACUUM FITTING 1/4" ID HOSE X 1/8"NPT X 90° 122 DK-04006FILTERLOCK OUTLET FITTING 3/8" INV FL X 1/4"NPT X 90° 123 DK-04007TUBE ASSY 124 DK-04008 LPG SOLENOID VALVEINLET FITTING 3/8" INV FL X 1/4"NPT X 90° 125 DK-04009 LPG SOLENOID VALVE 12V 126 DK-04010 LPG SOLENOID VALVE OUELET FITTING 1/4"FNPT X 1/4" NPT X 90° 127 DK-04011 REGULATOR INLET FITTING 1/4"NPT X 1/4"NPT 128 DK-04012REGULATOR COBRA,CB-30177 129 DK-04013REGULATOR WATER OUTLET FITTING 3/8"NPT X 3/8" NPT X 90° 130 DK-04014THERMOSTATE 131 DK-04015THERMOSTATE WATER OUTLET FITTING 3/8" SAE FLARE X 3/8"NPT X 90° 132 DK-04016WATER RETURN HOSE 10mm ID HOSE, 600mm 133 DK-04017WATER HOSE CLAMP 10-18mm 234 DK-04018REGULATOR LPG OUTLET FITTING 5/8" ID HOSE X 1/2" NPT X 90° 135 DK-04019 LPG INLET HOSE 5/8 ID" HOSE X 850mm 136 DK-04020CLAMP 15-30mm 237 DK-04021ASSY's BRACKET 138 DK-04022BOLT 1/4"-20 X 3/4" 439 DK-04023FLATWASHER 1/4" 440 DK-04024 LOCKWASHER 1/4" 441 DK-04025REGULATOR WATER INLET FITTING 3/8"SAE FLARE X 3/8" NPT 142 DK-04026WATER SUPPLY HOSE 10mm ID HOSE, 1000mm 1
18-41 installed together43 DK-05001MIXER CA55-0258 144 DK-05002CONVERSION FITTING 1/8" FNPT X 1/8 NPT X 90° 1
10
45 DK-05003CRANKCASE VENTILATION HOSE FITTING1/2" HOSE X 1/8 NPT 146 DK-05004CRANKCASE VENTILATION HOSE 1/2" ID HOSE X 400mm 147 DK-05005VACUUM SIGNAL HOSE 1/4" ID HOSE X 60mm 148 DK-05006MIXER LPG INLET FITTING 5/8" ID HOSE X 3/8 NPT X 90° 149 DK-05007VACUUM FITTING 1/4" ID HOSE X 1/4"-28 15050 DK-06001NYLON STRAP 851 DK-06002GASOLINE FUEL GAUGE DECAL 152 DK-06003FUEL CHANGOVERIN STRUCTION DECAL 153 DK-06004REFUELING INSTRUCTION DECAL 154 DK-06005SAFETY MAINTENANCE 155 DK-06006PLASETIC CAP 1/2" ID CAP 1
2. K8634A Single-fuel switch device parts listSerial Code Name Specification Quantity1 DK-01001BRACKET-FUEL HOSE HOLDER 12 DK-01002COUPLING-MALE TANK CONNECTION 1-1/4"F.ACME X 3/8" FNPT 1
1-2 installed together
3 DK-01003COUPLING-FEMALE TANK CONNECTION1/4" FNPT X 1-1/4"M.ACME 14 DK-01004CONVERSION FITTING 3/8" SAE FLARE X 1/4"NPT X45° 1
5 DK-01005 LPG HOSE ASSY 800mm 1
3-5 installed together6 DK-02001BULKHEAD FITTING 1
7 DK-02002HYDROSTATIC RELIEF VALVE 400PSI 1
8 DK-02003 LOCKWASHER Star,7/8" 19 DK-02004NUT 7/8" 1
10 DK-02005BUCKHEAD OUTLET FITTING 3/8" SAE FLARE X 1/4"NPT X45° 1
11 DK-02006PLASTIC CAP 112 DK-02007BULKHEAD INLET FITTING 3/8" SAE FLARE X 1/4"NPT 1
6-12 installed together
13 DK-04002AUXILIARY FUEL LINT 1000mm X 2- 3/8 SAE FLARE FITTING 114 DK-04003FILTERLOCK INLET FITTING 3/8" SAE FLARE X 1/4"NPT 1
15 DK-04004FILTERLOCK VFF30-2 1
16 DK-04005VACUUM FITTING 1/4" ID HOSE X 1/8"NPT X 90° 117 DK-04006FILTERLOCK OUTLET FITTING 3/8" INV FL X 1/4"NPT X 90° 1
18 SK-04007 TUBE ASSY 1
19 DK-04011 REGULATOR INLET FITTING 1/4"NPT X 1/4"NPT 120 DK-04012REGULATOR COBRA,CB-30177 1
21 DK-04013REGULATOR WATER OUTLET FITTING 3/8"NPT X 3/8" NPT X 90° 1
22 DK-04014THERMOSTATE 123 DK-04015THERMOSTATE WATEROUTLET FITTING 3/8" SAE FLARE X 3/8"NPT X 90° 1
11
24 DK-04016WATER RETURN HOSE 10mm ID HOSE, 600mm 125 DK-04017WATER HOSE CLAMP 10-18mm 2
26 DK-04018REGULATOR LPG OUTLET FITTING 5/8" ID HOSE X 1/2" NPT X 90° 1
27 DK-04019 LPG INLET HOSE 5/8" ID HOSE X 850mm 128 DK-04020CLAMP 14-27mm 2
29 SK-04021 ASSY's BRACKET 1
30 DK-04022BOLT 1/4"-20 X 3/4" 431 DK-04023FLATWASHER 1/4" 4
32 DK-04024 LOCKWASHER 1/4" 4
33 DK-04025REGULATOR WATER INLET FITTING 3/8"SAE FLARE X 3/8" NPT 134 SK-04026 WATER SUPPLY HOSE 10mm ID HOSE, 600mm 1
14-34 installed together
35 SK-05001 MIXER I172 136 SK-05002 IDLE ADJUSTMENT SCREW 1
37 SK-05003 MIXER LPG INLET FITTING 5/8" ID HOSE X 3/8 NPT X 90° 1
38 SK-05004 VACUUM FITTING 1/4" ID HOSE X 1/4"-28 139 DK-05005VACUUM SIGNAL HOSE 1/4" ID HOSE X 600mm 1
40 SK-05006 GASKET 1
41 SK-05007 throttle lever bracket 142 SK-05008 conversion flange 1
43 SK-05009 return spring 1
44 SK-05010 DASHPOT 145 SK-05011 CABLE BRACKET 1
35-45 installed together
46 DK-06001NYLON STRAP 8
47 SK-06003 IDLE ADJUSTMENT HOSE 4mm ID X 300mm 1
48 DK-06004REFUELING INSTRUCTION DECAL 1
49 DK-06005SAFETY MAINTENANCE 1
12
3. Combustion system main parts illustrationCONNECTIONLINE
ITEM PART No NAME
1 DK-01001BRACKET-FUELHOSE HOLDER
2DK-01002
COUPLING-MALETANKCONNECTION
3DK-01003
COUPLING-FEMALETANKCONNECTION
4 DK-01004CONVERSIONFITTING
5 DK-01005 LPG HOSE ASSY
BULKHEAD ITEM PART No NAME
6 DK-02001 BULKHEADFITTING
7 DK-02002 HYDROSTATICRELIEF VALVE
8 DK-02003 LOCKWASHER9 DK-02004 NUT
10 DK-02005 BUCKHEADOUTLET FITTING
11 DK-02006 PLASTIC CAP
12 DK-02007 BULKHEADINLET FITTING
DFK8634A DUAL-FUELGASOLINESOLENOIDVALVE
ITEM PART No NAME
13DK-03001
GASOLINESOLENOIDVALVE
14 DK-03002SOLENOIDINLET FITTING
15 DK-03003SOLENOIDOUTLET FITTING
13
16 DK-03004CONVERSIONFITTING
DFK8634A DUAL-FUEL FILTERLOCK-REGULATORASSY
ITEM PART No NAME ITEM PART No NAME
18 DK-04002 AUXILIARY FUEL LINT 31 DK-04015 THERMOSTATE WATEROUTLET FITTING
19 DK-04003 FILTERLOCK INLET FITTING 32 DK-04016 WATER RETURN HOSE20 DK-04004 FILTERLOCK 33 DK-04017 WATER HOSE CLAMP
21 DK-04005 VACUUM FITTING 34 DK-04018 REGULATOR LPG OUTLETFITTING
22 DK-04006 FILTERLOCK OUTLET FITTING 35 DK-04019 LPG INLET HOSE23 DK-04007 TUBE ASSY 36 DK-04020 CLAMP
24 DK-04008 LPGSOLENOIDVALVEINLETFITTING 37 DK-04021 ASSY's BRACKET
14
25 DK-04009 LPG SOLENOID VALVE 38 DK-04022 BOLT
26 DK-04010 LPGSOLENOIDVALVEOUELETFITTING 39 DK-04023 FLATWASHER
27 DK-04011 REGULATOR INLET FITTING 40 DK-04024 LOCKWASHER
28 DK-04012 REGULATOR 41 DK-04025 REGULATOR WATER INLETFITTING
29 DK-04013 REGULATORWATEROUTLETFITTING 42 DK-04026 WATER SUPPLY HOSE
30 DK-04014 THERMOSTATE
DFK8634A DUAL-FUELCARBURETOR ASSY
ITEM PART No NAME
43 DK-05001 MIXER
44 DK-05002 CONVERSIONFITTING
45 DK-05003CRANKCASEVENTILATIONHOSE FITTING
46 DK-05004CRANKCASEVENTILATION
HOSE
47 DK-05005 VACUUMSIGNAL HOSE
48 DK-05006 MIXER LPGINLET FITTING
49 DK-05007 VACUUMFITTING
K8634A SINGL-FUELFILTERLOCK-REGULATOR ASSY
15
K8634A SINGLE-FUEL FILTERLOCK-REGULATOR ASSY13 DK-04002 AUXILIARY FUEL LINT 24 DK-04016 WATER RETURN HOSE14 DK-04003 FILTERLOCK INLET FITTING 25 DK-04017 WATER HOSE CLAMP
15 DK-04004 FILTERLOCK 26 DK-04018REGULATOR LPG OUTLET
FITTING16 DK-04005 VACUUM FITTING 27 DK-04019 LPG INLET HOSE17 DK-04006 FILTERLOCK OUTLET FITTING 28 DK-04020 CLAMP18 SK-04007 TUBE ASSY 29 DK-04021 ASSY's BRACKET19 DK-04011 REGULATOR INLET FITTING 30 SK-04022 BOLT20 DK-04012 REGULATOR 32 DK-04024 LOCKWASHER
21 DK-04013REGULATORWATEROUTLET
FITTING 33 DK-04025REGULATOR WATER INLET
FITTING22 DK-04014 THERMOSTATE 34 SK-04026 WATER SUPPLY HOSE
23 DK-04015THERMOSTATEWATEROUTLET
FITTING
16
K8634A SINGLE-FUELCARBURETOR
ITEM PART No NAME
35 SK-05001 MIXER
36 SK-05002
IDLEADJUSTMENT
SCREW
37 SK-05003MIXER LPG
INLET FITTING
38 SK-05004VACUUMFITTING
39 DK-05005VACUUM
SIGNAL HOSE40 SK-05006 GASKET
41 SK-05007
THROTTLELEVER
BRACKET
42 SK-05008CONVERSION
FLANGE
43 SK-05009RETURNSPRING
44 SK-05010 DASHPOT
45 SK-05011CABLE
BRACKET
OTHERS ITEM PART No NAME46 DK-06001 NYLON STRAP
47 SK-06002
IDLEADJUSTMENT
HOSE
48 DK-06003
REFUELINGINSTRUCTION
DECAL
49 DK-06004SAFETY
MAINTENANCE
17
4. VFF30-2 Filterlock disassembly and assembly flow
I Do not use the TELFON screw thread instead of NPT type, where the fuel pass through.II Use suds inspect all joints, fuel tank and covers.III Using the correct bolt to ensure the safety of lock valve, longer bolt may lead to serious damage.
G1-89 gasket
AF1-10 filterS7-3 screenBD1-26 diaphragmBD1-27 diaphragmBD1-27-5 diaphragmS1-59 Screw（2）S1-100 Screw（2）S4-18 valve seatS3-116 O-ringP1-15 valve operating pinW1-42 retaining washerPP-1-4-116 Installation guideH1-14236 holderP1-14235 Installation pin
2
Remove 10 screws from cover which has thewords "Fuel In" cast into it.
18
3
Remove the cover and the gasket
4
4Remove the filter and screen
5
Remove screw holding spring in p
19
6
Remove the valve spring
7
Remove valve seat
8
Remove valve operating pin
20
9
Using a bent paper clip or wire,fashion a hook as shown
10
Cut way show the relationship ofvalve spring, valve seat, valveoperating pin, seal retainingwasher and O-ring. Note thatremoval of valve pin allowsretaining washer to removedthrough the "Fuel out"(1/4" NPT)opening.
11
Insert wire hook through "FuelOut" threaded port to hook theretaining washer, then…
21
12
!-Pull the retaining washer out of thbody through the jet hole
Using the same hook/wire, pull the o-ring seal through the hole in the bodyfrom which you removed the valveoperating pin in step-7.wash body, coveand jet area as needed, using keroseneor equivalent petroleum solvent. DoNOT use carburetor, as it will attacksynthetic rubber seals.
13
Seal holder(H1-14236, bottom tool)should be placed as shown. place thegreased o-ring seal into the holder,usingthe installation pin(P1-14235 uppertool).recoat the seal with siliconegrease. The seal must be in the positionshown in the photo, groove facingup, and visible, Seal is tapered to matchhole in the seal holder.
14
22
15
Place the body with the filter sideup, as shown.
16
With the o-ring lip seal in theholder, groove visible and facingup, slide the holder into the body,look through the Fuel in port tocheck the position of seal, above thecavity of the seal recess(seecut way, step 10).
17
Coat the installation pin withsilicone grease and push the sealthrough the holder and into the sealrecess of the body, remove theinstallation pin and check forproper installation by looking intothe Fuel in port. O-ring seal shouldbe seated in the seal recess andgroove should be visible.
23
18
Use needle nose pilers to insert sealretainer washer through the fuel inthreaded port. Again refer tocut way drawing,step-10
19
Lubricate valve operating pin withsilicone grease and insert in body asshown, so that pin passes throughretainer washer and o-ring lip seal.Rotate pin showly to ease passagethrough washer and o-ring
20
Place valve seat on top of head ofoperating pin, with aluminum sidefacing up and dark, viton sideagainst head of pin
24
21
Add valve spring and secure with screw.
22
Lift the spring slightly to confirm itsfreedom of movement.
23
rInsert screen and filter
25
24
Place gasket on body and alignwith screw holes
25
Add filter cover and securewith screws, alternate side to another side.
26
Remove diaphragm cover retaining screws.
26
27
Cover and diaphragm areremoved, clean parts asnecessary, using only kerosene orequivalent petroleum solvent, DoNOT use carburetor cleaner
Check valve operating lever forfreedom of movement. Usesilicone grease to coat the surfaceof the gasket. Which will contactthe body. Note: gasket will onlyalign with holes when installedcorrectly, rivet heads indiaphragm plates should be onthe cover side, not the bodyside.
28
28
29
.Add diaphragm to body, then…
27
30
Add cover and securewith screws
28
5. COBRA-30177 Regulator disassembly and assembly flow
The Rk-J kit contains all parts requiredfor perodic service. In installation ofcomplete kit should be required only attime of a major overhual of theconverter, or the converter has been outof service for 30 days. Gasket anddiaphragms may deteriorate if theconverter has been stored afteruse. Inspect the gaskets before re-installing the converter
1
2
Remove the 6 screws from secondarycover assembly, Note the type of screwsremoved and sure the same type andsize of screws are used in the samelocations during reassembly
3
Loosen the secondary cover by tappingaround the circumference with a plasticscrewdriver handle
29
4
Remove the secondary cover andsecondary diaphragm as a unit.Note theseconday lever protruding through themetal tab slot of the secondarydiaphragm. Slide the conver anddiaphragm toward the gas inlet to freethe lever from the slotted tab of thediaphragm. take care not to bend thelever
5
Remove the seconday lever fulcrumretaining screw(S1-17460-001)
6
Remove the seconday lever and fulcrumpin. Be careful not to lose the fulcrumpin. Remove the seconday spring.
30
7
Turn the converter over. Removethe seven screws(S1-15265-005)and lift off the primary cover.
8Remove the primary diaphragmThe triangular lever riveted tothe diaphragm pivots on afulcrum cast into the cover. Thepivoting of the lever depressesthe control gas flow. The penpoints to the sensing port forpressure regulation
9
Remove the primary valve pinand regulator spring
31
10
Remove the cover plate and the gasket
11
Remove the gasket from the coverplate. Clean cover plate as needed toensure a good seal with a newgasket
12
The pen points to the aluminumalloy backing of the primaryregulator valve in the vaporizingchamber.
13
32
13Remove the primay regulatorvalve. Note: remove oil andforeign deposit from allchambers and parts. Do notapply liquid cleaners to thediaphragms and neoprene facedvalves. Inspect seat for wear orcuts. If the primary seat is wornor damaged, the regulator is notrebuildable and must be replaced
14
15
14
Install new primary regulator valve
15
Set new primary gasket, G1-35,from the kit on the convertercover plate. Screw hole spacingprevents improper orientation ofthe diaphragm. The primarypressure hole in the gasket mustline up with the hole in the bodyconver plate.
33
16
Place the cover plate and gasketon to the converter body andalign the cover screw holes.Insert the primary valve pin thethrough the spring and into thecover plate.
18
17
Insert the new primary valve pinthrough the previously removedspring and then into cover plate.
19
18
Set the primary diaphragm inplace on the converter body coverplate. Line up the screw holes tothe cover plate
34
19
Carefully place the primary cover over thediaphragm. hand-thread the screwsthrough the cover and cover plate into theconverter body.
21
20
22
Tighten the screws to 37 in.lbs(4.18 N.m)minimum, using a crisscross pattern.
21
Remove the old secondary seat and snapthe new seat into the opening of the lever,Be sure the new seat snap-locks intoplace
35
22
Position the secondary spring in placeon the body. Place the secondary leverassembly into place over the spring.
24
23Hold the lever assmebly with thefulcrum pin in place in its locatinggroove and fasten in place withscrew(S1-17460-001)
24
Tighten the screw to 32 in.lbs(3.62N.m) minimum
36
25
The secondary lever should be 1/32"below the level of the body. Use astraight edge or tool G2-2 tomeasure. Gently bend the lever ifnecessary to obtain the correct height. Becareful not to apply excessive force tothe secondary seat.
26
Align the secondary diaphragm to thesecondary lever as shown. The end of thelever must protrude through the tab sloton the bottom of the new diaphragmafter installation. The gap from which thelink is punched should be located towardthe gas inlet.
27
Install the secondary cover with the sixscrews(S1-15265-003).
37
28
Tighten the screws in a crisscrosspattern to 29 in.lbs.(3.29 N.m) minmum.To complete the installation of the repairkit components.
38
（二）、BRC Combustion systemThere are two kinds of BRC conversion kit.
1)、LPG dual-fuel conversion kit2)、LPG single-fuel conversion kitManuals are divided into parts list, and main parts disassembly and assembly, refer to the contents.
ContentBRC Dual-fuel, single-fuel parts listLPG Solenoid valve maintenanceBRC AT90 E Regulator adjustor maintenance
Compared BRC single-fuel with dual-fuel, the difference is
1． BRC dual-fuel, single-fuel parts catalog listCompared with BRC dual-fuel, BRC single-fuel only has no oil solenoid valve and serial number 28,29,30,the others are the same as BRC dual-fuel.
39
BRC dual-fuel systemBRC single-fuel system（No serial number 27,28,29,30）
40
ITEM
PART No NAME Q’ TY REMARKSSERIESNo.
1 GB93-87 Washer 6 4
2 GB5783-86 Bolt M6×25 3
3 GB6170-86 Nut M6 3
4 BRC-01RD00403004 LPG vaporizer 1 BRC AT90 E
5 TERL2.5-102-G00 Brass seal ringφ6 4 BRC
6 TERL2.5-103-G00 Fasten pipe fittingφ6 4
7 GB1527-87 Out let brass pipeφ6×1 1 L=450
8 BRC-03EV00100001 （LPG）solenoid valve 1 BRC ET98
9 GB6170-86 Nut M5 1
10 GB5783-86 Bolt M5×12 1
11 GB93-87 Washer 5 1
12 GB1527-87 Outlet brass pipeφ6×1 1 L=350
13 N171-360001-000 Bracket 1
14 H2-65 -G00 Dust cap 1 Parker
15 N171-361000-000 Tube assembly 1 30YDHBW11-351000
16 GB5783-86 Bolt M6×12 1
17 N171-360002-000 Bend tie-in 1 30YDHBW11-350001
18 JIS D2602-82-G00 Recycle-water pipe Dn16 1 L=350
19 TERL2.5-101A-G00 Recycle-water pipe joint 1 JiaxingTaishan
20 JIS D2602-82-G00 Recycle-water Dn16 1 L=650
21 BK16-G00 Hold hoopφ16-25 7 JiaxingTaishan
22 TERL2.5-4J-G00 Mixer 1 JiaxingTaishan
23 JISK6347-16-G00 Low Working Pressure Hose Dn16
1 L=350
24 TERL2.5-3-G00 Flow valve 1 JiaxingTaishan
41
ITEM
PART No NAME Q’ TY REMARKSSERIESNo.
25 JISK6347-25-G00 Low Working Pressure Hosen16Dn25
1 L=100
26 BK25-G00 Clampφ25-40 2 JiaxingTaishan
27 PV-10-G00 Petrol solenoid valve PSV3.0 1 JiaxingTaishansingle-fuel none
28 TERL2.5-5A-101B-G00 1 Single-fuel none
29 GB1054-89 Oil resistant rubber hose 5 ×3-2A
2 Single-fuel none
30 BK8-G00 Clampφ8-12 2 Single-fuel none
42
2． ET98 solenoid maintenance
Before overhauling the LPGET98 solenoid valve, be sure that the tank gas flow is interrupted byclosing a cock or another solenoid valve.
By dismounting the solenoid valve the LPG contained in the pipe between the tank interceptionelement and the solenoid valve is liberated in the environment. We there fore recommend to take thenecessary precautions.
The overhauling of the Flying Injection/Sequent ET98 LPG solenoid valve involves the replacement ofthe filter and of some O-Rings.
Unscrew the hexagonal nut (29) by using a 15 key.Remove the basin (3), where there is the permanent magnet (28), through a simple traction.To replace the filter unscrew the screw (2) by using a 14 key.Remove the washer (31) and the filter (4).Then replace the parts with the ones supplied in the overhauling envelope. In particular the overhauling
comprehends the following components:4 Complete filter5 OR 2037 Ring7 OR 3162 Ring27 OR 3081 Ring28 Permanent magnetAssemble the solenoid valve by using the new components.Position the O-Rings correctly in their housing with great care.Remount the screw (2) in the body (10) by putting some thread sealing fluid of the LOXEAL83-54
or83-21 type.Tighten the screw (2) by a 4 Nm torque, not to deform the filter excessively and to guarantee the correct
compression of the rings in the meantime.
43
The basin fixing nut must be tightened by a 18 Nm torque. If necessary disconnect the copper pipesfrom the solenoid valve and re-use them tightening them by a 16 Nm torque.3．Instructions for the overhauling of BRCAT90E-AT90E Turbo reducer
DISASSEMBLING Steps:1 - Disassembly the II°stage back cover (5).2 - Release the II°stage diaphragm (from items 6 to 6c) , by holding firmly the lever (20).3 - Disassembly the II°stage lever (20) and substitute the shutter (16).4 - Release (by rotating) the washer (8) and extract the spring (9).5 - Dismount the I°stage cover (7a).6 - Release the I°stage diaphragm (from items 10 to 10b)7 - Extract the lever (14) and substitute the I°stage valve (12).8 - Dismount the safety valve cap (21c) and extract the little piston (from items 21 to 21d).9 - Dismount the solenoid valve group (from items 29 to 34).10 - Substitute the O-Rings (31a) and (32), the keg (34-34a) and the spring (33).11 - Unscrew the idle adjusting screw (36a) and substitute the O-Ring (36).12 - Unscrew the sensivity adjusting screw (37c) and substitute the O-Ring (37a) and thespring (37).13 - Proceed on washing accurately the Body (26).14 - Verify the integrity of the I°stage seat, the II°stage one and the coil seat of the body (26).RE-ASSEMBLY steps:1 - Substitute all the worn parts with those included in the revision bag.
44
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).6 - Substitute the safety valve piston (from items 21 to 21d) and remount the cap (21c)7 - Remount the solenoid valve group composed by the items from 29 to 34.8 - Remount the sensivity adjusting screw (37c) about in the middle of the stroke and threlated spring (37).9 - Remount the II° stage lever group (20).10 - Remount the diaphragm of the II°stage (from items 6 to 6c) and the cover (5).
During the overhauling operations it is recommended NOT TO DISMOUNT THE COVER OF THEWATER ROOM (43) unless in case there are some leakages or in case of washing in acids.In case it should be necessary the overhauling, proceed as it follows:1 - Dismount the cover (43) and extract the seal (42).2 - Extract the two seegers (44).3 - Slip off the water elbows (46).4 - Substitute the four O-rings (45).5 - Remount the elbows (46) and secure with the seeger (44).6 - Remount the seal (42).7 - Remount the water cover (43).
45
3. Cylinder and its bracket assembly catalog list (IMPCO and BRC)1．Cylinder bracket assembly
ITEM
PART No NAME Q’ TY REMARTKSSERIES No.
1 N051-371100-000 Cylinder supportbase 1 1．5-1．8T
N171-371100-000 Cylinder supportbase 1 2-3．5T
2 N171-371001-000 Pin 23 GB894.1-86 Retainer ring 8 44 N171-371200-000 Bracket(top) 25 N171-371300-000 Buckle 26 N171-371002-000 Pin 27 N171-371400-000 connecting rod 28 N171-371003-000 straight pin 2
46
2 Cylinder assembly
ITEM
PART No NAME Q’TY
REMARKS SERIESNo.
1 CYSW314-35-2.2-G00 Cylinder 1 1．5-1．8TCYSW314-50-2.2-G00 Cylinder 1 2-3．5T
2 GB1527-87 Liquid brass pipeφ8×1 L=2703 TERL2.5-7-104-G00 Fasten pipe nut 8 4 Jiaxingtaishan4 TERL2.5-7-105-G00 Brass seal ring 8 4 Jiaxingtaishan5 TERL2.5-8-G00 Filling mouth 1 Jiaxingtaishan6 GB93-87 Washer 8 37 GB5783-86 Bolt M8×20 38 GB6170-86 Nut M8 39 N171-372001-000 Positing plat 110 H2-63-G00 Coupling male connection 1 Parker11 N171-372002-000 Pipe joint 1 30YDHBW11-36200212 H2-66-G00 Dust cap 1 Parker13 GB1527-87 Outlet brass pipeφ8×1 1 L=350
4. Notice
1． It is forbidden to adjust or maintain any part concerned of LPG fuel system without permission after
power performance and exhaust of the LPG fuel system are checked out.
2． Check the forklift truck fully ahead to ensure no leak of LPG, then open the LPG outpouring valve on
47
the LPG cylinder, check more to ensure no leak of LPG fuel system before starting-up.
3． Observe the level indication frequently during operation, if it is found that LPG consumption is not in
proportion to working time, you should stop to check where is leakage, and shut off power， the LPG
valve and all valves concerned at once to take good measure in time。
4． Park the truck at the shady and ventilated site，close the valves on the LPG cylinder。Never insolate the
truck in the sun long。
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.
48
List1 technique parameter of LPG special for vehicle
Item component com position
Quality parameter
Trialpropane for vehicle
Mixture of propane and
butane for vehicle
37.80C vapour (indication) kPa 1430 ≤1430According to
GB/T66021）
component
（Ψ）
%
propane — ≥60
SH/T0230Butane and advanced ≤2.5 —
Pentane and advanced — ≤2
propylene ≤5
remainder
100ml remainder after
evaporation ml ≤0.05 ≤0.05 According to
SY/T7509Observe soiled-oil pass pass
density（200C or 150C） kg/m3 actually measure actually measureAccording to
SH/T02212）
Sheet copper corrosion Not more than 1 level Not more than 1 levelAccording to
SH/T0232
Total sulfur content W（×10-6）（fraction of mass） ≤123 ≤140
According to
SY/T7508
dissociative water zero zero Eyeballing
1）Permit to calculate vapor tension according to GB/T12576，while arbitration should be according to
GB/T6602。
2）Permit to calculate density according to GB/T12576 ， while arbitration should be according to
SH/T0221。
Getting from：SY7548-1998 LPG for auto，Petrol & Natural Gas Trade Standard of P.R.C。
