ep CPQD15N-RW21-Y Service Manual Download

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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 IMPCO
single-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 forklift

Product Code

Configuration

Manuals Code

CPQD15/18N-RW21-Y

BRC dual-fuel(Italy)

CPQD15/18N-RW21-Y0

BRC single-fuel(Italy)

CPQD15/18N-RW21-Y1

IMPCO dual-fuel (USA)

CPQD15/18N-RW21-Y2

IMPCO single-fuel(USA)

CPQD15/18N-RW21-Y3

2-3.5T R Series LPG forklift

Product Code

Configuration

Manuals Code

CPQD20/25/30/35N-RW22-Y

BRC dual-fuel(Italy)

CPQD20/25/30/35N-RW22-Y0

BRC single-fuel(Italy)

CPQD20/25/30/35N-RW22-Y1

IMPCO dual-fuel (USA)

CPQD20/25/30/35N-RW22-Y2

IMPCO single-fuel(USA)

CPQD20/25/30/35N-RW22-Y3

CPQD20/25/30/35N-RW22A-Y BRC dual-fuel(Italy)

CPQD20/25/30/35N-RW22A-Y0

BRC single-fuel(Italy)

CPQD20/25/30/35N-RW22A-Y1

IMPCO dual-fuel (USA)

CPQD20/25/30/35N-RW22A-Y2

IMPCO single-fuel(USA)

CPQD20/25/30/35N-RW22A-Y3

CPQD20/25/30/35N-RW22B-Y BRC dual-fuel(Italy)

CPQD20/25/30/35N-RW22B-Y0

BRC single-fuel(Italy)

CPQD20/25/30/35N-RW22B-Y1

IMPCO dual-fuel (USA)

CPQD20/25/30/35N-RW22B-Y2

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

，

as well as its operation and maintenance,

OPERATION AND

MAINTENANCE MANUAL and SERVICE MANUAL of 1-3.5t R series are also concerned

. All the

personnel in charge of operation

，

maintenance and management should read all these three

manuals completely.

Owing to continuous update and improvement

，

there

is maybe something different between the explanations
in this manual and the forklift in your hand.

○

2008.03

1st EDITION

E - P E q u i p m e n t

Summary of Contents for CPQD15N-RW21-Y

Page 1: ...0 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 Eq u i pm e n t 2008 03 1st EDITION ...

Page 2: ...ly CPQD20 25 30 35N RW22A Y0 BRC single fuel Italy CPQD20 25 30 35N RW22A Y1 IMPCO dual fuel USA CPQD20 25 30 35N RW22A Y2 IMPCO single fuel USA CPQD20 25 30 35N RW22A Y3 CPQD20 25 30 35N RW22B Y BRC dual fuel Italy CPQD20 25 30 35N RW22B Y0 BRC single fuel Italy CPQD20 25 30 35N RW22B Y1 IMPCO dual fuel USA CPQD20 25 30 35N RW22B Y2 IMPCO single fuel USA CPQD20 25 30 35N RW22B Y3 This series of L...

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

Page 4: ...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 ...

Page 5: ...eight mm 140 140 155 155 Max 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 22 21 5 19 5 19 5 Min ground clearance mm 105 105 130 130 Min Turning radius Out side mm mm 2175 2255 2375 2430 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 4755 dimension L W ...

Page 6: ...55 155 Max 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 clearance mm 105 105 130 130 Min turning radium 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 4555 Dimension L W H include forks 3600...

Page 7: ...12 Max speed Unload Km h 21 21 20 20 Ground clearance mm 105 105 130 130 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 Kg 3440 3765 4255 4755 dimension L W H include forks 3600 1155 2120 3675 1155 2120 3820 1225 2150 3870 1225 2150 tires F R 7 00 12 12PR 6 00 9 10PR ...

Page 8: ...all 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 fu...

Page 9: ... 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 device 1 LPG dual fuel changi...

Page 10: ...4 NPT X 90 1 23 DK 04007 TUBE ASSY 1 24 DK 04008 LPG SOLENOID VALVEINLET FITTING 3 8 INV FL X 1 4 NPT X 90 1 25 DK 04009 LPG SOLENOID VALVE 12V 1 26 DK 04010 LPG SOLENOID VALVE OUELET FITTING 1 4 FNPT X 1 4 NPT X 90 1 27 DK 04011 REGULATOR INLET FITTING 1 4 NPT X 1 4 NPT 1 28 DK 04012 REGULATOR COBRA CB 30177 1 29 DK 04013 REGULATOR WATER OUTLET FITTING 3 8 NPT X 3 8 NPT X 90 1 30 DK 04014 THERMOS...

Page 11: ...M ACME 1 4 DK 01004 CONVERSION FITTING 3 8 SAE FLARE X 1 4 NPT X45 1 5 DK 01005 LPG HOSE ASSY 800mm 1 3 5 installed together 6 DK 02001 BULKHEAD FITTING 1 7 DK 02002 HYDROSTATIC RELIEF VALVE 400PSI 1 8 DK 02003 LOCKWASHER Star 7 8 1 9 DK 02004 NUT 7 8 1 10 DK 02005 BUCKHEAD OUTLET FITTING 3 8 SAE FLARE X 1 4 NPT X45 1 11 DK 02006 PLASTIC CAP 1 12 DK 02007 BULKHEAD INLET FITTING 3 8 SAE FLARE X 1 4...

Page 12: ...6 WATER SUPPLY HOSE 10mm ID HOSE 600mm 1 14 34 installed together 35 SK 05001 MIXER I172 1 36 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 1 39 DK 05005 VACUUM SIGNAL HOSE 1 4 ID HOSE X 600mm 1 40 SK 05006 GASKET 1 41 SK 05007 throttle lever bracket 1 42 SK 05008 conversion flange 1 43 SK 05009 ret...

Page 13: ... FITTING 5 DK 01005 LPG HOSE ASSY BULKHEAD ITEM PART No NAME 6 DK 02001 BULKHEAD FITTING 7 DK 02002 HYDROSTATIC RELIEF VALVE 8 DK 02003 LOCKWASHER 9 DK 02004 NUT 10 DK 02005 BUCKHEAD OUTLET FITTING 11 DK 02006 PLASTIC CAP 12 DK 02007 BULKHEAD INLET FITTING DFK8634A DUAL FUEL GASOLINE SOLENOID VALVE ITEM PART No NAME 13 DK 03001 GASOLINE SOLENOID VALVE 14 DK 03002 SOLENOID INLET FITTING 15 DK 03003...

Page 14: ...R OUTLET FITTING 19 DK 04003 FILTERLOCK INLET FITTING 32 DK 04016 WATER RETURN HOSE 20 DK 04004 FILTERLOCK 33 DK 04017 WATER HOSE CLAMP 21 DK 04005 VACUUM FITTING 34 DK 04018 REGULATOR LPG OUTLET FITTING 22 DK 04006 FILTERLOCK OUTLET FITTING 35 DK 04019 LPG INLET HOSE 23 DK 04007 TUBE ASSY 36 DK 04020 CLAMP 24 DK 04008 LPGSOLENOIDVALVEINLET FITTING 37 DK 04021 ASSY s BRACKET ...

Page 15: ...ET FITTING 29 DK 04013 REGULATORWATEROUTLET FITTING 42 DK 04026 WATER SUPPLY HOSE 30 DK 04014 THERMOSTATE DFK8634A DUAL FUEL CARBURETOR ASSY ITEM PART No NAME 43 DK 05001 MIXER 44 DK 05002 CONVERSION FITTING 45 DK 05003 CRANKCASE VENTILATION HOSE FITTING 46 DK 05004 CRANKCASE VENTILATION HOSE 47 DK 05005 VACUUM SIGNAL HOSE 48 DK 05006 MIXER LPG INLET FITTING 49 DK 05007 VACUUM FITTING K8634A SINGL...

Page 16: ...NG 16 DK 04005 VACUUM FITTING 27 DK 04019 LPG INLET HOSE 17 DK 04006 FILTERLOCK OUTLET FITTING 28 DK 04020 CLAMP 18 SK 04007 TUBE ASSY 29 DK 04021 ASSY s BRACKET 19 DK 04011 REGULATOR INLET FITTING 30 SK 04022 BOLT 20 DK 04012 REGULATOR 32 DK 04024 LOCKWASHER 21 DK 04013 REGULATORWATEROUTLET FITTING 33 DK 04025 REGULATOR WATER INLET FITTING 22 DK 04014 THERMOSTATE 34 SK 04026 WATER SUPPLY HOSE 23 ...

Page 17: ...ACUUM FITTING 39 DK 05005 VACUUM SIGNAL HOSE 40 SK 05006 GASKET 41 SK 05007 THROTTLE LEVER BRACKET 42 SK 05008 CONVERSION FLANGE 43 SK 05009 RETURN SPRING 44 SK 05010 DASHPOT 45 SK 05011 CABLE BRACKET OTHERS ITEM PART No NAME 46 DK 06001 NYLON STRAP 47 SK 06002 IDLE ADJUSTMENT HOSE 48 DK 06003 REFUELING INSTRUCTION DECAL 49 DK 06004 SAFETY MAINTENANCE ...

Page 18: ... to ensure the safety of lock valve longer bolt may lead to serious damage G1 89 gasket AF1 10 filter S7 3 screen BD1 26 diaphragm BD1 27 diaphragm BD1 27 5 diaphragm S1 59 Screw 2 S1 100 Screw 2 S4 18 valve seat S3 116 O ring P1 15 valve operating pin W1 42 retaining washer PP 1 4 116 Installation guide H1 14236 holder P1 14235 Installation pin 2 Remove 10 screws from cover which has the words Fu...

Page 19: ...18 3 Remove the cover and the gasket 4 4 Remove the filter and screen 5 Remove screw holding spring in p ...

Page 20: ...19 6 Remove the valve spring 7 Remove valve seat 8 Remove valve operating pin ...

Page 21: ... 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 NPT opening 11 Insert wire hook through Fuel Out threaded port to hook the retaining washer then ...

Page 22: ...ed using kerosene or equivalent petroleum solvent Do NOT use carburetor as it will attack synthetic rubber seals 13 Seal holder H1 14236 bottom tool should be placed as shown place the greased o ring seal into the holder using the installation pin P1 14235 upper tool recoat the seal with silicone grease The seal must be in the position shown in the photo groove facing up and visible Seal is tapere...

Page 23: ...rt to check the position of seal above the cavity of the seal recess see cut way step 10 17 Coat the installation pin with silicone grease and push the seal through the holder and into the seal recess of the body remove the installation pin and check for proper installation by looking into the Fuel in port O ring seal should be seated in the seal recess and groove should be visible ...

Page 24: ...p 10 19 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 20 Place valve seat on top of head of operating pin with aluminum side facing up and dark viton side against head of pin ...

Page 25: ...24 21 Add valve spring and secure with screw 22 Lift the spring slightly to confirm its freedom of movement 23 r Insert screen and filter ...

Page 26: ...25 24 Place gasket on body and align with screw holes 25 Add filter cover and secure with screws alternate side to another side 26 Remove diaphragm cover retaining screws ...

Page 27: ...arburetor cleaner Check valve operating lever for freedom of movement Use silicone grease to coat the surface of the gasket Which will contact the body Note gasket will only align with holes when installed correctly rivet heads in diaphragm plates should be on the cover side not the body side 28 28 29 Add diaphragm to body then ...

Page 28: ...27 30 Add cover and secure with screws ...

Page 29: ...een out of service for 30 days Gasket and diaphragms may deteriorate if the converter has been stored after use Inspect the gaskets before re installing the converter 1 2 Remove the 6 screws from secondary cover assembly Note the type of screws removed and sure the same type and size of screws are used in the same locations during reassembly 3 Loosen the secondary cover by tapping around the circu...

Page 30: ... secondary diaphragm Slide the conver and diaphragm toward the gas inlet to free the lever from the slotted tab of the diaphragm take care not to bend the lever 5 Remove the seconday lever fulcrum retaining screw S1 17460 001 6 Remove the seconday lever and fulcrum pin Be careful not to lose the fulcrum pin Remove the seconday spring ...

Page 31: ... cover 8 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 9 Remove the primary valve pin and regulator spring ...

Page 32: ...nd the gasket 11 Remove the gasket from the cover plate Clean cover plate as needed to ensure a good seal with a new gasket 12 The pen points to the aluminum alloy backing of the primary regulator valve in the vaporizing chamber 13 ...

Page 33: ...at for wear or cuts If the primary seat is worn or damaged the regulator is not rebuildable and must be replaced 14 15 14 Install new primary regulator valve 15 Set new primary gasket G1 35 from the kit on the converter cover plate Screw hole spacing prevents improper orientation of the diaphragm The primary pressure hole in the gasket must line up with the hole in the body conver plate ...

Page 34: ...Insert the primary valve pin the through the spring and into the cover plate 18 17 Insert the new primary valve pin through the previously removed spring and then into cover plate 19 18 Set the primary diaphragm in place on the converter body cover plate Line up the screw holes to the cover plate ...

Page 35: ...screws through the cover and cover plate into the converter 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 snap the new seat into the opening of the lever Be sure the new seat snap locks into place ...

Page 36: ... the body Place the secondary lever assembly into place over the spring 24 23 Hold the lever assmebly with the fulcrum pin in place in its locating groove and fasten in place with screw S1 17460 001 24 Tighten the screw to 32 in lbs 3 62 N m minimum ...

Page 37: ...Be careful not to apply excessive force to the secondary seat 26 Align the secondary diaphragm to the secondary lever as shown The end of the lever must protrude through the tab slot on the bottom of the new diaphragm after installation The gap from which the link is punched should be located toward the gas inlet 27 Install the secondary cover with the six screws S1 15265 003 ...

Page 38: ...37 28 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: ...nd 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 1 BRC dual fuel single fuel parts catalog list Compared 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 ...

Page 40: ...39 BRC dual fuel system BRC single fuel system No serial number 27 28 29 30 ...

Page 41: ...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 35 1000 16 GB5783 86 Bolt M6 12 1 17 N171 360002 000 Bend tie in 1 30YDHBW11 35 0001 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...

Page 42: ... Hose n16Dn25 1 L 100 26 BK25 G00 Clampφ25 40 2 JiaxingTaishan 27 PV 10 G00 Petrol solenoid valve PSV3 0 1 JiaxingTaishan single 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 ...

Page 43: ... 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 filter 5 OR 2037 Ring 7 OR 3162 Ring 27 OR 3081 Ring 28 Permanent magnet...

Page 44: ...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...

Page 45: ...sting screw 37c about in the middle of the stroke and th related 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 THE WATER ROOM 43 unless in case there are some leakages or in case of washing in acids In case it should be necessary the overhau...

Page 46: ...EMARTKS SERIES No 1 N051 371100 000 Cylinder support base 1 1 5 1 8T N171 371100 000 Cylinder support base 1 2 3 5T 2 N171 371001 000 Pin 2 3 GB894 1 86 Retainer ring 8 4 4 N171 371200 000 Bracket top 2 5 N171 371300 000 Buckle 2 6 N171 371002 000 Pin 2 7 N171 371400 000 connecting rod 2 8 N171 371003 000 straight pin 2 ...

Page 47: ... 87 Washer 8 3 7 GB5783 86 Bolt M8 20 3 8 GB6170 86 Nut M8 3 9 N171 372001 000 Positing plat 1 10 H2 63 G00 Coupling male connection 1 Parker 11 N171 372002 000 Pipe joint 1 30YDHBW11 362002 12 H2 66 G00 Dust cap 1 Parker 13 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 e...

Page 48: ...es 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 Not...

Page 49: ...erve soiled oil pass pass density 200C or 150C kg m3 actually measure actually measure According to SH T02212 Sheet copper corrosion Not more than 1 level Not more than 1 level According 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...

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