1-3.5R LPG Service Manual & Parts List

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
Original Instruction
ALL RIGHT RESERVED COPYRIGHT @Dec.2009 2nd EDITION

ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD.
FOREWORD
Thanks for your purchasing Hangzhou 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
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.
@Dec.2009 2nd EDITION

ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD.
Content
Ⅰ Parameter................................................................................................................................................... 1
Ⅱ Operations ................................................................................................................................................. 5
Ⅲ Fuel system parts catalog and maintenance manual.................................................................................. 7
1. IMPCO FUEL SYSTEM ......................................................................................................................................7

2. BRC COMBUSTION SYSTEM ............................................................................................................................37
3. CYLINDER AND ITS BRACKET ASSEMBLY CATALOG LIST (IMPCO AND BRC)...............................................42
Ⅳ Electrical system Contents…………………………………………………… ..…………44
Ⅴ Notice ...................................................................................................................................................... 72
Ⅰ Parameter
1.5~1.8t R series LPG forklift specification
Model CPQD15N-RW21-Y CPQD18N-RW21-Y

Combustion USA IMPCO Dual-Fuel Single-Fuel Dual-Fuel Single-Fuel
system Combustion system （Y2） (Y3) （Y2） (Y3)
configuration ITALY BRC Dual-Fuel Single-Fuel Dual-Fuel Single-Fuel
Combustion system （Y0） (Y1) （Y0） (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
3185×1080×1995 3222×1080×1995
（L×W×T）（include forks）
6.5-10-10PR/2 6.5-10-10PR/2
Tires（F/R）
5.00-8-8PR/2 5.00-8-8PR/2
Voltage V/Capacity Ah 12/60/20h 12/60/20h
Model NISSAN K21
Gasoline Rated power/rpm 31.2 KW /2250rpm
Engine
Max torque/rpm 143.7Nm/1600 rpm
displacement cc 1980
1
2~3.5t R series LPG forklift specification
CPQD25N- CPQD30N CPQD35N

Model CPQD20N –RW22-Y
RW22-Y –RW22-Y –RW22-Y
USA
IMPCO Single-Fuel Single-Fuel Single-Fuel Single-Fuel
Dual-Fuel Dual-Fuel Dual-Fuel Dual-Fuel
Combustion (Y3) (Y3) (Y3) (Y3)
Combustion （Y2）（Y2）（Y2）（Y2）
system
system
ITALY
configuration
BRC Single-Fuel Single-Fuel Single-Fuel Single-Fuel
Dual-Fuel Dual-Fuel Dual-Fuel Dual-Fuel
（Y0）（Y0）（Y0）（Y0）
system
Rated capacity Kg 2000 2500 3000 3500
Load center mm 500 500 500 500
Max lift height mm 3000 3000 3000 3000
Free lift height mm 140 140 155 155
Max lift speed mm/s 570 570 450 450
Mast tilt range F/R 6°/12° 6°/12° 6°/12° 6°/12°

Max speed(Unload)
20 20 18.5 18.5
Km/h
Min ground clearance
105 105 130 130
mm
Min Turning radius
2175 2255 2375 2430
(Out side) mm
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×H）
3600×1155×2120 3675×1155×2120 3820×1225×2150 3870×1225×2150
（include forks）
7.00-12-12PR 7.00-12-12PR 28×9-15-12PR/2 28×9-15-12PR/2
tires（F/R）
6.00-9-10PR 6.00-9-10PR 6.50-10-10PR/2 6.50-10-10PR/2
Voltage V/Capacity
Battery
Ah 12/60/20h
Model K25
Gasoline Rated power/rpm 37.4KW /2300rpm

engine Max torque/rpm 176.5Nm/1600 rpm
Displacement cc 2472
2
Model CPQD20N-RW22A-Y CPQD25N-RW22A-Y CPQD30N-RW22A-Y CPQD35N-RW22A-Y
USA Dual-Fuel Dual-Fuel Dual-Fuel Dual-Fuel

IMPCO （Y2） Single-Fuel （Y2） Single-Fuel （Y2） Single-Fuel （Y2） Single-Fuel
Combustion
system
system
ITALY Dual-Fuel Dual-Fuel Dual-Fuel Dual-Fuel
configuration
BRC （Y0） Single-Fuel （Y0） Single-Fuel （Y0） Single-Fuel （Y0） Single-Fuel
system


Max speed(Unload)
19.5 19.5 19.5 19.5
Km/h
Min ground clearance
105 105 130 130
mm
Min turning
2175 2235 2375 2415
radium(outside) mm
Gradeability
20 20 20 15
(Full load) %
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 3600×1155×2120 3675×1155×2120 3820×1225×2150 3870×1225×2150
forks）
7.00-12-12PR 7.00-12-12PR 28×9-15-12PR/2 28×9-15-12PR/2
Tires（F/R）
6.00-9-10PR 6.00-9-10PR 6.50-10-10PR/2 6.50-10-10PR/2
Voltage V/capacity
Battery 12/60/20h
Ah
Model K25
Displacement 2472
3
Model CPQD20N-RW22B-Y CPQD25N-RW22B-Y CPQD30N-RW22B-Y CPQD35N-RW22B-Y
Combustion Dual-Fuel Single-Fuel Dual-Fuel Single-Fuel Dual-Fuel Single-Fuel Dual-Fuel Single-Fuel

system configuration （Y2） (Y3) （Y2） (Y3) （Y2） (Y3) （Y2） (Y3)

Max speed(Unload)
Km/h 21 21 20 20
Ground clearance mm 105 105 130 130

Min turning radium
2175 2235 2375 2430
(outside) mm
Gradeability (full
20 20 20 15
load)%
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）
3600×1155×2120 3675×1155×2120 3820×1225×2150 3870×1225×2150
（include forks）
7.00-12-12PR 7.00-12-12PR 28×9-15-12PR/2 28×9-15-12PR/2
tires（F/R）
6.00-9-10PR 6.00-9-10PR 6.50-10-10PR/2 6.50-10-10PR/2
battery Voltage V/Capacity Ah 12/60/20h
Model K25

Displacement cc 2472
4
Ⅱ Operations
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. 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
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.
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
5
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.
6
Ⅲ 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 device
1)、LPG dual-fuel changing device-DFK8634A
2)、LPG single-fuel changing device-K8634A
There are three sections in Impco parts catalog and maintenance manual, they are list, illustration and
dismantle of main pars. For details, please see the reference content.
1． DFK8634A dual-fuel list
2． K8634A single-fuel list
3． Fuel system main parts’ illustration
4． Main part VFF30-2 valve dismantle process.
5． Main part COBRA-30177 Pressure reducer dismantle process
1. DFK8634A dual-fuel convert device list
Serial Code Name Specification Quantity
1 DK-01001 BRACKET-FUEL HOSE HOLDER 1
2 DK-01002 COUPLING-MALE TANK CONNECTION 1-1/4"F.ACME X 3/8" FNPT 1
1-2 Installed together
3 DK-01003 COUPLING-FEMALE TANK CONNECTION 1/4" FNPT X 1-1/4"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"NPT 1
6-12 installed together
13 DK-03001 GASOLINE SOLENOID VALVE 12V 1
7
14 DK-03002 SOLENOID INLET FITTING 1/4"SAE FLARE X 1/4"NPT X 90° 1
15 DK-03003 SOLENOID OUTLET FITTING 1/4"NPT X 1/8"NPT 1
16 DK-03004 CONVERSION FITTING 1/8" FPTX 1/8BSP X 90 1
17 DK-04001 Fuel change switch assemble 12V 1
18 DK-04002 AUXILIARY FUEL LINT 1000mm X 2- 3/8 SAE FLARE FITTING 1
19 DK-04003 FILTERLOCK INLET FITTING 3/8" SAE FLARE X 1/4"NPT 1
20 DK-04004 FILTERLOCK VFF30-2 1
21 DK-04005 VACUUM FITTING 1/4" ID HOSE X 1/8"NPT X 90° 1
22 DK-04006 FILTERLOCK OUTLET FITTING 3/8" INV FL X 1/4"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 THERMOSTATE 1
31 DK-04015 THERMOSTATE WATER OUTLET FITTING 3/8" SAE FLARE X 3/8"NPT X 90° 1
32 DK-04016 WATER RETURN HOSE 10mm ID HOSE, 600mm 1
33 DK-04017 WATER HOSE CLAMP 10-18mm 2
34 DK-04018 REGULATOR LPG OUTLET FITTING 5/8" ID HOSE X 1/2" NPT X 90° 1
35 DK-04019 LPG INLET HOSE 5/8 ID" HOSE X 850mm 1
36 DK-04020 CLAMP 15-30mm 2
37 DK-04021 ASSY's BRACKET 1
38 DK-04022 BOLT 1/4"-20 X 3/4" 4
39 DK-04023 FLATWASHER 1/4" 4
8
40 DK-04024 LOCKWASHER 1/4" 4
41 DK-04025 REGULATOR WATER INLET FITTING 3/8"SAE FLARE X 3/8" NPT 1
42 DK-04026 WATER SUPPLY HOSE 10mm ID HOSE, 1000mm 1
43 DK-05001 MIXER CA55-0258 1
44 DK-05002 CONVERSION FITTING 1/8" FNPT X 1/8 NPT X 90° 1
45 DK-05003 CRANKCASE VENTILATION HOSE FITTING 1/2" HOSE X 1/8 NPT 1
46 DK-05004 CRANKCASE VENTILATION HOSE 1/2" ID HOSE X 400mm 1
47 DK-05005 VACUUM SIGNAL HOSE 1/4" ID HOSE X 60mm 1
48 DK-05006 MIXER LPG INLET FITTING 5/8" ID HOSE X 3/8 NPT X 90° 1
49 DK-05007 VACUUM FITTING 1/4" ID HOSE X 1/4"-28 1
50
50 DK-06001 NYLON STRAP 8
51 DK-06002 GASOLINE FUEL GAUGE DECAL 1
52 DK-06003 FUEL CHANGOVERIN STRUCTION DECAL 1
53 DK-06004 REFUELING INSTRUCTION DECAL 1
54 DK-06005 SAFETY MAINTENANCE 1
55 DK-06006 PLASETIC CAP 1/2" ID CAP 1
9
2. K8634A Single-fuel switch device parts list
1 DK-01001 BRACKET-FUEL HOSE HOLDER 1
2 DK-01002 COUPLING-MALE TANK CONNECTION 1-1/4"F.ACME X 3/8" FNPT 1
3 DK-01003 COUPLING-FEMALE TANK CONNECTION 1/4" FNPT X 1-1/4"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
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"NPT 1
13 DK-04002 AUXILIARY FUEL LINT 1000mm X 2- 3/8 SAE FLARE FITTING 1
14 DK-04003 FILTERLOCK INLET FITTING 3/8" SAE FLARE X 1/4"NPT 1
15 DK-04004 FILTERLOCK VFF30-2 1
16 DK-04005 VACUUM FITTING 1/4" ID HOSE X 1/8"NPT X 90° 1
17 DK-04006 FILTERLOCK 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 1
20 DK-04012 REGULATOR COBRA,CB-30177 1
21 DK-04013 REGULATOR WATER OUTLET FITTING 3/8"NPT X 3/8" NPT X 90° 1
22 DK-04014 THERMOSTATE 1
23 DK-04015 THERMOSTATE WATEROUTLET FITTING 3/8" SAE FLARE X 3/8"NPT X 90° 1
24 DK-04016 WATER RETURN HOSE 10mm ID HOSE, 600mm 1
10
25 DK-04017 WATER HOSE CLAMP 10-18mm 2
26 DK-04018 REGULATOR 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 1
28 DK-04020 CLAMP 14-27mm 2
29 SK-04021 ASSY's BRACKET 1
30 DK-04022 BOLT 1/4"-20 X 3/4" 4
31 DK-04023 FLATWASHER 1/4" 4
32 DK-04024 LOCKWASHER 1/4" 4
33 DK-04025 REGULATOR WATER INLET FITTING 3/8"SAE FLARE X 3/8" NPT 1
34 SK-04026 WATER SUPPLY HOSE 10mm ID HOSE, 600mm 1
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 return spring 1
44 SK-05010 DASHPOT 1
45 SK-05011 CABLE BRACKET 1

NYLON STRAP 8
46 DK-06001
47 SK-06003 IDLE ADJUSTMENT HOSE 4mm ID X 300mm 1

REFUELING INSTRUCTION DECAL 1
48 DK-06004
SAFETY MAINTENANCE 1
49 DK-06005
11
3. Combustion system main parts illustration
CONNECTION
ITEM PART No NAME
LINE
BRACKET-FUEL
1 DK-01001
HOSE HOLDER
COUPLING-MALE
2 DK-01002 TANK
CONNECTION
COUPLING-FEMALE
3 DK-01003 TANK
CONNECTION
CONVERSION
4 DK-01004
FITTING
5 DK-01005 LPG HOSE ASSY
BULKHEAD ITEM PART No NAME
BULKHEAD
6 DK-02001
FITTING
HYDROSTATIC
7 DK-02002
RELIEF VALVE
8 DK-02003 LOCKWASHER
9 DK-02004 NUT
BUCKHEAD
10 DK-02005
OUTLET FITTING
11 DK-02006 PLASTIC CAP
BULKHEAD
12 DK-02007
INLET FITTING
DFK8634A DUAL-FUEL
GASOLINE
ITEM PART No NAME
SOLENOID
VALVE
GASOLINE
13 DK-03001 SOLENOID
VALVE
SOLENOID
14 DK-03002
INLET FITTING
SOLENOID
15 DK-03003
OUTLET FITTING
CONVERSION
16 DK-03004
FITTING
12
DFK8634A DUAL-FUEL FILTERLOCK-REGULATOR
ASSY
ITEMPART No NAME ITEMPART No NAME

18 DK-04002 AUXILIARY FUEL LINT 31 DK-04015THERMOSTATE WATER 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
LPGSOLENOIDVALVEINLET
24 DK-04008 37 DK-04021 ASSY's BRACKET
FITTING
25 DK-04009 LPG SOLENOID VALVE 38 DK-04022 BOLT
LPGSOLENOIDVALVEOUELET
26 DK-04010 39 DK-04023 FLATWASHER
FITTING
27 DK-04011 REGULATOR INLET FITTING 40 DK-04024 LOCKWASHER
28 DK-04012 REGULATOR 41 DK-04025 REGULATOR WATER INLET FITTING
REGULATORWATEROUTLET
29 DK-04013 42 DK-04026 WATER SUPPLY HOSE
FITTING
30 DK-04014 THERMOSTATE
13
DFK8634A DUAL-FUEL ITEM PART No NAME
CARBURETOR ASSY
43 DK-05001 MIXER
CONVERSION
44 DK-05002
FITTING
CRANKCASE
45 DK-05003 VENTILATION
HOSE FITTING
CRANKCASE
46 DK-05004 VENTILATION
HOSE
VACUUM
47 DK-05005
SIGNAL HOSE
MIXER LPG
48 DK-05006
INLET FITTING
VACUUM
49 DK-05007
FITTING
14
K8634A SINGL-FUEL
FILTERLOCK-REGULATOR ASSY
K8634A SINGLE-FUEL FILTERLOCK-REGULATOR ASSY

13DK-04002 AUXILIARY FUEL LINT 24 DK-04016 WATER RETURN HOSE
14DK-04003 FILTERLOCK INLET FITTING 25 DK-04017 WATER HOSE CLAMP
15DK-04004 FILTERLOCK 26 DK-04018 REGULATOR LPG OUTLET FITTING
16DK-04005 VACUUM FITTING 27 DK-04019 LPG INLET HOSE
17DK-04006 FILTERLOCK OUTLET FITTING 28 DK-04020 CLAMP
18SK-04007 TUBE ASSY 29 DK-04021 ASSY's BRACKET
19DK-04011 REGULATOR INLET FITTING 30 SK-04022 BOLT
20DK-04012 REGULATOR 32 DK-04024 LOCKWASHER
REGULATORWATEROUTLET
21DK-04013 33 DK-04025 REGULATOR WATER INLET FITTING
FITTING
22 DK-04014 THERMOSTATE 34 SK-04026 WATER SUPPLY HOSE
THERMOSTATEWATEROUTLET
23 DK-04015
FITTING
15
K8634A SINGLE-FUEL
ITEM PART No NAME
CARBURETOR
35 SK-05001 MIXER
IDLE
36 SK-05002 ADJUSTMENT
SCREW
MIXER LPG
37 SK-05003
INLET FITTING
VACUUM
38 SK-05004
FITTING
VACUUM
39 DK-05005
SIGNAL HOSE
40 SK-05006 GASKET
THROTTLE
41 SK-05007 LEVER
BRACKET
CONVERSION
42 SK-05008
FLANGE
43 SK-05009 RETURN SPRING
44 SK-05010 DASHPOT
CABLE
45 SK-05011
BRACKET
OTHERS ITEM PART No NAME
46 DK-06001 NYLON STRAP

IDLE
47 SK-06002 ADJUSTMENT
HOSE
REFUELING
48 DK-06003 INSTRUCTION
DECAL
SAFETY
49 DK-06004
MAINTENANCE
16
4. VFF30-2 Filter lock disassembly and assembly flow
a) Do not use the TELFON screw thread instead of NPT type, where the fuel pass through.
b) Use suds inspect all joints, fuel tank and covers.
c) Using the correct bolt 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
Remove 10 screws from cover which has the

words "Fuel In" cast into it.
17
3
Remove the cover and the gasket
4
Remove the filter and screen
Remove fixed screw of valve spring
18
6
Remove the valve spring
Remove valve seat
Remove valve operating pin
19
9
Using a bent paper or wire, take a hook as

shown
10
Sectional view shows that: the relationship of

valve spring, valve seat, valve operating pin,
seal retaining washer and O-ring. Note that at
first, remove valve operating pin, and then
remove retaining washer from the hole of
"Fuel out”.
11
Insert wire hook through "Fuel Out" to hook

the retaining washer.
20
12
Pull the retaining washer out of the body

through the jet hole
13
Using the same hook/wire, pull the
o-ring seal out from the hole of valve
operating pin, if necessary, clean
valve body ,cover ,injecting area with
paraffin or the same gasoline fluid.
Prohibit using carburetor, as it will
damage synthetic rubber seals.
14 Installation tools should be placed as

shown. Place the greased o-ring seal
into the circle hole of holder, and the
bigger circle of surface should be up,
recoat the seal with silicone grease. The
seal must be in the position shown in
the photo, groove facing up, and
visible, Seal is tapered to match hole in
the seal holder.
21
15
Place the body on the filter and lay up, as

shown.
16
With the o-ring lip seal in the holder, groove

is visible and facing up, put the holder into
the body, look through the Fuel in port to
check the position of seal.
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 input.
O-ring seal should be seated in the seal recess
and groove should be visible.
22
18
Use needle nose pliers to insert seal retainer

washer through the fuel threaded port. refer
to step-10
19
Lubricate valve operating pin with silicone

grease and insert it into body as shown, so
that pin passes through retainer washer and
o-ring lip seal. Rotate pin slowly 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
fluoride side against head of pin
23
21
Add valve spring and tighten with screw.
22
Lift the spring slightly to confirm its freedom

of movement.
23
Insert screen and filter
24
24
Place gasket on body and align

with screw holes
25
Add filter cover and fix with screws,

alternate side to another side.
26
Remove diaphragm cover retaining screws.
25
27
Cover and diaphragm are removed, clean

parts as necessary, only using kerosene or
equivalent petroleum solvent, Do not use
carburetor cleaner.
28
Check freedom of movement of valve

operating lever .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
29
.
Add diaphragm to body, then…
26
30
Add cover and tighten with screws
5. COBRA-30177 Regulator disassembly and assembly flow
1
The Rk-J kit contains all parts required for
periodic service. In installation of complete kit
should be required only at time of a major
overhaul of the converter, or the converter has
been 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
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
27
3
Loosen the secondary cover by tapping
around the circumference with a plastic
screwdriver handle
Remove the secondary cover and secondary

diaphragm as a unit.
Remove the secondary lever fulcrum

retaining screw.
28
6
Remove the secondary lever and fulcrum pin.

Be careful not to lose the fulcrum pin. Remove
the secondary spring.
Turn the relief valve over. Remove the seven

screws and take off the primary cover.
Remove the primary diaphragm The pen

pointed is the sensor port of pressure adjusting.
29
9
Remove the primary valve pin and regulator

spring
10
Remove the cover plate and the gasket
11
Remove the gasket from the cover plate. Clean

cover plate as needed to ensure a good seal
with a new gasket.
30
12
The pen points to the aluminum alloy is the

backside of the primary regulator, valve is in
the vaporizing chamber.
13
13
Remove the primacy regulator valve. Note:

remove oil and outer deposit from all chambers
and parts. Do not apply liquid cleaners to the
14 diaphragms .Inspect seat for wear or cuts.
15
14
Install a new primary regulator valve
31
15
Set a new washer on the relief valve 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 cover plate.
16
Place the cover plate and gasket on the

converter body and align the cover screw
holes. 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
32
18
Set the primary diaphragm in place on the

cover plate. Line up the screw holes to the
cover plate
19
Carefully place the primary cover over the

primary diaphragm. drill the screws through
21 the cover and cover plate, and screw into the
relief valve body.
20
22
Tighten the screws to minimum

torque:4.18 N.m, using a crisscross tool.
33
21
Remove the old secondary seat and snap

the new seat into the hole of the lever,
Be sure the new seat snap is locked into
it.
22
24 Position the secondary spring on the valve

body. Place the secondary lever assembly on
top of spring.
23
Keep the lever assembly condition, the
supporting pin is in its locating groove and
fasten in place with screw.
34
24
Tighten the screw to minimum torque:3.62

N.m.
25
The secondary lever should be 0.8mm higher

than valve 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.
26
Align the secondary diaphragm to the

secondary lever as shown.
35
27
Install the secondary cover with the six screws.
28
Tighten the screws in a crisscross pattern to

minimum torque: .3.29 N.m. To complete the
installation of the repair kit components.
36
2. 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
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.
BRC dual-fuel system
BRC single-fuel system（No serial number 27,28,29,30）
37
ITEM PART No NAME Q’ TY REMARKS SERIES
No.
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
25 JISK6347-25-G00 Low Working Pressure Hose n16Dn25 1 L=100
26 BK25-G00 Clampφ25-40 2 JiaxingTaishan

JiaxingTaishan
27 PV-10-G00 Petrol solenoid valve PSV3.0 1
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
38
b) 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. We there fore recommend to take the
necessary precautions.
The overhauling of the Flying Injection/Sequent ET98 LPG solenoid valve involves the replacement of
the 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) Filter
(5)O-ring 2037
（7）O-ring 3162
（28）Permanent magnet
Assemble 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.
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.
39
c) Instructions for the overhauling of BRC AT90E-AT90E Turbo reducer
DISASSEMBLING Steps:
1 - Disassembly the II stage back covers (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 sensitivity adjusting screw (37c) and substitute the O-Ring (37a) and the spring (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.
2 - Remount the idle adjusting screw (36a).
3 - Mount the stage I lever (14).
40
4 - Mount the diaphragm (10b) and the cover (7a) by securing it with the screws (4) having 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 sensitivity adjusting screw (37c) about in the middle of the stroke and the 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 overhauling, proceed as it follows:
1 - Dismount the cover (43) and extract the seal (42).
2 - Extract the two clamp spring (44).
3 - Slip off the water elbows (46).
4 - Substitute the four O-rings (45).
5 - Remount the elbows (46) and secure with the clamp spring (44).
6 - Remount the seal (42).
7 - Remount the water cover (43).
41
3. Cylinder and its bracket assembly catalog list (IMPCO and BRC)
a) Cylinder bracket assembly
REMARTKS
ITEM PART No NAME Q’ TY
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
42
b) Cylinder assemblies
Q’
ITEM PART No NAME REMARKS SERIES No.
TY
1 CYSW314-35-2.2-G00 Cylinder 1 1．5-1．8T
CYSW314-50-2.2-G00 Cylinder 1 2-3．5T
2 GB1527-87 Liquid brass pipeφ8×1 L=270
3 TERL2.5-7-104-G00 Fasten pipe nut 8 4 Jiaxingtaishan
4 TERL2.5-7-105-G00 Brass seal ring 8 4 Jiaxingtaishan
5 TERL2.5-8-G00 Filling mouth 1 Jiaxingtaishan
6 GB93-87 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
43
Ⅳ Electrical system Contents
图1 电气系统
CPQD15/18N-RW21-Y3
Fig.1 Electrical system
44
图1 电气系统
CPQD15/18N-RW21-Y3
序号代号名称数量备注或适用车型物料码
Item No. Part No. Description Q’ty Remarks or Series No Code No.
E02 分电器 Distributor （1）发动机配套 Supply by engine
E03 火花塞 Spark plug （1）发动机配套 Supply by engine
E05 汽化器 Carburetor （1）发动机配套 Supply by engine
E06 点火线圈 Ignition Coil （1）发动机配套 Supply by engine
F3-F10 N163-704000-820 保险丝盒 Fuse Box 1 N163-704000-820
G1 R9619-700001-000 蓄电池 Battery 1 R9619-700001-000
G2 发电机 Alternator （1）发动机配套 Supply by engine
H1-H2 N163-750000-000 前小灯总成 Front lamps assembly 1 N163-750000-000
H3-H4 GR505-740000-000 前大灯总成 Rear lamps assembly 2 GR505-740000-000
H5-H6 R960-770000-000 组合后灯 Combination tail lamp 1 R960-770000-000
H7 12V/2W 内照明灯 Instrument panel lamp 2
H8 R960-707100-500 警灯 Warning lamp 1 R960-707100-500
45
图1 电气系统
CPQD15/18N-RW21-Y3
H10 12V/2W 充电指示灯 Charge indicator lamp （1）组合仪表配套 Combination meter
H11 12V/2W 油压指示灯 Oil pressure indicator lamp （1）组合仪表配套 Combination meter
H12 12V/2W 油温指示灯 Oil temperature indicator lamp （1）组合仪表配套 Combination meter
H14 12V/2W 左转指示灯 Left turn signal lamp （1）组合仪表配套 Combination meter
H15 12V/2W 右转指示灯 Right turn signal lamp （1）组合仪表配套 Combination meter
H01 DL124ED-G00 电喇叭 Horn 1 DL124ED-G00
H02 DJB-12B-G00 倒车报警器 Reverse warner 1 DJB-12B-G00
K1 N163-702200-820 起动继电器 Start relay 1 N163-702200-820
K2 N163-700010-820 检查继电器 Check relay 1 N163-700010-820
K3 N163-700010-820 大灯继电器 Head lamp relay 1 N163-700010-820
K7 XF251-700200-000 汽化器继电器 Carburetor relay （1）发动机配套 Supply by engine XF251-700200-000
K11 N163-701100-000 闪光器 Flasher 1 N163-701100-000
46
图1 电气系统
CPQD15/18N-RW21-Y3
KZ H24C2-40601-G00 控制盒 Control box 1 H24C2-40601-G00
M1 起动机 Starter （1）发动机配套 Supply by engine
P1 DW-2HZA 水温表 Water temperature gauge （1）组合仪表配套 Combination meter 70021862
P2 DR-2HZ 油量表 Fuel quantity gauge （1）组合仪表配套 Combination meter 70021862
P3 D-704-1E 计时表 Timer （1）组合仪表配套 Combination meter 70021862
S1 R960-705000-000 组合开关总成 Multifunction Switch 1 R960-705000-000
S2 JK106-G00 警示灯开关 Warning lamp switch 1 JK106-G00
S3 N163-700600-000 制动灯开关 Brake switch 1 N163-700600-000
S4 喇叭按钮 Horn button （1）方向盘 Supply by steering wheel
S6 JK107-G00 大小灯开关 Head lamp & signal lamp switch 1 JK107-G00
S7 JK406C-G00 预热起动开关 Pre-heat & start switch 1 JK406C-G00
S8 ED250B-1-G00 紧急断电开关 Master disconnect 1 ED250B-1-G00
47
图1 电气系统
CPQD15/18N-RW21-Y3
S101 25240-89911 油压传感器 Oil pressure sensor （1）发动机配套 Supply by engine
S102 N163-700006-000 水温传感器 Water temperature sensor 1 N163-700006-000
S103 R960-700400-000 油量传感器 Water temperature sensor 1 R960-700400-000
S105 WG-2K(RC1/2)-G00 油温传感器 Oil temperature sensor 1 WG-2K(RC1/2)-G00
变速箱配套 Supply by
Y1 前进电磁阀 Forward solenoid valve （1）
transmission box
Y2 倒车电磁阀 Reverse solenoid valve （1）
transmission box
线号 001 R9624-703000-820 蓄电池接电源开关线 Battery to Master disconnect 1 R9624-703000-820
线号 002 R9619-700200-820 电源开关线接起动机线 Master disconnect to Starter 1 R9619-700200-820
线号 003-034 R9619-710000-820 车身主线束 Cable 1 R9619-710000-820
线号 003-033 R9711-710000-820 车身主线束 Cable 1 CPQD15/18N-RW21-Y3 R9711-710000-820
线号 0 R960-700300-820 起动机接地线 Starter to earth wire 1 R960-700300-820
线号 0 N163-700200-820 蓄电池负极引线 Battery negative cable 1 N163-700200-820
48
图2 电气系统
CPQD20/25N-RW22B-Y3
49
50
图2 电气系统
CPQD20/25N-RW22B-Y3
G1 R9619-700001-000 蓄电池 Battery 1 R9619-700001-000
51
图2 电气系统
CPQD20/25N-RW22B-Y3
K7 汽化器继电器 Carburetor relay （1）发动机配套 Supply by engine
K11 N163-701100-000 闪光器 Flasher 1 N163-701100-000
52
图2 电气系统
CPQD20/25N-RW22B-Y3
53
图2 电气系统
CPQD20/25N-RW22B-Y3
变速箱配
油温传感器 Oil temperature sensor （1） CPQD20/25N-RW22B-Y3
Supply by transmission box
变速箱配 Supply by transmission
box
box
线号 003-034 R9619-710000-820 车身主线束 Cable 1 R9619-710000-820
线号 003-034 R5619-710000-820 车身主线束 Cable 1 R5619-710000-820
线号 003-033 R576-710000-820 车身主线束 Cable 1 CPQD20/25N-RW22B-Y3 R576-710000-820
54
.图.3 电气系统
CPQD20/25N-RW22A-Y3
55
56
.图.3 电气系统
CPQD20/25N-RW22A-Y3
G1 R9619-700001-000 蓄电池 Battery 1 R9619-700001-000
57
.图.3 电气系统
CPQD20/25N-RW22A-Y3
K11 N163-701100-000 闪光器 Flasher 1 N163-701100-000
58
.图.3 电气系统
CPQD20/25N-RW22A-Y3
S5 R963-705000-000 转向灯开关 Turn signal lamp switch 1 R963-705000-000
S10 JK208A 空挡起动开关 Neutral start switch （1）
transmission box
59
.图.3 电气系统
CPQD20/25N-RW22A-Y3
S14 JK208A 倒车灯开关 Reversing lamp switch （1）
transmission box
S105 WG-2K(RC1/2)-G00 油温传感器 Oil temperature sensor 1
线号 003-032 R9620-710000-820 车身主线束 Cable 1 R9620-710000-820
线号 003-031 R9715-710000-820 车身主线束 Cable 1 CPQD20/25N-RW22A-Y3 R9715-710000-820
60
图4 电气系统
CPQD30/35N-RW22B-Y3
61
图4 电气系统
CPQD30/35N-RW22B-Y3
G1 R9619-700001-000 蓄电池 Battery 1 R9619-700001-000
62
图4 电气系统
CPQD30/35N-RW22B-Y3
K7 XF251-700200-000 汽化器继电器 Carburetor relay （1）发动机配套 Supply by engine XF251-700200-000
K11 N163-701100-000 闪光器 Flasher 1 N163-701100-000
63
图4 电气系统
CPQD30/35N-RW22B-Y3
P1 DW-2HZA 水温表 Water temperature gauge （1）组合仪表配套 Combination 70021862
P2 DR-2HZ 油量表 Fuel quantity gauge （1）组合仪表配 Combination meter 70021862
64
图4 电气系统
CPQD30/35N-RW22B-Y3
变速箱配
油温传感器 Oil temperature sensor （1） CPQD30/35N-RW22B-Y3
Supply by transmission box
box
box
线号 003-034 R9619-710000-820 车身主线束 Cable 1 R9619-710000-820
线号 003-034 R5619-710000-820 车身主线束 Cable 1 R5619-710000-820
线号 003-033 R576-710000-820 车身主线束 Cable 1 CPQD30/35N-RW22B-Y3 R576-710000-820
65
.图 5 电气系统
CPQD30/35N-RW22A-Y3
66
67
.图 5 电气系统
CPQD30/35N-RW22A-Y3
G1 R9619-700001-000 蓄电池 Battery 1 R9619-700001-000
68
.图 5 电气系统
CPQD30/35N-RW22A-Y3
K11 N163-701100-000 闪光器 Flasher 1 N163-701100-000
69
.图 5 电气系统
CPQD30/35N-RW22A-Y3
S5 R963-705000-000 转向灯开关 Turn signal lamp switch 1 R963-705000-000
S10 JK208A 空挡起动开关 Neutral start switch （1）
transmission box
70
.图 5 电气系统
CPQD30/35N-RW22A-Y3
S14 JK208A 倒车灯开关 Reversing lamp switch （1）
transmission box
S105 WG-2K(RC1/2)-G00 油温传感器 Oil temperature sensor 1
线号 003-032 R9620-710000-820 车身主线束 Cable 1 R9620-710000-820
线号 003-031 R9715-710000-820 车身主线束 Cable 1 CPQD30/35N-RW22A-Y3 R9715-710000-820
71
Ⅴ 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 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.
72
List1 technique parameter of LPG special for vehicle
Item component com position Quality parameter Trial
37.80C vapor pressure (indication) According to

≤1430 890～1430 660～1340
a
kPa GB/T 6602
40～
propane ＞85 ＞65～85
65
Butane and advanced ≤2.5 — —
component Pentane and advanced — ≤2.0 ≤2.0 b

（Ψ） % SH/T 0614
Total alkenes ≤10 ≤10 ≤10
Butadiene (1.3
≤0.5 ≤0.5 ≤0.5
butadiene)
100ml remainder after
≤0.05 ≤0.05 ≤0.05
evaporation ml According to
remainder
SY/T7509
Observe soiled-oil pass pass pass
actually actually According to

density（200C or 150C） kg/m3 actually measure
SH/T 0221
measure measure
According to
Sheet copper corrosion ≤1 ≤1 ≤1
SH/T 0232
According to
Total sulfur content /(mg/m3) ＜270 ＜270 ＜270 d
SH/T 0222
According to
sulfured hydrogen 0 0 0
SH/T 0125
free water 0 0 0 Eyeballing

Note 1：Total sulfur content is the gaseous content at 0℃、101.35kpa.
Note 2：could measure the density, at the same time, check whether free water exists by eyeballing.
a) Calculating vapor pressure according to GB/T 12576, but arbitrating vapor pressure according to GB/T
6602.
b) Components can be menstruated by SH/T 0230 method，but arbitrating according to SH/T 0614.
c) Density can be menstruated by GB/T 12576 method，but arbitrating according to SH/T 0221.
d) Total sulfur content can be menstruated by SY/T 7508 method, but arbitrating according to SH/T 0222.
Getting from：PRC standard《Automotive liquefied petroleum gas 》GB 19159-2003）
73
ZHEJIANG HANGCHA ENGINEERING MACHINERY CO., LTD
Manufacturing site:
88 Donghuan Road, LinAn Economic Development zone, Zhejiang, P.R.China ZIP:311305
Registered Address
398 Shi Qiao Road, Hangzhou, P.R. China) ZIP :310004
Fax: 0086-571-88132890 0086-571-88926789
Web: http://www.hcforklift.com
E-mail: sales@hcforklift.com

1-3.5R LPG Service Manual & Parts List

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1-3.5R LPG Service Manual & Parts List

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CPQD15/18N-RW21-Y CPQD20/25/30/35N-RW22-Y

1.5-3.5t R Series of LPG Forklift

（USA IMPCO Combustion System）

（ITALY BRC Combustion System）

SERVICE MANUAL & PARTS LIST

ALL RIGHT RESERVED COPYRIGHT @Dec.2009 2nd EDITION

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

@Dec.2009 2nd EDITION

Ⅲ Fuel system parts catalog and maintenance manual.................................................................................. 7

1. IMPCO FUEL SYSTEM ......................................................................................................................................7

1.5~1.8t R series LPG forklift specification

Model CPQD15N-RW21-Y CPQD18N-RW21-Y

Load center mm 500 500

Max lift height mm 3000 3000

Max speed(Unload) Km/h 15 15

Track（F/R）mm 890/900 890/900

Self weight Kg 2690 2880

CPQD25N- CPQD30N CPQD35N

Rated capacity Kg 2000 2500 3000 3500

Load center mm 500 500 500 500

Max lift height mm 3000 3000 3000 3000

Free lift height mm 140 140 155 155

Max lift speed mm/s 570 570 450 450

Mast tilt range F/R 6°/12° 6°/12° 6°/12° 6°/12°

trace（F/R）mm 965/970 965/970 1005/975 1005/975

Self weight Kg 3440 3765 4255 4755

Gasoline Rated power/rpm 37.4KW /2300rpm

USA Dual-Fuel Dual-Fuel Dual-Fuel Dual-Fuel

Rated capacity Kg 2000 2500 3000 3500

Load center mm 500 500 500 500

Mast tilt range F/R 6°/12° 6°/12° 6°/12° 6°/12°

Trace（F/R）mm 965/970 965/970 1005/975 1005/975

Gasoline Rated power/rpm 37.4KW /2300rpm

engine Max torque/rpm 176.5Nm/1600 rpm

Combustion Dual-Fuel Single-Fuel Dual-Fuel Single-Fuel Dual-Fuel Single-Fuel Dual-Fuel Single-Fuel

Rated capacity Kg 2000 2500 3000 3500

Load center mm 500 500 500 500

Ground clearance mm 105 105 130 130

Trace（F/R）mm 965/970 965/970 1005/975 1005/975

Gasoline Rated power/rpm 37.4KW /2300rpm

1. DFK8634A dual-fuel convert device list

Serial Code Name Specification Quantity

1 DK-01001 BRACKET-FUEL HOSE HOLDER 1

2 DK-01002 COUPLING-MALE TANK CONNECTION 1-1/4"F.ACME X 3/8" FNPT 1

1-2 Installed together

3 DK-01003 COUPLING-FEMALE TANK CONNECTION 1/4" FNPT X 1-1/4"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