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Service Manual Chassis & Mast GP15N GP18N GP20CN GP20N GP25N GP30N GP35N

ET34L-00011-up ET34L-40001-up ET34L-60001-up ET17DL-00011-up ET17DL-50001-up ET13FL-00011-up ET13FL-50001-up

MC/FC DP15N DP18N DP20CN DP20N DP25N DP30N DP35N

For use with S4Q2, S4S and K21/K25 Engine Service Manuals.

ET16D-00011-up ET16D-40001-up ET16D-60001-up ET18C-00011-up ET18C-50001-up ET14E-00011-up ET14E-50001-up

99719-69110


GROUP INDEX GROUP INDEX

Items

GENERAL INFORMATION

Model view, Truck models covered, Serial number locations, Dimensions, Technical data

1

COOLING SYSTEM

Fan removal and installation, Fan belt inspection and adjustment

2

ELECTRICAL SYSTEM

Console box, Chassis electrical devices, Battery maintenance, Electrical system schematic

3

CONTROLLERS

Main functions, Service tool functions, Input/output monitor, Error codes and troubleshooting

4

POWER TRAIN

Removal and installation

5

POWERSHIFT TRANSMISSION

Torque converter, 1-speed transmission, Control valve, Automatic 2-speed transmission

6

FRONT AXLE AND REDUCTION DIFFERENTIAL

Front tires, Front axle, Reduction and differential

7

REAR AXLE

Rear tires, Rear axle, Toe-in, Minimum turning radius

8

BRAKE SYSTEM

Master cylinder, Wheel cylinders, Wheel brakes, Brake booster

9

STEERING SYSTEM

Steering gear, Power cylinder, Flow divider

10

HYDRAULIC SYSTEM

Hydraulic tank, Gear pump, Control valve, Lift and tilt cylinders, Flow regulator valve, Down safety valve

11

MAST AND FORKS

Simplex mast, Duplex mast, Triplex mast

12

SERVICE DATA

Maintenance standards, Periodic service chart, Periodic replacement parts, Lubrication instructions, Special tools

13


GENERAL INFORMATION 1 Model View ............................................................................................... Truck Models Covered ........................................................................... Serial Number Locations ...................................................................... Dimensions ............................................................................................... Technical Data .........................................................................................

1– 1 1– 2 1– 3 1– 4 1– 5


GENERAL INFORMATION

Model View

MC Truck

210991

FC Truck

210992

1-1


GENERAL INFORMATION

Truck Models Covered This Service Manual furnishes servicing and maintenance information for the following trucks: Engine control

LPG engine

Diesel engine

Standard (Non-electronic control)

MC/FC

Electronic control

MC/FC

(FC type is used in torque converter model only.)

Diesel engine models

LPG engine models Truck class

1 ton class

2 ton class

3 ton class

Model code serial number

Engine mounted

GP15N

ET34L-00011-up

K21

GP18N

ET34L-40001-up

GP20CN

Model code serial number

Engine mounted

DP15N

ET16D-00011-up

S4Q2

K21

DP18N

ET16D-40001-up

S4Q2

ET34L-60001-up

K21

DP20CN

ET16D-60001-up

S4Q2

GP20N

ET17DL-00011-up

K21

DP20N

ET18C-00011-up

S4S

GP25N

ET17DL-50001-up

K21

DP25N

ET18C-50001-up

S4S

GP30N

ET13FL-00011-up

K25

DP30N

ET14E-00011-up

S4S

GP35N

ET13FL-50001-up

K25

DP35N

ET14E-50001-up

S4S

Truck model

1-2

Truck model


GENERAL INFORMATION

Serial Number Locations

210993

1-3


GENERAL INFORMATION

Dimensions

G

C

L

K

O

E J

A I

H

P

B

D

N

M F

210994

1-4


GENERAL INFORMATION

Technical Data Unit: mm (in.) Ref. No.

Model

Gasoline-engine Truck

Item

Diesel-engine Truck

GP15N

GP18N

(DP15N)

(DP18N)

A

Maximum lift

B

Free lift

C

Fork spread (outside)

D

Fork length

E

Tilt angle (forward – backward)

F

Overall length

G

Overall width (outside of tires)

H

Overall height (to top of mast lowered)

1995 (78.5)

I

Overall height (to top of overhead guard)

2065 (81.3)

J

Overall height (mast extended)

4055 (159.6)

K

Tread (front)

L

Tread (rear)

900 (35.4)

M

Wheelbase

1400 (55.1)

N

Front overhang

400 (15.7)

O

Minimum turning radius

P

Underclearance (at frame)

3000 (118) 115 (4.5) 200 to 920 (7.9 to 36.2) 920 (36.2) 6° – 12° 3180 (125.2)

3221 (126.8)

Single tire

1065 (41.9)

Dual tire

1330 (52.4)

Single tire

890 (35)

Dual tire

1025 (40.4)

1950 (76.8)

1980 (78) 150 (5.9)

1-5


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GENERAL INFORMATION

Unit: mm (in.) GP20CN

GP20N

GP25N

GP30N

GP35N

(DP20CN)

(DP20N)

(DP25N)

(DP30N)

(DP35AN)

3000 (118.1) 115 (4.5)

140 (5.5)

150 (5.9)

220 to 1000 (8.7 to 39.4)

250 to 1000 (9.8 to 39.4)

920 (36.2)

1070 (42.1) 6° – 12°

3279 (129.1)

3408 (134.2)

3625 (142.7)

1065 (41.9)

1150 (45.3)

1480 (58.3)

2070 (81.5) 4055 (159.6)

890 (35)

3860 (152)

1275 (50.2)

1290 (50.8)

1490 (58.7)

1995 (78.5) 2065 (81.3)

3795 (149.4)

2045 (80.5)

2180 (85.8)

2095 (82.5)

2105 (82.9)

4085 (160.8)

4055 (159.6)

960 (37.8)

1060 (41.7)

1140 (44.9)

900 (35.4)

980 (38.6)

1400 (55.1)

1600 (63)

1700 (66.9)

415 (16.3)

455 (17.9)

490 (19.3)

2020 (79.5) 150 (5.9)

2200 (86.6)

2230 (87.8)

160 (6.3)

1-6

2380 (93.7)

2440 (96.1)

190 (7.5)

200 (7.9)


COOLING SYSTEM Specification ............................................................................................ Structure .................................................................................................... Removal and Installation ...................................................................... Inspection and Adjustment ..................................................................

2– 1 2– 2 2– 3 2– 5

Fan Belt Inspection .................................................................................... 2 – 5 Fan Belt Tension ........................................................................................ 2 – 5 Connecting Radiator Hoses ....................................................................... 2 – 5 Unit Layout ................................................................................................ 2 – 5 Coolant ...................................................................................................... 2 – 6 Radiator Cap ............................................................................................. 2 – 6

2


COOLING SYSTEM

Specification Truck Models Items

1 ton class

Type Cooling System

2 ton class Water-cooled, forced circulation

Radiator

Corrugated fin (pressure) type

Water pump

Centrifugal type

Thermostat

Wax Pellet Type

2-1

3 ton class


COOLING SYSTEM

Structure

Fan (directly coupled to engine)

209610

Radiator Shroud

Hose layout

S4Q2 engine Lower hose

K21, K25 engines

Upper hose

S4Q2, S4S

Reservoir tank K21, K25

S4S engine

209611

2-2


COOLING SYSTEM

Removal and Installation Fan Belt Removal Engine

Fan

1

2 209612

Sequence 1 2

Tension pulley assembly, Bolt Fan belt

Start by:

Remove the radiator cover.

Suggestion for Removal (1) Loosen the tension pulley lock bolt by three or four turns. If the bolt is loosened insufficiently, the tension pulley will not be moved.

Note: Do not loosen the lock bolt to such an extent that the bolt would be removed.

Fan

Tension pulley

(2) Move the tension pulley fully toward the fan, then remove the belt. 209613

2-3


COOLING SYSTEM

Installation To install, follow the removal sequence in reverse. Also follow the instructions given below. (1) Before installing the belt, turn the fan to check for smooth rotation. Replace the bearing if it generates abnormal sound. (2) After installing the belt, push it to make sure that the tension pulley moves, then tighten the pulley lock bolt firmly.

2-4

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