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
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)
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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