Service Manual Chassis, Mast & Options GC20N GC25N GC28N GC30N GC33N
AT90-10121-up AT90-10121-up AT83F-10121-up AT83F-10121-up AT83F-60121-up
For use with K25 Engine Service Manual.
99719-6C120
GROUP INDEX GROUP INDEX
Items
GENERAL INFORMATION
Model View, Truck Models Covered, Serial Number Locations, Dimensions, Technical Data
1
COOLING SYSTEM
Specification, Structure, Removal and Installation, Inspection and Adjustment
2
ELECTRICAL SYSTEM
Chassis Electrical Devices Wiring Outline, Structure, Console Box, Battery, Wire Color, Troubleshooting, Electrical Schematic
3
CONTROLLERS
Outline, Main Functions, Service Tool Functions, Locations of Sensors and Switches
4
POWER TRAIN
Removal and Installation
5
POWERSHIFT TRANSMISSION
Structure and Function, Removal and Installation, Control Valve, Input Shaft Assembly, Oil Pump Assembly, Inspection and Adjustment, Troubleshooting, Tightening Torque, Service Data
6
FRONT AXLE
Structure, Removal and Installation, Disassembly and Reassembly, Service Data
7
REDUCTION DIFFERENTIAL
Structure and Function, Removal and Installation, Disassembly and Reassembly, Troubleshooting
8
REAR AXLE
Structure and Functions, Removal and Installation, Disassembly and Reassembly, Troubleshooting, Service Data
9
BRAKE SYSTEM
Structure, Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, Service Data
10
STEERING SYSTEM
Structure and Functions, Disassembly and Reassembly, Steering Valve, Trobleshooting, Service Data
11
HYDRAULIC SYSTEM
Structure and Functions, Disassembly and Reassembly, Inspection and Adjustment, Troubleshooting, Service Data, Control Valve
12
MAST AND FORKS
Mast Systems, Structure, Removal and Installation, Disassembly and Reassembly, Inspections and Adjustment, Troubleshooting, Service Data
13
SERVICE DATA
Maintenance Schedule, Tightening Torques for Standard Bolts and Nuts, Parts to be Changed Periodically, Lubrication Instructions, Weight of Major Components, Special Service Tool
14
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
Truck Models Covered This Service Manual provides servicing and maintenance information for the following trucks:
Truck class
Gasoline-engine models Truck model
Serial number
Engine mounted
2 ton class
GC20N GC25N
AT90-10121-up AT90-10121-up
K25 K25
3 ton class
GC28N GC30N GC33N
AT83F-10121-up AT83F-10121-up AT83F-60121-up
K25 K25 K25
Truck class
Dual fuel Gasoline-engine models Truck model
Serial number
Engine mounted
2 ton class
GC20N GC25N
AT90-10121-up AT90-10121-up
K25 K25
3 ton class
GC28N GC30N GC33N
AT83F-10121-up AT83F-10121-up AT83F-60121-up
K25 K25 K25
Truck class
LPG-engine models Truck model
Serial number
Engine mounted
2 ton class
GC20N GC25N
AT90-10121-up AT90-10121-up
K25 K25
3 ton class
GC28N GC30N GC33N
AT83F-10121-up AT83F-10121-up AT83F-60121-up
K25 K25 K25
1-2
GENERAL INFORMATION
Serial Number Locations
210693
1-3
GENERAL INFORMATION
Dimensions
G C
K
L
E J
A H
I
P
B D
M
N
O
F
209608
1-4
GENERAL INFORMATION
Technical Data Unit: mm (in.) Ref. No.
Truck Model GC20N
GC25N
GC28N
GC30N
GC33N
Item
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)
2110 (83.1)
I
Overall height (to top of overhead guard)
2072 (81.6)
J
Overall height (mast extended)
K
Tread (front)
L
Tread (rear)
990 (39.0)
M
Wheelbase
1400 (55.2)
N
Front overhang
O
Rear overhang
P
Underclearance (at frame)
3340 (131.5)
3315 (130.5)
130 (5.1)
135 (5.3)
220 to 920 (8.7 to 36.2)
200 to 960 (7.9 to 37.8) 1070 (42.1)
5° – 9°
5° – 6°
3358 (132.2) 3419 (134.6) 3484 (137.2)
3518 (138.5)
Single tire
1064 (41.9)
1115 (43.9)
Wide-Stance
1128 (44.4)
1155.2 (45.5)
4570 (179.9)
4540 (178.7)
4570 (179.9)
Single tire
886 (34.9)
912 (35.9)
Wide-Stance
950 (37.4)
952 (37.5)
414 (16.3) 474 (18.7)
535 (21.1)
436 (17.2) 578 (22.8) 139 (5.5)
1-5
612 (24.1)
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 – 6 Coolant ...................................................................................................... 2 – 6 Radiator Cap ............................................................................................. 2 – 6
2
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COOLING SYSTEM
Specification Truck Models
2 ton class
Items Type Cooling System
3 ton class
Water-cooled, forced circulation
Radiator
Corrugated fin (pressure) type
Water pump
Centrifugal type
Thermostat
Wax Pellet Type
2-1
COOLING SYSTEM
Structure
Fan (directly coupled to engine)
209610
210696
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.
Suggestions 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.
Fan
Tension pulley
NOTE Do not loosen the lock bolt to such an extent that the bolt would be removed. (2) Move the tension pulley fully toward the fan, then remove the belt.
2-3
209613
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