Service Manual

Chassis & Mast MC/FC

GP15N T25C-50001-up GPE15N T25C-58001/68001-up
GP15ZN T34-50011-up GPE15ZN T34-58011/68001-up
GP18N T25C-70001-up GPE18N T25C-78001/88001-up
GP18ZN T34-70001-up GPE18ZN T34-78001/88001-up
GP20CN T34-20001-up GPE20CN T34-28001/38001-up
GP20N T17D-00011-up GPE20N T17D-08011/18001-up
GP20ZN T35-00011-up GPE20ZN T35-08011/18001-up
GP25N T17D-50001-up GPE25N T17D-58001/68001-up
GP25ZN T35-50001-up GPE25ZN T35-58001/68001-up
GP30N T13F-30011-up GPE30N T13F-38011/48001-up
GP35AN T13F-50001-up GPE35AN T13F-58001/68001-up

DP15N T16D-50001/60001-up
DP18N T16D-70001/80001-up
DP20CN T16D-85001/87001-up
DP20N T18C-00011/10001-up
DP25N T18C-50001/60001-up
DP30N T14E-30011/40001-up
DP35AN T14E-50001/60001-up

For use with S4Q2, S4S and K15/K21/K25 Engine

Service Manuals. 99719-35120
 FOREWORD

®
This service manual is a guide for servicing Cat Lift Trucks. For your convenience the
instructions are grouped by systems as a ready reference.

The long productive life of your lift truck(s) depends on regular and proper servicing.
Servicing consistent with what you will learn by reading this service manual. Read the
respective sections of this manual carefully and familiarize yourself with all of the components
before attempting to start a test, repair or rebuild job.

The descriptions, illustrations and specifications contained in this manual are for trucks with
serial numbers in effect at the time of printing. Cat Lift Trucks reserve the right to change
specifications or design without notice and without incurring obligation.

The trucks listed in this manual are powered by K15/K21/K25 gasoline engines or S4Q2/S4S
diesel engines. For engine servicing, please refer to the applicable engine service manual.

Safety Related Signs

The following safety related signs are used in this service

manual to emphasize important and critical instructions:

Indicates a potentially hazardous

! WARNING situation which, if not avoided, could
result in death or serious injury.

Indicates a potentially hazardous

! CAUTION
situation which, if not avoided, may
result in death or serious injury or
damage to the machine.

Indicates a condition that can cause

NOTE
damage to, or shorten service life of,
the machine.

Pub. No. 99719-35120

 ! WARNING
SAFETY
! WARNING
The proper and safe lubrication and
maintenance for these lift trucks,
recommended by Cat Lift Trucks, are outlined
in the OPERATION & MAINTENANCE MANUAL.
Improper performance of lubrication or
maintenance procedures is dangerous and
could result in injury or death. Read and
understand the OPERATION & MAINTENANCE
MANUAL before performing any lubrication or
maintenance on these trucks.
The serviceman or mechanic may be unfamiliar with
many of the systems on this truck. This makes it
important to use caution when performing service
work. A knowledge of the system and/or components
is important before the removal or disassembly of any
component.
Because of the size of some of the truck components,
the serviceman or mechanic should check the weights
noted in this Manual. Use proper lifting procedures
when removing any components.
Following is a list of basic precautions that should
always be observed.
1. Read and understand all warning plates and decals
on the truck before operating, lubricating or
repairing the product.
2. Always wear protective glasses and protective
shoes when working around trucks. In particular,
wear protective glasses when pounding on any part
of the truck or its attachments with a hammer or
sledge. Use welders gloves, hood/goggles, apron
and other protective clothing appropriate to the
welding job being performed. Do not wear loose-
fitting or torn clothing. Remove all rings from
fingers when working on machinery.
3. Do not work on any truck that is supported only by
lift jacks or a hoist. Always use blocks or jack
stands to support the truck before performing any
disassembly.
! WARNING
Do not operate these trucks unless you have
read and understood the instructions in the
OPERATION & MAINTENANCE MANUAL.
Improper truck operation is dangerous and
could result in injury or death.
4. Lower the forks or other implements to the ground
before performing any work on the truck. If this
cannot be done, make sure the forks or other
implements are blocked correctly to prevent them
from dropping unexpectedly.
5. Use steps and grab handles (if applicable) when
mounting or dismounting a truck. Clean any mud
or debris from steps, walkways or work platforms
before using. Always face truck when using steps,
ladders and walkways. When it is not possible to
use the designed access system, provide ladders,
scaffolds, or work platforms to perform safe repair
operations.
6. To avoid back injury, use a hoist when lifting
components which weigh 23 kg (50 lb.) or more.
Make sure all chains, hooks, slings, etc., are in
good condition and are of the correct capacity. Be
sure hooks are positioned correctly. Lifting eyes
are not to be side loaded during a lifting operation.
7. To avoid burns, be alert for hot parts on trucks
which have just been stopped and hot fluids in
lines, tubes and compartments.
8. Be careful when removing cover plates. Gradually
back off the last two bolts or nuts located at
opposite ends of the cover or device and pry cover
loose to relieve any spring or other pressure, before
removing the last two bolts or nuts completely.
9. Be careful when removing filler caps, breathers and
plugs on the truck. Hold a rag over the cap or plug
to prevent being sprayed or splashed by liquids
under pressure. The danger is even greater if the
truck has just been stopped because fluids can be
hot.
10. Always use tools that are in good condition and be 19. Tighten connections to the correct torque. Make
sure you understand how to use them before sure that all heat shields, clamps and guards are
performing any service work. installed correctly to avoid excessive heat, vibration
11. Reinstall all fasteners with same part number. Do or rubbing against other parts during operation.
not use a lesser quality fastener if replacements are Shields that protect against oil spray onto hot
necessary. exhaust components in event of a line, tube or seal
failure, must be installed correctly.
12. If possible, make all repairs with the truck parked
on a level, hard surface. Block truck so it does not 20. Relieve all pressure in air, oil or water systems
roll while working on or under truck. before any lines, fittings or related items are
disconnected or removed. Always make sure all
13. Disconnect battery and discharge any capacitors
raised components are blocked correctly and be
(electric trucks) before starting to work on truck.
alert for possible pressure when disconnecting any
Hang “Do not Operate” tag in the Operator’s
device from a system that utilizes pressure.
Compartment.
21. Do not operate a truck if any rotating part is
14. Repairs, which require welding, should be
damaged or contacts any other part during
performed only with the benefit of the appropriate
operation. Any high speed rotating component that
reference information and by personnel adequately
has been damaged or altered should be checked for
trained and knowledgeable in welding procedures.
balance before reusing.
Determine type of metal being welded and select
correct welding procedure and electrodes, rods or
wire to provide a weld metal strength equivalent at
least to that of parent metal.
15. Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will it
be damaged in operation by contacting sharp
corners, or by rubbing against some object or hot
surface. Place wiring away from oil pipe.
16. Be sure all protective devices including guards and
shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair work,
use extra caution.
17. Always support the mast and carriage to keep
carriage or attachments raised when maintenance
or repair work is performed, which requires the
mast in the raised position.
18. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Pin hole (very small) leaks can result
in a high velocity oil stream that will be invisible
close to the hose. This oil can penetrate the skin
and cause personal injury. Use cardboard or paper
to locate pin hole leaks.
 HOW TO USE THIS MANUAL

Truck models covered in this manual:

• MC Truck (Mechanical Control System)
Mechanically controlled hydraulic system (conventional lever system)
• FC Truck (Finger-tip Control System)
Electronically controlled hydraulic system

MC Truck
Lever

Control
valve

FC Truck

FC lever box

Flow regulator Controller

valve Electric wiring

209601
Lever

Electromagnetic
control valve

Same as MC Truck except

electronic control system
Hydraulic
transducer
209602

• Gasoline Engine Truck (GPE, GP) . . . . . . . . . . . . . Equipped with K15/K21 or K25 Gasoline Engine
• Diesel Engine Truck (DP) . . . . . . . . . . . . . . . . . . . . Equipped with S4Q2 or S4S Diesel Engine
• Powershift Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipped with Powershift Transmission
• Manual Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipped with Manual Transmission
(2 Types of Clutch; Dry and Wet)
HOW TO USE THIS MANUAL (continued)
(Removal, Installation, Assembly and Disassembly)

Disassembly diagram (example)

Procedures are described in the text.

Disassembling sequence

209603

Sequence
1 Cover, Bolt, Washer (part name)
2 Snap ring ................ (part name)

Suggestion for disassembling

1. Output shaft, Removing
Remove output shaft using a special tool.

209604

Service Data

0.11 to 0.28 mm
A
Gear Backlash (0.0043 to 0.0110 in.)
B 0.5 mm (0.020 in.)
A: Standard Value
B: Repair or Service Limit
Symbols or abbreviation
OP Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)

Units
1. SI Units are used in this manual.
2. The following table shows the conversion of SI unit and customary unit.

Item SI unit Customary unit

1N 0.1020 kgf
Force
1 lbf 0.4536 kgf
1 kPa 0.0102 kgf/cm2
Pressure
1 psi 0.0703 kgf/cm2
1 N·m 0.1020 kgf·m
Torque
1 lbf·ft 0.1383 kgf·m
 GROUP INDEX

GROUP INDEX Items

Model view, Truck models covered, Serial number locations,
GENERAL INFORMATION Dimensions, Technical data 1

Specification, Structure, Removal and installation, Inspection and

COOLING SYSTEM adjustment 2

Chassis electrical devices wiring outline, Structure, Console box, Battery

ELECTRICAL SYSTEM maintenance, Wire color, Troubleshooting, Electrical schematics 3

Outline, Main functions, Service tool functions, Locations of sensors

CONTROLLERS and switches 4

Removal and installation (MC models), Removal and installation (FC

POWER TRAIN models) 5
Advantages and disadvantages of clutches by type of drive system, Principal
CLUTCHES differences between dry-type and wet-type clutches, Structure and function of 6
clutch, Adjustment, Troubleshooting, Service data

Structures, Removal and installation, Disassembly, Inspection and

MANUAL TRANSMISSION repair, Reassembly, Troubleshooting, Service data 7

Structure and function, Removal and installation, Disassembly and

POWERSHIFT TRANSMISSION reassembly, Inspection and adjustment, Troubleshooting, Service data 8

FRONT AXLE AND Structure, Removal and installation, Disassembly and reassembly,
REDUCTION DIFFERENTIAL Troubleshooting, Service data 9

Structure and functions, Removal and installation, Disassembly and

REAR AXLE reassembly 10

Structure, Disassembly and reassembly, Inspection and adjustment,

BRAKE SYSTEM Troubleshooting, Service data 11

Structure and function, Disassembly and reassembly, Steering valve,

STEERING SYSTEM Troubleshooting, Service data 12
Structure and functions, Disassembly and reassembly, Inspection and
HYDRAULIC SYSTEM adjustment, Troubleshooting, Service data, MC control valve, FC control
valve 13
Mast system, Structure and function, Removal and installation,
Disassembly and reassembly, Removal and installation of mast rollers and
MAST AND FORKS strips without removing mast from truck, Inspection and adjustment, 14
Troubleshooting, Service data
Maintenance schedule, Tightening torque for standard bolts and nuts,
SERVICE DATA Periodic replacement parts, Lubrication instructions, Special service 15
tools
 GENERAL INFORMATION

1
Model View ............................................................................................... 1– 1
Truck Models Covered ........................................................................... 1– 2
Serial Number Locations ...................................................................... 1– 4
Dimensions ............................................................................................... 1– 5
Technical Data ......................................................................................... 1– 6
 GENERAL INFORMATION

Model View

MC Truck

209605

FC Truck

210780

1-1
GENERAL INFORMATION

Truck Models Covered

This Service Manual provides servicing and maintenance information for the following trucks:

Engine control Gasoline engine Diesel engine LPG engine

Standard
MC/— MC/FC —
(Non-electronic control)
Electronic control MC/FC — MC/FC
(FC type is used in torque converter model only.)

Standard gasoline engine models Diesel engine models

Truck class Model code - Engine Model code - Engine
Truck model Truck model
serial number mounted serial number mounted
GP15N T25C-50001~ K15 DP15N T16D-50001~ S4Q2
— — — DP15N(F) T16D-60001~ S4Q2
GP18N T25C-70001~ K15 DP18N T16D-70001~ S4Q2
1 ton class
GP15ZN T34-50011~ K21 DP18N(F) T16D-80001~ S4Q2
GP18ZN T34-70001~ K21 DP20CN T16D-85001~ S4Q2
GP20CN T34-20001~ K21 DP20CN(F) T16D-87001~ S4Q2
GP20N T17D-00011~ K21 DP20N T18C-00011~ S4S
GP25N T17D-50001~ K21 DP20N(F) T18C-10001~ S4S
2 ton class
GP20ZN T35-00011~ K25 DP25N T18C-50001~ S4S
GP25ZN T35-50001~ K25 DP25N(F) T18C-60001~ S4S
GP30N T13F-30011~ K25 DP30N T14E-30011~ S4S
— — — DP30N(F) T14E-40001~ S4S
3 ton class
GP35AN T13F-50001~ K25 DP35AN T14E-50001~ S4S
— — — DP35AN(F) T14E-60001~ S4S

Notice: Characters at the end of truck model should be read as follows:

(F) : Finger-tip-controlled model
None: Mechanically-controlled model
Z : High-power engine model
C : Short body model

1-2
 GENERAL INFORMATION

Electronically-controlled gasoline engine models Electronically-controlled LPG engine models

Truck class Model code - Engine Model code - Engine
Truck model Truck model
serial number mounted serial number mounted
GPE15N T25C-58001~ K15
GPE15N(F) T25C-68001~ K15
GPE18N T25C-78001~ K15
GPE18N(F) T25C-88001~ K15 — — —
GPE15ZN T34-58011~ K21
1 ton class
GPE15ZN(F) T34-68001~ K21
GPE18ZN T34-78001~ K21
GPE18ZN(F) T34-88001~ K21
GPE20CN T34-28001~ K21
GPE20CN(F) T34-38001~ K21
GPE20N T17D-08011~ K21
GPE20N(F) T17D-18001~ K21
GPE25N T17D-58001~ K21
GPE25N(F) T17D-68001~ K21 — — —
2 ton class
GPE20ZN T35-08011~ K25
GPE20ZN(F) T35-18001~ K25
GPE25ZN T35-58001~ K25
GPE25ZN(F) T35-68001~ K25
GPE30N T13F-38011~ K25 — — —
GPE30N(F) T13F-48001~ K25 GPE30N(F) T13F-49001~ K25
3 ton class
GPE35AN T13F-58001~ K25 — — —
GPE35AN(F) T13F-68001~ K25 — — —

1-3
GENERAL INFORMATION

Serial Number Locations

Name Plate Chassis Serial Number Gasoline Engine Serial Number

Diesel Engine Serial Number

(2, 3 ton classes)

Diesel Engine Serial Number

(1 ton class and DP20N–25N)

Mast Serial Number Transmission Serial Number Transmission Serial Number

(Manual Transmission Truck) (Powershift Transmission Truck)

209607

1-4
 GENERAL INFORMATION

Dimensions

G C K L

A
I
H

P
B

D N M
F

210781

1-5
GENERAL INFORMATION

Technical Data
Unit: mm (in.)
Ref. Model Gasoline-engine GP15N GP18N
No. Truck GP15ZN GP18ZN
GPE15N GPE18N
GPE15ZN GPE18ZN
Diesel-engine
Truck (DP15N) (DP18N)
Item
A Maximum lift 3000 (118)
B Free lift 115 (4.5)
200 to 920
C Fork spread (outside) (7.9 to 36.2)
D Fork length 920 (36.2)
E Tilt angle (forward – backward) 6° – 12°
F Overall length 3180 (125.2) 3220 (126.8)
Single tire 1065 (41.9)
G Overall width (outside of tires)
Dual tire 1330 (52.4)
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)
Single tire 888.5 (35)
K Tread (front)
Dual tire 1025 (40.4)
L Tread (rear) 900 (35.4)
M Wheelbase 1400 (55.1)
N Front overhang 400 (15.7)
O Minimum turning radius 1950 (76.8) 1980 (78)
P Underclearance (at frame) 150 (5.9)

1-6
 GENERAL INFORMATION

Unit: mm (in.)
GP20N GP25N
GP20CN GP20ZN GP25ZN GP30N GP35AN
GPE20CN GPE20N GPE25N GPE30N GPE35AN
GPE20ZN GPE25ZN

(DP20CN) (DP20N) (DP25N) (DP30N) (DP35AN)

3000 (118) 3030 (119) 3000 (118)

115 (4.5) 140 (5.5) 145 (5.7) 150 (5.9)
220 to 920 220 to 1000 250 to 1000
(8.7 to 36.2) (8.7 to 39.4) (9.8 to 39.4)
920 (36.2) 1070 (42.1)
6° – 12°
3280 (129.1) 3410 (134.3) 3625 (142.7) 3795 (149.4) 3860 (152)
1065 (41.9) 1150 (45.3) 1275 (50.2) 1290 (50.8)
— 1480 (58.3) 1490 (58.7)
1995 (78.5) 2045 (80.5) 2180 (85.8)
2065 (81.3) 2070 (81.5) 2095 (82.5) 2105 (82.9)
4055 (159.6) 4085 (160.8) 4055 (159.6)
890 (35) 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) 2200 (86.6) 2230 (87.8) 2380 (93.7) 2440 (96.1)
150 (5.9) 160 (6.3) 190 (7.5) 200 (7.9)

1-7
GENERAL INFORMATION

Unit: mm (in.)
Model Gasoline-engine GP15N GP18N
Truck GP15ZN GP18ZN
GPE15N GPE18N
GPE15ZN GPE18ZN
Diesel-engine
Truck (DP15N) (DP18N)
Item
1500/500 1750/500
Capacity/load center kgf/mm (lbf/in.)
(3310/20) (3860/20)
GP15N: 500 (98) GP18N: 500 (98)
GP15ZN: 570 (112) GP18ZN: 570 (112)
rate load
GPE15N: 560 (110) GPE18N: 560 (110)
mm/sec (fpm)
Performance

GPE15ZN: 640 (126) GPE18ZN: 640 (126)

DP15N: 600 (118) DP18N: 600 (118)
Lift speed
GP15N: 560 (110) GP18N: 560 (110)
GP15ZN: 640 (126) GP18ZN: 640 (126)
unload
GPE15N: 570 (112) GPE18N: 570 (112)
mm/sec (fpm)
GPE15ZN: 650 (128) GPE18ZN: 650 (128)
DP15N: 650 (128) DP18N: 650 (128)
rate load
19/(11.8)
km/h (mph)
Travel speed
unload
19.5/(12.1)
km/h (mph)

1-8
 GENERAL INFORMATION

Unit: mm (in.)
GP20N GP25N
GP20CN GP20ZN GP25ZN GP30N GP35AN
GPE20CN GPE20N GPE25N GPE30N GPE35AN
GPE20ZN GPE25ZN

(DP20CN) (DP20N) (DP25N) (DP30N) (DP35AN)

2000/500 2000/500 2500/500 3000/500 3500/500

(4410/20) (4410/20) (5510/20) (6610/20) (7720/20)
GP20N: 510 (100) GP25N: 510 (100)
GP20CN: 570 (112) GP20ZN: 590 (116) GP25ZN: 590 (116) GP30N: 470 (93) GP35AN: 400 (79)
GPE20CN: 640 (126) GPE20N: 590 (116) GPE25N: 590 (116) GPE30N: 520 (102) GPE35AN: 430 (85)
DP20CN: 600 (118) GPE20ZN: 680 (134) GPE25ZN: 680 (134) DP30N: 510 (100) DP35AN: 430 (85)
DP20N: 640 (126) DP25N: 640 (126)
GP20N: 600 (118) GP25N: 600 (118)
GP20CN: 640 (126) GP20ZN: 680 (134) GP25ZN: 680 (134) GP30N: 515 (101) GP35AN: 430 (85)
GPE20CN: 650 (128) GPE20N: 610 (120) GPE25N: 610 (120) GPE30N: 530 (104) GPE35AN: 440 (87)
DP20CN: 650 (128) GPE20ZN: 690 (136) GPE25ZN: 690 (136) DP30N: 545 (107) DP35AN: 460 (91)
DP20N: 670 (132) DP25N: 670 (132)

19/(11.8)

19.5/(12.1)

1-9
 COOLING SYSTEM

Specification ............................................................................................ 2– 1
Structure .................................................................................................... 2– 2
2
Removal and Installation ...................................................................... 2– 3
Inspection and Adjustment .................................................................. 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
 COOLING SYSTEM

Specification

Truck Models
1 ton class 2 ton class 3 ton class
Items

Type Water-cooled, forced circulation

Radiator Corrugated fin (pressure) type

Cooling
System
Water pump Centrifugal type

Thermostat Wax Pellet Type

2-1
COOLING SYSTEM

Structure

Fan (directly coupled to engine)

209610

Hose layout

Radiator
Shroud
S4Q2 engine

Fan guard

K15, K21,
K25 engines
Lower hose

S4S engine
Reservoir tank
Upper hose S4Q2 K15, K21, K25
S4S

212800

2-2
 COOLING SYSTEM

Removal and Installation

Fan Belt Removal

Engine

Fan

1 2
209612

Sequence
1 Tension pulley assembly, Bolt
2 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 Fan
pulley will not move.

Tension
! CAUTION
pulley
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. 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
 COOLING SYSTEM

Inspection and Adjustment

Fan Belt Inspection

(1) Check the belt for contamination from oil, grease or
dust. Replace the belt if required. When the Fan pulley
contamination is slight, clean the belt with a rag or
paper towel. Do not use gasoline, oil or any other
solvent to clean the belt. Tension
pulley
(2) During the engine overhaul or belt tension adjustment,
check the condition of the belt. Replace the belt if it
has any damage.

Fan Belt Tension 209614

Apply a force of 98 N (10 kgf) [22 lbf] perpendicularly to

the belt at a point midway between the fan pulley and
tension pulley. Adjust the tension until belt deflection is
between 11 to 13 mm (0.43 to 0.51 in.) for the gasoline-
engine truck and 10 to 12 mm (0.39 to 0.47 in.) for the
diesel-engine truck.

Connecting Radiator Hoses

When connecting the hoses to the radiator, fit their ends Hose
fully on the fittings and secure them with clamps. Tighten
the clamp bolts to the torque indicated below. Make sure
that each hose is correctly connected and over the flare of
the fitting.
Clamp bolt tightening torque
3.92 to 5.88 N·m
Upper and lower hoses (0.4 to 0.6 kgf·m)
[2.9 to 4.3 lbf·ft]
2.94 to 4.9 N·m
209615
Cooler hose (0.3 to 0.5 kgf·m)
[2.2 to 3.6 lbf·ft]

Unit Layout
Electronic control type Standard type

209616

2-5
COOLING SYSTEM

Coolant
Fill the radiator with coolant containing antifreeze. After
starting the engine and letting it warm up during operation,
check for abnormal noises. Check the coolant level in the
reserve tank to ensure it meets the specification.

Quantity of coolant
Unit: liter (U.S. gal.)
Truck Models
1 ton class 2 ton class 3 ton class
Items
Reserve tank (FULL level) 0.65 (0.17) 0.65 (0.17) 0.65 (0.17)
Total quantity of coolant
6.8 (1.80) 7.4 (1.96) 8.7 (2.30)
(including coolant in hoses)

Radiator Cap

88 ± 14.7 kPa
Opening pressure (0.90 ± 0.15 kgf/cm2)
[12.8 ± 2.1 psi]
0 to 4.9 kPa
Vacuum valve (0 to 0.05 kgf/cm2)
[0 to 0.71 psi]

2-6
 ELECTRICAL SYSTEM

Chassis Electrical Devices Wiring Outline ....................................... 3 – 1

Structure .................................................................................................... 3 – 3
Console box .............................................................................................. 3 – 3
Major Electrical Components ..................................................................... 3 – 5
3
Lamp Bulb Specifications .......................................................................... 3 – 16
Console Box ............................................................................................. 3 – 17
Disassembly .............................................................................................. 3 – 17
Instrument Panel ....................................................................................... 3 – 18
Battery Maintenance .............................................................................. 3 – 19
Wire Color .................................................................................................. 3 – 20
Troubleshooting ........................................................................................ 3 – 21
Electrical Schematics ........................................................................... 3 – 25
 ELECTRICAL SYSTEM

Chassis Electrical Devices Wiring Outline (No. 1)

Main harness

Harness, rear
combination

Harness, front
combination

Harness, front
combination

209620

3-1
ELECTRICAL SYSTEM

Chassis Electrical Devices Wiring Outline (No. 2)

Key

Starter switch

Harness,
rear combination
Clip

Select switch
Warning buzzer Back buzzer

Harness, front
combination

Controller

Battery seat

Fuse box,
QGS controller Fuse
(Diesel truck only)

Harness, front
Horn combination

Connector Relay box,

bracket Relay

Vehicle speed sensor

(Pulse generator)

Transmission
212801

3-2
 ELECTRICAL SYSTEM

Structure 4 3
1
Console box
2
1 Water temperature gauge
2 Fuel gauge 6
3 Various warning lights
4 Instrument panel
5 Starter switch
6 Lighting switch, turn signal switch
7 Forward-reverse lever 7

213005

3-3
ELECTRICAL SYSTEM

Function of Instrument Panel

A B C D E F G H

J L1 L L2 L3 K 212802

Description of function
When illuminated
Code Name of monitor When not illuminated Remarks
or flashing
A Brake fluid level warning lamp Normal level Low level
ATM: Torque converter fluid temperature warning lamp Normal temperature Overheat ATM truck
B
MTM: Clutch wear lamp Normal Clutch worn MTM truck
C Engine oil pressure warning lamp Normal oil pressure Low oil pressure
D Seat belt reminder warning lamp Fastened Not fastened
Multi-purpose warning lamp (illuminates when
E warnings indicated by printed symbols occur or minor Normal Malfunction Printed symbol
failures occur)
Abnormal charging
F Charge warning lamp Normal charging
system
Engine being
G Glow pilot lamp Preheating completed Diesel-engine truck
preheated
H Load/unload interlock lamp Free Locked
Fr, Re interlock lamp Free Locked (flashing)
I
Neutral lamp F or R Neutral
J Fuel gauge Indicates remaining fuel amount with key in “ON” position.
K Water temperature gauge Indicates “Overheat” condition if pointer enters the red zone.
L Liquid crystal (normally acting as hour meter) Indicates operating hours with key in “ON” position.
Position and content
of printed symbols

L1 Fuel filter warning lamp Normal Water drain required Diesel-engine truck

L2 Coolant level warning lamp Normal level Low level Option

L3 Clogged air cleaner element warning lamp Normal element Clogged Option

When major failures occur, bulbs A, C, D, E, and H simultaneously flash.

Inspection method of blown bulbs for Instrument panel

All warning and indicator lamps are normal, if they illuminate, when the starter switch is turned to ON position.

3-4
 ELECTRICAL SYSTEM

Major Electrical Components

Starter switch
The diesel-engine truck, which uses a distributor type injection pump, is provided with an engine automatic stop
mechanism of the fuel cut system by the starter switch.
The gasoline-engine truck is also provided with an engine automatic stop mechanism of the fuel cut system.

Starter switch (with Anti-Restart Lock)

This switch has a built-in anti-restart lock, so the key cannot be turned from (ON) to (START) position while
the engine is running. This prevents starter breakage or flywheel damage caused by an operator restarting the truck
when the engine is running The gasoline- and diesel-engine models use the same starter switch. In the diesel-engine
models, (ON) position of the switch is for energizing the glow plugs.

(OFF)
(ON)
G1
M
B2
(START)
G2
B1
S

208540

Connection Table
Gasoline-engine truck (12 V)

Terminal B1, B2 G1 G2 M S
Connected to Battery,
alternator, Fuse box FNR lever
Key position fuse box
OFF
ON (when driving)
START (when starting engine)

Diesel-engine truck (12 V)

Terminal B1, B2 G1 G2 M S
Connected to Battery, Neutral switch
alternator, Fuse box (starter),
Key position fuse box QGS controller
OFF
ON (when preheating) (when driving)
START (when starting engine)

3-5
ELECTRICAL SYSTEM

Lighting switch and turn signal switch

Lighting and
turn signal lever

Boot

Horn contact

Steering angle sensor

Boot

Forward-reverse lever

Forward of truck
Lighting switch, turn signal switch

209625

Forward of truck
Lighting switch,
turn signal switch
F

Forward-reverse
selector switch

212804

Lighting switch and

Forward-reverse turn signal switch
selector switch
T-3 L-2
4 T-1 L-4
2

T-2 L-5
L-1 L-3
5 Steering angle sensor
1 3
Horn contact
4
1 2
Horn

3 5
209627

3-6
 ELECTRICAL SYSTEM

Horn
Check that the horn sounds when applying the specified Up
voltage to both terminals of the horn, T1 and T2.
Replace the horn if it does not sound or its sound is
abnormal.
T1
Operating voltage: DC 12 V
Notice: The installed position in an actual truck is as per
the illustration. T2
Down

Vent hole

Contact

Coil

209628

Tank Unit (gasoline-engine truck)

3/4

1/2 Fuel pump

Pressure relief
valve
1/4 Fuel filter

Referential Standards

Float position E 1/4 1/2 3/4 F

Standard resistance value (ohm) 80 49.5 32 19 10
+12 +1.0
Tolerance (ohm) – ±3 –
+2 -0.5

210782

3-7
ELECTRICAL SYSTEM

Brake fluid sensor

Refer to the brake system.

Indicator ON activating position

(emergency energization)
(0.12 ± 0.08 in.)
3 ± 2 mm
206672

Stop lamp switch

Connect a tester across the terminals and check that the
lamps turn ON and OFF when the push rod extended Unit : mm (in.)

projection is to the specified value.

Measure the insulation resistance value across the terminals Push
when the push rod is pushed in. rod

Replace the switch if the measured insulation resistance

4
value is not more than the value listed below. (0.16)
2 (0.08)

M10x1.25 OFF ON
1 M ohm or more (illuminates)
Insulation resistance value
(at 500 V megger) 208543

Rated voltage: DC 12 V

3-8
 ELECTRICAL SYSTEM

Forward-reverse lever assembly (ATM truck)

Forward of vehicle

F Forward
(10 ) (10 )

N Neutral

R Reverse

Connection table

Terminal 1 2 3 4 5
Wire color
Lever position *1 B G/R B L/W

F (Forward)
N (Neutral)
R (Reverse)
*1 G/W: Gasoline-engine truck
GY/L: Diesel-engine truck
212805

Backup lamp switch (MTM truck)

19.5 mm ON OFF
(0.77 in.)

2 mm 2 mm
Shift rail Backup lamp switch
(0.08 in.) (0.08 in.)
(for forward-reverse)
Transmission case

M12x1.75

208545 200013

3-9
ELECTRICAL SYSTEM

Sender unit (engine coolant temperature)

1. Apply an ohmmeter between the terminal and body of
the sender unit and check for continuity (resistance Body Terminal
value).
2. Replace the sender unit if there is no continuity or the
measured resistance value is outside the standard
resistance value.
Notice: The illustration is for a gasoline-engine truck.

208546

Gasoline-engine truck

Temperature 60±0.2 65±0.2 80±0.2 100±0.3 115±0.3 125±0.3 130±0.3

[°C (°F)] (140±0.4) (149±0.4) (176±0.4) (212±0.5) (239±0.5) (257±0.5) (266±0.5)
Standard resistance
80±10 64±7.8 40.6±3.7 22.2±1.4 14.6±0.6 11.3±0.6 10±0.6
value (ohm)

Diesel-engine truck

Temperature 50±0.2 60±0.2 80±0.2 100±0.3 106±0.3 120±0.3

[°C (°F)] (122±0.4) (140±0.4) (176±0.4) (212±0.5) (223±0.5) (248±0.5)
Standard resistance
80±10 56.3±5 29.5±2.5 16.5±0.9 14.3±0.5 10±0.3
value (ohm)

3-10
 ELECTRICAL SYSTEM

Thermoswitch (T/C oil)

Apply an ohmmeter between the terminal and body and
check for continuity (resistance value). Replace the Terminal Body
thermoswitch if the measured insulation resistance value is
not more than the value listed in the table below.

1 M ohm or more
Insulation resistance value (with contact OFF)
(at 500 V megger)

Internal resistance: 0.5 ohm or less (with contact ON)

Allowable load: 0.5 A

NOTE
When installing the thermoswitch, tighten it to the 208547
specified torque.

31.4 to 47.1 N·m

Tightening torque (3.2 to 4.8 kgf·m)
[23.2 to 34.7 lbf·ft]

! CAUTION
Replace the thermoswitch if it was dropped or
abused.

Main specifications
122 ± 3 °C
OFF→ON
(251.6 ± 5.4 °F)
Operating temperature
115 °C (239 °F)
ON→OFF
or higher
Insulation resistance
1 M ohm or more
(with contact OFF)

3-11
ELECTRICAL SYSTEM

Power relay (ATM truck, for backup lamps)

Inspection of coil
Apply an ohmmeter across terminal 1 and terminal 2 and
measure the resistance value of the relay coil. If there is no
continuity or the resistance value measured is outside the
standard resistance value, replace the coil.

Resistance value of coil

Gasoline/Diesel-engine 80 ohm ± 10 % 2
Connection diagram

Inspection of contact 2
3 1
1. Measure the insulation resistance value between
3
terminal 3 and terminal 4. Replace the contact if the 4
measured insulation resistance value is not more than 1 4
the value listed in the table below. 213066

20 M ohm or more
Insulation resistance value
(at 500 V megger)

2. Apply an ohmmeter across terminal 3 and terminal 4.

3. When applying a voltage of 12 V ON and OFF across
terminal 1 and terminal 2 under the above condition,
check to see if the relay activates to cause continuity
between terminal 3 and terminal 4. Replace the relay
if it does not activate properly.

! CAUTION
As the relay has an integrated diode between
terminals, be careful about the polarity when
inspecting. Replace the relay if it was dropped or
abused.

Coil rating [at 20 °C (68°F)]

Truck type Gasoline/Diesel-engine truck
Item
Rated operating voltage DC 12 V
Working voltage DC 3 to 7 V
Open-circuit voltage DC 1.2 to 3.9 V
Coil resistance 80 ohm ± 10 %
Rated exciting current 168 mA ± 10 %

3-12
 ELECTRICAL SYSTEM

QGS controller (diesel-engine truck)

The QGS controller turns on the glow lamp and glow plugs
during the time indicated in the following table, when the
starter switch is turned from OFF to ON position.
It turns on the glow lamp and glow plugs while the starter
switch is turned to START position.

Water temperature
Item (Sensor resistance Time turned on
value) Connector A Connector B
-15 °C [+5 °F]
10.0 ± 2.0 sec.
(12.1 kΩ)
Glow lamp, 0 °C [32 °F]
6.4 ± 1.3 sec.
Glow plugs (5.9 kΩ)
Connection diagram
+10 °C [50 °F]
3.0 ± 0.6 sec. Starter switch
(3.8 kΩ) OFF
ON

ST
Rated operating voltage: DC 12 V Glow lamp
3 1
A
QGS
4
Battery B controller
DC12V
5 6

Glow Water temperature

plug sensor

212806

Fuel pump (gasoline-engine truck)

Fuel pump

209640

3-13
ELECTRICAL SYSTEM

Solenoid valve (for SR-SF selector valve)

This is an ON/OFF valve (normal open type).
Connector
The valve opens the IN/OUT circuit in a non-energized SOL a
condition.
Rated operating voltage: DC 12 V

SOL b
! CAUTION
P
The valve for DC 12 V has an identification mark
“12 V NO” on the body side.
B A

Solenoid valve b A B a

PT
213067

3-14
 ELECTRICAL SYSTEM

Fuse Box

Fuse box, Fuse

209645

Wiper
Back up/Others Working lamp 15A
15A 15A ETC Head lamp
Meter panel 15A 15A Stop lamp
10A Spare A/C
QGS/Others Horn 10A EGI
20A 10A EGI 30A
10A 20A 30A 30A
VCM Fuse puller
20A

10A 15A
SBF 100A SBF 100A SBF 50A
Spare Battery Alternator Glow

212807

3-15
ELECTRICAL SYSTEM

Lamp Bulb Specifications

Item Watts
No. of
Color of lens Shape Remarks
bulbs
Type of lamp 12 volt

Head lamps 2 Colorless 55

Turn
2 Amber 27
signals
Standard:
Combination
Installed on
lamps (front)
overhead guard
Clearance
2 Amber 10
lamps

Turn
2 Amber 20
signals

Combination Tail/stop
2 Red 8/23
lamps (rear) lamps

Backup
2 Colorless 18.4
lamps

213068

3-16
 ELECTRICAL SYSTEM

Console Box

Disassembly

2
5

209648

(1) Disconnect the electrical wiring from connector 1.

(2) Remove the screw using a flatblade screwdriver and
remove cover 2.
(3) Remove the screw and then, remove cover 3.
(4) Remove the screw and then, remove cover 4.
(5) Remove the forward-reverse lever (FNR lever) and turn
signal lever 5.
(6) Remove the bolt and then, remove console box
assembly 6.

Reassembly
Follow the disassembly sequence in reverse.

3-17
ELECTRICAL SYSTEM

Instrument Panel
Disassembly

2
5

8
9
206480

Sequence
1 Meter cover 6 Meter case
2 Dial 7 Rigid board
3 Water temperature gauge 8 Bulb
4 Liquid crystal 9 Socket
5 Fuel gauge

! CAUTION
Be careful not to damage the rigid board when
disassembling the instrument panel.

Reassembly Bulb replacement

To reassemble the instrument panel, follow the reverse For bulb replacement, remove the socket from the rigid
of disassembly procedure. board by turning it counterclockwise. For configuration
of the indicator lights, refer to page 3-4.

3-18
 ELECTRICAL SYSTEM

Battery Maintenance

1. State of charge and electrolyte specific gravity (S.G.) adjustment

Specific gravity reading

at 20°C (68°F) State of charge Adjustment

1.280 to 1.265 Fully charged If difference in S.G. between any two cells is 0.020 or more,
discharge the battery to minimize the difference and then
recharge battery. Adjust S.G. during recharging.
1.260 to 1.225 One-half charged Recharge battery and adjust electrolyte S.G. Make sure there
is neither faulty components, loosely connected cord nor
corroded connection.
1.220 or below Discharged Recharge battery. If difference in S.G. is large, adjust it
during recharging.
If difference in S.G. is A cell with a low S.G. Recharge until voltage and S.G. stabilize and have remained
more than 0.040 is in shorted condition. constant for more than 2 hours.
Electrolyte leakage, During recharging, adjust S.G. to 1.280 to 1.265.
or excessive/diluted If difference in S.G. is more than 0.040 and a low S.G. is
electrolyte. found in certain cells only, replace battery. After leaving
battery for 12 to 96 hours, conduct a high current discharge
test.

2. Specific gravity reading and state of charge

! CAUTION
To check the battery for state of charge, take
Be sure to turn OFF the starter switch and
hydrometer readings on its electrolyte. The battery may
lighting switch before disconnecting or
be fully charged if the S.G. reading is 1.280 to 1.265 at
connecting the battery cables to prevent the IC
20°C (68°F). The state of charge can be told from the
regulator from suffering damage.
way the electrolyte level goes down to expose the cell
plates. If addition of distilled water is necessary every
month or so, the battery is overcharged. If addition is
not required for more than 3 months, it is likely that the
battery is inadequately charged.
3. Charging precautions
(1) In slow charging, the charging current should be
about 1/10 the capacity of the battery to be charged.
(2) In quick charging, the battery capacity in ampere
should not be exceeded.
(3) During charging, adjust the charging current to
prevent the electrolyte temperature from rising
beyond 45°C (113°F).
(4) When connecting the cables to the battery, begin by IDENTIFICATION
installing the cable to the positive (+) terminal. 34B19L
(Gasoline-engine truck)
When disconnecting them from the battery, begin 55D23L
by removing the cable from the negative (−) 75D26L
95D31L (Diesel-engine truck)
terminal.
209650

3-19
ELECTRICAL SYSTEM

Wire Color

Wire colors listed in the table below show standard colors (base colors). For wiring composed of two colors, the first
color shows a base color and the second color a marking color.
Example: The wire color of BW shows that its base color is B with a marking W.

BW
Marking color
Base color

Notice: For wiring identification, the same color, in principle, must be used for the circuit from the power supply to
the load.

! CAUTION
Be careful that allowable current differs between solid wires and stranded wires even if they are of the
same gauge.

List of wire colors

Wire color Color

B BLACK
W WHITE
R RED
G GREEN
Y YELLOW
Br BROWN
L BLUE
Lg LIGHT GREEN
O ORANGE
P PINK
Gr GRAY
Lb LIGHT BLUE
Dg DARK GREEN
ch CHOCOLATE

3-20
 ELECTRICAL SYSTEM

Troubleshooting

Starter System
Weak or dead battery Recharge or replace.
Short or open circuit Repair or replace.
Starter will not crank
Poor continuity in starter switch Replace.
engine
Starter or starter relay defective Replace.
Forward-reverse lever not in neutral Move lever to neutral
Starter switch position (ATM truck) position.
Turning off starter Open or short circuit Repair or replace.
switch will not stop Engine stop solenoid defective Replace or readjust.
engine Control timer defective Replace.

Gauges
Rigid board defective Replace.
Will not indicate at Open or short circuit Repair or replace.
all Gauge internally defective Replace.
Gauge unit defective Replace.
Water Gauge or gauge unit not of the type Replace to a correct
Will not indicate called for one.
temperature
accurately
gauge Loose terminal connection Repair.
Will indicate higher Circuit between gauge and gauge unit Repair.
than actual grounded
temperature Gauge internally defective Replace.

Rigid board defective Replace.

Will not indicate at Open or short circuit Repair or replace.
all Gauge internally defective Replace.
Gauge unit defective Replace.
Gauge or gauge unit not of the type Replace to a correct
Will not indicate called for one.
accurately
Loose terminal connection Repair.
Fuel gauge Circuit between gauge and gauge unit Repair.
Will indicate “full” open or short
regardless of amount
Gauge internally defective Replace.
of fuel left in tank
Gauge unit defective Replace.
Will indicate Circuit between gauge and gauge unit Repair.
“empty” regardless grounded
of amount of fuel Gauge unit defective Replace.
left in tank Gauge internally defective Replace.

3-21
ELECTRICAL SYSTEM

Lighting System
Weak or dead battery Recharge or replace.
Fuses blown out Check and replace.
Open or short circuit Repair or replace.
Will not light Poor grounding Clean ground spot and
re-make connection.
Switch defective Replace.
Lamps - general Bulbs burnt out Replace.
Weak battery Check and recharge.
Contact points in switches defective Repair or replace.
Loose terminals Repair.
Will light dimly
Dirty lenses Clean.
Water drops inside lenses Dry and replace packings.
Bulbs expired in service life Replace.
Lighting switch defective Replace.
Head lamps Will not light
Bulbs burnt out Replace.
Turn signal switch defective Replace.
Will not flicker
Turn signal relay defective Replace.
Turn signal relay defective Replace.
Will not go out
Bulbs burnt out Replace.
Turn signals Low wattage of bulbs Replace to a correct one.
Will flicker too
slow Bulbs burnt out Replace.
Turn signal relay defective Replace.
Will flicker too High wattage of bulbs Replace to a correct one.
fast Turn signal relay defective Replace.

Backup lamps Backup lamp switch defective Repair or replace.

will not light Bulbs burnt out Replace.
Other lamps
License number Lighting switch defective Replace.
plate lamp will
not light Bulb burnt out Replace.

Alarm Unit
Fuse blown out Check and replace.
Open or short circuit Repair or replace.
Will not sound Horn switch defective Replace.
Horn defective Replace.
Horn Horn button defective Repair or replace.
Will give an Horn switch defective Replace.
offensive blast
of sound Horn defective Replace.

3-22
 ELECTRICAL SYSTEM

Battery
Drive belt slipping Readjust.
❋ Alternator
Stator coil grounded or open-circuited Repair or replace.
Rotor coil open Replace.
Brushes poorly seating on slip rings Replace brushes if worn.
Clean holder and polish
slip rings.
Diode ruptured Replace.
❋ Regulator
Regulated voltage setting too low Replace.
Tends to run down
rapidly ❋ Battery
Not enough electrolyte or wrong concentration of acid Refill and check specific
to water gravity.
Battery cell plates deteriorated (forming, possibly Replace.
internal short-circuit)
Terminal connections loose Clean and retighten.
❋ Wiring
Open or loose connection between starter switch and Repair.
regulator IC terminal
Fuse blown, or loosely set in holder Replace and repair.
Open or loose connection between F terminals of Repair.
regulator and alternator

❋ Wiring
Regulator IC and F terminals shorted or miswired Repair.
Poor grounding of regulator F terminal Repair.
Tends to get
overcharged ❋ Regulator
Pressure coil open-circuited Replace.
Regulated voltage too high Replace.

3-23
 ELECTRICAL SYSTEM

Electrical Schematics

Electrical Schematic (1/6): GP15N to GP35AN (MC Truck) ................................ 3 – 27

Fuse, Starter, Alternator, License Lamp ............................................................. 3 – 29
Head Lamp, Tail Lamp, Parking Lamp, T/S Lamp ............................................... 3 – 31
Horn, Stop Lamp, Back Buzzer, Warning Buzzer................................................ 3 – 33
Strobe Lamp, Working Lamp, Front Wiper .......................................................... 3 – 35
Meter Panel ........................................................................................................ 3 – 37
Seat Switch, Lift Cylinder, Tilt Cylinder ............................................................... 3 – 39
Steering, Hydraulic Sensor................................................................................. 3 – 41
Electrical Schematic (2/6): GPE15N to GPE35AN (MC Truck)............................ 3 – 43
Fuse, Starter, Alternator, License Lamp ............................................................. 3 – 45
Head Lamp, Tail Lamp, Parking Lamp, T/S Lamp ............................................... 3 – 47
Horn, Stop Lamp, Back Buzzer, Warning Buzzer................................................ 3 – 49
Strobe Lamp, Working Lamp, Front Wiper .......................................................... 3 – 51
Meter Panel ........................................................................................................ 3 – 53
Seat Switch, Lift Cylinder, Tilt Cylinder ............................................................... 3 – 55
Steering, Hydraulic Sensor................................................................................. 3 – 57
Electrical Schematic (3/6): GPE15N to GPE35AN (FC Truck)............................. 3 – 59
Fuse, Starter, Alternator, License Lamp ............................................................. 3 – 61
Head Lamp, Tail Lamp, Parking Lamp, T/S Lamp ............................................... 3 – 63
Horn, Stop Lamp, Back Buzzer, Warning Buzzer................................................ 3 – 65
Strobe Lamp, Working Lamp, Front Wiper .......................................................... 3 – 67
Meter Panel ........................................................................................................ 3 – 69
Seat Switch, Lift Cylinder, Tilt Cylinder ............................................................... 3 – 71
Steering, Hydraulic Sensor................................................................................. 3 – 73
Armrest .............................................................................................................. 3 – 75
Electrical Schematic (4/6): GPE15N to GPE35AN (MC/FC Truck) ECM ............ 3 – 77
Gas Injection, Ignition Coil.................................................................................. 3 – 79
LPG Injection, GLE Engine................................................................................. 3 – 81
Electrical Schematic (5/6): DP15N to DP35AN (MC Truck) ................................ 3 – 83
Fuse, Starter, Alternator, License Lamp ............................................................. 3 – 85
Head Lamp, Tail Lamp, Parking Lamp, T/S Lamp ............................................... 3 – 87
Horn, Stop Lamp, Back Buzzer, Warning Buzzer................................................ 3 – 89
Strobe Lamp, Working Lamp, Front Wiper .......................................................... 3 – 91
3-25
ELECTRICAL SYSTEM

Meter Panel ........................................................................................................ 3 – 93

Seat Switch, Lift Cylinder, Tilt Cylinder ............................................................... 3 – 95
Steering, Hydraulic Sensor................................................................................. 3 – 97
Electrical Schematic (6/6): DP15N to DP35AN (FC Truck) ................................. 3 – 99
Fuse, Starter, Alternator, License Lamp ............................................................. 3 – 101
Head Lamp, Tail Lamp, Parking Lamp, T/S Lamp ............................................... 3 – 103
Horn, Stop Lamp, Back Buzzer, Warning Buzzer................................................ 3 – 105
Strobe Lamp, Working Lamp, Front Wiper .......................................................... 3 – 107
Meter Panel ........................................................................................................ 3 – 109
Seat Switch, Lift Cylinder, Tilt Cylinder ............................................................... 3 – 111
Steering, Hydraulic Sensor................................................................................. 3 – 113
Armrest .............................................................................................................. 3 – 115

3-26
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