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Towmotor GP20S-30S, DP20HS-30HS Chassis and Mast Service Manual 99729-90100
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Towmotor GP20S-30S, DP20HS-30HS Chassis and Mast Service Manual 99729-90100

$50.00

  • Type Of Manual: Service Manual
  • Manual ID: 99729-90100
  • Number of Pages: 483
  • Size: 49.3MB
  • Format: PDF
Category:
  • Model List:

    • GP20S, GP25S, GP30S, DP20HS, DP25HS, DP30HS
  • 1. vol1
  • 1.1. FOREWORD
  • 1.1.1. SAFETY PRECAUTIONS
  • 1.1.2. HOW TO USE THIS MANUAL
  • 1.1.2.1. Truck Models
  • 1.1.3. Symbols and Abbreviations
  • 1.1.4. Units
  • 1.2. Chapter 1 GENERAL INFORMATION
  • 1.2.1. Model View
  • 1.2.2. Applicable Truck Model
  • 1.2.3. Serial Number Locations
  • 1.2.4. Dimensions
  • 1.2.5. Technical Data
  • 1.2.6. Performance
  • 1.3. Chapter 2 COOLING SYSTEM
  • 1.3.1. Specifications
  • 1.3.2. Structure
  • 1.3.3. Removing Fan Belt
  • 1.3.3.1. Preparation
  • 1.3.3.2. Removal Sequence
  • 1.3.3.3. Suggestions for Removal
  • 1.3.4. Installing Fan Belt
  • 1.3.4.1. Suggestions for Installation
  • 1.3.5. Inspecting and Adjusting Cooling System
  • 1.3.5.1. Fan Belt Inspection
  • 1.3.5.2. Fan Belt Tension Adjustment
  • 1.3.5.3. Connecting Hoses
  • 1.3.5.4. Cooling Water
  • 1.3.5.5. Radiator Cap
  • 1.4. Chapter 3 ELECTRICAL SYSTEM
  • 1.4.1. Electrical Components and Wiring Outline
  • 1.4.1.1. Locations of Electrical Components
  • 1.4.2. Console Box
  • 1.4.2.1. Console Box Outline
  • 1.4.2.2. Disassembling Console Box
  • 1.4.2.3. Assembling Console Box
  • 1.4.3. Meter Panel
  • 1.4.3.1. Disassembling Meter Panel
  • 1.4.3.2. Assembling Meter Panel
  • 1.4.3.3. Bulb Replacement
  • 1.4.3.4. Warning Lamps and Indicators
  • 1.4.3.5. Hour Meter
  • 1.4.3.6. Fuel Gauge
  • 1.4.3.7. Connector
  • 1.4.4. Main Electrical Components
  • 1.4.4.1. Key Switch
  • 1.4.4.2. Key Switch (Anti-Restart Switch)
  • 1.4.4.3. Light Switch and Turn Signal Switch
  • 1.4.4.4. Direction (FNR) Switch
  • 1.4.4.5. GAS/LPG Select Switch
  • 1.4.4.6. Horn
  • 1.4.4.7. Tank Unit
  • 1.4.4.8. Brake Oil Level
  • 1.4.4.9. Stop Light Switch
  • 1.4.4.10. Thermoswitch (Engine Coolant Temperature)
  • 1.4.4.11. Relay
  • 1.4.4.12. Fuse Box
  • 1.4.4.13. Glow Timer and Glow Relay (Diesel Model)
  • 1.4.4.14. Front Combination Light
  • 1.4.4.15. Front Combination Harness
  • 1.4.4.16. Rear Combination Light (Option)
  • 1.4.4.17. Rear Combination Harness (Option)
  • 1.4.4.18. List of Lights
  • 1.4.5. Battery and Maintenance
  • 1.4.5.1. State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment
  • 1.4.5.2. Specific Gravity Reading and State of Charge
  • 1.4.5.3. Precautions for Battery Charging
  • 1.4.6. Wire Color
  • 1.4.6.1. List of Wire Color Codes
  • 1.4.7. Troubleshooting
  • 1.4.7.1. Starter System
  • 1.4.7.2. Gauges
  • 1.4.7.3. Lighting System
  • 1.4.7.4. Alarm Unit
  • 1.4.7.5. Battery
  • 1.5. Chapter 4 POWER TRAIN
  • 1.5.1. Installation of Engine and Transmission Assembly (for Dual Gas/LPG Models)
  • 1.5.1.1. Removal Sequence of Overhead Guard Cover, Air Cleaner, and Others
  • 1.5.1.2. Suggestions for Removing Overhead Guard Cover, Air Cleaner, and Others
  • 1.5.1.3. Removal Sequence of Controls
  • 1.5.1.4. Suggestions for Removing Controls
  • 1.5.1.5. Suggestions for Installing Controls
  • 1.5.1.6. Preparation for Removing Pipes and Radiator
  • 1.5.1.7. Removal Sequence of Pipes and Radiator
  • 1.5.1.8. Suggestions for Installing Pipes and Radiator
  • 1.5.1.9. Preparation for Removing Engine and Transmission Assembly
  • 1.5.1.10. Removal Sequence of Engine and Transmission Assembly
  • 1.5.1.11. Suggestions for Removing Engine and Transmission Assembly
  • 1.5.1.12. Suggestions for Installing Engine and Transmission Assembly
  • 1.5.2. Installation of Engine and Transmission Assembly (for Diesel Model)
  • 1.5.2.1. Removal Sequence of Overhead Guard Cover, Air Cleaner, and Others
  • 1.5.2.2. Suggestions for Removing Overhead Guard Cover, Air Cleaner, and Others
  • 1.5.2.3. Preparation for Removing Pipes and Radiator
  • 1.5.2.4. Removal Sequence of Pipes and Radiator
  • 1.5.2.5. Suggestions for Removing Pipes and Radiator
  • 1.5.2.6. Suggestions for Installing Pipes and Radiator
  • 1.5.2.7. Preparation for Removing Engine and Transmission Assembly
  • 1.5.2.8. Removal Sequence of Engine and Transmission Assembly
  • 1.5.2.9. Suggestions for Removing Engine and Transmission Assembly
  • 1.5.2.10. Suggestions for Installing Engine and Transmission Assembly
  • 1.6. Chapter 5 POWERSHIFT TRANSMISSION
  • 1.6.1. Structure
  • 1.6.1.1. External View of Torque Converter Transmission
  • 1.6.1.2. External View of Control Valve
  • 1.6.1.3. Transmission Components
  • 1.6.1.4. Torque Converter Components
  • 1.6.1.5. Torque Converter Drive Control Components
  • 1.6.1.6. Schematic Diagram of Powershift Transmission Hydraulic System
  • 1.6.2. Removing Transmission
  • 1.6.2.1. Suggestions for Removal
  • 1.6.3. Installing Transmission
  • 1.6.3.1. Suggestions for Installation
  • 1.6.4. Disassembling Torque Converter Transmission
  • 1.6.4.1. Preparation
  • 1.6.4.2. Removing Transmission Accessories
  • 1.6.4.3. Removing Oil Pump
  • 1.6.4.4. Removing Transmission Housing
  • 1.6.4.5. Removing Input Shaft, Idler Shaft, and Output Gear
  • 1.6.4.6. Disassembling Transmission Housing
  • 1.6.4.7. Disassembling Torque Converter Housing
  • 1.6.4.8. Disassembling Idler Shaft
  • 1.6.4.9. Disassembling Output Gear
  • 1.6.4.10. Disassembling Forward Side Input Shaft Gear Assembly
  • 1.6.4.11. Disassembling Reverse Side Input Shaft Gear
  • 1.6.4.12. Disassembling Oil Pump
  • 1.6.5. Assembling Torque Converter Transmission
  • 1.6.5.1. Assembling Transmission Housing
  • 1.6.5.2. Assembling Idler Shaft Assembly
  • 1.6.5.3. Assembling Output Gear Assembly
  • 1.6.5.4. Inspecting Input Shaft Gear Assembly
  • 1.6.5.5. Assembling Forward Side Input Shaft Gear Assembly
  • 1.6.5.6. Assembling Reverse Side Input Shaft Gear Assembly
  • 1.6.5.7. Assembling and Installing Oil Pump Assembly
  • 1.6.5.8. Assembling Torque Converter Housing
  • 1.6.5.9. Installing Transmission Housing
  • 1.6.5.10. Installing Transmission Accessories
  • 1.6.5.11. Installing Servo Case Assembly
  • 1.6.6. Disassembling Control Valve
  • 1.6.6.1. Removing Control Valve Accessories
  • 1.6.6.2. Removing Valve Body Plate
  • 1.6.6.3. Removing Plugs
  • 1.6.6.4. Removing Strainer
  • 1.6.6.5. Disassembling Regulator Valve Section
  • 1.6.6.6. Disassembling Accumulator Valve Section
  • 1.6.6.7. Disassembling Inching Valve Section
  • 1.6.6.8. Removing Oil Seal and Plug
  • 1.6.7. Assembling Control Valve
  • 1.6.7.1. Assembly Sequence of Control Valve
  • 1.6.7.2. Suggestions for Assembly
  • 1.6.7.3. Washing and Inspecting
  • 1.6.7.4. Installing Valve Plug and Oil Seal
  • 1.6.7.5. Assembling Inching Valve Section
  • 1.6.7.6. Assembling Accumulator Valve Section
  • 1.6.7.7. Assembling Regulator Valve Section
  • 1.6.7.8. Installing Strainer
  • 1.6.7.9. Installing Plug
  • 1.6.7.10. Installing Valve Body Plate and Breather Cover
  • 1.6.7.11. Assembling Control Valve Accessories
  • 1.6.8. Inspection and Adjustment
  • 1.6.8.1. Oil Pressure Measurement
  • 1.6.8.2. Adjusting Brake (Inching) Pedal
  • 1.6.8.3. Adjusting Inching Cable
  • 1.6.9. Troubleshooting
  • 1.6.10. Service Data
  • 1.6.10.1. Pump Boss
  • 1.6.10.2. Pilot Boss
  • 1.6.10.3. Oil Pump
  • 1.6.10.4. Flexible Plate
  • 1.6.10.5. Clutches
  • 1.6.10.6. Input Shaft
  • 1.7. Chapter 6 FRONT AXLE AND REDUCTION DIFFERENTIAL
  • 1.7.1. Structure
  • 1.7.1.1. Ton Class
  • 1.7.1.2. Ton Class
  • 1.7.2. Removing Front Wheels
  • 1.7.2.1. Preparation
  • 1.7.2.2. Removal
  • 1.7.3. Installing Front Wheels
  • 1.7.4. Removing Front Axle and Reduction Differential
  • 1.7.4.1. Preparation
  • 1.7.4.2. Removal Sequence
  • 1.7.4.3. Suggestions for Removal
  • 1.7.5. Installing Front Axle
  • 1.7.6. Disassembling Front Axle
  • 1.7.6.1. Disassembly Sequence
  • 1.7.6.2. Suggestions for Disassembly
  • 1.7.7. Inspection and Repair After Disassembling Front Axle
  • 1.7.8. Assembling Front Axle
  • 1.7.9. Disassembling Reduction Differential
  • 1.7.9.1. Disassembly Sequence
  • 1.7.9.2. Suggestions for Disassembly
  • 1.7.10. Inspection and Repair After Disassembling Reduction Differential
  • 1.7.11. Assembling Reduction Differential
  • 1.7.11.1. Assembly Sequence
  • 1.7.11.2. Suggestions for Assembly
  • 1.7.11.3. Adjustment
  • 1.7.12. Troubleshooting
  • 1.7.13. Service Data
  • 1.7.13.1. Hub and Wheels
  • 1.7.13.2. Reduction Differential
  • 1.8. Chapter 7 REAR AXLE
  • 1.8.1. Rear Axle Structure
  • 1.8.1.1. Main Components
  • 1.8.1.2. Specifications for Wheel Alignment and Steering Angle
  • 1.8.1.3. Main Components of Wheel Hub Section
  • 1.8.1.4. Main Components of Kingpin Section
  • 1.8.1.5. Main components of Tie Rod Section
  • 1.8.1.6. Main Components of Rear Axle Center Section
  • 1.8.1.7. Main Components of Steering Cylinder
  • 1.8.2. Removing Rear Wheels
  • 1.8.2.1. Suggestions for Removal
  • 1.8.3. Installing Rear Wheels
  • 1.8.4. Removing Rear Axle Assembly
  • 1.8.4.1. Removal Sequence
  • 1.8.4.2. Suggestions for Removal
  • 1.8.5. Inspection and Repair After Disassembling Rear Axle Assembly
  • 1.8.6. Installing Axle Assembly
  • 1.8.7. Disassembling Wheel Hub
  • 1.8.7.1. Disassembly Sequence
  • 1.8.7.2. Suggestions for Disassembly
  • 1.8.8. Inspection and Repair After Disassembling Wheel Hub Section
  • 1.8.9. Assembling Wheel Hub Section
  • 1.8.9.1. Suggestions for Assembly
  • 1.8.9.2. Assembling and Adjusting Wheel Bearing
  • 1.8.10. Disassembling Knuckle Section (Kingpin)
  • 1.8.10.1. Preparation
  • 1.8.10.2. Suggestions for Disassembly
  • 1.8.11. Inspection After Disassembly Knuckle Section (Kingpin)
  • 1.8.12. Assembling Knuckle Section (Kingpin)
  • 1.8.12.1. Suggestions for Assembly
  • 1.8.13. Removing Steering Cylinder
  • 1.8.13.1. Preparation
  • 1.8.13.2. Suggestions for Removal
  • 1.8.14. Disassembling Steering Cylinder
  • 1.8.14.1. Disassembly Sequence
  • 1.8.14.2. Suggestions for Disassembly
  • 1.8.15. Inspection and Repair After Disassembling Steering Cylinder
  • 1.8.16. Assembling Steering Cylinder
  • 1.8.16.1. Suggestions for Assembly
  • 1.8.17. Disassembling Tie Rod
  • 1.8.17.1. Disassembly Sequence
  • 1.8.17.2. Suggestions for Disassembly
  • 1.8.18. Assembling Tie Rod
  • 1.8.18.1. Suggestions for Assembly
  • 1.9. Chapter 8 BRAKE SYSTEM
  • 1.9.1. Structure of Brake System
  • 1.9.2. Disassembling Master Cylinder
  • 1.9.2.1. Disassembly Sequence
  • 1.9.3. Inspection and Repair After Disassembling Master Cylinder
  • 1.9.4. Assembling Master Cylinder
  • 1.9.4.1. Suggestions for Assembly
  • 1.9.5. Structure of Wheel Brakes
  • 1.9.6. Disassembling Wheel Brakes
  • 1.9.6.1. Preparation
  • 1.9.6.2. Disassembly Sequence
  • 1.9.6.3. Suggestions for Disassembly
  • 1.9.7. Inspection and Repair After Disassembling Wheel Brakes
  • 1.9.8. Assembling Wheel Brakes
  • 1.9.8.1. Assembly Sequence
  • 1.9.8.2. Suggestions for Assembly
  • 1.9.9. Disassembling Wheel Cylinder
  • 1.9.9.1. Disassembly Sequence
  • 1.9.10. Inspection and Repair After Disassembling Wheel Cylinder
  • 1.9.11. Assembling Wheel Cylinder
  • 1.9.12. Inspecting and Adjusting Brake System
  • 1.9.12.1. Operation Test of Automatic Adjuster
  • 1.9.12.2. Manual Adjustment Procedure
  • 1.9.12.3. Adjusting Parking Brake Cable
  • 1.9.12.4. Adjusting Brake Pedal
  • 1.9.12.5. Bleeding Brake Oil Line
  • 1.9.12.6. Braking Performance Test
  • 1.9.12.7. Adjusting Parking Brake Lever
  • 1.9.13. Troubleshooting
  • 1.9.14. Service Data
  • 1.10. Chapter 9 STEERING SYSTEM
  • 1.10.1. Structure and Functions
  • 1.10.1.1. General
  • 1.10.1.2. Steering Valve
  • 1.10.1.3. Steering Column
  • 1.10.2. Disassembling and Assembling Pipes and Hoses
  • 1.10.2.1. Suggestions for Disassembly and Assembly
  • 1.10.3. Disassembling Steering Wheel and Steering Valve
  • 1.10.3.1. Disassembly Sequence
  • 1.10.3.2. Suggestions for Disassembly
  • 1.10.4. Installing Steering Wheel and Steering Valve
  • 1.10.5. Installation
  • 1.10.5.1. Inspection After Installation
  • 1.10.6. Removing Steering Valve
  • 1.10.7. Installing Steering Valve
  • 1.10.8. Disassembling Tilt Lock Lever
  • 1.10.9. Assembling Tilt Lock Lever
  • 1.10.10. Disassembling Steering Valve
  • 1.10.10.1. Disassembly Sequence
  • 1.10.10.2. Suggestions for Disassembly
  • 1.10.11. Inspection After Disassembly
  • 1.10.12. Assembling Steering Valve
  • 1.10.12.1. Assembly Sequence
  • 1.10.13. Troubleshooting
  • 1.10.14. Service Data
  • 2. vol2
  • 2.1. Chapter 9 STEERING SYSTEM
  • 2.1.1. Structure and Functions
  • 2.1.1.1. General
  • 2.1.1.2. Steering Valve
  • 2.1.1.3. Steering Column
  • 2.1.2. Disassembling and Assembling Pipes and Hoses
  • 2.1.2.1. Suggestions for Disassembly and Assembly
  • 2.1.3. Disassembling Steering Wheel and Steering Valve
  • 2.1.3.1. Disassembly Sequence
  • 2.1.3.2. Suggestions for Disassembly
  • 2.1.4. Installing Steering Wheel and Steering Valve
  • 2.1.5. Installation
  • 2.1.5.1. Inspection After Installation
  • 2.1.6. Removing Steering Valve
  • 2.1.7. Installing Steering Valve
  • 2.1.8. Disassembling Tilt Lock Lever
  • 2.1.9. Assembling Tilt Lock Lever
  • 2.1.10. Disassembling Steering Valve
  • 2.1.10.1. Disassembly Sequence
  • 2.1.10.2. Suggestions for Disassembly
  • 2.1.11. Inspection After Disassembly
  • 2.1.12. Assembling Steering Valve
  • 2.1.12.1. Assembly Sequence
  • 2.1.13. Troubleshooting
  • 2.1.14. Service Data
  • 2.2. Chapter 10 HYDRAULIC SYSTEM
  • 2.2.1. Structure and Functions
  • 2.2.1.1. Outline
  • 2.2.1.2. Hydraulic Lines Diagram
  • 2.2.1.3. Hydraulic Tank
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