Towmotor GP20S, GP25S, GP30S, DP20HS, DP25HS, DP30HS Forklift Service Manual
473 pages · Publication 99729-90100
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- Models
- GP20S, GP25S, GP30S, DP20HS, DP25HS, DP30HS
- Serial coverage
- GP20S: CT54-10011-up
- GP25S: CT54-50011-up
- GP30S: CT55-10011-up
- DP20HS: CT50-10011-up
- DP25HS: CT50-50011-up
- DP30HS: CT51-10011-up
- Manual type
- Service Manual
- Pages
- 473
- Publication
- 99729-90100
- Condition
- Brand new
What's inside
From the manual's own table of contents: 339 topics. See sample pages (PDF, 419 KB)
- Model View
- Applicable Truck Model
- Serial Number Locations
- Dimensions
- Technical Data
- Performance
- Specifications
- Structure
- Removing Fan Belt
- Preparation
- Removal Sequence
- Suggestions for Removal
- Installing Fan Belt
- Suggestions for Installation
- Inspecting and Adjusting Cooling System
- Fan Belt Inspection
- Fan Belt Tension Adjustment
- Connecting Hoses
- Cooling Water
- Radiator Cap
- Electrical Components and Wiring Outline
- Locations of Electrical Components
- Console Box
- Console Box Outline
Show all 339 topics
- Disassembling Console Box
- Assembling Console Box
- Meter Panel
- Disassembling Meter Panel
- Assembling Meter Panel
- Bulb Replacement
- Warning Lamps and Indicators
- Hour Meter
- Fuel Gauge
- Connector
- Main Electrical Components
- Key Switch
- Key Switch (Anti-Restart Switch)
- Light Switch and Turn Signal Switch
- Direction (FNR) Switch
- GAS/LPG Select Switch
- Horn
- Tank Unit
- Brake Oil Level
- Stop Light Switch
- Thermoswitch (Engine Coolant Temperature)
- Relay
- Fuse Box
- Glow Timer and Glow Relay (Diesel Model)
- Front Combination Light
- Front Combination Harness
- Rear Combination Light (Option)
- Rear Combination Harness (Option)
- List of Lights
- Battery and Maintenance
- State of Charge and Electrolyte Specific Gravity (S.G.) Adjustment
- Specific Gravity Reading and State of Charge
- Precautions for Battery Charging
- Wire Color
- List of Wire Color Codes
- Troubleshooting
- Starter System
- Gauges
- Lighting System
- Alarm Unit
- Battery
- (for Dual Gas/LPG Models)
- Removal Sequence of Overhead Guard Cover, Air Cleaner, and Others 4-1
- and Others
- Removal Sequence of Controls
- Suggestions for Removing Controls
- Suggestions for Installing Controls
- Preparation for Removing Pipes and Radiator
- Removal Sequence of Pipes and Radiator
- Suggestions for Installing Pipes and Radiator
- Preparation for Removing Engine and Transmission Assembly
- Removal Sequence of Engine and Transmission Assembly
- Suggestions for Removing Engine and Transmission Assembly
- Suggestions for Installing Engine and Transmission Assembly
- (for Diesel Model)
- Removal Sequence of Overhead Guard Cover, Air Cleaner, and Others 4-7
- Suggestions for Removing Pipes and Radiator
- External View of Torque Converter Transmission
- External View of Control Valve
- Transmission Components
- Torque Converter Components
- Torque Converter Drive Control Components
- Schematic Diagram of Powershift Transmission Hydraulic System
- Removing Transmission
- Installing Transmission
- Disassembling Torque Converter Transmission
- Removing Transmission Accessories
- Removing Oil Pump
- Removing Transmission Housing
- Removing Input Shaft, Idler Shaft, and Output Gear
- Disassembling Transmission Housing
- Disassembling Torque Converter Housing
- Disassembling Idler Shaft
- Disassembling Output Gear
- Disassembling Forward Side Input Shaft Gear Assembly
- Disassembling Reverse Side Input Shaft Gear
- Disassembling Oil Pump
- Assembling Torque Converter Transmission
- Assembling Transmission Housing
- Assembling Idler Shaft Assembly
- Assembling Output Gear Assembly
- Inspecting Input Shaft Gear Assembly
- Assembling Forward Side Input Shaft Gear Assembly
- Assembling Reverse Side Input Shaft Gear Assembly
- Assembling and Installing Oil Pump Assembly
- Assembling Torque Converter Housing
- Installing Transmission Housing
- Installing Transmission Accessories
- Installing Servo Case Assembly
- Disassembling Control Valve
- Removing Control Valve Accessories
- Removing Valve Body Plate
- Removing Plugs
- Removing Strainer
- Disassembling Regulator Valve Section
- Disassembling Accumulator Valve Section
- Disassembling Inching Valve Section
- Removing Oil Seal and Plug
- Assembling Control Valve
- Assembly Sequence of Control Valve
- Suggestions for Assembly
- Washing and Inspecting
- Installing Valve Plug and Oil Seal
- Assembling Inching Valve Section
- Assembling Accumulator Valve Section
- Assembling Regulator Valve Section
- Installing Strainer
- Installing Plug
- Installing Valve Body Plate and Breather Cover
- Assembling Control Valve Accessories
- Inspection and Adjustment
- Oil Pressure Measurement
- Adjusting Brake (Inching) Pedal
- Adjusting Inching Cable
- Service Data
- Pump Boss
- Pilot Boss
- Oil Pump
- Flexible Plate
- Clutches
- Input Shaft
- Ton Class
- Removing Front Wheels
- Removal
- Installing Front Wheels
- Removing Front Axle and Reduction Differential
- Installing Front Axle
- Disassembling Front Axle
- Disassembly Sequence
- Suggestions for Disassembly
- Inspection and Repair After Disassembling Front Axle
- Assembling Front Axle
- Disassembling Reduction Differential
- After Disassembling Reduction Differential
- Assembling Reduction Differential
- Assembly Sequence
- Adjustment
- Hub and Wheels
- Reduction Differential
- Rear Axle Structure
- Main Components
- Specifications for Wheel Alignment and Steering Angle
- Main Components of Wheel Hub Section
- Main Components of Kingpin Section
- Main components of Tie Rod Section
- Main Components of Rear Axle Center Section
- Main Components of Steering Cylinder
- Removing Rear Wheels
- Installing Rear Wheels
- Removing Rear Axle Assembly
- Installing Axle Assembly
- Disassembling Wheel Hub
- Assembling Wheel Hub Section
- Assembling and Adjusting Wheel Bearing
- Disassembling Knuckle Section (Kingpin)
- Inspection After Disassembly Knuckle Section (Kingpin)
- Assembling Knuckle Section (Kingpin)
- Removing Steering Cylinder
- Disassembling Steering Cylinder
- Inspection and Repair After Disassembling Steering Cylinder
- Assembling Steering Cylinder
- Disassembling Tie Rod
- Assembling Tie Rod
- Structure of Brake System
- Disassembling Master Cylinder
- Inspection and Repair After Disassembling Master Cylinder
- Assembling Master Cylinder
- Structure of Wheel Brakes
- Disassembling Wheel Brakes
- Inspection and Repair After Disassembling Wheel Brakes
- Assembling Wheel Brakes
- Disassembling Wheel Cylinder
- Inspection and Repair After Disassembling Wheel Cylinder
- Assembling Wheel Cylinder
- Inspecting and Adjusting Brake System
- Operation Test of Automatic Adjuster
- Manual Adjustment Procedure
- Adjusting Parking Brake Cable
- Adjusting Brake Pedal
- Bleeding Brake Oil Line
- Braking Performance Test
- Adjusting Parking Brake Lever
- Structure and Functions
- General
- Steering Valve
- Steering Column
- Disassembling and Assembling Pipes and Hoses
- Suggestions for Disassembly and Assembly
- Disassembling Steering Wheel and Steering Valve
- Installing Steering Wheel and Steering Valve
- Installation
- Inspection After Installation
- Removing Steering Valve
- Installing Steering Valve
- Disassembling Tilt Lock Lever
- Assembling Tilt Lock Lever
- Disassembling Steering Valve
- Inspection After Disassembly
- Assembling Steering Valve
- Outline
- Hydraulic Lines Diagram
- Hydraulic Tank
- Gear Pump
- Control Valve
- Down Safety Valve
- Lift Cylinder (First Cylinder for Duplex and Triplex Mast)
- Lift Cylinder (Second Lift Cylinder for Simplex Mast and Triplex Mast)
- Lift Cylinder (Second Lift Cylinder for Duplex Mast)
- Tilt Cylinder
- Removing Hydraulic Pump
- Installing Hydraulic Pump
- Disassembling Hydraulic Pump
- Inspecting and Repairing Hydraulic Pump
- Assembling Hydraulic Pump
- Operation Test
- Removing Lift Cylinders
- (First Cylinder for Duplex and Triplex Masts)
- (Second Cylinder for Simplex Mast and Triplex Mast)
- Removing Tilt Cylinders
- Installing Tilt Cylinders
- Disassembling Tilt Cylinder
- Inspection After Disassembling Tilt Cylinder
- Assembling Tilt Cylinder
- Piping
- Piping for Diesel Engine Models
- Piping for Dual Gas/LPG Engine Models
- Removing Suction Strainer and Return Filter
- Inspecting Suction Strainer and Return Filter
- Installing Suction Strainer and Return Filter
- Inspecting and Adjusting Hydraulic Tank
- Inspecting Control Valve
- Vertical Drift Test
- Tilt Drift Test
- Lift and Tilt Cylinders
- First Cylinder for Duplex and Triplex Masts
- Second Cylinder for Simplex and Triplex Masts
- Second Cylinder for Duplex Mast
- Outline of Control Valve
- Hydraulic Lines Diagram of Hydraulic Control Valve
- Inlet Section
- Lift and Tilt Section (Lift Function)
- Lift and Tilt Section (Tilt Function)
- Unload Valve
- Removing Control Valve
- Installing Control Valve
- Disassembling Control Valve - Inlet Section
- Disassembling Control Valve - Lift Valve
- Disassembling Control Valve - Tilt Valve
- Disassembling Control Valve - End Cover Section
- Assembling Control Valve - End Cover Section
- Assembling Attachment Section (Option)
- Simplex Mast
- Mast System
- Structure and Functions (5V25D to 5V30D)
- Removal Sequence of Mast and Lift Bracket Assembly
- Suggestions for Removing Mast and Lift Bracket Assembly
- Suggestions for Installing Mast and Lift Bracket Assembly
- Removal Sequence of Mast and Lift Bracket
- Suggestions for Disassembling Mast and Lift Bracket
- Inspection of Mast and Lift Bracket (All Mast Models)
- Assembly Sequence of Lift Bracket Roller (All Mast Models)
- Lift Bracket Clearance Adjustment (All Mast Models)
- Installing Mast Rollers (All Mast Models)
- Installing Mast Strips (All Mast Models)
- Installing Lift Cylinders
- Connecting Chains
- Installing Hydraulic Lines
- Without Removing Mast from Truck
- Inspecting Forks (All Mast Models)
- Inspecting and Adjusting Chain Tension (All Mast Models)
- Measuring Chain Elongation (All Mast Models)
- (All Mast Models)
- Adjusting Mast Roller Clearance (All Mast Models)
- Inspecting and Adjusting Mast Strip Clearance (All Mast Models)
- Adjusting Mast Tilt Angle (All Mast Models)
- Duplex Mast
- Structure and Functions (5F25C to 5F30C)
- Disassembly Sequence of Mast and Lift Bracket
- Preparation for Disassembling Mast and Lift Bracket
- Installing Second Lift Cylinder
- Installing First Lift Cylinder
- Triplex Mast
- Structure and Functions (5M25D to 5M30D)
- Disassembly Sequence of Mast and Lift Bracket (All Mast Models)
- Inspecting Mast and Lift Bracket (All Mast Models)
- Maintenance Schedule
- Tightening Torques for Standard Bolts and Nuts
- Metric Fine Thread
- Metric Coarse Thread
- Periodic Replacement Parts
- Safety Critical Parts
- Lubrication Schedule
- Lubrication Chart
- Fuel and Lubricant Specifications
- Adjustment Value and Oil Capacity
- Special tools
- Special Service Tools (Powershift Transmission)
- Special Service Tools (Front Axle and Reduction Differential)
- Special Service Tools (Brake System)
- Special Service Tools (Steering System)
- Special Service Tools (Hydraulic System)
- Description of Circuit Diagrams
- Circuit Diagrams
- Connector Diagrams
- How to Read Circuit Diagrams
- Symbols
- Sheet Symbol
- Connecting Lines
- Equipment
- Relay Contactor and Coil
- Connectors
- Indication of Connecting Line
- Indication of GND (Earth)
- Indication of Another Specification
- How to Read Connector Diagrams
Inside this manual
Real pages from this service manual (473 pages). Open the sample pages (PDF, 418 KB)
- Specifications, page 84: CHAPTER 5 POWERSHIFT TRANSMISSION
- Troubleshooting, page 399: CHAPTER 11 MAST AND FORKS
- Diagram, page 455: CHAPTER 15 CIRCUIT DIAGRAM FOR DIESEL ENGINE MODELS
- Color page, page 79: CHAPTER 5 POWERSHIFT TRANSMISSION
- Color page, page 111: CHAPTER 5 POWERSHIFT TRANSMISSION
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 473 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
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Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).