Format: PDF (Printable Document)
File Language: English
File Pages: 901
File Size: 93.53 MB (Speed Download Link)
Brand: Clark
Model: GTS20, GTS25, GTS30, GTS33L HMC Theta Engine Forklift
Book No: SM1170
Part No: 8163662
Type of Document: Service Manual
$ 40
These Clark GTS20–GTS33L forklifts spend their lives loading trucks, feeding production lines, and shuttling pallets around yards and warehouses, so downtime hurts fast. This SM1170 service manual is what I’d keep on the bench when I’m tracing engine-related issues on the HMC Theta powerplant and making sure the truck goes back out reliable. If, for example, the truck starts hard when hot and idles rough, I’d use this book to step through the checks in order—fuel, ignition, air, and mechanical—so I’m not just throwing parts at it. It also guides how to strip and reassemble components without missing seals or misaligning anything.
Applications & Use Cases
FAQ
Q: Can I use this manual on a tablet in the shop?
A: Yes, it’s practical to keep it open on a tablet or laptop so you can zoom diagrams and search quickly while working at the truck.
Q: Is it worth printing sections of this manual?
A: Many techs print the pages for the specific job they’re doing, mark notes or measurements, then keep those sheets with the work order.
Safety Note
Always follow lockout/tagout and support procedures before working under or around a raised mast or running engine.
SM-1170
CONTENTS
GROUP SA SAFE MAINTENANCE
Section 1 Safety
Section 2 Lifting, Jacking, and Blocking the Truck
Section 3 Towing
GROUP PS PERIODIC SERVICE
Section 1 Maintenance Schedules
Section 2 The Planned Maintenance Program
GROUP 00 ENGINE (HMC THETA 2.4L LPG)
Section 1 General Information
Section 2 Specification and Troubleshooting
Section 3 Disassembly and Reassembly
Section 4 Lubrication System
Section 5 Electrical System
Section 6 Emission Control System
Section 7 Handset
GROUP 01 ENGINE COOLING SYSTEM
Section 1 Specifications and Description
Section 2 Troubleshooting
Section 3 Testing and Maintenance
Section 4 Alternator Belt Service
Section 5 Radiator Removal and Replacement
GROUP 02 FUEL SYSTEM (WOODWARD)
Section 1 LPG System Overview
Section 2 Gasoline Engines
Section 3 Specifications
Section 4 Recommended Maintenance
Section 5 Installation Procedures
Section 6 Tests and Adjustments
Section 7 Basic Troubleshooting
Section 8 Advanced Diagnostics (DFC Codes)
Section 9 Appendix
GROUP 03 INTAKE AND EXHAUST SYSTEM
Section 1 Specifications and Description
Section 2 Troubleshooting
Section 3 Intake System Service
Section 4 Exhaust Systems
GROUP 06 TRANSMISSION (MS Precision)
Section 1 Structure and Functions
Section 2 Disassembly & Assembly
Section 3 Maintenance
Section 4 Troubleshooting and Repair
Section 5 Transmission Installation
GROUP 07 TRANSMISSION (Jindao)
Section 1 General
Section 2 Parameter
Section 3 Maintenance and Adjustment
Section 4 Structure and Mechanism
Section 5 Disassembly and Reassembly
Section 6 Transmission Installation
GROUP 13 ELECTRICAL SYSTEM
Section 1 Electrical System Cautions
Section 2 Specifications and Features
Section 3 Circuit Diagram & Parts Arrangement
Section 4 Instrument Panel
Section 5 Electrical Components Specification and Operation
Section 6 Air Conditioner & Heater System (Option)
Section 7 Electrical Circuit Diagram & Electrical Parts Arrangement (EN 1175)
Section 8 Speed Limit Function (EN 1175)
GROUP 19 CONTROLLER SYSTEM (EN 1175)
Section 1 Controller Installation
Section 2 Controller Description
Section 3 Handset
Section 4 Control Troubleshooting
Section 5 Factory Control Settings
GROUP 20 DRIVE AXLE (MS Precision)
Section 1 Structure and Operation Principle
Section 2 Disassembly and Assembly
Section 3 Lubrication and Maintenance
Section 4 Troubleshooting
GROUP 21 DRIVE AXLE (Jindao)
Section 1 General
Section 2 Parameter
Section 3 Maintenance and Adjustment
Section 4 Structure and Mechanism
Section 5 Disassembly and Reassembly
Section 6 Drive Axle Installation
GROUP 22 WHEELS AND TIRES
Section 1 Specifications and Description
Section 2 Pneumatic Wheels and Tires
GROUP 23 BRAKE SYSTEM
Section 1 Specifications and Description
Section 2 Troubleshooting
Section 3 Brake/Inching Pedals and Linkages Adjustments
Section 4 Brake System Bleeding
Section 5 Brake Master Cylinder Service
Section 6 Parking Brake Service
GROUP 25 STEERING COLUMN AND GEAR
Section 1 Specifications and Description
Section 2 Troubleshooting
Section 3 Steering Column Removal and Replacement
Section 4 Relief Pressure Check and Adjustment
Section 5 Steering Gear Overhaul
GROUP 26 STEER AXLE
Section 1 Specifications and Description
Section 2 Bearing Maintenance and Adjustment
Section 3 Steer Axle Overhaul
Section 4 Steer Cylinder Removal Replacement
Section 5 Steer Cylinder Overhaul
GROUP 29 HYDRAULIC SUMP, FILTERS, AND PUMP
Section 1 Specifications and Description
Section 2 Troubleshooting
Section 3 Filters and Fluid Maintenance
Section 4 Pump Removal and Replacement
Section 5 Pump Overhaul (Jinsung)
GROUP 30 HYDRAULIC CONTROL VALVE / LIFT CIRCUIT
Section 1 Specifications and Description
Section 2 Hydraulic System Schematics
Section 3 Troubleshooting
Section 4 Pressure Checks and Adjustments
Section 5 Hydraulic Control Valve Removal and Replacement
Section 6 Hydraulic Control Valve Overhaul
GROUP 32 TILT CYLINDERS
Section 1 Specifications and Description
Section 2 Checks and Adjustments
Section 3 Removal and Replacement
Section 4 Overhaul
GROUP 34 UPRIGHTS
Section 1 Specifications and Description
Section 2 Troubleshooting
Section 3 Upright Inspection
Section 4 Carriage and Upright Roller Clearance Check and Shim Adjustments
Section 5 Cylinder Removal, Shimming, Overhaul, and Replacement
Section 6 Upright Chain Inspection, Adjustment, and Replacement
Section 7 Fork and Carriage Removal and Replacement
Section 8 Upright Removal and Replacement
GROUP 38 COUNTERWEIGHT AND CHASSIS
Section 1 Specifications and Description
Section 2 Removal and Replacement
Section 3 Overhead Guard / Operator’s Cell Removal and Replacement
Section 4 Floorboard, Cowls, Seat Deck Removal and Replacement
Section 5 LPG Tank Removal and Replacement
GROUP 40 SPECIFICATIONS
Section 1 Nameplates and Decals
Section 2 General Specifications
Section 3 Hydraulic Fitting Tightening Procedure
