Format: PDF (Printable Document)
File Language: English
File Pages: 547
File Size: 64.01 MB (Speed Download Link)
Brand: Clark
Model: L20, L25, L30, L33, L35 L HMC Theta 2.4 Engine Forklift
Book No: SM1147
Part No: 3421049
Type of Document: Service Manual
$ 40
These Clark L20–L35 forklifts spend their lives loading trailers, feeding production lines, and shuttling pallets in tight warehouse aisles and yards. This service manual is what I’d keep open when I’m tracing a drivability or hydraulic issue back to the HMC Theta 2.4 engine and related systems. It walks you through the logic of checking, isolating, and then safely tearing down and reassembling components instead of just throwing parts at a problem. For example, if a truck starts hard and won’t hold idle when hot, this is the book I’d use to methodically test fuel, air, and ignition before I touch a wrench.
Applications & Use Cases
FAQ
Q: Can I use this manual on a tablet in the shop?
A: Yes, it works well digitally; you can zoom diagrams and use search to jump to the system you’re working on.
Q: Is it worth printing sections of this manual?
A: Many techs print just the pages for the current job, so they can mark notes and keep them next to the truck.
Safety Note
Always lock out the truck, block raised components, and let systems depressurize before you start any work guided by this manual.
SM-1147
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 LPG Fuel System (Woodward)
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 03 INTAKE AND EXHAUST SYSTEM
Section 1 Specifications and Description
Section 2 Troubleshooting
Section 3 Intake System Service
Section 4 Exhaust Systems
GROUP 07 TRANSMISSION
Section 1 Structure Overview
Section 2 Fault Cause and Troubleshooting
Section 3 Transmission Install
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
GROUP 20 DRIVE AXLE
Section 1 Drive Axle Mounting
Section 2 Exploded View
Section 3 System Diagnosis
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 / Inching Line 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 Removal and Replacement
Section 3 Overhaul
Section 4 Steer Cylinder Removal and 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
GROUP 30 HYDRAULIC CONTROL VALVE / LIFT CIRCUIT
Section 1 Specifications and Description
Section 2 Hydraulic System Schematic
Section 3 Troubleshooting
Section 4 Pressure Check and Adjustment
Section 5 Removal and Replacement
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
