Clark S20, S25, S30, S35L, S35G HMC Theta Engine Truck Forklift Service Manual (SM1181)

Clark S20, S25, S30, S35L, S35G HMC Theta Engine Truck Forklift Service Manual (SM1181)

Clark S20, S25, S30, S35L, S35G HMC Theta Engine Truck Forklift Index:

M-1181
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
GROUP 01 ENGINE COOLING SYSTEM
Section 1 Specifications and Description
Section 2 Troubleshooting
Section 3 Testing and Maintenance
Section 4 Radiator Removal and Replacement
GROUP 02 FUEL SYSTEM (WOODWARD)
Section 1 LPG Fuel 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 (DFCs)
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 (DIC)
Section 1 Specifications and Description
Section 2 Troubleshooting
Section 3 Oil and Filter
Section 4 Oil Cooler
Section 5 Overhaul Overview
Section 6 Overhaul Procedure
Section 7 Control Valve Overhaul
Section 8 Removal and Installation
GROUP 07 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 13 ELECTRICAL SYSTEM
Section 1 Electrical System Cautions
Section 2 Specifications and Features
Section 3 Circuit Diagram & Parts Arrangement
Section 4 Instrument Pod
Section 5 Components Specification and Operation
GROUP 20 DRIVE AXLE (DIC)
Section 1 Specifications and Description
Section 2 Disassembly and Assembly
Section 3 Troubleshooting
GROUP 21 DRIVE AXLE (MS PRECISION)
Section 1 Structure and Operation Principal
Section 2 Disassembling and Assembling
Section 3 Lubrication and Maintenance
Section 4 Troubleshooting
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 Service Brake Troubleshooting
Section 3 Pedals and Linkages Adjustments
Section 4 Brake Bleeding
Section 5 Brake Valve Service
Section 6 Parking Brake Service (DIC)
Section 7 Parking Brake Service (MS PRECISION)
Section 8 Parking Brake Troubleshooting
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 Removal and Replacement
Section 4 Steer Axle Overhaul
Section 5 Steer Cylinder Removal and Replacement
Section 6 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 (DIC)
Section 6 Pump Overhaul (MS PRECISION)
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 Control Valve Removal and Replacement
Section 6 Control Valve Disassembly and Assembly
Section 7 EHL Valve Disassembly and Assembly
Section 8 Testing of Hydraulic Valve
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 Operator’s Seat Removal and Replacement
GROUP 40 NAMEPLATES AND DECALS
Section 1 Nameplates and Decals
Section 2 Hydraulic Fitting Tightening Procedure

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