Clark S 20 D, S 25 D, S 30 D, S 35 D Service Manual SM-1081

Description

• Model List:
  • S 20 D
  • S 25 D
  • S 30 D
  • S 35 D

• 1. SM1081
• 2. CONTENTS
• 3. GROUP SA SAFE MAINTENANCE
• 3.1. Section 1 Safety
• 3.2. Section 2 Lifting, Jacking, and Blocking the Truck
• 3.3. Section 3 Towing
• 4. GROUP PS PERIODIC SERVICE
• 4.1. Section 1 Maintenance Schedules
• 4.2. Section 2 The Planned Maintenance Program
• 5. GROUP 00 (D4LE2X) DIESEL ENGINE (TIER 4) Model 4LE2X (ISUZU)
• 5.1. Section 1 15B. Maintenance Information
• 5.2. Section 2 15C. Functional Inspection
• 5.3. Section 3 15D. Symptom
• 5.4. Section 4 15E. DTC Information
• 5.5. Section 5 1A. Engine Control
• 5.6. Section 6 1B. Mechanical
• 5.7. Section 7 1C. Fuel System
• 5.8. Section 8 1D. Cooling
• 5.9. Section 9 1E. Lubrication
• 5.10. Section 10 1F. Induction
• 5.11. Section 11 1H. Aux. Emission Control Devices
• 5.12. Section 12 Electrical
• 5.13. Section 13 Wiring Diagram
• 6. GROUP 01 COOLING SYSTEM
• 6.1. Section 1 Cooling System Specifications and Description
• 6.2. Section 2 Cooling System Troubleshooting
• 6.3. Section 3 Cooling System Testing and Maintenance
• 6.4. Section 4 Radiator Removal and Replacemant
• 7. GROUP 03 INTAKE AND EXHAUST SYSTEM
• 7.1. Section 1 Intake and Exhaust Systems Specifications and Description
• 7.2. Section 2 Intake System Troubleshooting
• 7.3. Section 3 Intake System Service
• 7.4. Section 4 Exhaust Systems
• 8. GROUP 06 TRANSMISSION
• 8.1. Section 1 Transmission Specifications and Description
• 8.2. Section 2 Transmission Troubleshooting
• 8.3. Section 3 Transmission Oil and Filter
• 8.4. Section 4 Transmission Oil Cooler
• 8.5. Section 5 Transmission Overhaul Overview
• 8.6. Section 6 Transmission Overhaul Procedure
• 8.7. Section 7 Transmission Control Valve Overhaul
• 8.8. Section 8 Transmission Removal and Installation
• 9. GROUP 13 ELECTRICAL SYSTEM
• 9.1. Section 1 Cautions for working on the electrical system
• 9.2. Section 2 Electrical system Specifications and features
• 9.3. Section 3 Electrical Circuit Diagram Electrical Parts Arrangement
• 9.4. Section 4 Instrument Pod
• 9.5. Section 5 Electrical Components Specification and Operation
• 10. GROUP 20 DRIVE AXLE
• 10.1. Section 1 Drive Axle Specifications and Description
• 10.2. Section 2 Drive Axle Disassembly and Assembly
• 10.3. Section 3 Troubleshooting
• 11. GROUP 22 WHEELS AND TIRES
• 11.1. Section 1 Wheels and Tires Specifications and Description
• 11.2. Section 2 Pneumatic Wheels and Tires
• 12. GROUP 23 BRAKE SYSTEM
• 12.1. Section 1 Braking / Inching System Specifications and Description
• 12.2. Section 2 Service Brake Troubleshooting
• 12.3. Section 3 Brake/Inching Pedals and Linkages Adjustments
• 12.4. Section 4 Brake Bleeding
• 12.5. Section 5 Brake Valve Service
• 12.6. Section 6 Parking Brake Service
• 12.7. Section 7 Parking Brake Troubleshooting
• 13. GROUP 25 STEERING COLUMN AND GEAR
• 13.1. Section 1 Steering System Specifications and Description
• 13.2. Section 2 Steering System Troubleshooting
• 13.3. Section 3 Steering Column and Component Removal and Replacement
• 13.4. Section 4 Steering System Relief Pressure Check and Adjustment
• 13.5. Section 5 Steering Gear Overhaul
• 14. GROUP 26 STEER AXLE
• 14.1. Section 1 Steer Axle Specifications and Description
• 14.2. Section 2 Steer Axle Wheel Bearing Maintenance and Adjustment
• 14.3. Section 3 Steer Axle Removal and Replacement
• 14.4. Section 4 Steer Axle Overhaul
• 14.5. Section 5 Steer Cylinder Removal and Replacement
• 14.6. Section 6 Steer Cylinder Overhaul
• 15. GROUP 29 HYDRAULIC SUMP, FILTERS, AND PUMP
• 15.1. Section 1 Hydraulic Sump, Filters, and Pump Specifications and Description
• 15.2. Section 2 Main Hydraulic Pump Troubleshooting
• 15.3. Section 3 Hydraulic Filters and Fluid Maintenance and Change
• 15.4. Section 4 Hydraulic Pump Removal and Replacement
• 15.5. Section 5 Hydraulic Pump Overhaul
• 16. GROUP 30 HYDRAULIC CONTROL VALVE/LIFT CIRCUIT
• 16.1. Section 1 Hydraulic Control Valve/Lift Circuit Specifications and Description
• 16.2. Section 2 Hydraulic System Schematics
• 16.3. Section 3 Hydraulic System Troubleshooting
• 16.4. Section 4 Hydraulic System Pressure Checks and Adjustments
• 16.5. Section 5 Hydraulic Control Valve Removal and Replacement
• 16.6. Section 6 Hydraulic Control Valve (MCV) Disassembly and Assembly
• 16.7. Section 7 EHL Valve Disassembly and Assembly
• 16.8. Section 8 Testing of Hydraulic Valve
• 17. GROUP 32 TILT CYLINDERS
• 17.1. Section 1 Tilt Cylinder Specifications and Description
• 17.2. Section 2 Tilt Cylinder Checks and Adjustments
• 17.3. Section 3 Tilt Cylinder Removal and Replacement
• 17.4. Section 4 Tilt Cylinder Overhaul
• 18. GROUP 34 UPRIGHTS
• 18.1. Section 1 Upright Specifications and Description
• 18.2. Section 2 Troubleshooting
• 18.3. Section 3 Upright Inspection
• 18.4. Section 4 Carriage and Upright Roller Clearance Checks and Shim Adjustments
• 18.5. Section 5 Cylinder Removal, Shimming, Overhaul, and Replacement
• 18.6. Section 6 Upright Chain Inspection, Adjustment, and Replacement
• 18.7. Section 7 Fork and Carriage Removal and Replacement
• 18.8. Section 8 Upright Removal and Replacement
• 19. GROUP 38 COUNTERWEIGHT AND CHASSIS
• 19.1. Section 1 Counterweight Specifications and Description
• 19.2. Section 2 Counterweight Removal and Replacement
• 19.3. Section 3 Overhead Guard/Operators Cell Removal and Replacement
• 19.4. Section 4 Floorboard, Cowls, and Seat Deck Removal and Replacement
• 19.5. Section 5 Operators Seat Removal and Replacement
• 20. GROUP 40 SPECIFICATIONS
• 20.1. Section 1 Nameplates and Decals
• 20.2. Section 2 General Specifications
• 20.3. Section 3 Hydraulic Fitting Tightening Specification