Clark C15-33(35) D/L/G & C15-32C L/G Forklift Service Manual – SM-661

Description

Clark C15-33(35) D/L/G & C15-32C L/G Forklift Service Manual – SM-661

This Clark C15-33(35) D/L/G & C15-32C L/G forklift service manual is the complete technical resource for maintaining, repairing, and overhauling Clark forklift trucks with rated capacities from 1500 to 3500 kg. Published under Book No. SM-661, Part No. 8036090, Revision 3, dated March 2005, this manual covers diesel, LPG, and gasoline powered trucks across the C15, C18, C20s, C20, C25, C30, C32C, and C33(35) model ranges.

The Clark C15-33(35) D/L/G & C15-32C L/G service manual is arranged by standardized Groups, each beginning with its own table of contents. Every page carries a unique ID so technicians can locate Group, Section, and Page quickly using the headers and footers. This organization makes the SM-661 service manual practical for both routine maintenance and major component overhauls.

File Details

• Manual Type: Service Manual
• Brand: Clark Material Handling
• Models Covered: C15-33(35) D/L/G, C15-32C L/G
• Rated Capacity: 1500 – 3500 kg
• Language: English
• File Format: PDF
• Part Number: 8036090
• Book Number: SM-661
• Revision: Rev.3
• Publication Date: March 2005
• Page Count: Approximately 1,006 pages

Chapters Covered

The Clark C15-33(35) D/L/G & C15-32C L/G service manual is organized into the following Groups:

• Group SA – Safe Maintenance (Safety, Lifting/Jacking/Blocking, Towing)
• Group PS – Periodic Service (Maintenance Schedules, Planned Maintenance Program)
• Group 00(G) – Engine (4G63/4G64 Gas/LPG): Specifications, Troubleshooting, Oil and Filter, Tune-Up, RPM/Vacuum/Stall Checks, Compression Checks, Removal and Replacement, Overhaul
• Group 00(D) – Engine (4TNE94-SFW Diesel): Engine specifications, fuel system diagram, cooling system, lubrication system, disassembly/assembly, inspection and measurement, service standards, tightening torques
• Group 00(D-T2) – Diesel Engine (4TNV88/4TNV94L): Safety, General, Inspection and Adjustment, Troubleshooting, Disassembly/Inspection/Reassembly, Lubrication System, Cooling System, Fuel Injection Pump/Governor, Alternator, Electric Wiring, Service Standards, Tightening Torque
• Group 01 – Cooling System: Specifications, Troubleshooting, Testing and Maintenance, Belt Service, Radiator Removal and Replacement
• Group 02(LP) – LPG Fuel System: Specifications, Troubleshooting, Adjustments and Maintenance, Carburetor and Throttle Body, Vaporizer Removal and Overhaul, Fuel Lock Removal, Air Governor, Gas Fuel System
• Group 02 – MI-4 LP System (Tier2): Working with LPG Equipment, LPG and Fuel Tanks, MI-4 Operational Overview, Maintenance Schedule, Basic Troubleshooting, Advanced Diagnostics, Electrical Connections, N2001 Pressure Regulator/Converter, N-CA55-500TR Air/Fuel Mixer, Test and Adjustments
• Group 03 – Air Induction and Exhaust System: Specifications, Troubleshooting, Air Induction Service, Exhaust Systems
• Group 06 – Transaxle (TA12A1): Specifications, Disassembly, Reassembly
• Group 06(S) – Transaxle (TA-30): Specifications, Troubleshooting, Oil and Filter, Oil Cooler, Removal and Replacement, Overhaul, Drive Axle Ends Overhaul, Control Valve Overhaul
• Group 12 – Ignition System (Standard Electronic Ignition): Specifications, Troubleshooting, Inspection/Adjustments/Timing, Distributor Overhaul
• Group 13 – Electrical System: Cautions, Specifications and Features, Circuit Diagrams and Component Arrangement, Instrument Pod, Specification and Operation of Electrical Components, Troubleshooting
• Group 22 – Wheels and Tires: Specifications, Cushion Wheels and Tires, Pneumatic Wheels and Tires
• Group 23(S) – Brake System (TA12A1/TA30 Transaxle): Specifications, Service Brake Troubleshooting, Pedals and Linkages Adjustments, Brake Bleeding, Master Cylinder Service, Service Brake Adjustment and Overhaul, Parking Brake Service
• Group 25 – Steering Column and Gear: Specifications, Troubleshooting, Removal and Replacement, Relief Pressure Check and Adjustment, Steering Gear Overhaul
• Group 26 – Steer Axle: Specifications, Wheel Bearing Maintenance and Adjustment, Removal and Replacement, Overhaul, Steer Cylinder Removal and Replacement, Steer Cylinder Overhaul
• Group 29 – Hydraulic Sump, Filters, and Pump: Specifications, Troubleshooting, Filters and Fluid Maintenance, Pump Removal and Replacement, Pump Overhaul (Hanil and Jinsung)
• Group 30 – Hydraulic Control Valve/Lift Circuit: Specifications, Schematics, Troubleshooting, Pressure Checks and Adjustments, Removal and Replacement, Control Valve Overhaul (Hanil and Eaton)
• Group 32 – Tilt Cylinders: Specifications, Checks and Adjustments, Removal and Replacement, Overhaul
• Group 34 – Uprights: Specifications, Troubleshooting, Inspection, Roller Clearance Checks and Shim Adjustments, Cylinder Removal/Shimming/Overhaul/Replacement, Chain Inspection/Adjustment/Replacement, Fork and Carriage Removal/Replacement, Upright Removal/Replacement
• Group 38 – Counterweight and Chassis: Specifications, Counterweight Removal and Replacement, Overhead Guard/Operator’s Cell, Floorboard/Cowls/Radiator Cover/Seat Deck, Operator’s Seat
• Group 40 – Specifications: Nameplates and Decals, General Specifications, Hydraulic Fitting Tightening Procedures

Models and Engines Covered

This Clark service manual covers the following truck models:

• C15, C18, C20s, C20, C25, C30, C32C, C33(35) – Cushion tire and pneumatic tire configurations
• C15C, C18C, C20sC, C20C, C25C, C30C, C32C – Cushion tire variants

Engine coverage includes:

• 4G63 – Gas/LPG engine
• 4G64 – Gas/LPG engine
• 4TNE94-SFW – Diesel engine
• 4TNV88 – Diesel engine (Tier2)
• 4TNV94L – Diesel engine (Tier2)

What This Manual Enables

The Clark C15-33(35) D/L/G & C15-32C L/G service manual gives technicians, fleet maintenance managers, and forklift owners the complete procedures needed to service these trucks correctly. From scheduled planned maintenance to complete component overhaul, this manual covers every major system on the truck.

For engine service, the manual provides detailed troubleshooting charts, tune-up specifications, RPM and vacuum test procedures, stall tests, compression checks, and complete removal and overhaul procedures for both the 4G63/4G64 gas/LPG engines and the 4TNE94/4TNV88/4TNV94L diesel engines. Torque specifications, service limits, and tightening sequences are given throughout.

The transaxle section covers the TA12A1 and TA-30 transaxles, including complete disassembly and reassembly procedures, differential bearing preload checks, ring and pinion backlash adjustment, clutch pack overhaul, and control valve service. Hydraulic system coverage includes the main hydraulic pump, control valve, lift circuit, tilt cylinders, and upright components, with complete pressure check and adjustment procedures.

Brake system service covers the service brake, inching system, parking brake, master cylinder, and wheel cylinder overhaul. Steering system coverage includes the steering column, steering gear, steer axle, and steer cylinder. Electrical coverage includes complete wiring diagrams for diesel, gasoline, and LPG models, instrument pod diagnostics, and troubleshooting for every major electrical component.

Upright service is covered in detail, including carriage and upright roller clearance checks, shim adjustments, lift chain inspection and adjustment, cylinder removal and overhaul, and complete upright removal and replacement. The manual also covers wheels and tires, counterweight, overhead guard, operator’s cell, floorboard, cowls, radiator cover, and seat deck.

Safety is addressed in Group SA with safe maintenance practices, lifting and jacking procedures, and towing instructions. Group PS provides maintenance schedules and the planned maintenance program with service intervals for every system on the truck.

Why This Manual Matters

Correct service procedures and specifications are critical for forklift safety, reliability, and longevity. This Clark service manual provides the exact torque values, pressure settings, clearance specifications, and adjustment procedures that Clark specifies for these trucks. Using the right specifications prevents damage from over- or under-tightening, ensures hydraulic systems operate at correct pressures, and keeps engines running within design parameters.

The troubleshooting sections help technicians diagnose problems efficiently instead of replacing parts by guesswork. The overhaul procedures give step-by-step instructions with exploded views for major components, making even complex repairs manageable. The wiring diagrams and hydraulic schematics show how systems are connected, which is essential for diagnosing electrical and hydraulic faults.

Whether you are performing routine maintenance, diagnosing a fault, or rebuilding a component, this Clark C15-33(35) D/L/G & C15-32C L/G service manual provides the information needed to do the job correctly.

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Instant PDF Delivery

This Clark service manual is delivered as an instant PDF download after payment. No shipping, no waiting for a physical book. The PDF works on any device — laptop, desktop, tablet, or smartphone — and can be printed for use in the shop. Search, zoom, and navigate the entire manual with your PDF reader. Keep a copy on your computer and a printed copy in the service area for quick reference during repairs.