Clark C15-35 C15-32C Forklift Service Manual SM-709 2005 – Gas LPG Diesel Repair

Description

File Details

• Manual Type: Complete Service Manual (base module)
• Brand: Clark Material Handling
• Models Covered: C15-35 series and C15-32C series (gas, LPG, and diesel variants)
• Book / Part No.: SM-709 / Part No. 8036092, REV.2
• Publication Date: December 2005
• Language: English
• Page Count: 984 pages
• File Format: PDF
• Layout: Group / Section / Page ID structure (e.g., 00(G)-1-2 = Group 00 Gas engine, Section 1, page 2)

Overview

This is the Clark factory service manual for the C15-35 and C15-32C rated-capacity forklift series — a 1500–3500 kg class of internal-combustion counterbalance trucks. Book No. SM-709, REV.2 (December 2005), this 984-page manual covers the gas, LPG, and diesel engine variants in a single base module, plus dedicated sections for the LP-fueled Tier-2 engine management and the two transaxle families used in the series (TA12A1 and TA-30).

The manual is organized by Group (chapter) using Clark’s standard service numbering system, and each Group begins with its own table of contents. A revision-history table at the front tells the technician which pages are new, replaced, or deleted so an accurate, up-to-date copy can be maintained.

Chapters Covered

• Group SA — Safe Maintenance: safety signs and messages, safe maintenance practices, lifting, jacking and blocking, towing procedures
• Group PS — Periodic Service: maintenance schedules, the planned maintenance program, recommended periodic service chart
• Group 00(G) — Engine (4G63/4G64 Gas/LPG): specifications, troubleshooting, oil and filter, tune-up, RPM/vacuum/stall tests, compression checks, removal and replacement, full overhaul
• Group 00(D-Tier2) — 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 torques
• Group 01 — Engine Cooling System: specifications, troubleshooting, testing and maintenance, coolant and belt service, radiator removal and replacement
• Group 02(LP) — LPG Fuel System (Carbureted): specifications, troubleshooting, adjustments and maintenance, carburetor and throttle body overhaul, vaporizer-regulator, fuel lock-off, air governor, gas fuel system
• Group 02(LP-Tier2) — MI-4 LP System: working with LPG equipment, LPG and LPG fuel tanks, operational overview, maintenance schedule, basic and advanced diagnostics, electrical connections, N2001 regulator/converter, N-CA55-500TR air/fuel mixer, tests and adjustments
• Group 03 — Air Induction & Exhaust: specifications, troubleshooting, air induction service, exhaust systems
• Group 06 — Transaxle (TA12A1): specifications and description, transaxle disassembly and reassembly
• Group 06(S) — Transaxle (TA-30): specifications, troubleshooting, oil and filter, oil cooler, removal and replacement, overhaul, drive axle ends, control valve overhaul
• Group 12 — Ignition System: specifications, troubleshooting, inspection/adjustment/timing, distributor overhaul, starter motor, alternator
• Group 13 — Electrical System: working precautions, specifications, circuit diagrams and electrical parts arrangement, instrument pod, components, troubleshooting, instrument pod settings
• Group 22 — Wheels and Tires: specifications, cushion wheels and tires, pneumatic wheels and tires
• Group 23(S) — Brake System (TA12A1 / TA30): specifications, troubleshooting, pedal and linkage adjustments, brake bleeding, master cylinder service, service brake adjustment and overhaul, parking brake service
• Group 25 — Steering Column and Gear: specifications, troubleshooting, column component removal/replacement, relief pressure check and adjustment, steering gear overhaul
• Group 26 — Steer Axle: specifications, wheel bearing maintenance and adjustment, axle removal/replacement, overhaul, steer cylinder removal and overhaul
• Group 29 — Hydraulic Sump, Filters, and Pump: specifications and description, pump troubleshooting, filter and fluid maintenance, pump removal/replacement, Hanil and Jinsung pump overhaul
• Group 30 — Hydraulic Control Valve/Lift Circuit: specifications, system schematics, troubleshooting, pressure checks and adjustment, valve removal/replacement, Hanil and Eaton valve overhaul
• Group 32 — Tilt Cylinders: specifications, tilt checks and adjustments, removal and replacement, overhaul
• Group 34 — Uprights: specifications, troubleshooting, inspection, roller clearance and shim adjustments, cylinder service, chain inspection/adjustment/replacement, fork and carriage service, upright removal and replacement
• Group 38 — Counterweight and Chassis: counterweight specifications and service, 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

What This Manual Gives You

This is a full dealership-level service publication covering the entire truck, not just the engine. For the driveline you get both the TA12A1 and TA-30 transaxle sections with complete disassembly and reassembly procedures, clutch pack overhaul, differential bearing preload and ring-and-pinion backlash setup, and drive-axle-end overhaul. The hydraulic group covers the main pump (including Hanil and Jinsung rebuilds), the open-center main control valve used for lift and tilt, the tilt lock and load-lowering valves, and the steering gear. The upright group walks through carriage and rail roller clearance checks, shim adjustment, chain inspection and length setting, cylinder overhaul, and complete upright removal.

Engine coverage is split cleanly between the 4G63/4G64 gas/LPG family and the 4TNV88/4TNV94L Tier-2 diesel family. Each engine chapter includes compression checks, tune-up data, RPM and vacuum and stall tests, removal and replacement, and a full overhaul section with measurement specs and tightening torques. The MI-4 LP system chapter covers the closed-loop SECM-controlled fuel system used on the Tier-2 LPG trucks, including fault-code retrieval through the MIL, sensor resistance checks, regulator and mixer service, and the fuel trim valve.

Electrical coverage is unusually deep for a lift truck manual: full circuit diagrams and physical parts-arrangement illustrations for the diesel, gasoline, LPG, and dual-fuel variants across both C15-20s and C20-35 chassis, plus a dedicated instrument pod section with menu mode structure, fault-code list, and diagnostic flowchart troubleshooting.

Coverage Notes

This is Clark’s base service module — it covers the truck itself, not every attachment. Emissions and fuel-system variants are handled in separate Groups (e.g., carbureted LPG in Group 02(LP) versus Tier-2 MI-4 LP in Group 02(LP-Tier2); gas/LPG 4G63/4G64 versus Tier-2 diesel 4TNV88/4TNV94L), so the correct Group must be selected based on the actual truck configuration. Coverage spans a 1500–3500 kg rated-capacity range with multiple engine and transmission combinations, so the technician should confirm the truck’s data plate before starting a job.

Standard maintenance intervals in the manual are written for normal operation, with explicit direction to shorten them under severe or extreme conditions — relevant if the truck operates in dusty, high-temperature, or rapid-temperature-change environments.

Why This Manual Matters

Clark forklift specifications are not generic — torque values, clearances, shim stacks, and pressure settings in this manual are specific to the C15-35 / C15-32C series and its engine and transaxle variants. Using the wrong value on a differential bearing preload, ring-and-pinion backlash, cylinder gland torque, or hydraulic relief setting can cause premature failure, oil leaks, or unsafe operation. The Group/Section/Page ID system used throughout the manual makes it fast to cross-reference a procedure with its specification page in Group 40.

The manual also gives you the fault-code tables and diagnostic flowcharts needed to service the SECM-controlled MI-4 LP system properly, rather than swapping parts. Sections for the instrument pod menu mode allow configuration changes (service interval reminders, lamp behavior, speed limit options, seat switch mode) that would otherwise require a dealer visit.

Delivery

IMAGES PREVIEW

Instant PDF download after payment — no shipping, no waiting. The file is fully printable and can be opened on a laptop, tablet, or phone in the workshop, or printed section-by-section for the job at hand. Use the revision-history pages at the front to confirm you are referencing the current REV.2 content for any procedure.