Clark C20/25/30/35 L/G Forklift Service Manual – Ford 2.5L LPG Engine Repair Guide

Description

File Details

• Manual Type: Service Manual
• Brand: Clark
• Models Covered: C20/25/30/35 L/G, C20/25/30/32C L/G (Ford Engine Truck)
• Rated Capacity: 2000 – 3500 kg
• Engine: Ford 2.5L LPG
• Language: English
• Page Count: 614 pages
• File Format: PDF
• Part No.: 8136113
• Book No.: SM 1044 (Rev 1.3)
• Date: December 2016

Chapters Covered

• Group SA – Safe Maintenance: Safety signs and messages, safe maintenance practices, lifting/jacking/blocking, towing
• Group PS – Periodic Service: Maintenance schedules, service chart/lubrication points, planned maintenance program, PM task chart
• Group 00 – Engines (FORD 2.5 LPG): General information, engine overview, maintenance, LPG fuel system overview, troubleshooting guides, engine electrical, Spectrum Engine Monitor DST, IMPCO A36 ECM DTCs, servicing the fuel system, definitions, appendix with specifications and torque values
• Group 01 – Cooling System: Specifications and description, troubleshooting, testing and maintenance, radiator removal and replacement
• Group 03 – Intake and Exhaust System: Specifications, troubleshooting, intake system service, exhaust systems
• Group 06 – Transaxle (TA-30): Specifications and description, troubleshooting, oil and filter, oil cooler, removal and replacement, overhaul, drive axle ends overhaul, control valve overhaul
• Group 13 – Electrical System: Cautions for electrical work, specifications and features, wiring diagrams and component arrangement, instrument pod operation and settings, electrical components specification and operation, troubleshooting
• Group 22 – Wheels and Tires: Specifications and description, cushion wheels and tires, pneumatic wheels and tires
• Group 23 – Brake/Inching System: Specifications and description, service brake 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 and description, troubleshooting, column and component removal/replacement, relief pressure check and adjustment, steering gear overhaul
• Group 26 – Steer Axle: Specifications and description, wheel bearing maintenance and adjustment, removal and replacement, overhaul, steer cylinder removal/replacement, steer cylinder overhaul
• Group 29 – Hydraulic Pump, Sump, and Filters: Specifications and description, pump troubleshooting, filters and fluid maintenance, pump removal and replacement, pump overhaul (Hanil Pump)
• Group 30 – Hydraulic Control Valve/Lift Circuit: Specifications and description, hydraulic system schematics, troubleshooting, pressure checks and adjustments, control valve removal/replacement, disassembly and assembly, testing
• Group 32 – Tilt Cylinders: Specifications and description, checks and adjustments, removal and replacement, overhaul
• Group 34 – Uprights: Specifications and description, troubleshooting, inspection, carriage and upright roller clearance checks/shim adjustments, cylinder removal/shimming/overhaul/replacement, chain inspection/adjustment/replacement, fork and carriage removal/replacement, upright removal/replacement
• Group 38 – Counterweight, Sheet Metal & Chassis: Specifications and description, counterweight removal/replacement, overhead guard/operator’s cell removal/replacement, floorboard/cowls/seat deck removal/replacement, operator’s seat removal/replacement
• Group 40 – Specifications: Nameplates and decals, general specifications, hydraulic fitting tightening procedures

This Clark C20/25/30/35 L/G forklift service manual is a complete workshop reference for the Ford 2.5L LPG engine truck platform. Covering both cushion-tire and pneumatic-tire variants across the 2000 to 3500 kg capacity range, it gives technicians and maintenance teams the procedures, specifications, and diagnostic information needed to service every major system on these machines. From routine periodic maintenance through complete transaxle overhaul and upright rebuild, the manual breaks each job into step-by-step instructions with torque values, clearances, and adjustment settings throughout.

The Ford 2.5L LPG engine section is particularly detailed, covering the IMPCO A36 ECM diagnostic trouble codes, the Spectrum Engine Monitor diagnostic scan tool, the LPG fuel system from tank to injectors, and comprehensive troubleshooting guides for both no-start and driveability issues. Electrical coverage includes full wiring diagrams, instrument pod configuration and diagnostics, and component testing procedures for sensors, switches, relays, and the alternator/charging system. The transaxle group provides complete overhaul procedures for the TA-30 unit including clutch packs, differential, pinion shaft, and control valve, while the hydraulic section covers pump overhaul, control valve testing and adjustment, tilt cylinder rebuild, and upright chain and roller service.

What This Manual Enables You to Do

With this Clark C20-35 L/G service manual in hand, you can confidently tackle jobs ranging from a simple oil and filter change to a complete transaxle rebuild. The Group PS periodic service section lays out maintenance intervals for every system on the truck, so you can build a proper PM schedule and avoid costly breakdowns. The troubleshooting guides in Group 00 for the Ford 2.5L LPG engine walk through diagnostic steps for no-start conditions, rough running, fuel system faults, and ignition problems, using the Spectrum Engine Monitor and DTC tables to pinpoint issues quickly rather than guessing at parts replacement.

For hydraulic work, Group 29 and Group 30 together give you the full picture of the lift/tilt/aux circuit, including relief pressure checks, flow control adjustments, control valve disassembly and reassembly, and the testing procedures to verify proper operation after a rebuild. The upright section (Group 34) covers chain inspection and adjustment, roller shimming, cylinder overhaul, and carriage removal, with drift test procedures and load test guidance to confirm the upright is performing correctly under load. The brake and steering sections provide the adjustments, bleeding procedures, and overhaul steps needed to keep these safety-critical systems in proper working order.

The specifications in Group 40 bring together general truck data, critical fastener torque values, hydraulic fitting tightening procedures, and capacity/weight information in one place. The nameplate and decal section shows the required safety markings and their correct locations, which is useful when replacing damaged decals or verifying a truck’s configuration. Everything is organized by system group, so you can go straight to the section you need without searching through unrelated content.

Why This Manual Matters

Clark forklifts are built to work hard, and keeping them running reliably depends on correct maintenance and repair procedures. Using the wrong torque value, clearance, or adjustment setting can lead to premature failure, costly downtime, or unsafe operating conditions. This service manual gives you the manufacturer’s own specifications and procedures for every major component on the C20-35 L/G and C20-32C L/G trucks, so you can work to the same standards the factory specifies. Whether you’re a fleet maintenance operation, an independent repair shop, or an owner-operator who prefers to handle your own service, having the complete factory service information on hand means fewer mistakes and better results.

The diagnostic content for the Ford 2.5L LPG engine is especially valuable because these engines rely on electronic controls that require proper scan tool diagnostics rather than traditional mechanical troubleshooting alone. The manual explains how to use the Spectrum Engine Monitor, how to interpret DTCs, and how to work through the diagnostic flow charts for fuel, ignition, and sensor faults. That kind of guided diagnostics saves hours of trial-and-error and helps you get the truck back in service faster.

IMAGES PREVIEW

This Clark C20/25/30/35 L/G forklift service manual is delivered as an instant PDF download after payment. There’s no shipping, no waiting for a physical book, and no restriction on where you use it. The file works on any device that can open a PDF, and you can print individual pages or entire sections for use in the shop. Keep it on a laptop, tablet, or shop computer and have the complete service information for your Clark forklift available whenever you need it.