Clark C20, 25, 30, 35 D, L, G, C20, 25, 30, 32C L Service Manual SM-996

Description

• Model List:
  • C 20 D
  • C 25 D
  • C 30 D
  • C 35 D
  • C 20 L
  • C 25 L
  • C 30 L
  • C 35 L
  • C 20 G
  • C 25 G
  • C 30 G
  • C 35 G
  • C 20C L
  • C 25C L
  • C 30C L
  • C 32C L

• 1. CONTENTS
• 2. GROUP SA SAFE MAINTENANCE
• 2.1. Section 1 Safety
• 2.2. Section 2 Lifting, Jacking, and Blocking the Truck
• 2.3. Section 3 Towing
• 3. GROUP PS PERIODIC SERVICE
• 3.1. Section 1 Maintenance Schedules
• 3.2. Section 2 The Planned Maintenance Program
• 4. GROUP 00 (D4TNE98) DIESEL ENGINE (Tier 3)
• 4.1. Section 1 GENERAL SERVICE INFORMATION
• 4.2. Section 2 Periodic Maintenance
• 4.3. Section 3 ENGINE
• 4.4. Section 4 FUEL SYSTEM
• 4.5. Section 5 COOLING SYSTEM
• 4.6. Section 6 LUBRICATION SYSTEM
• 4.7. Section 7 STARTER MOTOR
• 4.8. Section 8 ALTERNATOR
• 4.9. Section 9 TROUBLESHOOTING
• 5. GROUP 00 (LMMC) ENGINE (4G64 GAS/LPG) For C2035
• 5.1. Section 1 Engine Specifications (4G64 Gas/LPG Engine)
• 5.2. Section 2 Engine Troubleshooting (4G64 Gas/LPG Engine)
• 5.3. Section 3 Engine Oil and Filter (4G64 Gas/LPG Engine)
• 5.4. Section 4 Engine TuneUp (4G64 Gas/LPG Engine)
• 5.5. Section 5 RPM, Vacuum, and Stall Tests (4G64 Gas/LPG Engine)
• 5.6. Section 6 Compression Checks (4G64 Gas/LPG Engine)
• 5.7. Section 7 Engine Removal and Replacement (4G64 Gas/LPG Engine)
• 5.8. Section 8 Engine Overhaul (4G64 Gas/LPG Engine)
• 5.9. Section 9 Ignition System (4G64 Gas/LPG Engine)
• 5.10. Section 10 Fuel System (Tier 2)
• 5.11. Section 11 Fuel System (Tier 3)
• 6. GROUP 00 (LHMC) ENGINE (HMC THETA 2.4 LPG)
• 6.1. Section 1 General Information (HMC THETA 2.4 LPG)
• 6.2. Section 2 Specification and Troubleshooting (HMC THETA 2.4 LPG)
• 6.3. Section 3 Disassembly and Reassembly (HMC THETA 2.4 LPG)
• 6.4. Section 4 Lubrication System (HMC THETA 2.4 LPG)
• 6.5. Section 5 Electrical System (HMC THETA 2.4 LPG)
• 6.6. Section 6 Emission Control System (HMC THETA 2.4 LPG)
• 6.7. Section 7 LPG Fuel System (Juniper)
• 7. GROUP 00 (LGM) ENGINE (GM 3.0 LPG)
• 7.1. Section 1 Specifications and Information (GM 3.0 LPG)
• 7.2. Section 2 Diagnostic Information and Procedures
• 7.3. Section 3 Engine Removal and Installation
• 7.4. Section 4 Description and Operation
• 7.5. Section 5 PSI Fuel System
• 8. GROUP 00 (MMCPSI) LPG ENGINE (MMC PSI 4G64)
• 8.1. Section 1 General Information
• 8.2. Section 2 Timing Belt
• 8.3. Section 3 Water Pump
• 8.4. Section 4 Rocker Arms and Camshaft
• 8.5. Section 5 Cylinder Head and Valves
• 8.6. Section 6 Front Case, Silent Shaft and Oil Pan
• 8.7. Section 7 Piston and Connecting Rod
• 8.8. Section 8 Crankshaft and Cylinder Block
• 8.9. Section 9 Engine Compression Test
• 8.10. Section 10 Maintenance
• 8.11. Section 11 LPG Fuel System
• 8.12. Section 12 Gasoline Fuel System
• 8.13. Section 13 Emissions Control System
• 8.14. Section 14 Electrical Section
• 8.15. Section 15 Diagnostic Service Tool (DST)
• 8.16. Section 16 Engine Wire Harness Repair
• 8.17. Section 17 Diagnostic Trouble Code (DTC)
• 8.18. Section 18 Definitions
• 9. GROUP 01 ENGINE COOLING SYSTEM
• 9.1. Section 1 Engine Cooling System Specifications and Description
• 9.2. Section 2 Engine Cooling System Troubleshooting
• 9.3. Section 3 Engine Cooling System Testing and Maintenance
• 9.4. Section 4 Engine Cooling System and Alternator Belt Service
• 9.5. Section 5 Radiator Removal and Replacemant
• 10. GROUP 03 INTAKE AND EXHAUST SYSTEM
• 10.1. Section 1 Intake and Exhaust Systems Specifications and Description
• 10.2. Section 2 Intake System Troubleshooting
• 10.3. Section 3 Intake System Service
• 10.4. Section 4 Exhaust Systems
• 11. GROUP 06 TRANSAXLE (TA30 TRANSAXLE) C2035
• 11.1. Section 1 Transaxle Specifications and Description
• 11.2. Section 2 Transaxle Troubleshooting
• 11.3. Section 3 Transaxle Oil and Filter
• 11.4. Section 4 Transaxle Oil Cooler
• 11.5. Section 5 Transaxle Removal and Replacement
• 11.6. Section 6 Transaxle Overhaul
• 11.7. Section 7 Drive Axle Ends Overhaul
• 11.8. Section 8 Transaxle Control Valve Overhaul
• 12. GROUP 13 ELECTRICAL SYSTEM
• 12.1. Section 1 Cautions for working on the electrical system
• 12.2. Section 2 Electrical system Specifications and features
• 12.3. Section 3 Electrical Circuit Diagram Electrical Parts Arrangement
• 12.4. Section 4 Instrument Pod
• 12.5. Section 5 Electrical Components Specification and Operation
• 12.6. Section 6 Troubleshooting of Electrical System
• 13. GROUP 22 WHEELS AND TIRES
• 13.1. Section 1 Wheels and Tires Specifications and Description
• 13.2. Section 2 Cushion Wheels and Tires
• 13.3. Section 3 Pneumatic Wheels and Tires
• 14. GROUP 23 BRAKE SYSTEM
• 14.1. Section 1 Braking / Inching System Specifications and Description
• 14.2. Section 2 Service Brake Troubleshooting
• 14.3. Section 3 Brake / Inching Pedals and Linkages Adjustments
• 14.4. Section 4 Brake System Bleeding
• 14.5. Section 5 Brake Master Cylinder Service
• 14.6. Section 6 Service Brake Adjustment and Overhaul
• 14.7. Section 7 Parking Brake Service
• 15. GROUP 25 STEERING COLUMN AND GEAR
• 15.1. Section 1 Steering System Specifications and Description
• 15.2. Section 2 Steering System Troubleshooting
• 15.3. Section 3 Steering Column and Component Removal and Replacement
• 15.4. Section 4 Steering System Relief Pressure Check and Adjustment
• 15.5. Section 5 Steering Gear Overhaul
• 16. GROUP 26 STEER AXLE
• 16.1. Section 1 Steer Axle Specifications and Description
• 16.2. Section 2 Steer Axle Wheel Bearing Maintenance and Adjustment
• 16.3. Section 3 Steer Axle Removal and Replacement
• 16.4. Section 4 Steer Axle Overhaul
• 16.5. Section 5 Steer Cylinder Removal and Replacement
• 16.6. Section 6 Steer Cylinder Overhaul
• 17. GROUP 29 HYDRAULIC SUMP, FILTERS, AND PUMP
• 17.1. Section 1 Hydraulic Sump, Filters, and Pump Specifications and Description
• 17.2. Section 2 Main Hydraulic Pump Troubleshooting
• 17.3. Section 3 Hydraulic Filters and Fluid Maintenance and Change
• 17.4. Section 4 Hydraulic Pump Removal and Replacement
• 17.5. Section 5 Hydraulic Pump Overhaul (Hanil Pump)
• 18. GROUP 30 HYDRAULIC CONTROL VALVE/LIFT CIRCUIT
• 18.1. Section 1 Hydraulic Control Valve / Lift Circuit Specifications and Description
• 18.2. Section 2 Hydraulic System Schematics
• 18.3. Section 3 Hydraulic System Troubleshooting
• 18.4. Section 4 Hydraulic System Pressure Checks and Adjustments
• 18.5. Section 5 Hydraulic Control Valve Removal and Replacement
• 18.6. Section 6 Disassembly and Assembly
• 18.7. Section 7 Testing of Hydraulic Valve
• 19. GROUP 32 TILT CYLINDERS
• 19.1. Section 1 Tilt Cylinder Specifications and Description
• 19.2. Section 2 Tilt Cylinder Checks and Adjustments
• 19.3. Section 3 Tilt Cylinder Removal and Replacement
• 19.4. Section 4 Tilt Cylinder Overhaul
• 20. GROUP 34 UPRIGHTS
• 20.1. Section 1 Upright Specifications and Description
• 20.2. Section 2 Troubleshooting
• 20.3. Section 3 Upright Inspection
• 20.4. Section 4 Carriage and Upright Roller Clearance Checks and Shim Adjustments
• 20.5. Section 5 Cylinder Removal, Shimming, Overhaul, and Replacement
• 20.6. Section 6 Upright Chain Inspection, Adjustment, and Replacement
• 20.7. Section 7 Fork and Carriage Removal and Replacement
• 20.8. Section 8 Upright Removal and Replacement
• 21. GROUP 38 COUNTERWEIGHT AND CHASSIS
• 21.1. Section 1 Counterweight Specifications and Description
• 21.2. Section 2 Counterweight Removal and Replacement
• 21.3. Section 3 Overhead Guard / Operators Cell Removal and Replacement
• 21.4. Section 4 Floorboard, Cowls, and Seat Deck Removal and Replacement
• 21.5. Section 5 Operators Seat Removal and Replacement
• 22. GROUP 40 SPECIFICATIONS
• 22.1. Section 1 Nameplates and Decals
• 22.2. Section 2 General Specifications
• 22.3. Section 3 Hydraulic Fitting Tightening Procedure