Engines, transaxle, fuel and ignition, brakes, steering, the lift circuit and uprights are each followed from inspection through overhaul in 657 pages covering the Clark CGC and CGP 40/70 lift truck series, nine models in all. Wiring diagrams in this Clark CGC 40, CGC 50, CGC 55, CGC 60, CGC 70, CGP 40, CGP 45, CGP 50, CGP 55 service manual PDF trace the ignition, starter, and instrument pod circuits, while hydraulic schematics show oil moving from pump through control valve to the lift and tilt cylinders. About a third of the book goes to engine work, and the upright chapter takes you through roller clearance checks, shim adjustments, and chain replacement. Fill the sump to 4.7 L (5 qt); on LPG CGP 40/55 trucks, gap the plugs at 0.89 mm (0.035 in). Every hour it sits parked, the dock backs up. Bookmarks and a searchable text layer land you on the right procedure, so your truck is lifting loads again.
What's Inside This Manual
| System | Pages | Key Topics |
|---|
| Periodic Service | 5-21 | Maintenance Schedules, The Planned Maintenance Program, The PM Inspection Form |
| Safe Maintenance | 22-30 | Safety, Lifting, Jacking, And Blocking the Truck, Towing |
| Engines | 31-264 | Engine Troubleshooting, Engine RPM and Stall Tests, Engine Removal and Replacement, L, V6 Engine Overhaul, Diesel Engine |
| Cooling System | 265-277 | Cooling System Testing and Maintenance |
| Fuel System | 278-310 | Carburetor, Fuel Inlet System, Fuel Filter Element, Atomisers, Fuel Lift Pump, Fuel Injection Pump |
| Air Induction System | 311-321 | Air Induction System Service |
| Transmission | 322-373 | Transaxle Troubleshooting and Checks, Transaxle Removal, Transaxle Overhaul |
| Ignition System | 374-386 | Ignition System Troubleshooting, Ignition System Inspection, Timing, And Repair |
| Instrument Pod | 387-399 | Instrument Pod Troubleshooting |
| Electrical System | 400-436 | Starter and Battery Troubleshooting, Alternator Overhaul |
| Wheels and Tires | 437-451 | Pneumatic Wheels and Tires |
| Brake System | 452-472 | Brake/Inching Pedals and Linkages Adjustments, Parking Brake Service |
| Steering Column and Gear | 473-496 | Steering Column and Component Removal and Replacement, Steering Gear Overhaul |
| Steer Axle | 497-515 | Steer Axle Lubrication and Adjustment, Steer Axle Removal and Replacement, Steer Cylinder Overhaul |
| Hydraulic Pump, Sump, and Filters | 516-532 | Hydraulic Filters and Fluid Maintenance, Hydraulic Pump Overhaul |
| Hydraulic Control Valve/Lift Circuit | 533-548 | Hydraulic Control Valve Removal and Replacement, Hydraulic Control Valve Overhaul |
| Tilt Cylinders | 549-560 | Tilt Cylinder Removal and Replacement, Tilt Cylinder Overhaul |
| Uprights | 561-631 | Upright Inspection, Roller Clearance Checks and Shim Adjustments, Cylinder Replacement, Shimming, And Overhaul, Upright Chain Inspection, Adjustment, And Replacement |
| Counterweight, Sheet Metal, & Chassis | 632-644 | Counterweight Removal and Replacement, Floorboard, Radiator Cover, And Seat Deck Removal and Replacement |
| Specifications | 645-657 | Nameplates and Decals, General Specifications |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| Cylinder Bore | 101.6 mm (4.0 in) | p. 32 |
| Piston Stroke | 88.392 mm (3.48 in) | p. 32 |
| LPG Fuel System Spark Plug Gap | 0.89mm (0.035") | p. 32 |
| Battery voltage for ignition system | 9.6 volts | p. 295 |
| Balance Gear Driven Gear Bolt | 20 N·m (15 lb. ft.) plus a 35° turn | p. 101 |
| Connecting Rod Bolt Nuts | 27 N·m (20 lb. ft.) plus a 70° turn | p. 101 |
| Control cover bolt torque | 42-46 N·m or 31-34 LBS. FT. | p. 372 |
| Differential bearing carrier pre-load | 1,4-2,3 N·m or 8-13 LB. IN. | p. 372 |
| Pod-to-dash mounting bolts torque | 8-10 N·m (71-88 in-lb) | p. 388 |
| Connector jack screw torque | 2.5 N·m (22 in-lb) | p. 388 |
| Pneumatic Drive and Steer Tire Inflation Pressure | 861 kPa (125 psi) | p. 438 |
| Torque pneumatic steer tires | 418-476 N·m (315-350 ft-lb) | p. 441 |
