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 Clark CGC40-CGC70, CGP40-CGP70 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 |
Clark CGC40-CGC70, CGP40-CGP70 Common Problems This Manual Covers
Clark CGC 40/70 and CGP 40/70 lift truck engine running with low engine oil pressure
Check the oil level first; the sump holds 4.7 L (5 qt), and running it low is the cheapest problem you'll ever fix. Then work through the low oil pressure causes in the engine troubleshooting chart starting, one at a time, before you tear into the engine.
Manual Section: Engine TroubleshootingEngine overheating during operation with water pump leaking coolant or making noise
Inspect the water pump for leaks and noise with the engine running, then work through the overheating causes in the cooling system section beginning on page 265. After any repair, refill to 15.8 L (15 qt) on gas engine trucks or 16.9 L (16 qt) on diesel trucks.
Manual Section: Cooling System p. 265Upright lift and tilt functions slow or jerky, or load won't lift
Test main relief valve pressure at the control valve and compare it to 17,240 to 17,940 kPa (2500 to 2600 psi) at rated flow, listed on page 534. If pressure is on spec, check the fluid for foaming or overheating and inspect the pump for low output.
Manual Section: Hydraulic Control Valve/Lift Circuit p. 534Raised upright rails creep down over time and the load won't hold position
Measure how far the upright rails drift over five minutes with the load raised, following the drift check on page 579. If the rails drop 25 mm (1 in) or more in that time, work through the Drift Causes and Remedies procedure in the Uprights section before returning the truck to service.
Manual Section: Uprights p. 579Steering wheel hard to turn with slow response and jerky steering action
Check steering system relief pressure against 9990.5 to 10679.5 kPa (1450 to 1550 psi), listed on page 474. If pressure is in range, work through the hard steering, slow response and jerky entries in the steering troubleshooting chart before you overhaul the steering gear.
Manual Section: Steering Column and Gear p. 474Upright roller sets showing excessive clearance at the widest rail set span
Clamp the rails together opposite the roller you're checking, using wooden shim blocks to protect the rails, and torque the clamp to 25 N·m (20 ft-lb) per page 583. Measure clearance at the widest rail set span; anything over 2.25 mm (0.09 in) means the roller set needs shimming, as shown on page 584.
Manual Section: Uprights p. 584Frequently Asked Questions
What are the fork replacement specifications for the Clark CGC40-CGC70, CGP40-CGP70 lift truck?
Forks must be replaced if the blade at the heel is worn down by more than 10 percent of its original thickness. This reduction in thickness reduces the load capacity of the forks. p. 14
What is the torque specification for the cylinder head bolts on the 4.3L V6 in the Clark CGC40-CGC70, CGP40-CGP70?
The cylinder head bolts on the 4.3L V6 engine must be tightened in three steps: first to 34 N·m (25 lbs. ft.), second to 61 N·m (45 lbs. ft.), and finally to 90 N·m (65 lbs. ft.). p. 94
What is the recommended engine oil for the 4.3L V6 engine?
The engine requires API classifications CD, CC/SG/SF and API CF-4 SAE 15w-40 oil. For gas engines, API SD SAE 10w-30 or better is also acceptable. p. 38
What is the correct torque for the counterweight mounting bolts on a Clark CGC40-CGC70, CGP40-CGP70 lift truck?
The counterweight mounting bolts must be torqued to 580-650 N·m (428-479 ft-lb). p. 633
How do I check the hydraulic system relief pressure?
The hydraulic system relief pressure should be checked using a pressure gauge with a capacity of 0 to 27,580 kPa (0 to 4000 psi). With the engine at no-load governed speed, move the tilt control lever to the full tilt relief position and read the gauge, which should be about 17,240 kPa (2500 psi). p. 539
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