A Clark CMP forklift that lifts, steers, and stops the way it did when new is what these 281 pages exist to give you, across all five models from CMP 15 up to CMP 30. The electrical chapter of this Clark CMP 25 service manual PDF opens on the full circuit diagram, and hydraulic schematics trace oil from the pump through the control valve to the lift and tilt cylinders. Engine service takes the largest share of the book, from troubleshooting and compression checks through to overhaul, while the transaxle, steer unit, and lift and tilt cylinders each get their own overhaul procedure. Set spark plug gap at 0.7-0.8 mm (0.027-0.031 in) and seat each plug at 25 N·m (18.4 ft-lb). A parked forklift costs you by the hour. Bookmarked and text searchable, the PDF also prints clean, so the chapter you need can go to the bench and take the grease.
What's Inside This Clark CMP15/18/20/25/30 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safe Maintenance | 4-14 | Safety, Lifting, Jacking, And Blocking, Towing |
| Periodic Service | 15-30 | Maintenance Schedules, Planned Maintenance, PM Inspection Form |
| Engine | 31-93 | Specifications and Description, Troubleshooting, Engine Oil, Tune-Up, RPM, Vacuum, And Stall Checks, Compression Checks |
| Cooling System | 94-97 | Cooling System Specifications, Cooling System Troubleshooting |
| Fuel System | 98-109 | LPG Fuel System, Gasoline Fuel System |
| Transaxle | 110-150 | Specifications and Description, Checks and Troubleshooting, Removal and Replacement, Overhaul |
| Ignition System | 151-167 | Specifications and Description, Troubleshooting, Ignition Timing, Distributor Overhaul |
| Electrical | 168-187 | Circuit Diagram, Starter, Alternator, Instrument Pod |
| Wheels and Tires | 188-203 | Wheels and Tires Specifications, Cushion Wheels and Tires, Pneumatic Wheels and Tires |
| Brake System | 204-212 | Service Brake, Parking Brake |
| Steer System | 213-229 | Specifications and Description, Troubleshooting, Steering System Pressure Check, Steering System Removals & Installations, Steering Unit Overhaul, Priority Valve Overhaul |
| Hydraulic System | 230-246 | Specifications and Description, Troubleshooting, Hydraulic Pump Overhaul, Control Valve Overhaul |
| Uprights | 247-266 | Specifications and Description, Upright Checks and Adjustments, Lift Chain Service, Removals and Replacements, Lift and Tilt Cylinder Overhaul |
| Counterweight | 267-268 | Inspection, Removal and Replacement |
| Specifications | 269-281 | Dimensions and Weights, Performance Specifications, Critical Torque Specifications |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Charging pump bolt torque | 16-22 N·m (12-16 lbf·ft) | p. 150 |
| Control valve assembly bolt torque | 16-22 N·m (12-16 lbf·ft) | p. 150 |
| Spark plug gap | 0.7-0.8 mm (0.027-0.031 in) | p. 152 |
| Spark plug tightening torque | 25 N·m (18.4 ft-lb) | p. 152 |
| Spark plug wire resistance | 8,000 ohms per foot | p. 161 |
| Plug Gap | 0.7-0.8 mm (0.028-0.031 in) | p. 162 |
| Steer Tire Mounting Nut Torques | 16.0-19.7 kgf·m (116-142 ft-lb) | p. 189 |
| Drive Wheel Mounting Nut Torques | 29.7-31.0 kgf·m (215-225 ft-lb) | p. 189 |
| Cushion Tire Separation Limit | 12 mm (0.5 in) | p. 190 |
| Cushion Tire Damage Limit | 12 mm (0.5 in) deep and 50 x 50 mm (2 x 2 in) area | p. 190 |
| Brake fluid capacity | 1 L (0.26 gal) | p. 205 |
| Brake pedal freeplay | 4-6 mm (0.157-0.236 in) | p. 205 |
Clark CMP15/18/20/25/30 Common Problems This Manual Covers
Clark CMP 15 through CMP 30 forklift ignition system, engine cranks over but does not start
Check each spark plug and set the gap to 0.7-0.8 mm (0.027-0.031 in) per page 152. Measure plug wire resistance next; page 161 calls for about 8,000 ohms per foot. Then test the ignition coil primary between the (+) and (-) terminals against 1.18-1.32 ohms, as page 163 lists.
Manual Section: Ignition System TroubleshootingEngine runs but not smoothly, misses and backfires, and shows low engine power
Verify initial timing at 4° BTDC at 800 rpm following page 164. Then raise engine speed and confirm centrifugal advance begins at 0° at 400 rpm and ends at 20° at 2500 rpm, as page 165 shows. Check vacuum advance too: 0° at 80 mmHg rising to 23° at 280 mmHg.
Manual Section: Ignition System p. 164Engine running too hot, water pump leaking or noisy, oil showing in the coolant
Inspect the water pump for leaks and noise, then check the coolant for oil before chasing anything else. Work through the cooling system troubleshooting steps in the section starting at page 94, and compare readings against the cooling system specifications listed there. If the engine runs too cold instead, use the same troubleshooting steps.
Manual Section: Cooling System p. 94Transaxle shows low clutch pressure, low converter out pressure, overheating and loss of power
Test clutch pressure and converter out pressure first, following the transaxle checks on page 114, before you pull anything. If the readings point to the charging pump or control valve assembly, torque both sets of mounting bolts to 16-22 N·m (12-16 lbf·ft) on reassembly, as page 150 specifies.
Manual Section: Transmission Checks and Troubleshooting p. 114Steering heavy or slow, with kick-back and backlash felt through the steering wheel
Test steering system pressure before replacing parts. On CMP 15 and CMP 18 trucks, relief pressure should read 92-97 kgf/cm2 (1308-1380 psi) per page 223. If pressure checks good, inspect the steering unit and priority valve, and torque steer cylinder tie rod nuts to 5.0 ± 0.5 kgf·m (36 ± 4 lbf·ft) as page 229 lists.
Manual Section: Steer System p. 223Hydraulic system shows slow action or no motion, load will not hold, pump noise
Check hydraulic system pressure first, then inspect the control valve for leaks and confirm the relief valve is acting. If the pump is noisy or not delivering fluid, go to the hydraulic pump overhaul; if the load will not hold, work through the control valve overhaul. Trace the circuit on the hydraulic schematic at page 232.
Manual Section: Hydraulic System p. 230Frequently Asked Questions
What are the torque specifications for the CMP 15/18 counterweight bolts?
The mounting bolts for the counterweight on the CMP 15/18 model should be tightened to a torque of 45-50 kgf·m (325-362 lbf·ft). p. 267
What is the recommended engine oil for the 4G6 series engine?
The recommended engine oil for the 4G6 series engine is 10W30, API, CC, CD/SG, SF engine oil. p. 32
What is the procedure for checking the engine oil level?
The engine oil level should be checked every 8 hours with the engine stopped. Allow 5 minutes for the oil level to stabilize, then pull the dipstick out, wipe it with a clean wiper, and reinsert it fully into the dipstick tube before checking the level. p. 37
What is the standard ignitor air gap setting on the Clark CMP15/18/20/25/30 forklift?
The standard air gap setting for the ignitor is 0.8 mm (0.031 in). p. 160
What is the cylinder head bolt torque spec for the 4G6 engine in the Clark CMP15/18/20/25/30?
The cylinder head bolts should be tightened to 75 Nm (7.5 kgm, 54 ft. lbs.), then loosened completely, then torqued to 20 Nm (2 kgm, 14.5 ft. lbs.), followed by two additional 1/4 turns (90 degrees each). p. 75
Is this Clark CMP 15 manual a download or a disc?
All 281 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Am I able to print pages from this Clark CMP 15 manual?
No restrictions at all. Print individual pages, full chapters, or the entire manual. The PDF is completely unlocked.
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