Clark CGC40 L Operator's Manual
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Clark CGC40 L Operator's Manual

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INTERNAL COMBUSTION LIFT TRUCKS
[Do not remove this manual from the truck]
CGC 40/50/55/60/70 L
Part No. 8058502 (eng)
Book No. OM-764 (Rev 1.2)
Jun. 2019

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  • Page 1 INTERNAL COMBUSTION LIFT TRUCKS [Do not remove this manual from the truck] CGC 40/50/55/60/70 L Part No. 8058502 (eng) Book No. OM-764 (Rev 1.2) Jun. 2019...
  • Page 3 Operator’s Manual You must be trained and authorized to operate a lift truck. YOU can prevent accidents First: Learn safe operating rules and your company rules. Next: Read your Operator’s Manual. If you do not understand it, ask your supervisor for help. Learn about the unit you operate.

  • Page 4: A Message To Clark Lift Truck Operators

    They require specific instructions and rules for safe operation and maintenance. Safe operation of lift trucks is of primary importance to CLARK. Our experience with lift truck accidents has shown that when accidents happen and people are killed or injured, the causes are: •...
  • Page 5 If you think you need training in operating or inspecting your lift truck, ask your supervisor. CLARK lift trucks are built to take hard work, but not abuse. They are built to be dependable, but they are only as safe and efficient as the operator and the persons responsible for maintaining them.

  • Page 7: Table Of Contents

    Contents of this Manual A Message to CLARK Lift Truck Operators....... ii Introduction ................. vi How to Use this Manual ............ viii Safety Signs and Safety Messages ........x Section 1. General Safety Rules ........1-1 Section 2. Operating Hazards ..........2-1 Section 3.

  • Page 8: Introduction

    CLARK lift truck in a safe and correct manner. Your CLARK lift truck has been designed and built to be as safe and efficient as today’s technology can make it. As manufactured, it meets all the applicable mandatory requirements of ANSI / ITSDF B56.1 Safety Standard for Powered Industrial Trucks.
  • Page 9 The procedures for a periodic planned maintenance program that covers inspections, operational checks, cleaning, lubrication, and minor adjustments are outlined in this manual. Your CLARK dealer is prepared to help you with a Planned Maintenance Program by trained service personnel who know your lift truck and can keep it operating safely and efficiently.

  • Page 10: How To Use This Manual

    Also, the Index helps you locate information about various topics. NOTICE: The descriptions and specifications included in this manual were in effect at the time of printing. CLARK Material Handling Company reserves the right to make improvements and changes in specifications or design.
  • Page 11 If the truck you operate is not equipped with a manual, ask your supervisor to obtain one and have it attached to the truck. And, remember, your CLARK dealer is pleased to answer any questions about the operation and maintenance of your lift truck and will provide you with additional information should you require it.

  • Page 12: Safety Signs And Safety Messages

    Damage to the truck, death, or serious injury to you or other persons may result if these messages are not followed. If warning decals are damaged, they must be replaced. Contact your CLARK dealer for replacements. NOTICE This message is used when special information, instruc-...
  • Page 13 Section 1. General Safety Rules General Safety Rules Contents Contents ................1-1 Daily Inspection .............. 1-2 Do’s and Don’ts ............... 1-3 Seat Belts ................. 1-4 No Riders ................. 1-5 Pedestrians ..............1-6 Operator Protection ............1-7 Fork Safety ..............1-8 Pinch Points ..............

  • Page 14: Daily Inspection

    Daily Inspection At the beginning of each shift, inspect your truck and fill out a daily inspection sheet. Check for damage and maintenance problems. Have repairs made before you operate the truck. CAUTION DO NOT MAKE REPAIRS YOURSELF. Lift truck mechanics are trained professionals.

  • Page 15: Do's And Don'ts

    Section 1. General Safety Rules Do’s and Don’ts Don't mix drugs or alcohol with your job. Do watch for pedestrians. Don't block safety or emergency equipment. Do wear safety equipment when required. Don't smoke in "NO SMOKING" areas or when refueling. Don't use the similar fuel.

  • Page 16: Seat Belts

    Seat Belts ALWAYS BUCKLE UP Seat belts can reduce injuries. Seat Belts...

  • Page 17: No Riders

    Section 1. General Safety Rules No Riders The operator is the only one who should be on a truck. Never transport personnel on the forks of a lift truck. No Riders...

  • Page 18: Pedestrians

    Pedestrians Watch where you are going. Look in the direction of travel. Pedestrians may use the same roadway you do. Sound your horn at all intersections or blind spots. Watch for people in your work area even if your truck has warning lights or alarms.

  • Page 19: Operator Protection

    Section 1. General Safety Rules Operator Protection Keep under the overhead guard. Always keep your body within the confines of the truck. Operator Protection...

  • Page 20: Fork Safety

    Fork Safety Never allow anyone to walk under raised forks. DANGER There is special equipment to raise 2372604 people for overhead work. DO NOT USE LIFT TRUCKS. Fork Safety...

  • Page 21: Pinch Points

    Section 1. General Safety Rules Pinch Points WARNING Keep hands, feet and legs out of the upright. WARNING Don't use the upright as a ladder. CAUTION Never try to repair the upright, carriage, chain, or attachment yourself! Always trained mechanic. Pinch Points...

  • Page 22: Travel

    Travel Travel with the load near the floor/ground with upright tilted back cradle load whenever possible. Never lift or lower the load when the truck is in motion. When handling bulky loads that restrict your vision operate your truck reverse improve visibility.

  • Page 23: Grades, Ramps, Slopes, And Lnclines

    Section 1. General Safety Rules Grades, Ramps, Slopes, and lnclines Unloaded Forks Downgrade WARNING Never turn on a grade, either loaded or unloaded. Loaded Forks Upgrade Grades, Ramps, Slopes, and lnclines 1-11...

  • Page 24: Surface And Capacity

    Surface and Capacity SAND GRAVEL WEAK FLOORS Avoid these conditions. They can cause a truck to tip over or lose traction for braking or driving. WARNING Know the weight of your truck and load. Especially when using elevators. Know the capacity of the elevator you intend to use.

  • Page 25: Tip-Over

    Section 1. General Safety Rules Tip-Over Lateral Tip-over • Lateral tip-over can occur with a com- bination of speed and sharpness of turn. This combination will exceed the stability of the truck. This condition is even more likely with an unloaded truck.

  • Page 26: What To Do In Case Of A Tip-Over

    What to do in Case of a Tip-over If your truck starts to tip over, WARNING DO NOT JUMP!!! IMPORTANT Your chances for survival in a tip-over are better if you stay with the truck, in your seat. Brace yourself as illustrated below! 1.

  • Page 27: Parking

    Section 1. General Safety Rules Parking • Never park on a grade. • Always come to a complete stop before leaving truck. • Be sure travel control is in NEUTRAL. • Lower forks fully to floor and tilt forward. • Set parking brake. •...

  • Page 28: General Tire Maintenance, Inspection, And Repair

    General Tire Maintenance, Inspection, and Repair 1. Park the truck as described on page 1-15 and check for correct tire inflation air pressure. See specifications in this OM for cor- rect tire pressure for your truck. CAUTION Check tire pressure from a position facing the tread of the tire, not the side.

  • Page 29: Carbon Monoxide And Fumes

    Section 1. General Safety Rules Carbon monoxide and fumes Be sure your employees understand that they must not use an internal combustion engine in a closed area such as a cold storage locker. Carbon monoxide is a colorless, odorless, poisonous gas which can overcome your employees without warning.
  • Page 31 Section 2. Operating Hazards Operating Hazards Contents Loose Loads ..............2-2 Long and Wide Loads / Rear Swing ....... 2-3 Low Overhead Clearance Fast Turns and High Loads ..........2-4 Drop-Offs ................2-5 Right-Angle Stacking ............2-6 Chain Slack ............... 2-7 Pallets and Skids .............

  • Page 32: Loose Loads

    Loose Loads WARNING Loose or unbalanced loads dangerous. Observe these precautions. Never carry loose or uneven material. Center wide loads. Stack and band loose material. Loose Loads...

  • Page 33: Long And Wide Loads / Rear Swing

    Section 2. Operating Hazards Long and Wide Loads / Rear Swing WARNING With long or wide loads, you need more room. So slow down and watch your clearance. A long load reduces the capacity of the truck. Know and understand your truck load rating. When extra-long material makes it necessary to travel with the load elevated, do so with extreme care and be alert to load end- swing when turning.

  • Page 34: Low Overhead Clearance Fast Turns And High Loads

    Low Overhead Clearance Fast Turns and High Loads WARNING Know the height of your truck, with and without a load. Check your clearances. Keep the load low and tilted back. WARNING Watch overhead clearance: Moving into overhead structures can tip a truck over, or spill a load. WARNING Slow down before turning.

  • Page 35: Drop-Offs

    Section 2. Operating Hazards Drop-Offs WARNING To avoid these hazards, you must: • Talk to the truck driver yourself; make sure the driver does not move the trailer until you are done! • Apply trailer brakes. • Use wheel chocks. •...

  • Page 36: Right-Angle Stacking

    Right-Angle Stacking SLOWLY WARNING When right-angle stacking or moving with a raised load to clear low objects, avoid sharp turns and move slowly. Right-Angle Stacking...

  • Page 37: Chain Slack

    Section 2. Operating Hazards Chain Slack WARNING Slack chains mean rail or carriage hang-up. Raise the forks before you move, or broken chains can result. Chain Slack...

  • Page 38: Pallets And Skids

    Pallets and Skids WARNING Do not move or store materials on damaged pallets or skids. Items can fall through them causing severe injury or death! Be sure the pallet or skid you are using is in good condition and does not have defective or missing components and fasteners.
  • Page 39 Section 3. Operator Compartment and Controls Operator Compartment and Controls Contents Truck Description ..........3-2 Operators Compartment ........3-3 Dash Pod Display ..........3-4 Dash Pod Symbols ..........3-5 Hydrostatic Operators Compartment ...... 3-6 Hydrostatic Controls ..........3-8 Operator Controls ..........3-10 Contents...

  • Page 40: Truck Description

    4. Counterweight 5. Steer Axle, Wheels/Tires 6. Upright and Carriage 7. Load Backrest 8. Forks 9. Drive Axle, Wheels/Tires The truck shown above is a typical representation of a Clark internal combustion lift truck. Your model may vary slightly. Truck Description...

  • Page 41: Operators Compartment

    Section 3. Operator Compartment and Controls Operators Compartment 1. Steering Handwheel 10. Key Switch 2. Dash Display 11. Lift Control Lever 3. Forward/Reverse Lever 12. Tilt Control Lever 4. Parking Brake Release 13. Auxiliary Control Lever 5. Hood Release 14. Brake Pedal 6.

  • Page 42: Dash Pod Display

    Dash Pod Display LPG Truck Dash Display Dash Pod Display Familiarize yourself with the dash display and its warning indicators. Make viewing the indicators part of your normal operating routine. If any of these indicator lights show an irregularity or when they are not working properly, have them checked immediately.

  • Page 43: Dash Pod Symbols

    Section 3. Operator Compartment and Controls Dash Pod Symbols Ammeter: This symbol displays when the alternator is not charging the battery. Engine Oil Pressure: This symbol displays when the engine oil pressure reaches the minimum allowable limit. The indicator will also display along with the automatic engine shutdown in case of low oil pressure.

  • Page 44: Hydrostatic Operators Compartment

    Hydrostatic Operators Compartment Standard Operating Controls Two Pedal Controls Unitrol Pedal Controls 11. Direction Control (standard) 1. Steering Handwheel 12. Parking Brake Release 2. Key Switch 13. Hood Release 3. Lift Control Lever 14. Parking Brake Pedal 4. Tilt Control Lever 15.
  • Page 45 IMPORTANT For safety reasons, your CLARK forklift truck is fitted with a neutral start switch. The purpose of this is to prevent the engine from being started while the transmission is in gear. Thus the engine may only start when the direction control lever is in the neutral position.

  • Page 46: Hydrostatic Controls

    Brake ground speed pedal, the truck will Pedal then come to a stop. IMPORTANT Standard Control The Clark Hydrostatic Lift Truck uses pump dynamic braking to slow down and stop the trucks direction of travel. The brake pedal can still be used in extreme conditions.
  • Page 47 Section 3. Operator Compartment and Controls Ground Speed Control (acceleration) With the parking brake released and the direction control in FWD or REV, put your foot on the pedal (depending on configuration), push down smoothly until the truck is moving at the desired speed. Stopping the Truck IMPORTANT The preferred method of braking is...

  • Page 48: Operator Controls

    Operator Controls Key / Start Switch The Key / Start Switch: • Turns the truck electrical system on and off. • Connects and tests the warning indicator lights. • Connects the starter motor circuit when engine is to be started. The Key / Start Switch has three positions.
  • Page 49 Section 3. Operator Compartment and Controls Seat Adjustment The fore and aft adjustment lever is located on the front under the seat. To unlock, pull the lever to the left Back and adjust the seat, release the declining adjustment lever. Be sure that the seat locking mechanism is engaged.
  • Page 50 Parking Brake Pedal Parking Brake To apply the parking brake push the Release pedal down with your left foot until pedal stops. The parking brake re-lease is located just above the brake pedal as shown. To release the parking brake pull toward you.
  • Page 51 IMPORTANT For safety reasons, every CLARK forklift truck is fitted with a neutral start switch. The purpose of this is to prevent the engine from being started while the transmission is in gear.
  • Page 52 IMPORTANT The hydraulic levers shown are Tilt typical representations of a CLARK internal combustion lift truck. Your model may vary slightly.
  • Page 53 Section 3. Operator Compartment and Controls Auxiliary Control Lever (Optional) An auxiliary control lever is mounted to the right of the tilt control lever. If your lift truck is equipped with an optional attachment, this lever lets you control the flow and direction of the hydraulic oil to the attachment.
  • Page 54 CLARK dealer. The serial number is also stamped on the frame. 3. Attachment description (if any installed)—The user must see that the truck is marked to identify the attachment(s), including the weight of the truck/attachment combination and truck capac- ity with the attachment.
  • Page 55 Section 3. Operator Compartment and Controls Operator Safety Warning Decal WARNING Read the manual Buckle up! Apply brake when leaving truck Watch Out For Other People Most lift truck INJURIES are to other people near IMPORTANT the lift truck. Safety and warning decals are placed in conspicuous Prevent Overturns! locations on the truck to remind you of essential...
  • Page 56 Upright Warning Decal This safety decal is on the upright to warn of the danger of injury from movement between rails, chains, sheaves, fork carriage, and other parts of the upright assembly. Do not climb on or reach into the upright. Personal injury will result if any part of your body is put between moving parts of the upright.
  • Page 57 Section 4. Operating Procedures Operating Procedures Contents Before Operating the Truck ........4-2 Starting from a Safe Condition ......4-3 Contents...
  • Page 58 Before Operating the Truck Be sure that you have read and understand the information in this Operator's Manual before operating the lift truck. The Operator's Manual Holder is located on the back of the seat. WARNING • This equipment can be dangerous if not used properly. Safe operation is the responsibility of the operator.
  • Page 59 Section 4. Operating Procedures Starting from a Safe Condition Always start from a safe condition. Before operating a lift truck, make sure that: 1. Parking brake is applied. 2. Forks are fully lowered to the floor or ground. 3. You are familiar with how all the controls function and have read the Operator Manual.
  • Page 60 Adjusting the Seat Adjust the seat to a comfortable position for you. Adjust the seat by moving and holding the release lever at the front under of the seat. Back declining Put the seat in a position that will adjustment provide easy reach to all controls.
  • Page 61 Section 4. Operating Procedures Positioning Forks and Upright When driving, with or without a load, it is good practice to have the forks slightly raised and tilt the upright (forks) backward. Having the forks raised and tilting back prevents the fork tips from catching on possible obstructions and reduces the wear on the fork blades from striking or dragging on the floor or...
  • Page 62 Controlling Speed With the direction control in FORWARD or REVERSE, the parking brake released, put your foot on the accelerator pedal and push down smoothly until the truck is moving at the desired speed. Braking To stop the truck, lift your foot from the accelerator pedal and put it on the brake pedal.
  • Page 63 Section 4. Operating Procedures Operating Safely IMPORTANT Safe operation is the responsibility of the operator. Watch where you are going. Don't go if you can't see. Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.
  • Page 64 Keep all other persons clear of the load and upright mechanism while attempting to handle a load. No riders... Do not carry passengers. The operator is the only one who should be on the truck. Always be in full control of your lift truck... Never operate a lift truck or its attachments if you are not in the designated operator's position.
  • Page 65 Section 4. Operating Procedures Grades, ramps, and inclines... Use special care when operating on ramps, inclines, and uneven areas. Travel slowly. Travel straight up and down. Do not turn or drive at an angle across an incline or ramp. When the truck is loaded, travel with the load upgrade. When the truck is empty, travel with lifting mechanism (upright) downgrade.
  • Page 66 CAUTION Operate your lift truck only in areas that have been approved for your lift truck type designation. Certain areas contain flammable gases, liquids, dust, fibers, or other hazardous materials. Lift truck operations in these areas must have special approval. These areas must be designated to show the type of lift truck approval required for operation in the area.
  • Page 67 Section 4. Operating Procedures Load Handling Handle only loads that are within the truck rated capacity as shown on the nameplate. This rating specifies the maximum load that should be lifted. However, other factors such as special load handling attachments, loads having a high center of gravity, or uneven terrain may dictate that the safe working load be less than the rated capacity.
  • Page 68 The capacity load shown on the nameplate is represented by a cube in which the weight is evenly distributed, with the center of gravity located a standard distance from the face of the forks. If the weight of the actual load to be handled is not evenly distributed, put the heaviest part closest to the carriage.
  • Page 69 Section 4. Operating Procedures Picking Up and Moving Loads When picking up a load from the ground, approach the load slowly and carefully align the truck square with the load. The forks should be adjusted to fit the load or pallet being handled and spread as wide as possible to provide good stability and balance.
  • Page 70 Stacking To put a load on a stack: 1. Approach slowly and align the lift truck and load squarely with the stack. 2. Raise (elevate) the load as the lift truck is nearing the stack. 3. Move forward, slowly, until the load is almost touching the stack.
  • Page 71 Section 4. Operating Procedures 6. Lower (drop) the forks slightly to clear (disengage) the load pallet. Tilt the forks forward slightly, if necessary. 7. Check your travel path, then carefully back away until the forks are clear of the stack. Stop and lower the forks to the travel position (6 to 8 inches above the ground), then tilt back to travel.
  • Page 72 After Operating the Truck Always leave your lift truck in a safe condition. When you leave your truck, or park it, follow these safety rules: • Park in a safe area away from normal traffic. • Never park on a grade. •...
  • Page 73 Section 5. Operator Maintenance and Care Operator Maintenance and Care Contents Daily Safety Inspection ......... 5-2 Fuel Safety Practices ..........5-5 Refueling LPG Tanks ..........5-6 NOTICE The Occupational Safety and Health Act (OSHA) requires that truck users examine their trucks before each shift to be sure they are in safe working order.
  • Page 74 In general, the daily inspection should include the visual and functional checks described on the following pages. As an aid in carrying out this inspection, CLARK has prepared a form called the "Driver's Daily Checklist." We recommend that you use this form to make a daily record of your inspections and truck condition.
  • Page 75 Section 5. Operator Maintenance and Care Visual Checks First, perform a visual inspection of the truck and its major components: 1. Walk around your lift truck and take note of obvious damage that may have been caused by operation during the last shift. 2.
  • Page 76 Functional Checks Check the operation of the truck as follows. NOTICE Before performing these checks, familiarize yourself with the starting, operating, and shutdown procedures in Sec- tion 4 of this manual. Also, know the safety rules given in Section 1 of this manual. 1.
  • Page 77 Section 5. Operator Maintenance and Care Fuel Safety Practices Use clean, properly marked fuel cans. Clean up spills. Fuel Safety Practices...
  • Page 78 Refueling LPG Tanks When changing liquefied petroleum gas (LPG), tanks follow these basic rules: • Change only in well ventilated areas. • Never allow open flames. • Turn the ignition switch to the OFF position. • Check for leaks. • Check condition of the O-ring. •...
  • Page 79 Section 5. Operator Maintenance and Care RECOMMENDED SAFETY MAINTENANCE PROCEDURES FOR LPG FUELED LIFT TRUCKS WARNING LPG is a combustible fuel that is heavier than air. Escaping gas may accumulate in low areas. The fuel cylinder should be mounted so that it does not extend outside the truck and should also be properly positioned by using the locating pin or key way.
  • Page 81 Section 6. Emergency Starting and Towing Emergency Starting and Towing Contents How to Tow a Disabled Truck ....... 6-2 How to Use Battery Jumper Cables ..... 6-4 Contents...
  • Page 82 (This bolt is made of a special high-tensile steel and is not commercially available. Replace it, when necessary, only with a genuine Clark replacement part). 5. Use an approved, solid metal tow bar with towing couplers that connect to the towing pins in the counterweights.
  • Page 83 Always engage the parking brake when parking a lift truck. The truck can move and cause injury or death to personnel near it. Towing a Disabled Hydrostatic Truck Clark does not recommend towing a WARNING disabled Hydrostatic lift truck with- out first consulting your service manual.
  • Page 84 How to Use Battery Jumper Cables If your lift truck battery is discharged (“dead”), you can start your lift truck by “jumping” it from another lift truck that has a 12-volt, negative-ground electrical system. The “booster” battery must be fully charged and in good condition. This section explains how to perform this procedure safely.
  • Page 85 Section 6. Emergency Starting and Towing WARNING BATTERIES EMIT EXPLOSIVE GAS. Do not smoke or have open flames or sparks in battery charging areas or near batteries. An explosion can result and cause injury or death. Hydrogen gas is produced during normal battery operation.
  • Page 86 4. Connect the jumper cables in the following sequence: a. Connect a jumper cable from the positive (+; red) terminal on one battery to the positive (+; red) terminal on the other bat- tery. Never connect positive (+; red) to negative (-; black), or negative to positive.
  • Page 87 Section 7. Planned Maintenance and Lubrication Planned Maintenance and Lubrication Contents Introduction ............7-2 Safe Maintenance Practices ........7-3 Major Component Locations ........ 7-8 Planned Maintenance Intervals ......7-9 PM Report Form ........... 7-12 How to Perform Planned Maintenance ....7-14 NOTICE THIS SECTION IS FOR TRAINED SERVICE PERSONNEL to use as a reference for Planned Maintenance proce-...

  • Page 88: Introduction

    In addition to the operator’s daily inspection, CLARK recommends that the owner set up and follow a periodic planned maintenance (PM) and inspection program. Performed on a regular basis by trained personnel, the program provides thorough inspections and checks of the safe operating condition of the lift truck.

  • Page 89: Safe Maintenance Practices

    Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please contact your local CLARK dealer. 1. Powered industrial trucks can become hazardous if mainte- nance is neglected. Therefore, suitable maintenance facilities and trained personnel and procedures shall be provided.
  • Page 90 CAUTION Refer to the “Jacking and Blocking” section in the Service Manual for proper procedures. 9. Operation of the truck to check performance must be conducted in an authorized, safe, clear area. 10. Before starting to operate the truck: a. Be seated in a safe operating position and fasten your seat belt.
  • Page 91 Section 7. Planned Maintenance and Lubrication 14. Fuel systems must be checked for leaks and condition of parts. Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected.
  • Page 92 Be sure that lifting and handling equipment is of the correct capacity and in good condition. IMPORTANT Your new CLARK lift truck has been built to meet all appli- cable mandatory requirements of ANSI / ITSDF B56.1 Safety Standard for Powered Industrial Trucks. Each truck also includes certain safety devices—such as horn, over-...
  • Page 93 Section 7. Planned Maintenance and Lubrication NOTICE You should be familiar with additional operating and maintenance safety instructions contained in the follow- ing publications: ANSI / ITSDF B56.1: Safety Standard for Low Lift and High Lift Trucks (Safety Code For Powered Industrial Trucks). NFPA 505:Fire Safety Standard for Powered Industrial Trucks: Type Designations, Areas of Use, Maintenance and Operation.

  • Page 94: Major Component Locations

    11. Sheet Metal 5. Transaxle 12. Upright and Carriage 6. Wheels and Tires 7. Frame and Counter- weight The truck shown above is a typical representation of a CLARK internal combustion lift truck. Your model may vary slightly. Major Component Locations...

  • Page 95: Planned Maintenance Intervals

    Section 7. Planned Maintenance and Lubrication Planned Maintenance Intervals Time intervals between maintenances are largely determined by operating conditions. For example, operation in sandy, dusty locations requires shorter maintenance intervals than operation in clean warehouses. The indicated intervals are intended for normal operation.
  • Page 96 The maintenance time intervals referred to in this manual relate to truck operating hours as recorded on the hourmeter, and are based on experience CLARK has found to be convenient and suitable under typical (normal or average) operating conditions. The periods...
  • Page 97 Section 7. Planned Maintenance and Lubrication NOTES: Air filter change interval may be determined by using an air restriction indicator. ** Hydraulic filter change interval may be determined by hydraulic filter restriction indicator. Diesel fuel filter change interval may be determined by fuel filter indicator.

  • Page 98: Pm Report Form

    CLARK has prepared a Gas, LPG, or Diesel Planned Maintenance Report Form. Copies of this form may be obtained from your authorized CLARK dealer. We recommend that you use this form as a checklist and record of your inspection and truck condition.
  • Page 99 Section 7. Planned Maintenance and Lubrication PM Report Form 7-13...

  • Page 100: How To Perform Planned Maintenance

    How to Perform Planned Maintenance Visual Inspection First, perform a visual inspection of the lift truck and its components. Walk around the truck and take note of any obvious damage or maintenance problems. Check to be sure all capacity, safety, and warning plates are attached and legible.
  • Page 101 Section 7. Planned Maintenance and Lubrication wear, rust, corrosion, cracked or broken links, stretching, etc. Check that the lift and carriage chains are correctly adjusted to have equal tension. Check that the lift chain anchor fasteners and locking means are in place and tight. Inspect all lift line hydraulic connections for leaks.
  • Page 102 If the fork blades are obviously bent or damaged, have them inspected by a trained maintenance person before operating the truck. Inspect the fork locking pins for cracks or damage. Reinsert them and note whether they fit properly. Wheels and Tires Check the condition of the drive and steer wheels and tires.
  • Page 103 Section 7. Planned Maintenance and Lubrication Disassembling the split rim wheel When you disassemble the split-rim wheel, NEVER remove the tire before you deflate the tire pressure. First, deflate the tire pressure and then loosen the wheel bolts and nuts. Failure to do so could result in serious personal injury.
  • Page 104 Indicator Lights Check that all lights are functioning and indicate normal truck operation as described in Section 3, “Operator Compartment and Controls,” in this manual. Service Brakes and Inching Pedal With the direction control in NEUTRAL and the engine running, push the service brake pedal fully down and hold.
  • Page 105 Section 7. Planned Maintenance and Lubrication If the maximum fork height is not reached, this indicates there is an inadequate (low) oil level in the hydraulic sump tank or severe binding within the upright. Push forward on the lift control lever. Watch the upright as it lowers. When the forks reach the floor, release the lever.
  • Page 106 2. Remove your right foot from the service brake pedal and put it on the accelerator pedal. Push down until the truck moves slowly forward. Remove your foot from the accelerator pedal and push down on the service brake pedal to stop the truck. The brakes should apply smoothly and equally.
  • Page 107 Battery Inspect the battery for damage, cracks, leaking condition, etc. If the terminals are corroded, clean and protect them with CLARK Battery Saver (available from your CLARK dealer). If your battery has removable cell caps, check to be sure the cells are all filled. Refill them with distilled water.
  • Page 108 IMPORTANT The recovery bottle shown is a typical illustration of overflow system. Your actual system may vary slightly. IMPORTANT A level anywhere between the HOT and COLD marks is normal. IMPORTANT COLD Inspect the coolant level in the overflow bottle only. WARNING Do not remove the radiator cap when the radiator is hot.
  • Page 109 Section 7. Planned Maintenance and Lubrication NOTICE Your lift truck cooling system is filled with a factory- installed solution of 50% water and 50% permanent-type antifreeze containing rust and corrosion inhibitors. You should leave the solution in year around. Plain water may be used in an emergency, but replace it with the specified coolant as soon as possible to avoid damage to the sys- tem.
  • Page 110 Engine Oil Performance Designation : Refer to the “Engine Oil” in Section 8. Hydraulic Sump Tank Check the hydraulic sump tank fluid level. Correct fluid level is important for proper system operation. Low fluid level can cause pump damage. Overfilling can cause loss of fluid or lift system malfunction.
  • Page 111 With the engine operating at idle and the transmission in NEUTRAL, and the parking brake set, check the fluid on the dipstick. Fill, if necessary, to the FULL mark on the dipstick, using CLARK transmission fluid. If unable to determine actual oil temperature, use...
  • Page 112 (forward end) and both the base rod-end bushings (rear end). Clean and lubricate the upright trunnion bushings Lift Chains Lubricate the entire length of the upright rail lift and carriage chains with CLARK Chain and Cable Lube. IMPORTANT Do not lubricate the carriage roller rails. Air Cleaning Always maintain a lift truck in a clean condition.
  • Page 113 Section 7. Planned Maintenance and Lubrication CAUTION Wear suitable eye protection and protective clothing when air cleaning. Never point the air nozzle at anyone. Air clean the upright assembly, drive axle, radiator—from both counterweight and engine side, engine and accessories, driveline and related components, and steer axle and cylinder.
  • Page 114 The lift chains operate under heavy loadings and function more safely and have longer life if they are regularly and correctly lubricated. CLARK chain lubricant is recommended; it is easily sprayed on and provides superior lubrication. Heavy motor oil may also be used as a lubricant and corrosion inhibitor.
  • Page 115 All chains must be replaced if any link has wear of 3% or more, or if any of the damaged conditions noted above are found during inspection. Order replacement chains from your CLARK dealer. Replace all chains as a set. Do not remove factory lubrication or paint new chains.
  • Page 117 Section 8. Specifications Specifications Contents CGC40-70 ..............8-2 Engine Oil ............... 8-4 Contents...
  • Page 118 CGC40-70 Clark products and specifications are subject to improvements and changes without notice or obligation. Model Designation - Rated Load Capacity CGC 40 3630kg @600mm load center [8,000lbs@24in] [4000kg@500mm] CGC 50 4540kg @600mm load center [10,000lbs@24in][5000kg@500mm] CGC 55 5500kg @600mm load center [12,000lbs@24in]...
  • Page 119 Engine oil: Spin-on Transmission: Spin-on Hydraulic system oil: 100 mesh suction screen in sump tank and filter in return line-B10=5.0; (used for steering and brake system) Hydraulic sump breather cap: Replaceable element Use genuine CLARK parts. See your CLARK dealer. CGC40-70...
  • Page 120 NOTICE This mixture provides antifreeze protection level of -37 °C (-34 °F), approximately. Transmission Fluid Recommendation Use CLARK Transmission Fluid. Hydraulic Fluid Recommendation Use CLARK Specification MS-68 Hydraulic Oil, with anti-wear additives, or equivalent, only. CGC40-70...
  • Page 121 Section 8. Specifications Engine Oil Use these SAE viscosity grades. SAE 0W-30 SAE 5W-30 SAE 5W-40 SAE 10W-30 SAE 10W-40 SAE 15W-40 SAE 20W-50 SAE 10W SAE 20W SAE 30 SAE 40 Engine Oil Recommendations American Petroleum Institute (API) classifications SM and SAE 5W- 30 for gas engines.

  • Page 123: Index

    Index A Message to CLARK Lift Truck Engine Accessories ....7-21 Operators ........ii Engine Air Cleaner ....7-21 Adjusting the Load Forks ..4-10 Engine Cooling System ...7-21 Adjusting the Seat ..... 4-4 Engine Oil ........8-4 After Operating the Truck ..4-16 Engine Oil and Filter ....7-23...
  • Page 124 Hydraulic Fluid and Filter Change ......... 7-24 Operating Safely ......4-7 Hydrostatic Controls ....3-8 Operator Daily Inspection ....vii Hydrostatic Operators Operators Compartment ....3-3 Compartment ......3-6 Optional Hydraulic Control Hydraulic Sump Tank ..... 7-24 Levers (Deck Mounted) ....3-9 Operator Protection ....1-7 Operator Safety Warning Indicator Lights .......
  • Page 125 Safety Signs and Safety Messages ........x What to do in Case of a Seat Adjustment ..... 3-11 Tip-over .........1-14 Seat Belts ......... 1-4 Wheels and Tires ....7-16 Steering Column Pylon ..... 3-3 Steering Column Pylon ... 3-15 Service Brakes and Inching Pedal ........
  • Page 128 Additional copies of this manual may be purchased from YOUR AUTHORIZED CLARK DEALER CLARK MATERIAL HANDLING COMPANY 700 Enterprise Drive Lexington, Kentucky 40510 [ www.clarkmhc.com ] ● Printed Date ; Jun. 2019...

This manual is also suitable for:

Cgc50 lCgc55 lCgc60 lCgc70 l

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