Format: PDF (Printable Document)
File Language: English
File Pages: 1178
File Size: 66.87 MB (Speed Download Link)
Brand: Clark
Model: C40, C45, C50s, C55s D, L Forklift
Book No: SM942
Type of Document: Service Manual
$ 40
These Clark C40–C55s forklifts spend their lives in warehouses, yards, and loading docks, moving pallets and heavy product all day. This service manual is what I reach for when I need to trace a hydraulic issue, pull a mast component, or verify an adjustment after a repair. If, for example, the truck won’t lift under load or the tilt is chattering, this book walks you through a logical check sequence so you can confirm whether it’s a control problem, a leaking cylinder, or a pump issue before you start buying parts.
Applications & Use Cases
FAQ
Q: Is this manual useful if I only do basic maintenance?
A: Yes, it helps you inspect, service, and test systems properly so small issues don’t turn into major failures.
Q: Can I use a digital copy at the truck?
A: You can, but many techs print the key procedures or diagrams so they can mark notes and keep the book off greasy surfaces.
Safety Note
Always support the truck and mast exactly as described before working underneath or loosening any structural components.
SM-942
CONTENTS
GROUP SA SAFE MAINTENANCE
Section 1 Safety
Section 2 Lifting, Jacking, and Blocking the Truck
Section 3 Towing
GROUP PS PERIODIC SERVICE
Section 1 Maintenance Schedules
Section 2 The Planned Maintenance Program
GROUP 00 (D-KUBOTA) ENGINE (KUBOTA – TIER 3)
Section 1 GENERAL
Section 2 CHECK AND MAINTENANCE
Section 3 Mechanism
Section 4 Servicing
GROUP 00 (D-DEUTZ) ENGINE ( DEUTZ TD3.6 L4 – TIER 4)
Section 1 GENERAL
Section 2 Servicing and maintenance work
Section 3 Removing and installing
Section 4 Special tools
GROUP 00(L) ENGINE (GM V6 4.3L) (TIER 0 & TIER 4)
Section 1 ENGINE REMOVAL AND REPLACEMENT
Section 2 4.3 LITER V6 ENGINE REPAIR PROCEDURES
Section 3 COOLING SYSTEM
GROUP 01 ENGINE COOLING SYSTEM
Section 1 Engine Cooling System Specifications and Description
Section 2 Engine Cooling System Troubleshooting
Section 3 Engine Cooling System Testing and Maintenance
Section 4 Radiator Removal and Replacemant
GROUP 02(LP-TIER3) MI-07 LP SYSTEM (GM V6 4.3)
Section 0 REGULATORY COMPLIANCE
Section 1 LPG SYSTEM OVERVIEW
Section 2 SPECIFICATIONS
Section 3 RECOMMENDED MAINTENANCE
Section 4 INSTALLATION PROCEDURES
Section 5 TESTS AND ADJUSTMENTS
Section 6 BASIC TROUBLESHOOTING
Section 7 ADVANCED DIAGNOSTICS
Section 8 PARTS DESCRIPTION
GROUP 02 (GM-TIER4) PSI FUEL SYSTEM (GM V6 4.3)
Section 1 General Information
Section 2 Maintenance
Section 3 LPG Fuel System
Section 4 Fuel System Diagnosis
Section 5 Electrical Section
Section 6 Definitions
GROUP 03 INTAKE AND EXHAUST SYSTEM
Section 1 Intake and Exhaust Systems Specifications and Description
Section 2 Intake System Troubleshooting
Section 3 Intake System Service
Section 4 Exhaust Systems
GROUP 06 TRANSMISSION
Section 1 Torque Converter
Section 2 Testing and Adjusting
Section 3 Transmission Specifications
Section 4 Transmission
Section 5 Disassembly and Assembly of the Control Valve
Section 6 Transmission Disassembly and Assembly
Section 7 Transmission Removal and Installation
GROUP 13 ELECTRICAL SYSTEM
Section 1 Cautions for working on the electrical system
Section 2 Electrical system Specifications and features
Section 3 Electrical Circuit Diagram & Electrical Parts Arrangement
Section 4 Instrument Pod
GROUP 20 DRIVE AXLE
Section 1 Introduction
Section 2 Differential Carrier Assembly
Section 3 Drive Axle
Section 4 Troubleshooting
Section 5 Disassembly and Assembly
Section 6 Drive Axle Removal and Installation
GROUP 22 WHEELS AND TIRES
Section 1 Wheels and Tires Specifications and Description
Section 2 Pneumatic Wheels and Tires
GROUP 23 BRAKE SYSTEM
Section 1 Braking / Inching System Specifications and Description
Section 2 Service Brake Troubleshooting
Section 3 Brake / Inching Pedals and Linkages Adjustments
Section 4 Brake System Bleeding
Section 5 Brake Master Cylinder Service
Section 6 Parking Brake Service
GROUP 25 STEERING COLUMN AND GEAR
Section 1 Steering System Specifications and Description
Section 2 Steering System Troubleshooting
Section 3 Steering Column and Component Removal and Replacement
Section 4 Steering System Relief Pressure Check and Adjustment
Section 5 Steering Gear Overhaul
GROUP 26 STEER AXLE
Section 1 Steer Axle Specifications and Description
Section 2 Steer Axle Wheel Bearing Maintenance and Adjustment
Section 3 Steer Axle Removal and Replacement
Section 4 Steer Axle Overhaul
Section 5 Steer Cylinder Removal and Replacement
Section 6 Steer Cylinder Overhaul
GROUP 29 HYDRAULIC SUMP, FILTERS, AND PUMP
Section 1 Main Hydraulic Sump, Filters, and Pump Specifications and Description
Section 2 Main Hydraulic Pump Troubleshooting
Section 3 Main Hydraulic Removal and Installation
GROUP 30 HYDRAULIC CONTROL VALVE (DAESUNG NACHI)
Section 1 Operation of Hydraulic Control Valve
Section 2 Hydraulic Circuit
Section 3 Disassembling Hydraulic Valve
Section 4 Assembling Hydraulic Control Valve
Section 5 Testing of Hydraulic Valve
GROUP 32 TILT CYLINDERS
Section 1 Tilt Cylinder Specifications and Description
Section 2 Tilt Cylinder Checks and Adjustments
Section 3 Tilt Cylinder Removal and Replacement
Section 4 Tilt Cylinder Overhaul
GROUP 34 UPRIGHTS
Section 1 Upright Specifications and Description
Section 2 Troubleshooting
Section 3 Upright Inspection
Section 4 Carriage and Upright Roller Clearance Checks and Shim Adjustments
Section 5 Cylinder Removal, Shimming, Overhaul, and Replacement
Section 6 Upright Chain Inspection, Adjustment, and Replacement
Section 7 Fork and Carriage Removal and Replacement
Section 8 Upright Removal and Replacement
GROUP 38 COUNTERWEIGHT AND CHASSIS
Section 1 Counterweight Specifications and Description
Section 2 Counterweight Removal and Replacement
Section 3 Overhead Guard / Operator’s Cell Removal and Replacement
Section 4 Floorboard, Cowls, and Seat Deck Removal and Replacement
GROUP 40 SPECIFICATIONS
Section 1 Nameplates and Decals
Section 2 General Specifications
Section 3 Hydraulic Fitting Tightening Procedure
