Clark CGC 40, CGC 50, CGC 55, CGC 60, CGC 70 Service Manual SM-1058

Description

• Model List:
  • CGC 40
  • CGC 50
  • CGC 55
  • CGC 60
  • CGC 70

• 1. SM1058
• 2. CONTENTS
• 3. GROUP SA SAFE MAINTENANCE
• 3.1. Section 1 Safety
• 3.2. Section 2 Lifting, Jacking, and Blocking the Truck
• 3.3. Section 3 Towing
• 4. GROUP PS PERIODIC SERVICE
• 4.1. Section 1 Maintenance Schedules
• 4.2. Section 2 The Planned Maintenance Program
• 5. GROUP 00 (LPSI 4X) ENGINE (LPG PSI 4X 4.3L)
• 5.1. Section 1 Engine Mechanical
• 5.2. Section 2 Diagnostic Information and Procedures
• 5.3. Section 3 Inspection, Removal and Installation
• 5.4. Section 4 Description and Operation
• 5.5. Section 5 PSI Fuel System
• 5.6. Section 6 Special Tools and Equipment
• 6. GROUP 01 COOLING SYSTEM
• 6.1. Section 1 Cooling System Specifications and Description
• 6.2. Section 2 Cooling System Troubleshooting
• 6.3. Section 3 Cooling System Testing and Maintenance
• 6.4. Section 4 Fan Belt Checks, Replacement, and Tensioning
• 6.5. Section 5 Radiator Removal and Replacemant
• 7. GROUP 03 INTAKE AND EXHAUST SYSTEM
• 7.1. Section 1 Intake and Exhaust Systems Specifications and Description
• 7.2. Section 2 Intake System Troubleshooting
• 7.3. Section 3 Intake System Service
• 7.4. Section 4 Exhaust Systems
• 8. GROUP 06 TRANSAXLE
• 8.1. Section 1 Transaxle Troubleshooting and Checks
• 8.2. Section 2 Transaxle Drain and Refill
• 8.3. Section 3 Transaxle Removal
• 8.4. Section 4 Transaxle Overhaul (H200 Transmission)
• 8.5. Section 5 Control Valve Replacement and Overhaul
• 9. GROUP 12 IGNITION SYSTEM
• 9.1. Section 1 Ignition Specifications and Description
• 9.2. Section 2 Ignition System Troubleshooting
• 9.3. Section 3 Ignition System Inspection, Timing, and Repair
• 10. GROUP 13 INSTRUMENT POD
• 10.1. Section 1 Instrument Pod Description and Specifications
• 10.2. Section 2 Instrument Pod Troubleshooting
• 10.3. Section 3 Instrument Pod Removal and Installation
• 11. GROUP 14 ELECTRICAL SYSTEM
• 11.1. Section 1 Electrical Specifications and Wiring Diagrams
• 11.2. Section 2 Starter and Battery Troubleshooting
• 12. GROUP 20 DRIVE AXLE
• 12.1. Section 1 Axle End Lubrication
• 12.2. Section 2 Axle End Removal
• 12.3. Section 3 Axle End Overhaul
• 12.4. Section 4 Differential Overhaul
• 13. GROUP 22 WHEELS AND TIRES
• 13.1. Section 1 Wheels and Tires Specifications and Description
• 13.2. Section 2 Cushion Wheels and Tires
• 14. GROUP 23 BRAKE SYSTEM
• 14.1. Section 1 Braking/Inching Specifications and Description
• 14.2. Section 2 Service Brake Troubleshooting
• 14.3. Section 3 Brake / Inching Pedals and Linkages Adjustments
• 14.4. Section 4 Brake System Bleeding
• 14.5. Section 5 Brake Valve Service
• 14.6. Section 6 Disc Brake Inspection and Overhaul
• 14.7. Section 7 Parking Brake Service
• 15. GROUP 25 STEERING COLUMN AND GEAR
• 15.1. Section 1 Steering System Specifications and Description
• 15.2. Section 2 Steering System Troubleshooting
• 15.3. Section 3 Steering Column and Component Removal Replacement
• 15.4. Section 4 Steering System Relief Pressure Check and Adjustment
• 15.5. Section 5 Steering Gear Overhaul
• 16. GROUP 26 STEER AXLE
• 16.1. Section 1 Steer Axle Specifications and Description
• 16.2. Section 2 Steer Axle Lubrication and Adjustment
• 16.3. Section 3 Steer Axle Removal and Replacement
• 16.4. Section 4 Steer Axle Overhaul
• 16.5. Section 5 Steer Cylinder Removal and Replacement
• 16.6. Section 6 Steer Cylinder Overhaul
• 17. GROUP 29 HYDRAULIC SUMP, FILTERS, AND PUMP
• 17.1. Section 1 Hydraulic Sump, Filters, and Pump Specifications and Description
• 17.2. Section 2 Main Hydraulic Pump Troubleshooting
• 17.3. Section 3 Hydraulic Filters and Fluid Maintenance and Change
• 17.4. Section 4 Hydraulic Pump Removal and Replacement
• 17.5. Section 5 Hydraulic Pump Overhaul
• 18. GROUP 30 HYDRAULIC CONTROL VALVE / LIFT CIRCUIT
• 18.1. Section 1 Hydraulic Control Valve / Lift Circuit Specifications and Description
• 18.2. Section 2 Hydraulic System Schematic
• 18.3. Section 3 Hydraulic System Troubleshooting
• 18.4. Section 4 Hydraulic System Pressure Checks and Adjustments
• 18.5. Section 5 Hydraulic Control Valve Removal and Replacement
• 18.6. Section 6 Hydraulic Control Valve Overhaul
• 19. GROUP 32 TILT CYLINDERS
• 19.1. Section 1 Tilt Cylinder Specifications and Description
• 19.2. Section 2 Tilt Cylinder Checks and Adjustments
• 19.3. Section 3 Tilt Cylinder Removal and Replacement
• 19.4. Section 4 Tilt Cylinder Overhaul
• 20. GROUP 34 UPRIGHTS
• 20.1. Section 1 Upright Specifications and Description
• 20.2. Section 2 Troubleshooting
• 20.3. Section 3 Upright Inspection
• 20.4. Section 4 Carriage and Upright Roller Clearance Checks and Shim Adjustments
• 20.5. Section 5 Cylinder Removal, Shimming, Overhaul, and Replacement
• 20.6. Section 6 Upright Chain Inspection, Adjustment, and Replacement
• 20.7. Section 7 Fork and Carriage Removal and Replacement
• 20.8. Section 8 Upright Removal and Replacement
• 20.9. Section 9 CGC 60/70 Upright 10,000 to 20,000 lbs Upright
• 21. GROUP 38 COUNTERWEIGHT AND CHASSIS
• 21.1. Section 1 Counterweight Specifications and Description
• 21.2. Section 2 Counterweight Removal and Replacement
• 21.3. Section 3 Overhead Guard / Operators Cell Removal and Replacement
• 21.4. Section 4 Floorboard, Cowl Covers, Radiator Cover, and Seat Deck Removal and Replacement
• 21.5. Section 5 Operators Seat Removal and Replacement
• 22. GROUP 40 SPECIFICATIONS
• 22.1. Section 1 Nameplates and Decals
• 22.2. Section 2 General Specifications
• 22.3. Section 3 Hydraulic Fitting Tightening Procedure