Clark CGC, CGP 40, 70 Service Manual SM-612

Description

• Model List:
  • CGC40
  • CGC 70
  • CGP 40
  • CGP 70

• 1. SERVICE MANUAL
• 2. CONTENTS
• 3. GROUP SASAFE MAINTENANCE
• 3.1. Safety
• 3.2. Lifting, Jacking, and Blocking the Truck
• 3.3. Towing
• 4. GROUP PSPeriodic Service
• 4.1. Maintenance Schedules
• 4.2. The Planned Maintenance Program
• 4.3. The PM Form
• 5. GROUP 00(G)GAS/LPG Engine
• 5.1. Engine Specifications
• 5.2. Troubleshooting
• 5.3. Engine Oil and Filter
• 5.4. Engine TuneUp
• 5.5. RPM, Vacuum, and Stall Tests
• 5.6. Engine Removal and Replacement
• 5.7. Engine Overhaul
• 6. GROUP 00(D)Diesel Engine
• 6.1. Trottle Linkage Checks and Adjustment
• 6.2. Engine RPM Settings and Stall Tests
• 6.3. Engine Removal and Replacement
• 6.4. Engine Manual
• 7. GROUP 01Engine Cooling System
• 7.1. Cooling System Specifications and Description
• 7.2. Cooling System Troubleshooting
• 7.3. Cooling System Testing and Maintenance
• 7.4. Fan Belt Check, Replacement, and Tensioning
• 7.5. Radiator Removal and Replacemant
• 8. GROUP 02(G)GASOLINECARB FUEL SYSTM
• 9. GROUP 02(LP)LPG FUEL SYSTM (CARBURETED)
• 9.1. Fuel System Checks and Troubleshooting
• 9.2. The IMPCO LPG Fuel System
• 10. GROUP 02(LPTIER2) MI4 LP SYSTEM (V6)
• 10.1. Working With Lpg Equipment
• 10.2. Lpg And Lpg Fuel Tanks
• 10.3. Mi4 Lpg System Operational Overview
• 10.4. Mi4 Maintenance Schedule
• 10.5. Mi4 Lp Basic Troubleshooting
• 10.6. Mi4 Lp Advanced Diagnostics
• 10.7. Mi4 Electrical Connections
• 10.8. N2001 Pressure Regulator/converter
• 10.9. NCA100TR Air/fuel Mixer
• 10.10. Test And Adjustments
• 11. GROUP 02(LPTier3) MI07 LPG SYSTEM (V6)
• 11.1. Regulatory Compliance
• 11.2. LPG System Overview
• 11.3. Specifications
• 11.4. Recommended Maintenance
• 11.5. Installation Procedures
• 11.6. Tests And Adjustments
• 11.7. Basic Troubleshooting
• 11.8. Advanced Diagnostics
• 11.9. Parts Description
• 12. GROUP 03Air Induction and Exaust System
• 12.1. Specifications and Description
• 12.2. Troubleshooting
• 12.3. Air Induction System Service
• 12.4. Exhaust Systems
• 13. GROUP 06TRANSAXLE
• 13.1. Transaxle Troubleshooting and Checks
• 13.2. Transaxle Drain and Refill
• 13.3. Transaxle Removal
• 13.4. Transaxle Overhaul (H200 Transmission)
• 14. GROUP 12Ignition System
• 14.1. Description and Specifications
• 14.2. Troubleshooting
• 14.3. Inspection, Adjustment, and Timing
• 15. GROUP 13Instrument Pod
• 15.1. Instrument Pod Description and Specifications
• 15.2. Instrument Pod Troubleshooting
• 15.3. Instrument Pod Removal and Installation
• 16. GROUP 14Electrical System
• 16.1. Electrical Specification and Wiring Diagrams
• 16.2. Starter and Battery Troubleshooting
• 16.3. Alternator Onerhaul
• 17. GROUP 20Drive Axle
• 17.1. Axle End Lubrication
• 17.2. Axle End Removal
• 17.3. Axle End Overhaul
• 17.4. Differential Overhaul
• 18. GROUP 22Wheels and Tires
• 18.1. Specifications and Description
• 18.2. Pneumatic Wheels and Tires
• 18.3. Cushion Wheels and Tires
• 19. GROUP 23Brake System
• 19.1. Specifications and Description
• 19.2. Service Brake Troubleshooting
• 19.3. Brake/Inching Pedals and Linkages Adjustments
• 19.4. Brake System Bleeding
• 19.5. Brake Valve Service
• 19.6. Disc Brake Inspection and Overhaul
• 19.7. Parking Brake Service
• 20. GROUP 25Steering Column and Gear
• 20.1. Specifications and Description
• 20.2. Troubleshooting
• 20.3. Steering Column and ComponentRemoval and Replacement
• 20.4. Steering System Relief Pressure Checkand Adjustment
• 20.5. Steering Gear Overhaul
• 21. GROUP 26Steer Axle
• 21.1. Steer Axle Specifications and Description
• 21.2. Steer Axle Wheel Bearing Maintenance and Adjustment
• 21.3. Steer Axle Removal and Replacement
• 21.4. Steer Axle Overhaul
• 21.5. Steer Cylinder Removal and Replacement
• 21.6. Steer Cylinder Overhaul
• 22. GROUP 29Hydraulic Sump, Filters, and Pump
• 22.1. Specifications and Description
• 22.2. Hydraulic Pump Troubleshooting
• 22.3. Hydraulic Filters andFluid Maintenance
• 22.4. Hydraulic Pump Removal and Replacement
• 22.5. Hydraulic Pump Overhaul
• 23. GROUP 30Hydraulic Control Valve/Lift Circuit
• 23.1. Specifications and Description
• 23.2. Hydraulic System Schematics
• 23.3. Hydraulic System Troubleshooting
• 23.4. Hydraulic System Pressure Checks and Adjustments
• 23.5. Hydraulic Control Valve Removal and Replacement
• 23.6. Hydraulic Control Valve Overhaul
• 24. GROUP 32Tilt Cylinders
• 24.1. Specifications and Description
• 24.2. Tilt Cylinder Checks and Adjustments
• 24.3. Tilt Cylinder Removal and Replacement
• 24.4. Tilt Cylinder Overhaul
• 25. GROUP 34Uprights
• 25.1. Specifications and Description
• 25.2. Troubleshooting
• 25.3. Upright Inspection
• 25.4. Roller Clearance Checks and Shim Adjustments
• 25.5. Cylinder Replacement, Shimming and Overhaul
• 25.6. Upright Chain Inspection, Adjustment, and Replacement
• 25.7. Fork and Carriage Removal and Replacement
• 25.8. Upright Removal and Replacement
• 25.9. CGC6 0/70 Upright
• 26. GROUP 38Counterweight and Chassis
• 26.1. Specifications and Description
• 26.2. Counterweight Removal and Replacement
• 26.3. Overhead Guard/Operators Cell Removaland Replacement
• 26.4. Floorboard, Cowls, Radiator Cover, and Seat Deck Removal and Replacement
• 26.5. Operators Seat Removal andReplacement
• 27. GROUP 40SPECIFICATIONS
• 27.1. Nameplates and Decals
• 27.2. General Specifications
• 27.3. Hydraulic Fitting TighteningProcedures