Clark GCG, CGP 40-70 Forklift Index:

SERVICE MANUAL
CONTENTS
GROUP SA-SAFE MAINTENANCE
1.Safety
2.Lifting, Jacking, and Blocking the Truck
3.Towing
GROUP PS-Periodic Service
1.Maintenance Schedules
2.The Planned Maintenance Program
3.The PM Form
GROUP 00(G)-GAS/LPG Engine
1.Engine Specifications
2.Troubleshooting
3.Engine Oil and Filter
4.Engine Tune-Up
5.RPM, Vacuum, and Stall Tests
6.Engine Removal and Replacement
7.Engine Overhaul
GROUP 00(D)-Diesel Engine
1.Trottle Linkage Checks and Adjustment
2.Engine RPM Settings and Stall Tests
3.Engine Removal and Replacement
4.Engine Manual
GROUP 01-Engine Cooling System
1.Cooling System Specifications and Description
2.Cooling System Troubleshooting
3.Cooling System Testing and Maintenance
4.Fan Belt Check, Replacement, and Tensioning
5.Radiator Removal and Replacemant
GROUP 02(G)-GASOLINE-CARB FUEL SYSTM
GROUP 02(LP)-LPG FUEL SYSTM (CARBURETED)
1.Fuel System Checks and Troubleshooting
2.The IMPCO LPG Fuel System
GROUP 02(LP-TIER2) MI-4 LP SYSTEM (V6)
0.Working With Lpg Equipment
1.Lpg And Lpg Fuel Tanks
2.Mi-4 Lpg System Operational Overview
3.Mi-4 Maintenance Schedule
4.Mi-4 Lp Basic Troubleshooting
5.Mi-4 Lp Advanced Diagnostics
6.Mi-4 Electrical Connections
7.N2001 Pressure Regulator/converter
8.N-CA100TR Air/fuel Mixer
9.Test And Adjustments
GROUP 02(LP-Tier3) MI-07 LPG SYSTEM (V6)
0.Regulatory Compliance
1.LPG System Overview
2.Specifications
3.Recommended Maintenance
4.Installation Procedures
5.Tests And Adjustments
6.Basic Troubleshooting
7.Advanced Diagnostics
8.Parts Description
GROUP 03-Air Induction and Exaust System
1.Specifications and Description
2.Troubleshooting
3.Air Induction System Service
4.Exhaust Systems
GROUP 06-TRANSAXLE
1.Transaxle Troubleshooting and Checks
2.Transaxle Drain and Refill
3.Transaxle Removal
4.Transaxle Overhaul (H-200 Transmission)
GROUP 12-Ignition System
1.Description and Specifications
2.Troubleshooting
3.Inspection, Adjustment, and Timing
GROUP 13-Instrument Pod
1.Instrument Pod Description and Specifications
2.Instrument Pod Troubleshooting
3.Instrument Pod Removal and Installation
GROUP 14-Electrical System
1.Electrical Specification and Wiring Diagrams
2.Starter and Battery Troubleshooting
3.Alternator Onerhaul
GROUP 20-Drive Axle
1. Axle End Lubrication
2. Axle End Removal
3. Axle End Overhaul
4.Differential Overhaul
GROUP 22-Wheels and Tires
1.Specifications and Description
2.Pneumatic Wheels and Tires
3.Cushion Wheels and Tires
GROUP 23-Brake System
1.Specifications and Description
2.Service Brake Troubleshooting
3.Brake/Inching Pedals and Linkages Adjustments
4.Brake System Bleeding
5.Brake Valve Service
6.Disc Brake Inspection and Overhaul
7.Parking Brake Service
GROUP 25-Steering Column and Gear
1.Specifications and Description
2.Troubleshooting
3.Steering Column and Component
Removal and Replacement
4.Steering System Relief Pressure Check
and Adjustment
5.Steering Gear Overhaul
GROUP 26-Steer Axle
1.Steer Axle Specifications and Description
2.Steer Axle Wheel Bearing Maintenance and Adjustment
3.Steer Axle Removal and Replacement
4.Steer Axle Overhaul
5.Steer Cylinder Removal and Replacement
6.Steer Cylinder Overhaul
GROUP 29-Hydraulic Sump, Filters, and Pump
1.Specifications and Description
2.Hydraulic Pump Troubleshooting
3.Hydraulic Filters andFluid Maintenance
4.Hydraulic Pump Removal and Replacement
5.Hydraulic Pump Overhaul
GROUP 30-Hydraulic Control Valve/Lift Circuit
1.Specifications and Description
2.Hydraulic System Schematics
3.Hydraulic System Troubleshooting
4.Hydraulic System Pressure Checks and Adjustments
5.Hydraulic Control Valve Removal and Replacement
6.Hydraulic Control Valve Overhaul
GROUP 32-Tilt Cylinders
1.Specifications and Description
2.Tilt Cylinder Checks and Adjustments
3.Tilt Cylinder Removal and Replacement
4.Tilt Cylinder Overhaul
GROUP 34-Uprights
1.Specifications and Description
2.Troubleshooting
3.Upright Inspection
4.Roller Clearance Checks and Shim Adjustments
5.Cylinder Replacement, Shimming and Overhaul
6.Upright Chain Inspection, Adjustment, and Replacement
7.Fork and Carriage Removal and Replacement
8.Upright Removal and Replacement
9.CGC6 0/70 Upright
GROUP 38-Counterweight and Chassis
1.Specifications and Description
2.Counterweight Removal and Replacement
3.Overhead Guard/Operator’s Cell Removal
and Replacement
4.Floorboard, Cowls, Radiator Cover, and Seat Deck Removal and Replacement
5.Operator’s Seat Removal and
Replacement
GROUP 40-SPECIFICATIONS
1.Nameplates and Decals
2.General Specifications
3.Hydraulic Fitting Tightening
Procedures