Clark CGC, CGP, CDP 20-30 Forklift Index:

SERVICE MANUAL
Use of this Manual
Contents
SAFE MAINTENANCE
Section 1. Safety
Lifting, Jacking, and Blocking
Towing
PERIODIC SERVICE
Maintenance Schedules
The Planned Maintenance Program
The PM Inspection Form
S4S DIESEL ENGINE
Engine Oil and Filter
Throttle Linkage Checks and Adjustment
. Fuel Supply System
RPM Settings and Stall Tests
Engine Removal and Replacement
S4S Diesel Engine Service Manual
Balancer for S4S Diesel Engine
4G64 GAS/LPG/CNG ENGINE
Engine Specifications
Engine Troubleshooting
Engine Oil and Filter
Engine Tune-Up
RPM, Vacuum, and Stall Tests
Compression Checks
Engine Removal and Replacement
Engine Overhaul
GM ENGINE
Specifications
Troubleshooting
Oil and Filter
Tune-Up
RPM, Vacuum, and Stall Tests
Compression Checks
Removal and Replacement
Engine Overhaul
ENGINE COOLING
Specifications and Description
Troubleshooting
Testing and Maintenance
Cooling System and Alternator Belt Service
Radiator R&R
Radiator R&R (GM)
LPG FUEL SYSTEM
Specifications and Description
Troubleshooting
Adjustments and Maintenance
Carburetor and Throttle
Vaporizer-Regulator
Fuel Lock-off Valve
GASOLINE-CARB FUEL SYSTEM
Specifications and Description
Troubleshooting
Checks and Adjustments
Removal, Replacement, and Overhaul
Fuel Pump and Filter
AIR INDUCTION & EXHAUST
Specifications and Description
System Service
Exhaust Systems
TA-30 STANDARD TRANSAXLE
Specifications and Description
Troubleshooting
Oil and Filter
Oil Cooler
Transaxle R&R
Overhaul
Drive Axle Ends
Transaxle Control Valve
HYDROSTATIC TRANSMISSION
Specifications and Description
Troubleshooting and Adjustments
Using the SUSMIC DIA-3
Components Removals and Replacements
Hydrostatic Drive Pump Service
Hydrostatic Drive Motors Service
Drive Axle Ends
Axial Piston Pump & Motor
IGNITION SYSTEM
Description and Specifications
Troubleshooting
Inspection, Adjustment, and Timing
GM Ignition System
Distributor Overhaul
INSTRUMENT POD
Description & Specifications
Troubleshooting
Removal and Installation
ELECTRICAL SYSTEM
Specifications & Wire Diagrams
Starter and Battery
Alternator
Starter Maintenance and Overhaul
Alternator Maintenance
WHEELS AND TIRES
Specifications and Description
Cushion Wheels and Tires
Pneumatic Wheels and Tires
BRAKE/INCHING SYSTEM (Hydrostatic Trans)
Specifications and Description
Troubleshooting
Brake/Inching Pedals, Linkages, & Adjustments
Brake System Bleeding
Master Cylinder Overhaul
Service Brake Adjustment and Overhaul
Parking Brake Service
BRAKE SYSTEM (STANDARD TRANSAXLE)
Specifications and Description
Service Brake Troubleshooting
Brake/Inching Pedals and Linkage Adjustments
Bleeding
Brake Valve Service
Service Brake Adjustment and Overhaul
Parking Brake Service
STEERING COLUMN AND GEAR
Specifications and Description
Steering System Troubleshooting
Steering Column and Component Removal and Replacement
Steering System Relief Pressure Check and Adjustment
Steering Gear Overhaul
STEER AXLE
Specifications and Description
Wheel Bearing Maintenance and Adjustment
Steer Axle Removal and Replacement
Steer Axle Overhaul
Steer Cylinder Removal and Replacement
Steer Cylinder Overhaul
HYDRAULIC SUMP, FILTERS, AND PUMP
Specifications and Description
Main Hydraulic Pump Troubleshooting
Hydraulic Filters and Fluid Maintenance and Change
Hydraulic Pump Removal and Replacement
Hydraulic Pump Overhaul
HYDRAULIC CONTROL VALVA/LIFT CIRCUIT
Specifications and Description
Hydraulic System Schematics
Hydraulic System Troubleshooting
Hydraulic System Pressure Checks and Adjustments
Hydraulic Control Valve Removal & Replacement
Hydraulic Control Valve Overhaul
TILT CYLINDERS
Specifications and Description
Checks and Adjustments
Removal and Replacement
Overhaul
UPRIGHTS
Upright Specifications and Description
Troubleshooting
Inspection
Carriage and Upright Roller Clearance Checks
Cylinder Removal, Shimming, Overhaul, and Replacement
Upright Chain Inspection, Adjustment, and Replacement
Fork and Carriage Removal and Replacement
Upright Removal and Replacement
COUNTERWEIGHT AND CHASSIS
Counterweight Specifications and Description
Counterweight Removal and Replacement
Overhead Guard/Operator’s Cell R&R
Floorboard, Cowls, Radiator Cover, and Seat Deck R&R
Operator’s Seat R&R
SPECIFICATIONS
Nameplates and Decals
General Specifications
Hydraulic Fitting Tightening Procedure