Clark CGC40, CGC50, CGC55, CGC60, CGC70 PSI 4X Engine Truck Forklift Service Manual (SM1058)

Clark CGC40, CGC50, CGC55, CGC60, CGC70 PSI 4X Engine Truck Forklift Service Manual (SM1058)

Clark CGC40, CGC50, CGC55, CGC60, CGC70 PSI 4X Engine Truck Forklift Index:

SM-1058
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 (L-PSI 4X) ENGINE (LPG – PSI 4X 4.3L)
Section 1 Engine Mechanical
Section 2 Diagnostic Information and Procedures
Section 3 Inspection, Removal and Installation
Section 4 Description and Operation
Section 5 PSI Fuel System
Section 6 Special Tools and Equipment
GROUP 01 COOLING SYSTEM
Section 1 Cooling System Specifications and Description
Section 2 Cooling System Troubleshooting
Section 3 Cooling System Testing and Maintenance
Section 4 Fan Belt Checks, Replacement, and Tensioning
Section 5 Radiator Removal and Replacemant
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 TRANSAXLE
Section 1 Transaxle Troubleshooting and Checks
Section 2 Transaxle Drain and Refill
Section 3 Transaxle Removal
Section 4 Transaxle Overhaul (H-200 Transmission)
Section 5 Control Valve Replacement and Overhaul
GROUP 12 IGNITION SYSTEM
Section 1 Ignition Specifications and Description
Section 2 Ignition System Troubleshooting
Section 3 Ignition System Inspection, Timing, and Repair
GROUP 13 INSTRUMENT POD
Section 1 Instrument Pod Description and Specifications
Section 2 Instrument Pod Troubleshooting
Section 3 Instrument Pod Removal and Installation
GROUP 14 ELECTRICAL SYSTEM
Section 1 Electrical Specifications and Wiring Diagrams
Section 2 Starter and Battery Troubleshooting
GROUP 20 DRIVE AXLE
Section 1 Axle End Lubrication
Section 2 Axle End Removal
Section 3 Axle End Overhaul
Section 4 Differential Overhaul
GROUP 22 WHEELS AND TIRES
Section 1 Wheels and Tires Specifications and Description
Section 2 Cushion Wheels and Tires
GROUP 23 BRAKE SYSTEM
Section 1 Braking/Inching Specifications and Description
Section 2 Service Brake Troubleshooting
Section 3 Brake / Inching Pedals and Linkages Adjustments
Section 4 Brake System Bleeding
Section 5 Brake Valve Service
Section 6 Disc Brake Inspection and Overhaul
Section 7 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 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 Lubrication 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 Hydraulic Sump, Filters, and Pump Specifications and Description
Section 2 Main Hydraulic Pump Troubleshooting
Section 3 Hydraulic Filters and Fluid Maintenance and Change
Section 4 Hydraulic Pump Removal and Replacement
Section 5 Hydraulic Pump Overhaul
GROUP 30 HYDRAULIC CONTROL VALVE / LIFT CIRCUIT
Section 1 Hydraulic Control Valve / Lift Circuit Specifications and Description
Section 2 Hydraulic System Schematic
Section 3 Hydraulic System Troubleshooting
Section 4 Hydraulic System Pressure Checks and Adjustments
Section 5 Hydraulic Control Valve Removal and Replacement
Section 6 Hydraulic Control Valve Overhaul
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
Section 9 CGC 60/70 Upright 10,000 to 20,000 lbs Upright
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, Cowl Covers, Radiator Cover, and Seat Deck Removal and Replacement
Section 5 Operator’s Seat Removal and Replacement
GROUP 40 SPECIFICATIONS
Section 1 Nameplates and Decals
Section 2 General Specifications
Section 3 Hydraulic Fitting Tightening Procedure

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