Clark CGC, CGP, CDP 20, 30 Forklift Service Manual
961 pages · Publication SM-598S
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- Models
- CGC, CGP, CDP 20, 30
- Manual type
- Service Manual
- Pages
- 961
- Publication
- SM-598S
- Condition
- Brand new
What's inside
From the manual's own table of contents: 27 sections, 374 entries. See sample pages (PDF, 290 KB)
Title Page
Use of this Manual
SAFE MAINTENANCE11 topics
- Section 1. Safety
- Lifting, Jacking, and Blocking
- Safe Parking
- Lifting, Blocking, and Jacking Points
- Raising Drive Wheels Off Floor
- Raising Truck with A Hoist
- Blocking the Upright In Raised Position
- Raising Rear of Truck
- Raising Entire Truck
- Shipping Tie-Down Instructions
- Towing
PERIODIC SERVICE21 topics
- Maintenance Schedules
- Periodic Service
- Determining Maintenance Intervals
- Service Chart/Lubrication Points
- Recommended Periodic Service Schedule
- The Planned Maintenance Program
- introduction to Planned Maintenance
- The Basic PM Procedures
- Recommended PM Task Chart
- Visual Inspection
- Functional Tests
- Air Cleaning the Truck
- Truck Chassis Inspection and Lubrication
- Upright and Tilt Cylinder Lubrication
- Lift Chain Lubrication
- Under-the-Hood inspection
- Fluid Checks
- Stall Test
- Cranking Voltage Test
- Critical Fastener Torque Checks
- The PM Inspection Form
S4S DIESEL ENGINE19 topics
- 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
- HOW TO USE THIS MANUAL
- GENERAL
- MAINTENANCE STANDARDS
- SPECIAL TOOL LIST
- ENGINE PROPER
- INLET AND EXHAUST SYSTEMS
- LUBRICATION SYSTEM
- COOLING SYSTEM
- FUEL SYSTEM
- ELECTRICAL SYSTEM
- WORKSHOP THEORY
- TROUBLESHOOTING
- Balancer for S4S Diesel Engine
4G64 GAS/LPG/CNG ENGINE14 topics
- Engine Specifications
- Engine Troubleshooting
- Engine Tune-Up
- RPM, Vacuum, and Stall Tests
- Introduction
- Test Procedures
- Analysis of Stall Test
- Compression Checks
- Engine Overhaul
- Overhaul Specifications
- Service Precautions
- Tightening Method for Permanently
- Special Tools
- OVERHAUL PROCEDURES
GM ENGINE11 topics
- Specifications
- Troubleshooting
- Oil and Filter
- Tune-Up
- Introduction
- Test Procedures
- Analysis of Stall Test
- Removal and Replacement
- Engine Removal
- Engine Replacement
- Specifications
ENGINE COOLING7 topics
- Specifications and Description
- Testing and Maintenance
- Cooling System and Alternator Belt Service
- Radiator R&R
- Radiator Removal
- Radiator Replacement
- Radiator R&R (GM)
LPG FUEL SYSTEM4 topics
- Adjustments and Maintenance
- Carburetor and Throttle
- Vaporizer-Regulator
- Fuel Lock-off Valve
GASOLINE-CARB FUEL SYSTEM3 topics
- Checks and Adjustments
- Removal, Replacement, and Overhaul
- Fuel Pump and Filter
AIR INDUCTION & EXHAUST2 topics
- System Service
- Exhaust Systems
TA-30 STANDARD TRANSAXLE6 topics
- Transaxle Hydraulic Schematic
- Oil Cooler
- Transaxle R&R
- Overhaul
- Drive Axle Ends
- Transaxle Control Valve
HYDROSTATIC TRANSMISSION47 topics
- Troubleshooting and Adjustments
- Vehicle Does Not Move
- Vehicle Does Not Reach Maximum Speed
- Driving Behavior Abnormal
- Using the SUSMIC DIA-3
- Safe Maintenance Practices
- Introduction
- Battery Life
- Connection of the SUSMIC-DIA 3
- Activation of the SUSMIC-DIA 3
- Sensor Set-up
- Sensor Set-up Procedures
- Custom Adjustments of Driving Characteristics
- Sensor/Actuator Error Diagnosis
- Sensor Check Procedure
- LED INDICATORS
- DIA-3 Quick Reference
- Components Removals and Replacements
- Hydrostatic System Plumbing
- Drive Axle
- Drive Pump
- Engine
- Pump Adaptor and Couplings
- Control System
- Hydrostatic Drive Pump Service
- Hydrostatic Drive Motors Service
- DISMANTLING
- REASSEMBLY
- ASSEMBLY DRAWINGS
- TOOLING
- GREASE SPECIFICATION
- FAULT FINDING
- Axial Piston Pump & Motor
- Introduction
- General Description
- Hydraulic Support System
- Technical Data - Variable Displacement Pump
- Technical Data - Fixed Displacement Motor
- Technical Data - All Series 90 Pumps and Motors
- Controls and Options
- Start-Up Maintenance
- Troubleshooting
- Fault Logic Diagrams
- Inspections & Adjustments
- Minor Repair and Replacement
- General Parts ldentif ication
- Unit Identification
IGNITION SYSTEM22 topics
- Description and Specifications
- Specifications
- System Overview
- Schematic Drawing
- Distributor Components and Function
- Troubleshooting Tests
- Troubleshooting Chart
- Inspection, Adjustment, and Timing
- Distributor Inspection and Air Gap
- Spark Plug Wire Inspection
- Spark Plug Inspection and
- Ignition Coil Inspection
- Ignition Coil Tests
- Pick-Up Coil Tests
- Ignition Timing Checks and Adjustment
- GM Ignition System
- Ignition Timing
- Distributor Overhaul
- Replacing the lgnitor and Pick-Up Coil
- Removing the Distributor
- Installing the Distributor
- Distributor Disassembly and Assembly
INSTRUMENT POD9 topics
- Description & Specifications
- Fuel Gauge Failure
- Coolant Temperature Gauge Failure
- Indicator Light Failure
- Hour Meter Failure
- Buzzer Failure
- Key-On Horn Failure
- Shut-Down Mode Failure
- Removal and Installation
ELECTRICAL SYSTEM22 topics
- Specifications & Wire Diagrams
- System Specifications
- Wiring Color Codes
- Starter and Battery
- General Information
- Minimum Tools Required
- Starting System Inspection
- Electrical Checks
- Volt Drop Tests
- Alternator
- Alternator Maintenance Precautions
- Troubleshooting Procedures
- Symptoms, Causes, and Remedies
- Starter Maintenance and Overhaul
- External Inspection
- Installation and Removal
- Bench Tests and Adjustments
- Overhaul
- Alternator Maintenance
- External Inspection
- Installation and Removal
- Overhaul
WHEELS AND TIRES11 topics
- Cushion Wheels and Tires
- General Cushion Tire Maintenance
- Drive Wheel Removal/Installation
- Steer Wheel Removal/Installation
- Cushion Tire Replacement
- Pneumatic Wheels and Tires
- Pneumatic Tire Maintenance Precaution
- General Tire Maintenance, Inspection, & Repair
- Wheel Dismounting and Remounting
- Wheel Disassembly and Tire Removal
- Tire Replacement and Wheel Reasembly
BRAKE/INCHING SYSTEM (Hydrostatic Trans)14 topics
- Brake/Inching Pedals, Linkages, & Adjustments
- Brake Pedal Height Adjustment
- Overlap Adjustment
- Freeplay Adjustment
- Linkage and Sensor Installation
- Brake System Bleeding
- Master Cylinder Overhaul
- Service Brake Adjustment and Overhaul
- External Inspection
- Shoe-to-Drum Gap Adjustment
- Internal Inspection and Repair
- Wheel Cylinder Overhaul
- Brake Assembly Removal & Installation
- Parking Brake Service
BRAKE SYSTEM (STANDARD TRANSAXLE)25 topics
- Specifications
- General Description
- Inching Operation
- Braking Operation
- Service Requirements
- Service Brake Troubleshooting
- Brake/Inching Pedals and Linkage Adjustments
- Introduction
- Pedal Height Adjustment
- Overlap Adjustment
- Brake Yoke Adjustment
- Inching Cable Adjustment
- Bleeding
- Brake Valve Service
- Brake Valve Removal
- Brake Valve Replacement
- Brake Valve Overhaul
- External Inspection
- Shoe-to-Drum Gap Adjustment
- Internal Inspection and Repair
- Brake Shoe Removal
- Cylinder Removal and Replacement
- Adjuster Removal and Replacement
- Wheel Cylinder Overhaul
- Brake Assembly Removal, and
STEERING COLUMN AND GEAR9 topics
- Steering System Troubleshooting
- Steering Column and Component Removal and Replacement
- Steering Column and Component Removal
- Steer Column and Component Replacement
- Steering System Relief Pressure Check and Adjustment
- Steering Gear Overhaul
- Disassembly
- Parts Inspection
- Reassembly
STEER AXLE18 topics
- Wheel Bearing Maintenance and Adjustment
- Wheel Bearing Check
- Wheel Bearing Lubrication
- Wheel Bearing Adjustment
- Steer Axle Removal and Replacement
- Steer Axle Removal
- Steer Axle Replacement
- Steer Axle Overhaul
- Preparation For Steer Axle Disassembly Overhaul
- Steer Axle Disassembly
- Steer Axle Reassembly
- Steer Cylinder Removal and Replacement
- Steer Cylinder Overhaul
- Preparation for Steer Cylinder Disassembly
- Steer Cylinder Disassembly
- Parts Inspection
- Steer Cylinder Reassembly
- Operational Pressure Test
HYDRAULIC SUMP, FILTERS, AND PUMP12 topics
- Main Hydraulic Pump Troubleshooting
- Hydraulic Filters and Fluid Maintenance and Change
- Hydraulic Sump Fluid Level Check
- Hydraulic Filters Change
- Hydraulic Fluid Change
- Check Operation of Hydraulic System
- Hydraulic Pump Removal and Replacement
- Hydraulic Pump Overhaul
- Preparation for Pump Disassembly
- Pump Disassembly
- Parts Inspection
- Pump Reassembly
HYDRAULIC CONTROL VALVA/LIFT CIRCUIT12 topics
- Hydraulic System Schematics
- Hydraulic System Troubleshooting
- Hydraulic System Pressure Checks and Adjustments
- Hydraulic Control Valve Removal & Replacement
- Hydraulic Control Valve Removal
- Hydraulic Control Valve Replacement
- Hydraulic Control Valve Overhaul
- Preparation for Disassembly
- Disassembly
- Cleaning, Inspection, and Repair
- Reassembly
- Relief Valve Settings
TILT CYLINDERS6 topics
- Drift Check
- Racking Check
- Tilt Flow Control Adjustments
- Removal
- Parts Inspection
- Replacement
Show all 27 sections
UPRIGHTS31 topics
- Upright Specifications and Description
- Inspection
- Basic Visual Inspection
- Extended Inspection
- Carriage and Upright Roller Clearance Checks
- Introduction
- Roller Side Clearance Checks
- Directions for Checking Specific Rollers
- Internal Thrust Roller Adjustment
- Oversize Rollers
- Lift Roller Shimming
- Upright Roller Shimming
- Overshimming
- Cylinder Removal, Shimming, Overhaul, and Replacement
- Cylinder Types
- Lift Cylinder Shimming Procedure
- Primary Cylinder Removal and Replacement (TSU Only)
- Lift and Secondary Cylinder Removal and Replacementl
- Cylinder Overhaul
- Upright Chain Inspection, Adjustment, and Replacement
- Periodic Inspections
- Standard Upright Chain Length Adjustment
- Triple-Stage Upright (TSU) Chain Length Adjustments
- Chain Lubrication
- Chain Removal and Replacement
- Lift Chains (Standard and TSUs)
- Other Chain Service Notes
- Fork and Carriage Removal and Replacement
- Upright Removal and Replacement
- Upright Removal
- Upright Replacement
COUNTERWEIGHT AND CHASSIS5 topics
- 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
SPECIFICATIONS6 topics
- Nameplates and Decals
- General Specifications
- Weights and Performance Specifications
- Critical Fastener Torque Specifications
- Group Specifications
- Hydraulic Fitting Tightening Procedure
Inside this manual
Real pages from this service manual (961 pages). Open the sample pages (PDF, 290 KB)
- Troubleshooting, page 195: Group 00(G), Engine (Gas)
- Specifications, page 881: Group 34, Uprights
- Foldout diagram
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 961 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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Binder not included
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Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).