Clark CGC 20-30, CGP 20-30, CDP 20-30 Forklift Workshop Service Repair Manual

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM498S CGC, CGP, CDP 20-30 Shop Manual VOLUME 1 OF 2, GROUPS 00 - 03

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Truck Models Covered by this Manual This manual consists of a “base” module that pertains to ail Genesis models and other modules that pertain only to You may, however, purchase specific modules and expand specific models. Manuals shipped with the truck contain your manual to fully cover multiple models. To do so, the base module and the modules specific to the purchased order the desired modules as you would any other Clark part. truck. Arrangement and Use of this Manual Clark armuges parts and service procedures by standard- ized Groups. In this manual, Groups are similar to “chap- ters.” Groups are listed in the indexes on the next page. Each Group begins with a table of contents that shows the You can quickly locate a specific point in the manual by using the headers and footers that appear on every Section page. The following illustration points out these areas. Sections contained within the Group. Lengthy Sections also begin with a table of contents. Each Group and Section has an identifying name and number, or “ID.” Each page also has a unique ID The page ID consists of three numbers separated by hyphens. The three numbers represent the Group number, the Section number, and the page number. For example, “00-1-2” on the lower comer ns In Section ID / Mania, ID \ Section ID of the page indicates Group 00, Section 1, Page 2. The Group number sometimes has a letter or letters added to it in parentheses if one or more variations of the Group This manual is intended for the use of trained service exist. For example, if the truck has a standard transaxle, personnel. Please read Group SA, “Safe Maintenance,” Group 06 is expressed as “06(S);” if the truck has a hydro- and the Operator’s Manual before working on or operat- static transmission, Group 06 is expressed as “06(H).” ing the truck. 0 Copyright Clark Material Handling 1994 SM 598,Oct ‘94

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute CONTENTS Group SA. Safe Maintenance Group PS. Periodic Service Group 00. Engines Group 01. Cooling System Groupo2. Fuel System Group 03. Air Induction System Group 06. Transmission Group 12. Ignition System Group w. Instrument Pod Group 14. Electrical System Contents of this Manual Group Index Group 34. Uprights Y Group 22. Group 23. Group 25. Group 26. Group 29. Group 30. Group 32. Group 34. Group 38. Group 40. Alphabetical Index (SEE NEXT PAGE) Pictorial Index Wheels and Tires Brake System Steering Column and Gear Steer Axle Hydraulic Pump, Sump, and Filters Hydraulic Control Valve/Lii Circuit Tilt Cylinders uprights Counterweight, Sheet Metal, & Chassis Specifications Group 32. Tilt Cylinders \ n n /Group 06. Transmission II / Group 23. Brake/Inching System SM 598, Apr ‘96 Contents-l

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute GROUP SA GROUP SA SAFE MAINTENANCE Safety ............................................................................... Section 1 Lifting, Jacking, and Blocking the Truck ..................... Section 2 Towing .............................................................................. Section 2 SM 598, OCT ‘94 Safe Maintenance

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute CMRK Group SA, Safe Maintenance Section 1. Safety Safety Signs and Messages Safe Maintenance Practices Safety signs and messages in this manual and on the lii truck provide instructions and identify specific areas where potential hazards exist and special precautions should be taken. Be sure you know and understand the meaning of these instructions, signs, and messages. Damage to the truck, death, or serious injury to you or other persons may result if these messages are not followed. NOTE This message is used when special information, instructions or identification is required relating to procedures, equipment, tools, pressures, capacities, and other special data. The following instructions have been prepared from cur- rent industry and government safety standards applicable to industrial truck operation and maintenance. These rec- ommended procedures specify conditions, methods, and accepted practices that aid in the safe maintenance of industrial trucks. They are listed here for the reference and safety of all workers during maintenance operations. Care- fully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please con- tact your local Clark dealer. 1. IMPORTANT Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities, trained personnel, and procedures must be provided This message is used when special precautions should be taken to ensure a correct action or to avoid damage to, or malfunc- tion of, the truck or a component. 2. Maintenance and inspection of all powered industrial trucks shall be done in conformance with the manufacturer’s recommendations. 3. A CAUTION This message is used as a reminder of safety hazards that can result in personal injury if proper precautions are not taken. 4. A scheduled planned maintenance, lubrication, and inspection program shah be followed. Only trained and authorized personnel shah be permit- ted to maintain, repair, adjust, and inspect industrial trucks. Work should be performed in accordance with the manufacturer’s specifications. A WARNING This message is used when a hazard exists that can result in injury or death if proper precautions are not taken. 5. 6. A DANGER This message is used when an extreme hazard exists that can result in injury or death or serious injury if proper precautions are not taken. Properly ventilate work area vent exhaust fumes, and keep shop clean and floor dry. Avoid fire hazards and have fire protection equipment present in the work area Do not use an open flame to check for level or leakage of fuel, electrolyte, or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. 7. The above terms have been adopted by Clark Material Handling Company. The same terms may be used in differ- ent context in service literature supplied directly or indi- rectly by vendors of truck components. Before starting work on truck: a. Raise drive wheels off of floor or disconnect power source and use blocks or other positive truck positioning devices. b. Disconnect battery before working on the electrical system. 8. Before working on engine fuel system of gasoline- or diesel-powered trucks, be sure the fuel shut-off valve is closed. SM 598,Oct ‘94 Safety l SA-l-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Group SA, Safe Maintenance EUIRK 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Operation of the truck to check performance must be conducted in an authorized, safe, clear area. Before starting to drive truck: a. Be in operating position. b. Be sure parking brake is engaged. c. Put direction control in neutral. d. Start engine. e. Check functioning of direction and speed controls, steering, brakes, warning devices, and any load handling attachments. 19. 20. 21. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturer’s prior written approval. Capacity, operation and maintenance instruction plates, tags, or decals must be changed accordingly. This is an OSHA requirement. Care must be taken to assure that all replacement parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment. Parts, including tires, are to be installed per the manufacturer’s procedures. Always use genuine CLARK or CLARK-approved parts. Before leaving truck a. Stop truck. b. Put directional control in neutral. c. Apply the parking brake. d. Stop the engine by turning off the ignition circuit. e. Put blocks at the wheels if truck is on an incline. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, guards, safety devices, and frame members must be carefully and regu- larly inspected and maintained in a safe operating condition. Use special care when removing heavy components from the truck, such as counterweight, seat deck, upright, etc. Be sure that lifting and handling equipment is of the correct capacity and in good condition. Also, this removal may upset the stability of the truck. The frame must always be safely blocked for major component removal. NOTE Special trucks or devices designed and approved for hazardous area operation must receive special attention to ensure that maintenance preserves the original, approved, safe-operating features. You should also be familiar with additional operating and maintenance safety instructions contained in the following publica- tions: Fuel systems must be checked for leaks and condition of parts. Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected. ANSVASME B56.1- 1988 Operator Control-Industrial Tow Tractors (Safety Standard For Powered Industrial Trucks). Published by: Society of Mechanical Engineers, United Engineering Center, 345 E. 47th Street, New York, NY 10017. The truck manufacturer’s capacity, operation, and maintenance instruction plates, tags, or decals must be maintained in legible condition. NFPA 505-1982: Fire Safety Standard for Powered Indus- trial Trucks: Type Designations, Areas of Use, Mainte- nance and Operation. Available from: National Fire Protection Assoc., Inc., Batterymarch Park, Quincy, MA 02269. Batteries, motors, controllers, limit switches, protec- General Industrial Standards, OSHA 2206: OSHA Safety tive devices, electrical conductors, and connections and Health Standards (29 CFR 1910), Subpart N-Materials must be inspected and maintained in conformance Handling and Storage, Section 1910.178 Powered Indus- with good practice. Special attention must be paid to trial Trucks. For sale by: Superintendent of Documents, the condition of electrical insulation. U.S. Government Printing Office, Washington, DC 20402. To avoid injury to personnel or damage to the equipment, consult the manufacturer’s procedures in replac- ing contacts on any battery connection. Industrial trucks must be kept in a clean condition to minimize fire hazards and help in the detection of loose or defective parts. SA-1-2 l Safety SM 598,Oct ‘94

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute CMRK Group SA, Safe Maintenance Lifting, Jacking, and Blocking 3 Safe Parking ................................................................................................................................... .& Lifting, Jacking, and Blocking Points .......................................................................................... 2 Raising Drive Wheels Off Floor .................................................................................................... 2 Raising Truck with A Hoist .......................................................................................................... 3 Blocking the Upright in Raised Position ...................................................................................... 4 Raising Rear of Truck ................................................................................................................... 4 Section 2. Raising Entire Truck ... ...... ........... ....... .................................... ...... ...... ....................................... ... 5 Shipping Tie-Down Instructions ......... ........ . ... .......... .......................... .................. ........... ............. 6 A WARNING Lifting or jacking any large piece of equipment such as your fork truck presents obvious hazards. It must be done with great care and forethought. Consult the truck weight tabulations in Group 40, “Specifications” to ensure that your lifting equipment is of adequate capacity. SM 598,Oct ‘94 Lifting, Jacking, and Blocking l SA-2-1

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Group SA, Safe Maintenance CUlRK Safe Parking Before working on truck: 1. Park truck on a hard, level, and solid surface, such as a concrete floor with no gaps or breaks. 2. Put upright in vertical position and fully lower the forks or attachment. 3. Put all controls in neutral. Turn key switch OFF and remove key. 4. Apply the parking brake and block the wheels. A WARNING Defective equipment can cause accidents. All tools and lifting equipment must be in good condition, meet the load capacity re- quirements and have OSHA labels when required. Tools with defects can have fail- ures causing severe injury or death. Lifting, Blocking,and JackingPoints Use the following illustration to locate general lifting, blocking, and jacking points on the truck. Read the procedures for raising, blocking, or jacking specific components of the truck to make sure you understand the correct, safe procedures. ‘hnder Steer \L Under Frame L Under Upright Axle Frame Mount A WARNING Do not attempt to lift the truck by the overhead guard or the counterweight. Severe injury may result and the truck can be damaged. Raising Drive Wheels Off Floor This procedure uses the upright as a lever to lift the drive wheels off the floor and prevent accidents due to inadvert- ent powering of the drive wheels. Park truck safely as described in “Safe Parking.” Block steer wheels. Be sure upright trunnion bolts are tight. Bolt torques must be 75-80 Nom (55-59 ft-lb). Start the engine. Tilt the upright fully back. Adjust upright height as necessary to put blocking underneath the lower end of the upright. Put a solid 100 x 100 mm (4 x 4 in) hardwood block under the front section of each upright rail. Put a 3-6 mm (.125-.250 in) steel plate on top of each block. 5. Tilt upright fully forward. This raises the drive wheels off the floor. Release the tilt control lever and turn engine OFF. SA-2-2 . Lifting, Jacking, and Blocking SM 598,Oct ‘94

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ClRRK Group SA, Safe Maintenance 6. Insert blocking under the frame behind the drive wheels or slip wheel cradles under the drive wheels. If using blocking, check for safe clearance between drive wheels and floor and blocks. 7. 8. NOTE When forks are raised as in illustration above, use shop rags, paper, or bright tape on fork tips to signal the danger of trip- ping. Check for stable condition of the truck. Be sure that the blocks are located securely under the truck frame before operating the drive or working on truck. Lower the drive wheels to the floor and remove the blocks by reversing the above procedure. Raising Truck with A Hoist When suitable equipment is available, the front of the truck may be raised by means of a hoist, with wheel cradles placed under the wheels or blocking placed under the frame. n ! CAUTION When lifting the front of the truck watch truck for signs of lateral instability. It may tip sideways. You may have to support or guide the side of the truck or overhead guard to prevent tipping. 1. Park truck safely as described in “Safe Parking.” Block rear steer wheels. 2. Check trunnion bolts to make sure they are tightened to correct torque. Bolt torques must be 75-80N.m (55-59 ft-lb). 3. To raise the front of the truck using the upright, spread two chains on the outer rail tiebar of the upright. 4. A WARNING Chain and hoist used to lift truck should be checked to make sure they are of safe Iift- ing capacity. See the truck data plate for information. Slowly lift truck and lower drive wheels onto the cradles or place blocking under frame prop points. 5. When maintenance work is completed, lower the truck to the floor by reversing the lifting procedure. Check to be sure no tools or equipment are under the truck or wheels. SM 598,Oct ‘94 Lifting, Jacking, and Blocking l SA-2-3

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Group SA, Safe Maintenance ClmK Blocking the Upright In Raised Position This procedure is used to safely provide clearance for access from the front of truck to components on or near the drive axle. Illustrations show upright with forks removed however, fork removal is not necessary 1. 2. 3. 4. 5. 6. Park truck safely as described in “Safe Parking.” Put blocks in front of and behind drive wheels. Put wooden support blocks conveniently near upright rails before raising the upright. Use two 100 x 100 mm (4 x 4 in) hardwood blocks or equal, of about 300 x 300 mm (12 in) and 600 x 600 mm (24 in) length. NOTE For standard uprights, block may need length cut to suit. For triple stage uprights, the carriage may be blocked up, as shown. Start engine and raise the upright carriage. Hold the taller block against inner rail and lower the upright until carriage rests on block. Outer Rail Hold the shorter block against the outer rail and lower the upright until inner rail rests on the block. Outer Rail II II ” Al /II/l e Carriage .* II I Short Block 7. Reverse the procedure to remove blocking. Raising Rear of Truck The truck may be raised at the rear by jacking and blocking under the center of the frame member at either the front or rear steer axle mounting, or under the center section of the steer axle. Refer to truck data plate for truck weights. 1. A WARNING An incorrectly installed counterweight can move or fall unexpectedly. Never lift or block a truck using the counterweight. Fail- ure to follow procedures outlined in this manual can result in injury or death. Park truck safely as described in “Safe Parking.” Put blocks at front and rear of drive wheels. SA-2-4 l Lifting, Jacking, and Blocking SM 598,Oct ‘94

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Clark CGC 20-30, CGP 20-30, CDP 20-30 Forklift Workshop Service Repair Manual

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