Clark CGC 40, CGC 70, CGP 40, CGP 70 Forklift Workshop Service Repair Manual

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute SM-612 Rv 1 CGCKGP 40/70 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Clark arranges parts and service procedures by standard- You can quickly locate a specific point in the manual by ized Groups. In this manual, Groups are similar to “chap- using the headers and footers that appear on every Section ters.” Groups are listed in the indexes on the next page. page. The following illustration points out these areas. Each Group begins with a table of contents that shows the Sections contained within the Group. Lengthy Sections also begin with a table of contents. Group ID Each Group and Section has an identifying name and number, or “ID.” Each Section 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, “OO-l-2” on the lower corner of the page indicates Group 00, Section 1, Page 2. Page ID Section ID’ Manual ID ’ Section ID The Group number sometimes has a letter or letters added to it in parentheses if one or more variations of the Group exist. For example, if the truck has a standard transaxle, Group 06 is expressed as “06(S);” if the truck has a hydro- static transmission, Group 06 is expressed as “06(H).” This manual is intended for the use of trained service personnel. Please read Group SA, “Safe Maintenance,” and the Operator’s Manual before working on or operating the truck. 0 Copyright Clark Material Handling 1996 SM 612, Jun ‘97 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute CONTENTS Contents of this Manual Group Index Group SA. Safe Maintenance Group PS. Periodic Service Group 00. Engines Group 01. Cooling System Group 02. Fuel System Group 03. Air Induction System Group 06. Transmission Group 12. Ignition System Group 13. Instrument Pod Group 14. Electrical System Group 22. Group 23. Group 25. Group 26. Group 29. Group 30. Group 32. Group 34. Group 38. Group 40. Wheels and Tires Brake System Steering Column and Gear Steer Axle Hydraulic Pump, Sump, and Filters Hydraulic Control Valve/Lift Circuit Tilt Cylinders Uprights Counterweight, Sheet Metal, & Chassis Specifications Alphabetical Index (SEE NEXT PAGE) Pictorial Index Group 34. Uprights Group 06. Transmission / /’ Group 32. Tilt Cylinders Group 23. Brake/Inching System Group 30. Hydraulic Control Valve Group 29. Hydraulic Pump, Sump, Group 03. Air Induction System “‘\,,,Group 12. Ignition System Sheet Metal, & Chassis Group 26. Steer Axle SM 612, Jun ‘97 Contents-l Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Alphabetical Index Air Induction System Alternator Brake System Carburetor Cooling System Counterweight Drive Axle Electrical System Engines Fuel System Hydraulic Control Valve Hydraulic Pump, Filters Inching System Instrument Panel (Pod) Jacking & Blocking Lift Cylinder Oil Change Planned Maintenance Radiator Safety Sheet Metal, & Chassis Shop Supplies Specifications Starter Steer Axle Steering Column and Gear Tilt Cylinders Transmission Tune-Up Uprights Water Pump Wheels/Tires Group 03 Group 14 Group 23 Group 02 Group 01 Group 38 Group 06 Group 14 Group 00 Group 02 Group 30 Group 29 Groups 23,06 Group 13 Group SA Group 34 Group 00 Group PS Group 01 Group SA Group 38 Group 40 Group 40 Group 14 Group 26 Group 2.5 Group 32 Group 06 Group 00 Group 34 Groups 01,OO Group 22 Contents-2 SM 612, Jun ‘97 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute GROUP PS PERIODIC SERVICE Maintenance Schedules .................................................. Section 1 The Planned Maintenance Program ............................. Section 2 The PM Inspection Form ............................................... Section 3 SM 612, Jun ‘96 Periodic Service Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute CIRRK Group PS, Periodic Service Sect ion 1. Maintenanc e Schedules “PeriodicService”and “Planned Maintenance” The term “periodic service” includes all maintenance tasks that should be performed on a regularly scheduled basis. The term “Planned Maintenance” indicates a formalized program of basic inspections, adjustments, and lubrications that the Clark service organization provides customers at a prescribed interval, usually 50-250 hours. The recommended basic “Planned Maintenance” procedure is given in Section 2 of this Group. The current Section,“Maintenance Schedules,” specifies all maintenance tasks-including Planned Maintenance tasks-that should be performed periodically, and suggests intervals at which they should be performed. DeterminingMaintenanceIntervals Time intervals on the charts on the next four pages and elsewhere in this manual relate to truck operating hours as recorded on the hourmeter, and are based on experience Clark has found to be convenient and suitable under normal operation. Standard operating condition classifications are: Normal Operation: Eight-hour material handling, mostly in buildings or in clean, open air on clean, paved surfaces. Severe Operation: Prolonged operating hours or constant usage. Extreme Operation: In sandy or dusty locations, such as cement plants, lumber mills, and coal dust or stone crushing sites. High-temperature locations, such as steel mills and foundries. Sudden temperature changes, such as constant trips from buildings into the open air, or in refrigeration plants. If the lift truck is used in severe or extreme operating conditions, the maintenance intervals should be shortened accordingly. IMPORTANT MAINTENANCE INTERVALS. If the lift truck is used in severe or extreme operating conditions, the maintenance intervals should be shortened accordingly. Since the operating environments of lift trucks vary widely, the above descriptions are highly generalized and should be ap- plied as actual conditions dictate. SM 612, Jun ‘96 Maintenance Schedules l PSI-1 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Group PS, Periodic Service CICIRK Service Chart/Lubrication Points A decal, similar to the illustration below, is located on the underside of the truck’s engine cover. This decal is a basic guide to periodic maintenance intervals and tasks. A more detailed chart is supplied on the next page. Every 8 - 10 hours or daily Every 50 - 250 hours or monthly ____---_---------------- ---_ / ’ EVI 450 - 500 hours or eves months --- ’, -- -- --- / /-- Evey900 6 months --L - I i _ -------- 1000 hours or every --- \ \ , ’ I I”/ Every 2000 hours or every year 0 Check I Lubricate Change or Replace Clean / Air Clean 0 Drain / Flush 0 Check 0 Monitor Indicator Lights and Service as Required A - Engine Oil 15W40 B - Hydraulic Oil C - Engine Coolant D - MP Grease E - Transaxle Fluid API, CC, CD / SG, SF Clark # 2776239 50 / 50 Mixture NLG#2 Clark # 2776236 l intervals refer to elapsed hour meter time and are based on Clark’s experience found to be suitable and convenient under normal operating conditions. l Service and Maintain as per Service and Operator Manuals. Special or harsh conditions may need additional intervals. PSl-2 . Maintenance Schedules SM 612, Jun ‘96 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute CIRRK Group PS, Periodic Service Recommended Periodic Service Schedule This chart lists maintenance tasks that should be done periodically, the suggested time intervals, and the service manual Group in which the task is covered. Apply as appropriate for diesel, gas, and LFG trucks. Operators shou refer to Operator’s Manual for Daily Checks. * Oil change interval may be determined by laboratory analysis SM 612, Jun ‘96 Maintenance Schedules l PS-1-3 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute Group PS, Periodic Service elmu Air filter element - replace Air hoses/clamus - insnect Group 02 - Air Intake & Exhaust I I . I I I . 1 Exhaust pipe/muffler - inspect l I l I I I I Air vent - inspect, clean or replace on standard transaxle Group 06 - Transaxle . Axle end lube - clean/repack During brake repairs Axle mounting bolts - inspect/tightej Charging pump - stall test standard transaxle Clutch pack operation - stall test standard transaxle Pressure checks . . . . Fluid change - dram/fill Fluid filter - replace . . Fluid level/condition - check/sample . . Inching operation - check/test Oil cooler / lines - inspect Transmission strainer - clean on . . . standard transaxle I I I I I Group Z2 - Ignition and Starting System i Diesel cold starting plug - test Distributor cap/rotor - inspect Electronic ignition - test . . . Ignition timing - check/adjust I . I Ignition wiring - inspect I . I I I Neutral start - check I . I Parking brake interlock - check Spark plugs - regap/replace . . Starter motor - inspect/test I I . Starter solenoid - inspect/test I I I . Hourmeter - check Lamp check - at start-up Wiring harness - inspect I I I I I Group 13 - Gauges, Indicators . . . Group 14 - Electrical: Alternator, Regulator, Battery Alternator - inspect/test . Alternator drive belts - inspect/adjust . . Alternator output - test . Battery electrolyte level - check/add Battery condition - cranking voltage . . test Battery terminals/cables - . clean/tighten Group 22 - Wheels And Tires Wheel mounting bolts - tighten I . I . I I I Tire pressure/condition - check I . I . I I PS-1-4 l Maintenance Schedules SM 612, Jun ‘96 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute CIRRU Group PS, Periodic Service Steer axle mounting - inspect Steer wheel bearings - check Steer wheel bearings - lubricate/adjust Steering cylinder seals - check leakage Steering linkage - lubricate . . . Group 29 - Hydraulic Pump, Sump, and Filter Hydraulic fluid level/condition - check/sample Hydraulic fluid change - drain/fill Hydraulic suction screen - clean Hydraulic fluid filter - replace . . . . . Hydraulic tank breather - . . clean/replace Group 30 - Hydraulic Valve & Linkage Hydraulic system relief pressure - I I I I I . test/adjust I I I I I Group 32 - Tilt Cylinders Tilt cylinder adjustment - . check/adjust Tilt cylinder drift - test . Tilt cylinder mounting - . check/tighten Tilt cylinder rod ends - . check/tighten/lubricate Tilt cylinder rod/seals - check for . leaks SM 612, Jun ‘96 Maintenance Schedules l PS-1-5 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Clark CGC 40, CGC 70, CGP 40, CGP 70 Forklift Workshop Service Repair Manual

You're Reading a Preview

Recently Viewed