Clark CGC CGP CDP 20-30 Forklift Shop Manual – Service, Repair & Specifications PDF

Description

Clark CGC CGP CDP 20-30 Forklift Shop Manual – Service, Repair & Specifications PDF

The Clark CGC CGP CDP 20-30 Forklift Shop Manual – Service, Repair & Specifications PDF is a large technical workshop reference for CLARK CGC, CGP and CDP 20-30 lift trucks. It combines maintenance schedules, troubleshooting, inspection procedures, adjustments, component removal and installation, overhaul information, hydraulic and electrical schematics, service limits, torque data and truck specifications in one 961-page PDF. The manual addresses both standard transaxle and hydrostatic transmission configurations and includes gasoline, LPG/CNG and diesel engine service information shown in the publication.

File Details

• Manual type: Shop Manual
• Brand: CLARK
• Models: CGC, CGP, CDP 20-30
• Language: English
• Page count: 961 pages
• File format: PDF
• Publication identification: SM 598 / SM-598S markings appear throughout the manual
• Cover identification: Volume 1 of 2, Groups 00-03
• Publication dates visible in the file: October 1994, April 1996 and February 1998 revisions/pages

Equipment and Powertrain Coverage

This Clark CGC CGP CDP 20-30 shop manual covers the 20, 25 and 30 model families and includes procedures for the standard transaxle as well as the hydrostatic drive system used on the H variants. Engine material includes the Mitsubishi S4S diesel engine, Mitsubishi 4G64 gas/LPG/CNG engine and General Motors 3.0L LPG engine. The S4S section incorporates detailed engine specifications, maintenance standards, special tools, disassembly, inspection, repair and reassembly procedures. The file also contains dedicated fuel-system sections for carbureted LPG and gasoline systems, plus cooling, ignition, electrical and air-induction material.

The cover identifies the publication as Volume 1 of 2, Groups 00-03. The PDF file itself also contains later service groups through Group 40, including transmission, ignition, electrical, wheels and tires, brakes, steering, hydraulics, uprights, chassis and general specifications. That broader content makes this copy useful for work extending well beyond engine and fuel-system service.

Chapters Covered

• Group SA – Safe Maintenance
  • Safety signs and safe maintenance practices
  • Lifting, jacking, blocking and towing procedures
• Group PS – Periodic Service
  • Maintenance schedules and service intervals
  • Planned Maintenance Program and inspection procedures
  • PM inspection report
• Group 00(D) – S4S Diesel Engine
  • Engine oil and filter, throttle linkage and fuel supply
  • RPM settings, stall tests, compression checks and engine removal
  • Mitsubishi S4S engine service information, maintenance standards and special tools
  • Cylinder head, valves, timing gears, camshaft, pistons, crankshaft, lubrication, cooling, fuel and electrical systems
  • Engine troubleshooting, overhaul and balancer supplement
• Group 00(G) – 4G64 Gas/LPG/CNG Engine
  • Specifications and description
  • Troubleshooting, oil and filter, tune-up and RPM/vacuum/stall checks
  • Compression checks, removal and replacement, and overhaul
• Group 00(GM) – General Motors 3.0L LPG Engine
  • Specifications and description
  • Troubleshooting, engine oil and filter, tune-up and performance checks
  • Compression test, engine removal/replacement and overhaul
• Group 01 – Engine Cooling System
  • Cooling system specifications and troubleshooting
  • Testing, maintenance, belt service and radiator removal/replacement
• Group 02(LP) – LPG Fuel System
  • System specifications and troubleshooting
  • Adjustments and maintenance
  • Carburetor, throttle body, vaporizer and fuel-lock overhaul
• Group 02(G) – Gasoline-Carb Fuel System
  • Specifications, description and troubleshooting
  • Checks and adjustments
  • Carburetor overhaul, fuel pump and filter service
• Group 03 – Air Induction and Exhaust Systems
  • Specifications and system description
  • Air-induction troubleshooting and service
  • Exhaust-system service
• Group 06(S) – TA-30 Standard Transaxle
  • Specifications, troubleshooting, oil/filter and oil cooler
  • Removal and replacement, transaxle overhaul, drive axle ends and control valve
• Group 06(H) – Hydrostatic Transmission
  • Transmission specifications and description
  • Control-system troubleshooting, diagnostic control and adjustment
  • Component removal, drive pump and drive motor service, drive axle ends
• Group 12 – Ignition System
  • Specifications, troubleshooting, inspection, adjustment and timing
  • GM 3.0L ignition timing and distributor overhaul
• Group 13 – Instrument Pod
  • Description and specifications
  • Troubleshooting, removal and installation
• Group 14 – Electrical System
  • Electrical specifications and wiring diagrams
  • Starter, battery and alternator troubleshooting
  • Starter and alternator maintenance and overhaul
• Group 22 – Wheels and Tires
  • Specifications and description
  • Cushion and pneumatic wheel/tire service
• Group 23 – Brake/Inching System
  • Standard and hydrostatic brake/inching coverage
  • Service brake troubleshooting, pedal/linkage adjustment, bleeding and overhaul
  • Master cylinder and parking brake service
• Group 25 – Steering Column and Gear
  • Steering specifications, checks, adjustments and component service
• Group 26 – Steer Axle
  • Steer axle specifications, inspection and service procedures
• Group 29 – Hydraulic Sump, Filters and Pump
  • Specifications, hydraulic-pump troubleshooting and fluid/filter maintenance
  • Pump removal, replacement and overhaul
• Group 30 – Hydraulic Control Valve/Lift Circuit
  • Specifications and hydraulic system schematics
  • Troubleshooting, pressure checks and adjustments
  • Control-valve removal, replacement and overhaul
• Group 32 – Tilt Cylinders
  • Specifications, checks and adjustments
  • Cylinder removal, replacement and overhaul
  Complete PDF Bookmark Tree

  Complete Bookmarks

  The complete bookmarks in the “Clark CGC CGP CDP 20-30 Forklift Shop Manual – Service, Repair & Specifications PDF” are as follows:

  Title Pagep. 1

  Use of this Manualp. 2

  Contentsp. 3

  +SAFE MAINTENANCEp. 4

  Section 1. Safetyp. 5

  +Lifting, Jacking, and Blockingp. 7

  Safe Parkingp. 8

  Lifting, Blocking, and Jacking Pointsp. 8

  Raising Drive Wheels Off Floorp. 8

  Raising Truck with A Hoistp. 9

  Blocking the Upright In Raised Positionp. 10

  Raising Rear of Truckp. 10

  Raising Entire Truckp. 11

  Shipping Tie-Down Instructionsp. 12

  Towingp. 13

  +PERIODIC SERVICEp. 15

  +Maintenance Schedulesp. 16

  “Periodic Service”p. 16

  Determining Maintenance Intervalsp. 16

  Service Chart/Lubrication Pointsp. 17

  Recommended Periodic Service Schedulep. 18

  +The Planned Maintenance Programp. 21

  introduction to Planned Maintenancep. 22

  The Basic PM Proceduresp. 22

  Recommended PM Task Chartp. 23

  Visual Inspectionp. 24

  Functional Testsp. 25

  Air Cleaning the Truckp. 27

  Truck Chassis Inspection and Lubricationp. 28

  Upright and Tilt Cylinder Lubricationp. 28

  Lift Chain Lubricationp. 28

  Under-the-Hood inspectionp. 28

  Fluid Checksp. 28

  Stall Testp. 29

  Cranking Voltage Testp. 29

  Critical Fastener Torque Checksp. 29

  The PM Inspection Formp. 30

  +S4S DIESEL ENGINEp. 31

  Engine Oil and Filterp. 32

  Throttle Linkage Checks and Adjustmentp. 34

  . Fuel Supply Systemp. 36

  RPM Settings and Stall Testsp. 37

  Engine Removal and Replacementp. 39

  +S4S Diesel Engine Service Manualp. 45

  HOW TO USE THIS MANUALp. 46

  +GENERALp. 48

  SPECIFICATIONSp. 49

  SECTIONAL VIEWSp. 52

  PERFORMANCE CURVESp. 56

  +MAINTENANCE STANDARDSp. 58

  MAINTENANCE STANDARDSp. 59

  TIGHTENING TORQUEp. 68

  SEALANT APPLICATION DATAp. 72

  SPECIAL TOOL LISTp. 73

  +ENGINE PROPERp. 76

  CYLINDER HEAD AND VALVE MECHANISMp. 77

  TIMING ‘GEARS, CAMSHAFT AND OIL PANp. 92

  FLYWHEELp. 105

  PISTONS, CONNECTING RODS, CRANKSHAFT AND CRANKCASEp. 111

  +INLET AND EXHAUST SYSTEMSp. 135

  DESCRIPTIONp. 136

  EXHAUST MANIFOLDp. 136

  +LUBRICATION SYSTEMp. 137

  DESCRIPTIONp. 138

  Oil Pumpp. 139

  OIL FILTERp. 144

  RELIEF VALVEp. 145

  +COOLING SYSTEMp. 146

  DESCRIPTIONp. 147

  PUMPp. 148

  THERMOSTATp. 149

  +FUEL SYSTEMp. 150

  DESCRIPTIONp. 151

  FUEL FILTERp. 155

  INJECTION NOZZLESp. 156

  INJECTION PUMPp. 160

  +ELECTRICAL SYSTEMp. 163

  STARTERp. 164

  ALTERNATORp. 172

  HEATER PLUGSp. 177

  +WORKSHOP THEORYp. 178

  SUGGESTIONS ON DISASSEMBLY ANDp. 179

  TESTING THE COMPRESSIONp. 182

  +TROUBLESHOOTINGp. 183

  TROUBLESHOOTING CHART (1)p. 184

  TROUBLESHOOTING CHART (2)p. 188

  Balancer for S4S Diesel Enginep. 191

  +4G64 GAS/LPG/CNG ENGINEp. 193

  Engine Specificationsp. 194

  Engine Troubleshootingp. 195

  Engine Oil and Filterp. 199

  Engine Tune-Upp. 201

  +RPM, Vacuum, and Stall Testsp. 202

  Introductionp. 202

  Test Proceduresp. 203

  Analysis of Stall Testp. 205

  Compression Checksp. 206

  Engine Removal and Replacementp. 208

  +Engine Overhaulp. 214

  Overhaul Specificationsp. 215

  Service Precautionsp. 219

  Tightening Method for Permanentlyp. 220

  Special Toolsp. 221

  OVERHAUL PROCEDURESp. 223

  +GM ENGINEp. 259

  Specificationsp. 260

  Troubleshootingp. 261

  Oil and Filterp. 265

  Tune-Upp. 267

  +RPM, Vacuum, and Stall Testsp. 268

  Introductionp. 268

  Test Proceduresp. 269

  Analysis of Stall Testp. 271

  Compression Checksp. 272

  +Removal and Replacementp. 274

  Engine Removalp. 275

  Engine Replacementp. 277

  +Engine Overhaulp. 280

  Contentsp. 281

  Specificationsp. 284

  +ENGINE COOLINGp. 363

  Specifications and Descriptionp. 364

  Troubleshootingp. 367

  Testing and Maintenancep. 368

  Cooling System and Alternator Belt Servicep. 374

  +Radiator R&Rp. 379

  Radiator Removalp. 380

  Radiator Replacementp. 382

  Radiator R&R (GM)p. 384

  +LPG FUEL SYSTEMp. 387

  Specifications and Descriptionp. 388

  Troubleshootingp. 395

  Adjustments and Maintenancep. 398

  Carburetor and Throttlep. 405

  Vaporizer-Regulatorp. 409

  Fuel Lock-off Valvep. 413

  +GASOLINE-CARB FUEL SYSTEMp. 415

  Specifications and Descriptionp. 416

  Troubleshootingp. 424

  Checks and Adjustmentsp. 425

  Removal, Replacement, and Overhaulp. 430

  Fuel Pump and Filterp. 437

  +AIR INDUCTION & EXHAUSTp. 438

  Specifications and Descriptionp. 439

  System Servicep. 441

  Exhaust Systemsp. 445

  +TA-30 STANDARD TRANSAXLEp. 449

  +Specifications and Descriptionp. 450

  Transaxle Hydraulic Schematicp. 458

  Troubleshootingp. 461

  Oil and Filterp. 466

  Oil Coolerp. 468

  Transaxle R&Rp. 470

  Overhaulp. 475

  Drive Axle Endsp. 503

  Transaxle Control Valvep. 507

  +HYDROSTATIC TRANSMISSIONp. 509

  Specifications and Descriptionp. 510

  +Troubleshooting and Adjustmentsp. 514

  Vehicle Does Not Movep. 515

  Vehicle Does Not Reach Maximum Speedp. 517

  Driving Behavior Abnormalp. 519

  +Using the SUSMIC DIA-3p. 520

  Table of Contentsp. 521

  Safe Maintenance Practicesp. 522

  Introductionp. 523

  Battery Lifep. 523

  Connection of the SUSMIC-DIA 3p. 524

  Activation of the SUSMIC-DIA 3p. 524

  Sensor Set-upp. 525

  +Sensor Set-up Proceduresp. 527

  7.2.1 Set-up 00 Software version number indication procedurep. 528

  7.2.2 Set-up 01 Throttle pedal sensor calibration procedurep. 529

  7.2.3 Set-up 02 Brake pedal sensor calibration procedurep. 530

  7.2.4 Set-up 03 Lift valve sensor calibration procedurep. 531

  7.2.5 Set-up 04 Setting the parameter for the engine typep. 532

  7.2.6 Set-up Menu 05 Setting the parameter for the type of driving controlsp. 533

  7.2.7 Set-up Menu 06 Setting the parameter for driving characteristicsp. 534

  7.2.8 Set-up 07 Engine actuator calibrationp. 535

  7.2.9 Set-up 08 EDC minimum calibration procedurep. 536

  7.2.10 Set-up 09 EDC maximum calibration procedurep. 537

  +Custom Adjustments of Driving Characteristicsp. 538

  7.3.1 Set-up IO Adjustment of deceleration timep. 539

  7.3.2 Set-up 11 Adjustment of deceleration timep. 540

  7.3.3 Set-up 12 Adjustment of the Engine RPM’s when the Tiltp. 541

  7.3.4 Set-up 13 Adjustment of the Maximum Engine RPM’s when the Liftp. 542

  7.3.5 Set-up Menu 14 Adjustment of the EDC Current Limitationp. 543

  7.3.6 Set-up Menu 15 Adjustment of the EDC Current Limitationp. 544

  +7.4 Custom Adjustments of Driving Characteristicsp. 545

  7.4.1 Adjustment of the Deceleration Time When Shifting From Forward or Reverse to Neutral.p. 546

  7.4.2 Adjustment of the Deceleration Time When the Accelerator Pedal is Released.p. 547

  7.4.3 Adjustment of the Deceleration TimeWhen Shifting From Forward to Reverse or Reversep. 548

  7.4.4 Adjustment of the Engine RPM’s When the Tilt or Auxiliary Mast Functions are Operated.p. 549

  7.4.5 Adjustment of the Maximum Engine RPM’s When the Lift Lever is Moved to the Maximump. 550

  Sensor/Actuator Error Diagnosisp. 551

  +Sensor Check Procedurep. 553

  9.2.1 Check 00 Throttle Pedal Sensor Procedurep. 554

  9.2.2 Check 01 Pulse pick-up (PPU) on the Hydrostatic Pump Procedurep. 555

  9.2.3 Check 02 Brake Pedal Sensor Procedurep. 556

  9.2.4 Check 03 Directional Control Procedurep. 557

  9.2.5 Check 04 Parking Brake Switch Procedurep. 558

  9.2.6 Check 05 Lift Sensor Procedurep. 559

  9.2.7 Check 06 Tilt and Auxiliary Switch Procedurep. 560

  9.2.8 Check 07 Engine Actuator Feedback Procedurep. 561

  LED INDICATORSp. 562

  DIA-3 Quick Referencep. 563

  +Components Removals and Replacementsp. 564

  Hydrostatic System Plumbingp. 565

  Drive Axlep. 566

  Drive Pumpp. 567

  Enginep. 567

  Pump Adaptor and Couplingsp. 567

  +Control Systemp. 569

  Computerp. 569

  Engine (Throttle) Actuatorp. 570

  Lift , Tilt, and Aux Controlp. 571

  Brake Pedalp. 572

  Accelerator Pedal(p. 573

  Two-Pedal System-Pedal Lever and Sensorp. 574

  Two-Pedal System-Pedals and Direction Switchesp. 575

  Pedal System-Wiringp. 577

  Hydrostatic Drive Pump Servicep. 578

  +Hydrostatic Drive Motors Servicep. 579

  Contentsp. 580

  +DISMANTLINGp. 585

  Axle unit Dismantlinu Instructionsp. 586

  Dismantlina the Mid Casina Assemblyp. 586

  Dismantlina flushina assemblyp. 587

  Dismantlina Rotatina Assemblvp. 588

  Front Case Assemblvp. 588

  +REASSEMBLYp. 589

  Reassemblina flushina assemblvp. 590

  Reassemblina Mid Case Assemblyp. 591

  Reassemblina Rotatina Assemblyp. 591

  Front Case Assemblyp. 592

  Axle unit Assemblyp. 592

  +ASSEMBLY DRAWINGSp. 593

  Axle General Arrangementp. 594

  Left Sidep. 595

  Motor Assemblyp. 596

  Left Side Part Assemblyp. 597

  Rotational Assemblyp. 598

  Mid Case Assemblyp. 599

  Relief Valvep. 600

  Flushing Spoolp. 601

  TOOLINGp. 602

  GREASE SPECIFICATIONp. 605

  FAULT FINDINGp. 606

  Drive Axle Endsp. 607

  +Axial Piston Pump & Motorp. 611

  Introductionp. 612

  General Descriptionp. 613

  Hydraulic Support Systemp. 614

  Technical Data – Variable Displacement Pumpp. 616

  Technical Data – Fixed Displacement Motorp. 617

  Technical Data – All Series 90 Pumps and Motorsp. 617

  Controls and Optionsp. 618

  Start-Up Maintenancep. 621

  Troubleshootingp. 622

  Fault Logic Diagramsp. 623

  Inspections & Adjustmentsp. 625

  Minor Repair and Replacementp. 635

  General Parts ldentif icationp. 649

  Unit Identificationp. 653

  +IGNITION SYSTEMp. 660

  +Description and Specificationsp. 661

  Specificationsp. 661

  System Overviewp. 662

  Schematic Drawingp. 663

  Distributor Components and Functionp. 664

  +Troubleshootingp. 665

  Troubleshooting Testsp. 666

  Troubleshooting Chartp. 667

  +Inspection, Adjustment, and Timingp. 669

  +Distributor Inspection and Air Gapp. 670

  Distributor Capp. 670

  Rotorp. 670

  Centrifugal Advancep. 670

  Vacuum Advance Controlp. 671

  Pick-Up Air Gapp. 671

  Spark Plug Wire Inspectionp. 671

  +Spark Plug Inspection andp. 671

  Removing Spark Plugsp. 671

  Inspecting Spark Plugsp. 672

  Installing Spark Plugsp. 672

  Ignition Coil Inspectionp. 672

  Ignition Coil Testsp. 673

  Pick-Up Coil Testsp. 673

  +Ignition Timing Checks and Adjustmentp. 673

  Checking Ignition Timingp. 673

  Adjusting Ignition Timingp. 674

  +Checking Spark Advancep. 675

  Centrifugal Advancep. 675

  Vacuum Advancep. 675

  +GM Ignition Systemp. 676

  Ignition Timingp. 677

  +Distributor Overhaulp. 678

  Replacing the lgnitor and Pick-Up Coilp. 678

  Removing the Distributorp. 679

  Installing the Distributorp. 679

  Distributor Disassembly and Assemblyp. 680

  +INSTRUMENT PODp. 683

  Description & Specificationsp. 684

  +Troubleshootingp. 687

  Fuel Gauge Failurep. 688

  Coolant Temperature Gauge Failurep. 689

  Indicator Light Failurep. 690

  Hour Meter Failurep. 691

  Buzzer Failurep. 692

  Key-On Horn Failurep. 693

  Shut-Down Mode Failurep. 694

  Removal and Installationp. 695

  +ELECTRICAL SYSTEMp. 696

  +Specifications & Wire Diagramsp. 697

  System Specificationsp. 697

  Wiring Color Codesp. 698

  +Starter and Batteryp. 705

  General Informationp. 705

  Minimum Tools Requiredp. 705

  Starting System Inspectionp. 706

  +Electrical Checksp. 707

  Slow or Sluggish Crankingp. 707

  Nothing Happens When Startp. 708

  Volt Drop Testsp. 710

  +Alternatorp. 713

  Alternator Maintenance Precautionsp. 713

  +Troubleshooting Proceduresp. 714

  Abnormal Operation of Charge indicatorp. 715

  Abnormal Operation of Charging Systemp. 715

  Symptoms, Causes, and Remediesp. 715

  +Starter Maintenance and Overhaulp. 717

  External Inspectionp. 718

  Installation and Removalp. 718

  +Bench Tests and Adjustmentsp. 719

  Pinion Gap Adjustmentp. 719

  Pull-h Test of Solenoidp. 719

  Hold-in Test of Solenoidp. 719

  Return Test of Solenoidp. 720

  No-load Testp. 720

  +Overhaulp. 721

  Disassembly/Assemblyp. 721

  Cleaning of Starter Motor Partsp. 722

  Parts Inspectionp. 722

  +Alternator Maintenancep. 725

  External Inspectionp. 725

  Installation and Removalp. 726

  Overhaulp. 727

  +WHEELS AND TIRESp. 731

  Specifications and Descriptionp. 732

  +Cushion Wheels and Tiresp. 733

  General Cushion Tire Maintenancep. 733

  Drive Wheel Removal/Installationp. 733

  Steer Wheel Removal/Installationp. 734

  Cushion Tire Replacementp. 735

  +Pneumatic Wheels and Tiresp. 736

  Pneumatic Tire Maintenance Precautionp. 737

  +General Tire Maintenance, Inspection, & Repairp. 738

  Inspection and Minor Repairp. 738

  +Wheel Dismounting and Remountingp. 739

  Drive and Steer Wheel Dismountingp. 739

  Drive and Steer Wheel Remountingp. 739

  Dual-Drive Wheel Dismountingp. 740

  Dual-Drive Wheel Remountingp. 740

  Wheel Disassembly and Tire Removalp. 741

  +Tire Replacement and Wheel Reasemblyp. 743

  Tire-to-Wheel Mountingp. 744

  Filling Tires with Airp. 745

  Filling Tires with Nitrogenp. 745

  Checking and Adjusting Tire Pressurep. 746

  +BRAKE/INCHING SYSTEM (Hydrostatic Trans)p. 747

  Specifications and Descriptionp. 748

  Troubleshootingp. 750

  +Brake/Inching Pedals, Linkages, & Adjustmentsp. 751

  Brake Pedal Height Adjustmentp. 752

  Overlap Adjustmentp. 752

  Freeplay Adjustmentp. 753

  Linkage and Sensor Installationp. 754

  Brake System Bleedingp. 755

  Master Cylinder Overhaulp. 756

  +Service Brake Adjustment and Overhaulp. 758

  External Inspectionp. 758

  Shoe-to-Drum Gap Adjustmentp. 758

  Internal Inspection and Repairp. 759

  Wheel Cylinder Overhaulp. 761

  Brake Assembly Removal & Installationp. 761

  Parking Brake Servicep. 762

  +BRAKE SYSTEM (STANDARD TRANSAXLE)p. 764

  +Specifications and Descriptionp. 765

  Specificationsp. 765

  General Descriptionp. 766

  Inching Operationp. 767

  Braking Operationp. 767

  Service Requirementsp. 768

  Service Brake Troubleshootingp. 770

  +Brake/Inching Pedals and Linkage Adjustmentsp. 771

  Introductionp. 772

  Pedal Height Adjustmentp. 772

  Overlap Adjustmentp. 772

  Brake Yoke Adjustmentp. 772

  Inching Cable Adjustmentp. 774

  Bleedingp. 775

  +Brake Valve Servicep. 776

  Brake Valve Removalp. 777

  Brake Valve Replacementp. 778

  Brake Valve Overhaulp. 778

  +Service Brake Adjustment and Overhaulp. 779

  External Inspectionp. 779

  Shoe-to-Drum Gap Adjustmentp. 779

  Internal Inspection and Repairp. 780

  Brake Shoe Removalp. 780

  Cylinder Removal and Replacementp. 781

  Adjuster Removal and Replacementp. 781

  Wheel Cylinder Overhaulp. 782

  Brake Assembly Removal, andp. 782

  Parking Brake Servicep. 783

  +STEERING COLUMN AND GEARp. 785

  Specifications and Descriptionp. 786

  Steering System Troubleshootingp. 788

  +Steering Column and Component Removal and Replacementp. 790

  Steering Column and Component Removalp. 791

  Steer Column and Component Replacementp. 795

  Steering System Relief Pressure Check and Adjustmentp. 800

  +Steering Gear Overhaulp. 802

  Disassemblyp. 803

  Parts Inspectionp. 805

  Reassemblyp. 805

  +STEER AXLEp. 809

  Specifications and Descriptionp. 810

  +Wheel Bearing Maintenance and Adjustmentp. 812

  Wheel Bearing Checkp. 812

  Wheel Bearing Lubricationp. 812

  Wheel Bearing Adjustmentp. 815

  +Steer Axle Removal and Replacementp. 816

  Steer Axle Removalp. 817

  Steer Axle Replacementp. 818

  +Steer Axle Overhaulp. 820

  Preparation For Steer Axle Disassembly Overhaulp. 821

  Steer Axle Disassemblyp. 821

  Steer Axle Reassemblyp. 822

  Steer Cylinder Removal and Replacementp. 823

  +Steer Cylinder Overhaulp. 825

  Preparation for Steer Cylinder Disassemblyp. 826

  Steer Cylinder Disassemblyp. 826

  Parts Inspectionp. 826

  Steer Cylinder Reassemblyp. 827

  Operational Pressure Testp. 828

  +HYDRAULIC SUMP, FILTERS, AND PUMPp. 829

  Specifications and Descriptionp. 830

  Main Hydraulic Pump Troubleshootingp. 834

  +Hydraulic Filters and Fluid Maintenance and Changep. 836

  Hydraulic Sump Fluid Level Checkp. 837

  Hydraulic Filters Changep. 837

  Hydraulic Fluid Changep. 838

  Check Operation of Hydraulic Systemp. 839

  Hydraulic Pump Removal and Replacementp. 840

  +Hydraulic Pump Overhaulp. 842

  Preparation for Pump Disassemblyp. 842

  Pump Disassemblyp. 843

  Parts Inspectionp. 845

  Pump Reassemblyp. 847

  +HYDRAULIC CONTROL VALVA/LIFT CIRCUITp. 850

  Specifications and Descriptionp. 851

  Hydraulic System Schematicsp. 853

  Hydraulic System Troubleshootingp. 856

  Hydraulic System Pressure Checks and Adjustmentsp. 858

  +Hydraulic Control Valve Removal & Replacementp. 860

  Hydraulic Control Valve Removalp. 861

  Hydraulic Control Valve Replacementp. 862

  +Hydraulic Control Valve Overhaulp. 864

  Preparation for Disassemblyp. 864

  Disassemblyp. 865

  Cleaning, Inspection, and Repairp. 866

  Reassemblyp. 867

  Relief Valve Settingsp. 867

  +TILT CYLINDERSp. 868

  Specifications and Descriptionp. 869

  +Checks and Adjustmentsp. 870

  Drift Checkp. 870

  Racking Checkp. 871

  Tilt Flow Control Adjustmentsp. 872

  +Removal and Replacementp. 873

  Removalp. 874

  Parts Inspectionp. 875

  Replacementp. 875

  Overhaulp. 877

  +UPRIGHTSp. 880

  Upright Specifications and Descriptionp. 881

  Troubleshootingp. 887

  +Inspectionp. 891

  Basic Visual Inspectionp. 892

  +Extended Inspectionp. 893

  Forksp. 893

  Lift Chainsp. 894

  Carriage and Upright Weldmentsp. 895

  Carriage and Upright Rollersp. 896

  Cylindersp. 897

  Hydraulic Plumbingp. 899

  Upright Driftp. 899

  Trunnion Bearingsp. 900

  +Carriage and Upright Roller Clearance Checksp. 901

  Introductionp. 901

  Roller Side Clearance Checksp. 903

  Directions for Checking Specific Rollersp. 904

  Internal Thrust Roller Adjustmentp. 905

  Oversize Rollersp. 906

  Lift Roller Shimmingp. 906

  Upright Roller Shimmingp. 907

  Overshimmingp. 910

  +Cylinder Removal, Shimming, Overhaul, and Replacementp. 911

  Cylinder Typesp. 911

  Lift Cylinder Shimming Procedurep. 911

  Primary Cylinder Removal and Replacement (TSU Only)p. 912

  Lift and Secondary Cylinder Removal and Replacementlp. 913

  Cylinder Overhaulp. 914

  +Upright Chain Inspection, Adjustment, and Replacementp. 918

  Periodic Inspectionsp. 920

  Standard Upright Chain Length Adjustmentp. 922

  Triple-Stage Upright (TSU) Chain Length Adjustmentsp. 922

  Chain Lubricationp. 924

  Chain Removal and Replacementp. 924

  Lift Chains (Standard and TSUs)p. 924

  Other Chain Service Notesp. 925

  Fork and Carriage Removal and Replacementp. 926

  +Upright Removal and Replacementp. 930

  Upright Removalp. 931

  Upright Replacementp. 932

  +COUNTERWEIGHT AND CHASSISp. 934

  Counterweight Specifications and Descriptionp. 935

  Counterweight Removal and Replacementp. 936

  Overhead Guard/Operator’s Cell R&Rp. 938

  Floorboard, Cowls, Radiator Cover, and Seat Deck R&Rp. 940

  Operator’s Seat R&Rp. 944

  +SPECIFICATIONSp. 946

  Nameplates and Decalsp. 947

  +General Specificationsp. 951

  Weights and Performance Specificationsp. 952

  Critical Fastener Torque Specificationsp. 954

  Group Specificationsp. 955

  Hydraulic Fitting Tightening Procedurep. 961

• Group 34 – Uprights
  • Specifications, troubleshooting and inspection
  • Roller-clearance checks, shimming, cylinder service and chain adjustment
  • Fork, carriage and upright removal/replacement
• Group 38 – Counterweight and Chassis
  • Counterweight specifications and removal
  • Overhead guard/operator cell, floorboard, radiator cover, seat deck and seat service
• Group 40 – Specifications
  • Nameplates and decal locations
  • General truck specifications and performance data
  • Hydraulic fitting tightening procedures

Across these groups, the manual moves from routine planned maintenance into system diagnosis and major repair. It gives technicians the procedural context needed to inspect a truck, isolate faults, verify operating conditions, remove assemblies, measure wear, compare components against service limits and reinstall parts using specified tightening values. The technical drawings are extensive: engine sectional views and exploded assemblies, transmission and drive-system illustrations, wiring information, hydraulic circuit schematics, upright and cylinder diagrams, and chassis component layouts are used throughout the manual.

Engine, Transmission and Diagnostic Depth

The diesel section is especially detailed. The Mitsubishi S4S material includes engine specifications, performance data, maintenance standards, tightening torques, sealant application information, special tools and internal-engine procedures for the cylinder head, valve mechanism, timing gears, camshaft, flywheel, pistons, connecting rods, crankshaft and crankcase. It also covers lubrication, cooling, fuel injection, starter, alternator, heater plugs, compression testing and troubleshooting. For the gasoline/LPG side, the 4G64 and GM 3.0L groups provide specifications, tune-up data, troubleshooting, checks and engine repair procedures.

Drive-system coverage spans the TA-30 standard transaxle and the hydrostatic transmission. The standard unit includes troubleshooting, oil and filter service, cooler work, removal and replacement, overhaul, axle-end service and control-valve overhaul. Hydrostatic material includes system description, troubleshooting charts, hand-held diagnostic control information, component removal, drive-pump service and drive-motor service. Brake/inching procedures are separated for the relevant driveline configuration, while steering and hydraulic groups provide checks and repair steps for the systems that interact with travel and load handling.

Maintenance, Hydraulics and Load-Handling Service

The planned-maintenance material supports regular inspection of fluid levels, filters, wheels and tires, brakes, steering, lift mechanisms, chains, cylinders, critical fasteners and safety equipment. Service charts identify recurring maintenance tasks and intervals, while the PM section provides a systematic inspection flow. The hydraulic chapters then go deeper into the sump, filters, pump, control valve, lift circuit, pressure checks, tilt cylinders and related schematics.

For mast and load-handling work, the upright group covers inspection, roller clearance and shim adjustment, cylinder service, chain inspection and adjustment, fork and carriage removal and upright removal. Chassis coverage includes the counterweight, overhead guard/operator cell, floorboard, radiator cover, seat deck and operator seat. Group 40 consolidates truck-level performance and service data, including capacities, weights, gradeability, travel speeds, turning radius, lift and tilt drift, critical fastener torques and group specifications.

Repair With the Correct Procedures and Specifications

The Clark CGC CGP CDP 20-30 Forklift Shop Manual – Service, Repair & Specifications PDF is built for maintenance and repair work that depends on more than a generic parts diagram. It supports scheduled servicing, engine tune-up and overhaul, transmission diagnosis and repair, electrical testing, brake and steering work, hydraulic pressure checks, control-valve and cylinder service, upright adjustment and chassis component removal. Using the manual’s procedures, diagrams, service limits, torque values and system specifications helps technicians work from the correct reference for the covered CLARK lift-truck families rather than relying on approximate settings.

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