Clark Service Manual SM-593 Overview

Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
SM-593
GPX/DPX
30/55

Service
Manual
SM 593
G PXlDPX 30/35/40/405/50/55

Pictorial Index
Group23 -
Group 25
- Group 32
c
Group 34
!- Group 20
Group 22
Group 06
Group 29
Group 38l
Group 30
Group 40
+-z)
Group 14
SM 593, JAN ‘93

CONTENTS
Contents of this Manual
Group
00
00
00
00
01
01
01
01
01
02
02
02
02
02
02
06
06
06
06
06
14
14
14
14
20
20
20
20
20
22
22
22
Section Description
1
2
3
1
2
2
1
2
INTRODUCTION
Safety
Planned Maintenance
ENGINES
Engine Removal
Diesel Workshop Manual
Gas/LPG Workshop Manual
COOLING SYSTEM
Troubleshooting
Cooling System Testing and Maintenance
Fan Belt Replacement
Radiator Removal
FUEL SYSTEM
Fuel Pump Pressure .Test
The IMPCO Fuel System
Carburetor Overhaul
Velocity Governor Overhaul
Removal of IMPCO Vaporizing System
TRANSMISSION
Transmission Checks
Draining and Refill
Transmission Removal
Transmission Overhaul
ELECTRICAL SYSTEM
Wiring Color Code
Wiring Diagrams
Electrical Checks
DRIVE AXLE
Axle End Lubrication
Axle End Removal
Axle Ends Overhaul
Differential Overhaul
WHEELS AND TIRES
Lifting, Jacking, and Blocking
Wheels and Tires Mounting
(continued on next page)
SM 593, JAN ‘93 0 Clark Material Handling Company 1993 Contents-l

Group
23
23
23
23
23
23
23
23
25
25
25
25
26
26
26
26
26
26
26
29
29
29
30
30
30
30
30
32
32
32
32
34
34
34
34
34
34
34
34
38
38
40
40
40
40
40
40
Section Description
1
2
3
1
2
1
2
3
1
BRAKING/INCHING SYSTEM
System Description/Troubleshooting
Brake and Inching System Bleeding
Brake and Inching Pedals Adjustment
Master Cylinder Overhaul
Power Booster Overhaul
Brake Caliper Overhaul
Parking Brake
STEERING COLUMN AND GEAR
Troubleshooting
Steering Column and Gear Removal
Char-Lynn Steering Control Unit (Steering gear)
STEER AXLE
Steer Axle Removal
Steer Axle Overhaul
Steering System Adjustment
Steer Cylinder Removal
Steer Axle Wheel Bearings
Steer Cylinder Overhaul
HYDRAULIC SUMP, FILTERS, AND PUMP
Hydraulic Sump and Filters
Hydraulic Pump Troubleshooting & Overhaul (Vane Type)
HYDRAULIC VALVE/LIFT CIRCUIT
Hydraulic System Pressure Check
Hydraulic Valve Overhaul
Hydraulic Valves
Hydraulic Schematic
TILT CYLINDERS
Tilt Cylinder Removal
Tilt Cylinder Overhaul
Tilt Lock Valve
UPRIGHTS
Troubleshooting and Visual Inspection
Operational Checks
Carriage Check and Adjsutment
Upright Check and Adjustment
Cylinder Repair
Lift Chain Maintenance
Upright Removal and Replacement
COUNTERWEIGHTS
Counterweight Removal and Installation
SPECIFICATIONS
Namplates/Decals
General Specifications
PM Inspection and Drivers Daily Inspection Forms
Recommended Lubricants & Lubricant Specifications
Lubrication Intervals
Contents-2 SM 593, JAN ‘93

INTRODUCTION
INTRODUCTION
Safety ................................................................................. Section 1
Planned Maintenance ........................................................ Section 2
SM 593, JAN ‘93 Introduction

ElfIRK Introduction
Safety
Safety Signs and Messages ................................................................................... 2
User Safe Maintenance Practices ........................................................................ 2
SM 593, Jan ‘93 Safety-l

Introduction Cl!mK
Safety Signs and Messages
Safety signs and messages are placed in this manual
and also on the lift truck to provide instructions and
to 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.
NOTICE
This message is used when special in-
formation, instructions or identifica-
tion is required relating to procedures,
equipment, tools, pressures, capacities
and other special data.
IMPORTANT
This message is used when special pre-
cautions should be taken to ensure a
correct action or to avoid damage to
or malfunction of the truck or a com-
ponent.
A
! CAUTION
This message is used as a reminder of
safety hazards which can result in per-
sonal injury if proper precautions are
not taken.
A WARNING
This message is used when a hazard
exists which can result in injury or
death if proper precautions are not
taken.
A DANGER
This message is used when an extreme
hazard exists which can result in in-
jury or death. or serious injury if
proper precautions are not taken.
NOTE: The above terms have been adopted by
Clark Material Handling Company. The same terms
may be used in different context in service literature
supplied directly or indirectly by vendors of truck
components.
User Safe Maintenance
Practices
The following instructions have been prepared from
current industry and government safety standards
applicable to industrial truck operation and mainte-
nance. These recommended procedures specify con-
ditions, 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. Carefully read and
understand these instructions and the specific main-
tenance procedures before attempting to do any re-
pair work.
When in doubt of any maintenance procedure, please
contact your local Clark dealer.
1.
2.
3.
Powered industrial trucks can become haz-
ardous if maintenance is neglected. There-
fore, suitable maintenance facilities, trained
personnel, and procedures must be provided.
Maintenance and inspection of all powered
industrial trucks shall be done in conform-
ance with the manufacturer’s recommenda-
tions.
A scheduled planned maintenance, lubrica-
tion, and inspection program shall be fol-
lowed.
Safety-2 SM 593, Jan ‘93

Cl!YRK Introduction
4.
5.
6.
7.
8.
9.
10.
11.
Only trained and authorized personnel shall
be permitted to maintain, repair, adjust, and
inspect industrial trucks. Work should be
performed in accordance with the
manufacturer’s specifications.
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 leak-
age of fuel, electrolyte, or coolant. Do not use
open pans of fuel or flammable cleaning
fluids for cleaning parts.
Before starting work on truck:
a. Raise drive wheels off of floor or discon-
nect power source and use blocks or other
positive truck positioning devices.
b. Disconnect battery before working on the
electrical system.
Before working on engine fuel system of
gasoline- or diesel-powered trucks, be sure
the fuel shut-off valve is closed.
Operation of the truck to check performance
must be conducted in an authorized, safe,
clear area.
Before starting to drive truck:
a.
b.
C.
d.
e.
Be in operating position.
Be sure parking brake is engaged.
Put direction control in neutral.
Start engine.
Check functioning of direction and speed
controls, steering, brakes, warning de-
vices, and any load handling attachments.
Before leaving ttruck
a. Stop truck.
b. Put directional control in neutral.
c. Apply the parking brake.
12.
13.
14.
15.
16.
17.
18.
19.
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 mecha-
nisms, warning devices, lights, governors,
guards, safety devices, and frame members
must be carefully and regularly inspected and
maintained in a safe operating condition.
Special trucks or devices designed and ap-
proved for hazardous area operation must
receive special attention to ensure that main-
tenance preserves the original, approved, safe-
operating features.
Fuel systems must be checked for leaks and
condition of parts. Extra special consider-
ation 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.
The truck manufacturer’s capacity, opera-
tion, and maintenance instruction plates, tags,
or decals must be maintained in legible con-
dition.
Batteries, motors, controllers, limit switches,
protective devices, electrical conductors, and
connections must be inspected and main-
tained in conformance with good practice.
Special attention must be paid to the condi-
tion of electrical insulation.
To avoid injury to personnel or damage to the
equipment, consult the manufacturer’s pro-
cedures in replacing 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.
Modifications and additions that affect ca-
pacity and safe truck operation must not be
done without the manufacturer’s prior writ-
ten approval. Capacity, operation and main-
SM 593, Jan ‘93 Safety-3

Introduction
20.
21.
tenance instruction plates, tags, or decals must
be changed accordingly.
Care must be taken to assure that all replace-
ment parts, including tires, are interchange-
able 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.
Use special care when removing heavy com-
ponents 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.
NOTICE
You should also be familiar with addi-
tional operating and maintenance
safety instructions contained in the fol-
lowing publications:
ANSI/ASME B56.1 - 1988 Operator Control-Indus-
trial Tow Tractors (Safety Standard For Powered
Industrial Trucks). Published by: Society of Me-
chanical Engineers, United Engineering Center, 345
E. 47th Street, New York, NY 10017.
NFPA 505- 1982: Fire Safety Standard for Powered
Industrial Trucks: Type Designations, Areas of Use,
Maintenance and Operation. Available from: Na-
tional Fire Protection Assoc., Inc., Batterymarch Park,
Quincy, MA 02269.
General Industrial Standards, OSHA 2206: OSHA
Safety and Health Standards (29 CFR 1910), Sub-
part N-Materials Handling and Storage, Section
1910.178 Powered Industrial Trucks. For sale by:
Superintendent of Documents, U.S. Government
Printing Office, Washington, DC 20402.
Safety-4 SM 593, Jan ‘93

Group 06, Transmission CLRRK
Transmission Removal
The transmission removal process described below
requires that you first remove the uprights, discon-
nect all connections to the transmission, and “drop”
the transmission. The engine remains in the truck.
The procedure is as follows:
1.
2.
3.
4.
Block the wheels to prevent roll. Then put the
direction control in neutral.
Using a safety-inspected and approved hoist or
other lifting device of adequate capacity, raise
truck 12-18 inches (305-457 mm) off floor, as
described in Group 22, Section 1, “Lifting,
Jacking, and Blocking.” Put wheel cradles of
adequate capacity under rear wheels.
Put metal or narrow blocks under front frame.
Also block under counterweight so that the
truck will not tip backward after the upright
and transmission are removed.
Remove the uprights as described in Group 34,
Section 8, “Upright Removal.”
8.
9.
10.
11.
5. Remove the drive wheels.
6. Unlatch and swing back the hood. Disconnect
the battery cables.
7. Remove the floor plate.
Drain transmission oil.
Remove pin(s) from shift linkage(s) at
bellcrank on transmission.
Remove the parking brake yoke pin at the
transmission. Remove fasteners attaching park-
ing brake cable to transmission case.
At the transmission inching control valve, dis-
connect the inching line that comes from the
selector valve.
Inching Line
Disconnect
06-3-2 l Transmission Removal SM 593, Jan ‘93

c19Ru= Group 06, Transmission
12. At the brake line tee (on top of the transmis-
sion) that connects the wheel caliper lines to
the selector valve line, disconnect the line that
goes to the selector valve.
Brake Line
Disconnect,
13. Remove the accelerator cable bracket fasteners
from the accelerator pedal attaching bracket
and move the accelerator linkage to one side as
an assembly.
Bracket
Fastener
14. Disconnect two transmission oil cooling lines:
At the transmission control cover, disconnect
the line that goes to the radiator. At the tee on
the transmission, disconnect the line that goes
to the oil filter.
Disconnect
Disconnect /
15.
16.
Remove the electric wire leads to the transmis-
sion.
Remove the transmission inspection cover so
that you can see the bolts that mount the torque
converter drive plate to the engine flywheel.
17.
18.
Inspection Cover
Access Port
Remove the plug from the drive plate access
port in the transmission case, for best access to
the bolts that mount the torque converter drive
plate to the engine flywheel.
Rotate the flywheel so that a torque converter
drive plate mounting bolt lines up with the
access port. With an extension through the
access port, unscrew the bolt from the fly-
wheel. Repeat for each bolt.
NOTICE
Do not pry on the torque converter.
Nicks and scratches on the convertor
housing could lead to fatigue of the
metal and eventual leaks.
Bolt to ’
Engine Flywheel
SM 593, Jan ‘93 Transmission Removal l 06-3-3

Group 06, Transmission
19. Use a lift truck or safety-inspected and ap-
proved lifting device to support the transmis-
sion and use a jack to support the engine bell
housing.
20. Remove bolts that attach transmission to en-
gine bell housing. (See illustration in step 22.)
21. Remove bolts attaching transmission and dif-
ferential to frame.
Transmission
Mounting Bolt
CAUTION
Make sure blocking is not disturbed
when the transmission is removed.
22. Gradually pull the transmission from the en-
gine and lower it. Make sure that all connec-
tions to the transmission are free as you lower.
Transmission Installation
The following is a continuation of the process, de-
scribed above, by which the transmission was
“dropped” from the truck with the engine left in. The
instructions below first cover installation of the torque
converter into the transmission, then installation of
the transmission into the truck.
1.
2.
3.
4.
Make sure truck blocking is secure and cor-
rectly positioned, raising truck 12-18 inches
(305-457 mm) off floor.
Make sure transmission is secure on the lifting
device and that the insertion area beneath the
truck is clear of obstacles and blocking.
Remove the transmission inspection cover so
that you can see inside to mount the torque
converter drive plate to the engine flywheel.
Also remove the access port plug. You will
bolt the torque converter drive plate to the
engine flywheel through this port.
NOTICE
Keep inspection opening covered with
a clean shop rag to prevent foreign
material from getting inside transmis-
sion case.
Make sure the torque converter drive plate is
bolted to the torque converter. (See illustration
in step 1l-c.) Fastener torque is 28-32 lbf-ft
(37.9-43.4 Nmm).

Cl!!mK Group 06, Transmission
5. Lubricate the seal and bearing surface of the
transmission stator support to let the tang drive
of the convertor slide into the convertor pump
drive gear tangs.
Gear
6.
7.
8. Replace the gasket, and carefully insert trans-
1
mission assembly into position with the en-
gine.
Vlake sure the convertor pump drive gear is
:orrectly positioned on the stator support.
Carefully insert the torque convertor drive shaft
into the stator support. Rotate the transmission
gearing to align the tangs on the convertor
shaft; and push the convertor so its tangs drop
into the gear tangs.
Housing
Mounting 6
9.
10.
Check that the torque converter is free to rotate
with the flywheel.
Insert the bolts joining the transmission hous-
ing to the engine bell housing. Tighten the
fasteners to a torque of (33-37 Nom) 24-27
lbf-ft.
11. Bolt the torque converter drive plate to the
engine flywheel as follows:
a. Rotate the torque converter drive plate so
that a mounting bolt hole lines up with the
access port.
b. Rotate the engine flywheel so that a mount-
ing bolt hole lines up with the access port.
NOTICE
Do not pry on the torque converter.
Nicks and scratches on the convertor
housing could lead to fatigue of the
metal and eventual leaks.
c. Place a mounting bolt with washer in an
appropriate magnetic socket so that the
rounded-edge side of the washer will con-
tact the torque converter drive plate.
Flywheel
Washer (Rounded
Edges against Plate)
d.
e.
With the socket on an extension, insert the
mounting bolt through the access port and
through the torque converter drive plate.
Start the bolt into the engine flywheel.
Repeat for each mounting bolt. Tighten the
bolts gradually, making several rotations
of the drive plate/flywheel. Final torque for
each bolt should be 19-21 lbf-ft (25.8-28.5
Nom).
NOTICE
If a drive plate mounting bolt falls
into the transmission case, it must be
removed to avoid eventual destruc-
tion of the transmission.

Group 06, Transmission El!!WK
12.
13.
14.
15.
16.
17.
18.
Replace the inspection cover on the transmis-
sion and tighten the fasteners to a torque of 24-
27 lbf-ft. (33-37 Nom).
Replace the inspection port plug.
Remove the jack or blocking supporting the
engine bell housing.
Align center hole on each side of frame and
differential housing. Install one bolt and
lockwasher on each side and tighten to “finger
tight” torque.
Add shims to right and left side side to fill void.
Start all 10 transmission mounting bolts (with
lockwashers), but do not tighten.
Loosen two front engine mounting bolts.
Engine ,
Mounting Bolt
Washer/Shim -
19.
20.
21.
22.
23.
24.
25.
26.
Install hoist on front of engine.
Raise engine until all 10 transmission mount-
ing bolts freeplay out of bolt holes.
Add shims (flat washers) under front engine
mounts, if necessary, and loosely reinstall the
engine mounting bolts.
Let down hoist.
Torque all transmission mounting bolts to (550
Nom) 405-515 lbf-ft. Torque both engine
mounting bolts to 23-27 lbf-ft (32-36 Nom).
Replace the electric wire leads to the transmis-
sion.
Connect two transmission oil cooling lines: At
the transmission control cover, connect the line
that goes to the radiator. At the tee on the
transmission, connect the line that goes to the
oil filter. Be sure of correct assembly. Tighten
connectors to a torque of (25-27 Nom) 18-20
lbf-ft.
Connect -----
At the transmission inching control valve, con-
nect the inching line that comes from the selec-
tor valve.
Inching Line
Connection

CMRK Group 06, Transmission
27. At the brake line tee (on top of the transmis-
sion) that connects the wheel caliper lines to
the selector valve line, connect the line that
goes to the selector valve.
Brake Line
Disconnect.
28. Move the accelerator linkage into position and
install the accelerator cable bracket fasteners
into the accelerator pedal attaching bracket.
Torque fasteners to 83-94 lbf-in (9-l 1 N=m).
Bracket
Fastener
29. Replace fasteners attaching parking brake cable
to transmission case. Replace the parking brake
yoke pin and cotter pin. Spread cotter pin ends.
Yoke Pin
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
Install the connecting pin(s) in shift linkage
yoke(s) at bellcrank on transmission. Insert
cotter pin(s) and bend legs on cotter pin(s).
Replace the upright as described in Group 34,
Section 8, “Upright Removal.”
Fill transmission with correct fluid.
Fill hydraulic sump tank to correct level with
proper fluid.
Install battery and tighten battery terminal nuts
to a torque of 170-191 lbf-in (19-22 Nom).
Make sure terminal boots are fnmly in place.
Start truck, allow fluids to circulate, and shut
off truck.
Recheck fluid transmission and hydraulic fluid
levels.
Bleed the inching lines and bleed the brake
lines from the wheel caliper to the power boost-
ers, as described in Group 23, Section 2, “Brake
and Inching System Bleeding.”
Install the floor plate and tighten the fasteners.
Mount drive wheels on axle ends. Tighten wheel
nuts to a torque of 450-500 lbf-ft (610-678N.m).
Carefully raise truck using approved equip-
ment of adequate capacity and remove block-
ing.

Group 06, Transmission Cl!ARK
40.
41.
42.
47.
Make sure all warning decals are in place.
Carefully check all operating controls in accor-
dance with operator manual.
Check for any binding in control linkages and
make sure all controls return to position when
released.
Operate truck slowly and listen for any unusual
noise in transmission. Make sure truck responds
correctly to forward/reverse shifts, and to low/
high shifts if 2-speed.

Group 06, Transmission Cl!!YRK
HYDRATORK TRANSMISSION SINGLE SPEED AND
TWO SPEED FWD AND REV MODELS HZ00 THRU H213:
When the Hydratork transmission is disassembled,
the following steps must be carefully followed
for correct operation of the transmission. The
arrow shows the location of the model and part
numbers.
1. Remove the torque convertor.
2. Remove all fasteners from the axle adaptor
to transmission. Separate the adaptor from
the transmission by using jackscrews.
Remove the axle adaptor assembly.
3. Remove the axle adaptor adjustment shim(s)
and the O-ring seal.
1 n772
06-4-2 l Transmission Overhaul SM 593, Jan ‘93

CMRK Group 06, Transmission
4. Remove the convertor pump from the trans-
mission assembly.
10224
5. Remove the control cover assembly and
gasket.
6. Install the control cover capscrews into
the oil sleeves. After the capscrews are
in place, lift up on the capscrews (while
holding the oil tubes) to prevent damage
to the tubes.
7. Remove the forward and reverse oil tubes.
10225
10226
SM 593, Jan ‘93 Transmission Overhaul l 06-4-3

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Group 06, Transmission EL’YRK
8. Remove the high and low oil tubes.
NOTE
Single speed speed transmission
does not have hi and lo clutches
as shown in photo.
10228
9. Remove the speed selector oil distributor
retainer ring.
10234
10. Remove the speed selector oil distributor
by pulling out from the transmission.
10235
11. Use soft brass stock to keep the gears
from moving.
10236

Cl!lRK Group 06, Transmission
12. Remove the output shaft retainer.
Fig. 10383
13. Use a soft brass bar to remove the output
shaft from the converter end toward the
axle adaptor end.
Fig. 10237
14. After the shaft has been moved toward the
axle adaptor end, remove the gear, spacer
and thrust washer. Continue to move the
shaft until the shaft assembly is away from
the clutch pack.
Fig. 10238
SM 593, Jan ‘93 Transmission Overhaul l 06-4-5

Group 06, Transmission
Fig. 10244 (Output Shaft Assembly)
15. Remove the transmission input shaft cap
on the axle adaptor end of the transmission.
Later model transmissions do not have this
o-ring seal (a).
Fig. 10229

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