Clark service repair manual

1. Service
Manual
SM 591
GPH/DPH 50/60/70/75

2. Group 20
DriveAxle
Group 32
lilt Cylinders
Group 21
PropShaft
Group 06
Transmlsslon
Group 00
Group26/26
-!I
PictorialGroup Index
a_
Group 34
uprights
Group 23
Braklng/lnchlng
Group29/30
Hydraulic
Group 02
Fuel
- Group 01
Cooling
- Group 22
Wheelsand Tires
Usingthe PictorialGroupIndexandTableof Contents
Clakinangespartsandserviceproceduresby~~ Contentscombinewith a page number to provide a unique
Gro~~~s.MostoftheGroupsarereprewWabove.AllGmups identifierthat is printed on the loweroutsidecomer of each
arelistedintheTableofContentsbeginningonthenextpage. page.For example,“00-1-2”onthe lowercomer ofthe page
The groupnumberandsectionnumberlistedinthe Tableof indicatesGroup 00,Section1,Page2.
0 CopyrightClarkMaterlalHandling1993 SM 591,Aug ‘93

3. CONTENTS
Group#
00
00
al
00
00
00
01
01
01
01
01
02
02
02
02
02
06
06
06
06
06
06
14
14
14
14
14
20
20
20
20
20
20
20
20
Tableof Contents
Section# Group/Section Name
INTRODUCTION
Safety
PlannedMaintenance
ENGINES
Engine Troubleshooting
Perkins Diesel Engine Workshop Manual
GM “Detroit” Diesel EngineWorkshop Manual
Ford Gas/LPG BngineWorkshop Manu
Engine Removal
COOLING SYSTEM
Cooling System Troubleshooting
Cooling System Testing and Maintenance
Fan Belt Replacement
Radiator Removal and Replacement
FUEL SYSTEM
Fuel System Troubleshooting
Air Induction System
The IMPCO Fuel System
Removal of IMPCO Vaporizing System
TRANSMISSION
Transmission Maintenance and Service Manual
Transmission Removal and Installation
Transmission Drain and Refill
Transmission Oil Cooler Checks
Neutral Start Switch
ELECTRICAL SYSTEM
wiring C&r C5de.s
ElectricalDiagrzns
BlectlicalChecks
StarterandAltemator
DRIVEAXLE
Drive Axle Description
Drive Axle Dissassembly
Drive Axle Assembly
Drive Axle Adjustment and Fastener Torque Values
Drive Axle Ends Disassembly and Assembly
Drive Axle Removal and Installation
Drive Axle Lubrication
(continued on next page)
SM 591, Aug ‘93 COIlbltS-1

4. Group#
21
21
22
22
22
22
22
23
23
23
23
23
23
23
23
25
25
25
25
26
26
26
26
26
26
29
29
29
29
30
30
30
30
30
30
32
32
32
32
section# Group/Section Name
1 PropShaf&
Troubleshooting, Removal, and Service
1
2
3
1
2
3
1
2
3
PROP !sHAFr
WHEELSANDTIRES
Lifting,Jacking, and Blocking
Tire Removal and Mounting
Wheel Mounting
Towing
BRAKING/lNCHINGSYSTEM
System Description and Troubleshooting
Brake and Inching Pedal Adjustment
Brake and Inching System Bleeding
ServiceBrakeInqxctionandOverhaul
MasterCylin~
Hydrovac Overhaul
Parking Brake Adjustment
STEERING COLUMN AND GEAR
SteeringSystemTroubleshooting
Steering Column and Gear Removal
Hydraguide Steering Control Unit
STEER AXLE
SteeringSystemChecksand Adjustments
SteerAxleWheelBearings
Steer Axle Removal and Replacement
Steer Cylinder Removal and Replacement
SteerCylinder Overhaul
HYDRAuLIcsuMP,FJLTERs,ANDPuMP
Hydraulic Filters and Fluid Replacement
Hydraulic Pump Troubleshooting
HydraulicPumpOverhaul
HYDRAuLIccoNTRoLvALvE/LlFTcIRcurr
Hydraulic System Troubleshooting
Hydraulic SystemPressureQxck
Hydraulic Valve Owrhanl
Hydraulic Control Valve Linkage
Hydraulic Schematic
TILT CYLINDERS
Tilt Cylinder Removal and Replacement
Tilt Cylinder Overhaul
Tilt Lock Valve
Contents-2 SM 591, Aug ‘93

5. CONTENTS
Group # Section# Group/Section Name
34
34
34
34
34
34
34
34
38
38
40
40
40
40
40
40
40
1
1
2
3
4
5
6
UPRIGHTS
Troubleshooting and Visual Iqection
OpltiOIldChtXkS
Carriage
Check and Adjustment
Upright Check andAdjustment
Cylinder Repair
Lift ChainMaintenance
Upright Removal and Replacement
COUNTERWEIGHTS
Counterweight Removal and Replacement
SPEClFICATIONS
Namplates andDecals
GxxEralspecifications
PM and Driver’s Daily Inqection Forms
Lubricants and Shop Supplies
Special Tools
Lubrication charts and Intervals
SM591,Aug ‘93 C43ntents-3

6. Emw Introduction
PlannedMaintenance
The Importance of Planned Maintenance ......................................................... 2
PM Intervals ......................................................................................................... 2
PM Procedures ..................................................................................................... 3
PM Report Form
................................................................................................................
Precautions ........................................................................................................................ ;
Visual Inspection ............................................................................................................... 3
Decals,Fasteners,andLeaks ...................................................................................................
3
CarriageandUpright................................................................................................................
4
OverheadGuard.......................................................................................................................
4
Forks ........................................................................................................................................
4
Wheels andTires......................................................................................................................
5
Brake andInching Pedal Freeplay ...........................................................................................
Functional Tests ................................................................................................................ :
StartingSystem ........................................................................................................................
5
Gauges, Meters,andIndicators................................................................................................
6
Accelerator,Brake/InchingSystem,andParking Brake..........................................................
7
Lift Mechanismsand Controls.................................................................................................
7
AuxiliaryControls ...................................................................................................................
8
Steering System .......................................................................................................................
8
Shift Controland Brakes..........................................................................................................
Under the Hood ................................................................................................................. ;
Belts and Hoses........................................................................................................................
9
Engine Air Cleaner ..................................................................................................................
9
Battery......................................................................................................................................
9
Engine CoolingSystem............................................................................................................
9
Engine Gil ..............................................................................................................................
10
Engine Oil andFilter Change.................................................................................................
10
Hydraulic SumpTank ............................................................................................................
11
HydraulicFluid andFilter Change.........................................................................................
11
SumpTankBreather ..............................................................................................................
11
TransmissionFluid Check .....................................................................................................
11
Drive Axle Fluid Check .........................................................................................................
11
Air CleaningtheTruck .................................................................................................... 12
Critical
Fastener Torque Checks ..................................................................................... 12
Truck Chassis Inspection and Lubrication ...................................................................... 12
Upright and Tilt Cylinder Lubrication ............................................................................ 13
Lift Chain Maintenance ................................................................................................... 13
Lift ChainAdjustment Check ................................................................................................
13
Lift ChainInspection andMeasurement................................................................................
14
Lift ChainReplacement .........................................................................................................
14
Lift ChainLubrication ...........................................................................................................
14
SM 591, Aug ‘93 PlannedMaintenance-1

7. Introduction cl!!mK
The Importanceof Planned
Maintenance
A planned maintenance (PM) program of regular,
routine inspections and lubrication is important for
long life and trouble-free operation of your lift truck.
Make and keep records of your inspections. Use
these records to help establish the correct PM inter-
vals for your application and to indicate maintenance
required to prevent major problems from occurring
during operation.
PM Intervals
Time intervals on the following charts and elsewhere
in this Section relate to truck operating hours as
recorded on the hometer, and ate based on experi-
ence CLARK has found to be convenient and suit-
able under normal operation. The operatingcondition
classifications are:
Normal Operation: Eight-hour material handling,
mostly in buikiings or in clean, open air on clean
paved surfaces.
Severe Operation: Prolonged operating hours or
constantusage.
Extreme Operation:
Jn sandy or dusty locations, such as cement
plants,lumbermills,andcoaldustorstonecrush-
ing sites.
H&h-temperature locations, such as steel mills
and foundries.
Sudden temperature changes, such as constant
trips from buildings into the open air, or in re-
frigeration plants.
If thelift truck is used in severe or extreme operating
conditions, the maintenance intervals shouldbe short-
ened accordingly.
NOTICE
Siucethe operating environment of lift
trucksvarieswidely,theabovedescrip-
tions arehighly generalized andshould
be applied as actual conditions dictate.
“*Air restriction indicator may determine interval.
PlannedMaintenance-2 SM 591,Aug ‘93

8. Introduction
PM Procedures VisualInspection
Daily checks and periodic maintenance should be
performed according to the following procedures.
PM ReportForm
First, perform a visual inspection of the lift truck and
its components. Walk around the truck and take note
of any obvious damage andmaintenance problems.
A planned maintenance program of regular, routine
inspections and lubrication is important for long life
and trouble-free operation of your lift truck. Make
and keep records of your inspections. Use these
records to help establish the correct PM intervals for
your application and to indicate maintenance re-
quired to prevent major problems from occuning
during operation.
As an aid in performing and documenting your PM
inspections, Clark has prepared a “Gas, LPG or
Diesel Planned Maintenance Report” form. Copies
of this form may be obtained from your authorized
Clark dealer. We recommend that you use this form
as a checklist and to make a record of your inspec-
tion and truck condition. Please note the special
codingsystemforindicatingtheimportanceofneeded
repairs and/or adjustments.
The periodic maintenance procedures outlined in
thismanualateintendedtobeusedwiththePM
report form. They are arranged in groupings of main-
tenance work that are done in a logical and efficient
sequence.
Decals, Fasteners, and Leaks
Check for loose fasteners and fittings.
Check to be sure all capacity, safety, and warning
plates and decals are attached and legible.
NOTICE
Do not operate a lift truck with dam-
aged or missing decals and name-
plates. Replace them immediately.
They contain important iuformatio~~
When you have finished the PM inspections, be sure
to give a copy of the report to the designated author-
ity or the person responsible for lift truck mainte-
nance.
Inspectthe truck before and after starting engine for
any signs of extemal leakage: fuel, engine oil or
coolant, transmission fluid, etc.
Precautions
/ ! CAUTION
Do not make repairs or adjustments
unless authorized to do so.
Check for hydraulic oil leaks and loose fittings. DO
NOT USE BARE HANDS TO CHECK. Oil may
be hot or under pressure.
A
! CAUTION
Disconnect the battery ground cable (-) from the
engine or frame before working on electrical com-
ponents. Always wear safety glasses. Wear a safety
(hard) hat in industrial plants and in special areas
where protection is necessary or required Remove
alljewehy (watch rings, bracelets,etc.)before work-
ing on the truck
HYDRAULIC FLUID PREssuRE.
Do not use your hands to check for
hydraulic leakage. Fluid under pres-
surecaupenetrateyourskinandcause
serious injury.
SM 591,Aug ‘93 PlannedMaintenance-3

9. Introduction el!!mK
OverheadGuard Forks
Be sure that the driver’s overhead guard and any
other safety devices are in place, undamaged
and attached securely.
Inspecttheload forks for cracks, breaks, bending
and wear. The fork top surface should be level and
even with each other. The height difference be-
tween both fork tips should be no more that l/16
inch per foot of fork length.
Check the overhead guard for damage. Be sure that
it is properly positioned and all mounting fasteners
are in place and tight.
Carriageand Upright
Inspect
the welds on the carriage and upright for
cracks. Report any cracks noted immediately. Be
sum that the mounting fasteners are in place and
tight.
Inspect the upright assembly: rails, carriage rollers,
lift chains, and lift and tilt cylinders. Look for
obvious wear and maintenance problems, damaged
or missing parts. Check for any loose parts or
fittings. Check for leaks, any damaged or loose
rollers and rail wear (metal flaking). Carefully check
the lift chains for wear, rust and corrosion, cracked
or broken links, stretching, etc. Check that the hft
and carriage chains are cornxtly adjusted to have
equal tension. Check that the lift chain anchor fas-
teners and locking means are in place and tight
Besureallsafetyguardsandchainretainersamin
place and not damaged. Jnspect the carriage stops
and cylinder retainer bolts. Check all welded con-
nections.
Jnspect all lift line hydraulic connections for leaks.
Check the lift cylinder rods for wear marks, grooves
and scratches. Check the cylinder seals for leaks.
A WARNING
If the fork blade at the heel is worn
down by more than 10 percent, the
load capacity is reduced and the fork
must be replaced.
Inspecttheforksfortwistsandbends. Puta2”thick
metal block, at least 4” wide by 24” long on the
blade of the fork with the 4” surface against the
blade. Put a 24” carpenter’s square on the top of the
block and against the shank. Check the fork 20”
above the blade to make sure it is not bent more than
1” maximum.
If the fork blades ate obviously bent or damaged,
they mustbetepairedorreplacedbefore the track is
put into operation.
Inspect the fork locking pins for damage. Reinsert
them and note whether they fit properly.
PlannedMaintenance-rl SM 591, Aug ‘93

10. Introduction
Wheels and Tires
Check the condition of the drive and steer wheels
and tires. Remove objects that ate embedded in the
tread. Inspect the tires for excessive wear or breaks
or “chunking out”.
Check all wheel lug nuts or bolts to be surenone are
loose or missing. Have missing bolts or lug nuts
replaced and tightened to correct torque before
opemting truck (See ‘Torque Specifications” in
Group 40.)
A WARNING
Check tire pressure from a position
facing the tread of the tire, not the side.
Usea long handled gauge to keep your
body away from the side. If tires are
low, do not add air. Check with a
mechanic. The tire may require re-
moval and repair. Incorrect (low) tire
pressure can reduce stability of your
lift truck. See Group 40, Section 2,
T@ecification,” for proper inflation
Pm
Brake and Inching Pedal Freeplay
Pxessdownonthebrakepedalwithyourhandto
check for &play. The freeplay should be approxi-
mately 0.31 inch (8mm). Adjust fieeplay as de-
scribed in Group 23, if necessary.
checkinchingpedalfreeplayaswiththebrakepedal,
and adjust if necessary.
FunctionalTests
Besurethat:
l Parkingbrake is applied.
l Directional control is in ‘W’(neutral).
Test the horn, lights and all other safety equipment
and accessories. Be sure they are properly mounted
and working correctly.
Press the horn button to check horn function. If the
horn or any other part does not operate, report the
faihu-eand have it repaired before the truck is put in
operation.
Now prepare to start the truck so that you can test
gauges, accelerator service and parking brakes, all
hydraulic controls, directional controls, and steering
system. All controls must operate freely and return
to neutral properly.
Starting System
A 3position starter switch is standard equipment.
Check the operation of the
neutral start switch by plac-
ing direction control lever in
forwardorreverseandturning
key switch to START posi-
tion. Starter must not engage
until dim&ion control lever is
movedtoNEUTRALposition.
As you start the engine, check the instrument panel.
The oil pressure gauge and ammeter should register
when the key reaches the on position. The other
gauges should register as the engine cranks over.
To startengine, rotate the key clockwise. Release to
“run”position when engine starts. The “anti-
SM 591, Aug ‘93 PlannedMaintenance-5

11. Introduction lx!mu
restart” fm requims that the key be returned to
the “off’ position before it can again be turned to
“start” If engine does not start on the first attempt,
do not reengage the starter until engine comes to a
complete stop (approximately 5 seconds). After the
engine starts, let it warm up until it runs evenly.
Gauges,Meters,andIndicators
The gauges, hour meter, and indicator light in the
instrument panel tell you many important things
about the performance of your lift truck FamGrizc
you&f with their location and purpose and make it
a practice to scan the instrument panel as you start
the engine, after it starts, and periodically as you
operate the tmck.
Water Temperature Gauge
Indicatest.czqem of en-
gine coolant water in de-
grees,lOO-280°F
(3%138°C). Water tem-
peranne should be about
180°F (82°C) after 10
minutes of operation.Ifthe
indicator registers in the
‘hot” zone, turn off the en-
gine and troubleshoot the cooling sys-
tem.
Fuel Gauge
Indicates quantity of fuel re-
maininginthetanki&ac-
tions of the whole. Fuel
level should be checked
at the beginning of each
shift. The tank should be
fullatthebeginningof
each shift. (Notused onLPGl
CNG.)
Oil Pressure Gauge
Micaks engine oil pressure.
Oil pressure should be be-
tween3Opsi(207kPa)and
60 psi (414 kPa) at nor-
mal engine operating
speeds. At idle, pressure
should not fall below 20-
25 psi (138 kPa). If pres-
sure is low or erratic, shut
downtheengineandlocatetheprob
1enL
Ammeter
Indicatesrateofbatterycharge
or discharge. With the en-
gine running, the gauge
shouldmadslightlytothe
“+” side of 0. If theam-
meter shows a continu-
ous high rate of charge or
discharge, or reads errati-
tally, troubleshoot the bat-
tery charging system.
Transmission Temperature tight
This light comes on when oil temperature in the
torque converter is too high. Shift to a lower range.
If light stays on, shut the truck down and trouble-
shoot the transmission.
Air Restriction Indicator
Locatedon the seat deck of diesel models, this
indicator shows red when it is time to change the air
filter element.
NOTICE
Theelectrically-operated gauges reg-
ister correctly when the key switch is
in the ON position. When the key
switch is OFF, the indicator needle
willnotnecessarilgre~toanygiven
position.
PlannedMaintenance-5 SM591, Aug ‘93

12. Introduction
Hour Meter
Indicatestotal engine oper-
ating time in hours and
tenths. The indicated
hoursareusedforplanned
maintenance. Record the
hours on the PM Report
FolnL
Accelerator, Brake/Inching System, and
Parking Brake
1.
2.
3.
4.
Push the brake (right) pedal down fully and
hold. The brakes should apply before the
pedal reaches the floor-plate. If the pedal
continues to creep downwards, report ‘the
failure immediately. DO NOT OPERATE
THE TRUCKUNTILTHEBRAKESARE
REPAIRED.
Make sure the truck accelerates smoothly.
Depress the inching (left) pedal and depress
the accelerator to see if the transmission dis-
engages properly.
Check the function of the parking brake.
Apply and then put truck in gear and acceler-
ate to insure that brake holds. Park the truck
on a grade and apply the parking brake. The
parking brake should hold a lift truck with
rated load on a 15% grade.
A
! CAUTION
Donot operate a lift truck if tbe ser-
vice or parking brakes are notoperat-
ing properly.
Lift Mechanisms and Controls
1.
2.
3.
4.
Check the function of the lift system and
controls with the hydraulic pump (engine)
running.
Pull back on the tilt control lever and hold
until the upright reaches the full back tilt
position. Push forward on the lever to return
the upright to the vertical position. Release
the lever.
Be sure that tbere isadeqnate over-
head clearance before raising the up
right.
Pullbackontheliftcontrolleverandraisethe
fork carriage to full height. Watch the up-
right assembly as it rises. All movements of
the upright, fork carriage, and lift chains
must be even and smooth, without binding or
jerking. Watch for chain wobble or loose-
ness; the chains should have equal tension
and move smoothly without noticeable
wobble. Release the lever.
If the maximum fork height is not reached,
this indicates there is an inadequate (low) oil
level in the hydraulic sump tank or severe
binding within the upright.
Push forward on the lift control lever. Watch
the upright as it lowers. Whentheforks reach
the floor, release the lever.
SM 591,Aug ‘93 PlannedMaintenance-7

13. Introduction EmI5
AuxiliaryControls
If thetruck is equipped with an attachment, test the
control lever for correct function and briefly operate
the attachment.
SteeringSystem
The steetig system,steeraxle and steering linkage
shouldbeinspectedperiodically forabnormalloose-
ness and damage, leaking seals, etc. Also, be alert
for any changes in steering
action: Hard steering, e;
cessive freeplay (looseness)
or unusual sound when turn-
ingormaneuveringindicates II -
a need for inspection or ser-
vicing.
Check the steering system by moving the steering
handwheel in a full right turn and then in a full left
turn. Return the handwheel (steer wheels) to the
straight-ahead position. The steering system com-
ponents should operate smoothly when the steering
wheel is turned
Never operate a truck which has a steering sys-
tem fault.
A WARNING
Fasten
yourseatbelt before
the truck.
driving
ShiftControland Brakes
Check and make sure that the travel ama is clear in
front of the truck.
1.
2.
3.
Push firmly on the brake (right) pedal. Re-
lease the parking brake. Move the directional
control lever from “N” (neutral) to FOR-
WARD travel position.
Remove your right foot from the brake pedal
andput it on the accelerator
pedal. Push down
until the truck moves slowly forward. Re-
move your foot from the accelerator pedal
and push down on the brake pedal to stop the
truck. The brakes should apply smoothly and
ePallY*
Be sure the travel area is clear behind the
truck. Put the directional control lever in the
REVERSE travel position. Push down on the
accelerator pedal until the truck moves slowly
in the reverse direction. Remove your foot
from the accelerator pedal and push down on
the brake pedal to stop the truck. The brakes
should apply smoothly and equally.
When you have completed the operational tests,
park and leave truck according to standard shut-
down procedures. Be sure to make a record of all
maintenance and operating problems you find.
PlannedMaintenance-9 SM591, Aug ‘93

14. Cl!!lRK Introduction
Underthe Hood Battery
Check fluid levels and other components within the
engine compartment. Unlatch and open the hood to
access the engine compartment.
Inspect
thebattery for any damage, cracks, leaking
condition, etc. If the terminals are corroded clean
and protect them with CLARKBattery Saver (avail-
able from your Clark dealer). If the battery has
removable cell caps, checktobe sure the cells are all
filled. Ifnecessary, refill with distilled water.
A
! CAUTION
To avoid the possibility of personal
injury, never work in engine com-
partment with engine running except
when absolutely necessary to check or
makeadjustments. Takeextremecare
to keep face, hands, tools, loose cloth-
ing,etc.awayfromfananddrivebelts.
Also, remove
rings.
Belts and Hoses
watches, bracelets, and
Inspect the engine coolant hoses and fan belt(s).
Look for leaking and obvious damage, worn (frayed)
condition, breaks, etc. that could cause faihrre dur-
ing operation.
Engine Air Cleaner
Check the engine air cleaner for damage and con-
tamination (excessive dirt buildup and clogging).
Check for correct mounting attachments of the air
cleaner. Be sure that the air cleaner hose is securely
connected (not loose or leaking). Fan or cone shaped
dust deposits on tube or hose surfaces indicate a
leak.
Changeor service the air cleaner element every 50
to 250 operating hours, depending upon your appli-
cation. Air cleaner service intervals may also be
determined by the airrestriction indicator.
Engine Cooling System
Check radiator coolant level (on a daily basis in
highcycle applications):
1. Remove the radiator cap, only when the en-
gine is cold First turn the cap slowly to
release pressure that may be in the radiator.
Then push the cap down fully and turn to
release and remove the cap.
A ! CAUTION
STEAM. Do not remove the radiator
cap when the radiator is hot. Steam
from the radiator will cause severe
burns.
Never remove the radiator cap while the engine is
running. Stop the engine and wait until it has cooled.
Even then, use extreme care when removing the cap
i?omtheradiator. Itisgoodsafetypmcticetousea
shop cloth to cover the radiator cap while it is being
removed. Wrap the cloth around the cap and turn it
slowly to the first stop. Step back while the pressure
is released from the cooling system.
2. When you are sure all the pressure has been
released, press down on the cap, with the
cloth in place, turn and remove it. Stand clear
oftheradiator opening;hot coolant may splash
out. Failure to follow these instructions could
result in serious personal injury from hot
coolant or steam blowout and/or damage to
the cooling system or engine.
SM 591,Aug ‘93 PlannedMaintenance-9

15. Introduction m!!mK
3. The correct PULL level is the bottom edge of
the filler neck.
Fill
Level
4.
5.
If level is low, add a 50/50 mixture of speci-
fied coolant and water to the correct fii level.
If you have to add coolant more than once a
month or if you have to add more than one
quart at a time, check the cooling system for
leaks.
Inspect the coolant condition. Look for ex-
cessive contamination or rust or oil in the
coolant solution. Check the PM time interval
for need to change coolant.
Check condition of radiator cap rubber seal
and radiator filler neck for damage. Be sure
they are clean. Check overflow hose for clog-
ging or damage.
NOTICE
Your lift truckcooling
system is fiued
with a factory-installed solution of
50% water and 50% permanent-type
anti-freeze containing rust and corro-
sion inhibitors. You should leave it in
yeararound. Plainwatermaybeused
only in an emergency, but replace it
with the specified coolant as soon as
possible to avoid damage to the sys-
tem. With only water in the system
do not let the engine run hot. Do not
use alcohol or methanol antifreeze.
Engine Oil
With the truck level and the engine shutdown for at
least 2 minutes, check the engine oil level.
Locate the engine oil dipstick. Pull the dipstick out,
wipeitwith acleanwiperandrGnsertitfu.llyintothe
dipstick tube. Remove the dipstick and check oil
level.
It is normal to add some oil between oil changes.
Keep the oil level above the ADD mark on the
dipstick by adding oil asm@red. DO NOT OVER-
PILL. Use the correct oil as specified under Lubri-
cant specifications.
Engine Oil and Filter Change
It is recommended to:
Drain and replace the engine crankcase oil ev-
ery 50 to 250 operating hours. See NOTICE
below.
Replace the engine oil filter every oil change.
Remove the oil pan drain plug to drain old oil,
after truck has been in operation and engine
(oil) is hot (at operating temperature).
NOTICE
The time interval for changing en-
gine oil will depend upon your appli-
cation and operating tinditions. To
determine the correct schedule for
your truck it is qgested that you
periodically submit engine oil samples
to a commercial laboratory for analy
sis of the condition of the oil.
Planned Maintenance-1 0 SM 591, Aug ‘93

16. ELclRK Introduction
Oil performance designation: To help achieve
proper engine performance and durability, use only
engine lubricating oils of the proper quality. These
oils also help promote engine efficiency which re-
sults in improvedfueleconomy. A symbol has been
developed by the API (American Petroleum Insti-
tute) to help you select the proper engine oil. It
should be included on the oil container you pur-
chase. Fordieselengines, CLARK recommends that
you use motor oil that meets API Service Classilica-
tion CR/SF. CC/CD or CD/SF oils can be used in
areas where CE oil is not available. See “Lubrication
Specifications in Group 40.
HydraulicSumpTank
Check the hydraulic sump tank fluid level. Correct
fluid level is important for proper system operation.
Low fluid level can cause pump damage. Overfill-
ing can cause loss of fluid or lift system malfunction.
Hydraulic fluid expands as its temperanne rises.
Therefore, it is preferable to check the fluid level at
operating temperamre (after approximately 30 min-
utes of tmck operation). To check the fluid level,
first park the truck on a level surface and apply the
parking brake. Put the upright in a vertical position
and lower the fork carriage fully down. Pull the
dipstick out, (attached to the sump breather) wipe it
with a clean wiper and reinsert it. Remove dipstick
and check oil level. Keep the oil level above the
LOW mark on the dipstick by adding recommended
hydraulic fluid only, as required DO NOT OVER-
FLL.
Check the condition of the hydraulic fluid (age,color
or clarity, contamination). Change (replace) the oil
asnecessary.
HydraulicFluidand FilterChange
Drainand replace the hydraulic sump fluid every
2000 operating hours.
(Severe service or adverse conditions may require
mom frequent fluid change). Replace the hydraulic
oil filter elements every 1000hours and at every oil
change. Remove, clean, and reinstall the hydraulic
and steer system suction line screens a.tfirstPMand
every 500 hours thereafter. Check for leaks after
installation of the filters. Also, check that the hy-
draulic line connections at the filter adapter are tight-
ened correctly.
SumpTank Breather
Remove the sump tank fill cap/breather and inspect
for excessive (obvious) contammation and damage.
Clean or replace the fill cap/breather, per recom-
mended PM schedule or as required by opemting
conditions.
TransmissionFluidCheck
Before making check, run engine until unit is at
operating temperature. This is important as tmns-
mission oil temperature should be 200 degrees F and
the engine water jacket should be at opemting tem-
Apply parking brake. With the engine operating at
idle and the tmmmission in NEUTRAL, check the
fluid on the dipstick. Fill if necessary to the FULL
mark on the dipstick using “Amoco looo” (Clark
ti776236; 1 gal. can). Change fluid every 1000
hours.
DriveAxle FluidCheck
The drive axle fluid should be checked every PM
(typically 50-250 hours). Change fluid every 1000
hours.
SM 591, Aug ‘93 PlannedMaintenance-l1

17. Introduction CLRRK
Air Cleaningthe Truck
Always maintain a lift truck in a clean condition. Do
not allow dirt, dust, lint or other contaminants to
accumulate on the truck. Keep the truck fIee from
leaking oil and grease. Wipe up ah oil or fuel spills.
Keep the controls and floorboards clean dry, and
safe. A clean truck makes it easier to see leakage,
loose, missing, or damaged parts, and will help pre-
vent fires. A clean truck will run cooler.
The environment in which a lift truck operates will
determine how often and to what extent cleaning is
necessary. For example, trucks operating in manu-
facturing plants which have a high level of dirt, dust
or lint, (e.g. cotton fibers, paper dust, etc.) in the air
or on the floor or ground will require more frequent
cleaning. The radiator, especially, may require daily
aircleaningtoensurecorlectcooling. Jfairpressure
does not remove heavy deposits of grease, oil, etc., it
maybenecessaryto usesteam orliquidspmy cleaner.
LIFT TRUCKS SHOULD BE AJR CLEANED AT
EVERY PM INTERVAL AND OTHERWISE AS
OFTEN AS NECESSARY.
Air cleaning should be done using an air hose with
special adapter or extension having a control valve
and nozzle to direct the air properly. Use clean, dry,
low-pressumcompressedair. Restrictairpressureto
30 psi (207 kPa), maximum. (OSHA mquirement).
A
! CAUTION
Wear suitable eye protection and pro-
tective clothing.
Air clean: upright assembly, drive axle, radiator,
from both counterweight and engine side, engine
and accessories, driveline and related components,
steer axle and steer cylinder.
CriticalFastenerTorqueChecks
Fasteners in highly loaded (critical) components can
quickly fail if they become loosened; also, loose
fasteners can cause damage or failure of the compo-
nent. For safety it is important that the correct torque
be maintained on all critical fasteners of components
which directly support, handle or control the load
and protect the operator.
Check torque of critical items, including:
Drive axlemounting
Drive and steer wheel mounting
Counterweight mounting
Overhead guard mounting
Tilt cylinder mounting and yokes
Upright mounting and components.
TruckChassisInspectionand
Lubrication
Lubrication requirements are given in Group 40 in
Section 4, “Lubricant Recommendations,” and in
Section 5, ‘2ubrication Jntervals.”
Lubrication and inspection of truck chassis compo-
nents includes steer wheels, steer axle linkage, steer-
ing cylinder, and wheel bearings. To check these
items, the truck must be properly raised and blocked
as described in “Lifting, Jacking, and Blocking” in
Croup 22, section 1.
Check for play in wheel bearings by attempting to
move the wheel side to side and up and down, by
hand
Inspect the steering cylinder piston rods, seal, and
fastenersfordamageandleaks, andlooseness. Check
for leaks at the steering gear.
Check linkages by observing whether the steer
wheels lag when you turn the handwheel.
Lubricate the steer axle linkage rod ends and pivot
points. Be sure to clean the gmase fittings before
lubricating. Remove the excessgreasefrom allpoints
afterlubricating.Lubricatemiscellaneouslinkageas
needed,
PlannedMaintenance-1
2 SM 591, Aug ‘93

18. CldlRK Introduction
Uprightand Tilt CylinderLubrication
Clean
thefittingsand lubricate the tilt cylinder rod
end bushings (forward end). Clean the fittings and
lubricate the tilt cylinder base rod end bushings
(rear end). Clean and lubricate the upright trunnion
bushings.
LiftChain Maintenance
Lift chains are very important components of fork
lift trucks. The chain system on your upright was
designed for safe, efficient and reliable transmission
of lifting force from hydraulic cylinder to the forks.
Safe use of your truck with nrinimurn down-time
depends on the correct cam and maintenance of the
lift chains. Most complaints of unacceptable chain
pzrRnmance area resultofpoormaintenance.
Chains
need periodic maintenance to give maximum ser-
vice life.
A WARNING
Donotattempttorepairawornchai~.
Replace worn or damaged chains.
Lift Chain Adjustment Check
Lift chains am correctly adjusted if the lower car-
riage rollers reach their end (lowest) position ap-
proximately 0.50 inch (13mm) from the lower edge
of the inner rail.
On trucks with forks, measure the height of the
fork from the floor, which should be approximately
0.50 (13mrn) when the lift chain is corm&y ad-
justed.
On trucks with attachments without forks, raise
thecarriagetoa height that exposes several inches of
the inner rail at the roller path. Apply a light layer of
grease to the roller path on the inner rail. Lower the
carriage and pick up a rated capacity load, (tilt the
upright back slightly) and raise the load until the
carriage rollers have passed over the greased area.
Lower the load completely and remove the load
from the forks. Raise the carriage again to expose the
inner rail. Now check the track the roller left in the
grease and determine the correct adjustment of the
Chains.
Adjust lift chains by loosening or tightening of the
chain anchor nuts.
On trucks with triple stage uprights, adjust back
chains so that the inner rail top is 0.125 inch (3.2
mm) above the intermediate rail. Adjust chains for
even tension.
NOTICE
Itisimportanttomaketheliftchain
adjustment check with a rated load to
makesurethatthechainsarestretched
to their maximumlength.
SM591,Aug ‘93 PlannedMaintenance-13

19. Introduction cl!mK
Lift Chain Inspection and Measurement Lii Chain Lubrication
Inspezt
and lubricate the lift chains every truck PM
(50-250 hours). When operating in corrosive envi-
ronments, inspect the chains every 50 hours. During
the impection, check for the following conditions:
l Rust and corrosion
l Crackedplates
4aisedoltllmedpiils
l Tight joints
l Wear, wom pins or holes.
Lift chain lubrication is an important part of your
maintenance program. The lift chains operate un-
der heavy loadings and will function more safely
and have longer life if they are regularly and cor-
rectly lubricated. Clark chain lubricant is mcom-
mended;itiseasily sprayedonandprovidessuperior
lubrication. Heavymotoroilmayalsobeusedasa
lubricant and corrosion inhibitor.
Lubricate the entire length of the upright rail lift
and caniage chains with Clark Chain and Cable
Lube.
When the pins or holes become worn the chain
becomes longer. When a sectionof chainis3%
longer than a section of new chain, the chain is
worn and must be discarded.
Chainwearcanbemeasumdbyusingachainscale
or a steel tape measure. When checking chain wear,
be sure to measure a segment of chain that moves
over a sheave. Do not repair chains by cutting out
the worn section and joining in a new piece. If part
of a chain is wom, replace all the chains on a truck.
Clark provides a chain tool, part number 59-960-
9908, (shown below) that serves as ahandy guide for
inspecting a variety of chain types.
Lii Chain Replacement
All chains must be replaced if any strand has wear
of 3% or more, or if any of the damaged conditions
noted are found during inspection.
Chderreplacementchainsl?omyourCLARKdealer.
Replaceallchainsasaset.
Do not remove factory lubrication or paint new
Chains.
Replace anchor pins and worn or broken anchors
when instalhng new chains.
Adjust tension on new chains.
Lubricate chains when they are installed on the
upright.
Clarkchain tool,part number59-960-9908
PlannedMaintenance-14 SM591, Aug ‘93

20. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

21. GROUP 00, ENGINES
GROUP 00
ENGINES
Engine Troubleshooting..................................................... section 1
Perkins 4.248.2 Diesel Engine Workshop Manual ............ Section 2
GM 3-53N Detroit Diesel Engine Workshop Manual.. .....Section 3
Perkins G4.236 Engine Workshop Manual .......Section 4
Engine Removal and Replacement ................................... Section 5
SM 591, Aug ‘93 Group 00

22. Group 00, Engines
Section1.
EngineTroubleshooting
Engine Will Not Start..“..“...“......“..““....“....“....”.”.................“......”.....““........“.“...--.“..”..2
EngineDoesNot Run Evenly ....-..“““..““...m.....““~..“““...””....”””.”..-~.....“-“-.-..”..” ..2
EngineDoesNotRun Evenly .~m..~.......“.““.~..~.“..““~...””””..~..”.~~.”.-...~~..~.~. 2
A Loss of Power .“““““..~.~“.H”“.“~......“““.....~..”....~.”..~-................-.“.~“..“.~~.” .”2
EngineTemperatureaboveNormal“..m....W”..~“......~....~~“..~~..~.......~~”-”~~- - 3
Oil ConsumptionaboveNormal ........._............“.““..“.“.....“...”..”~.._””..”...__.“._“..~ ....3
BlackExhaust Smoke .“.“...“...........“..“.“.....“........”...._..““_“....~.”.”.............“_.“..“.“_” ”3
WhiteExhaust Smoke“~““....“...“.U”..“.“..“._.“.........”.”...”..”....................““..“.....“....“..“”
”3
Truck Slowto Accelerate
._
.“.“_..““..“.....“..“...“...““~“..”............“__.......”. _“..o.....U”““.
4
TimingWrong .....................................
.._.“......“...“......................”..”._”.....““......”...”~..“.”.”4
Engine Causesa LoudNoise ..“..“““...““.......................................“............................-“...“-~
.4
EngineNoises. General.......“._.._H....“..“.........““.“.................~.....“...................“....““...”
....”4
OtherTypesof EngineNoises...“....““.m.““..........“........-..”...”..”.””.....“...-”-”....-“.- ”4
CylinderHead,Valves,and RockerArms........._““....“..“.......“.....““..“......”...........“...“”
....”5
CylinderBlock,Liners,Pistons,and Rods.“.--.-.....“.-“..~“.“..........”......”.....-”-““.“. 5
Crankshaft,MainBearings,andPlywheel.........U_......“....“..........““.._.”..”..._””....”._” - 6
CoolingSystem.~.““...........H........“.......””.........~~..-..“..“..........““.........~...“.“...“...~”~ .- 6
Fuel System.“.H.U.........“............“.““.....”..””.....-.........”....”....“....-.“......-“.“-...“....-.- ...7
Chargingthe Circuit......““........U..“.“.“.....“......._............~....“““_.“....”.....““....““._._.“”
....8
NOTE
Thistroubleshootingchartlistsengineproblemsfollowedby causes.Each causeis
followed by a code indicatingwhetherit pertamsto w (A) or only to a
gasoline(G),dieSel@),LIX%),ornaturaiOOengine.
Additional troubleshootinginformationmay be found in the B
m locatedin Section2,3, or4 of Group00.
SM591, Aug ‘93 EngineTroubleshooting . 00-l -1

23. Group00, Engines CmK
EngineWill NotStart
FuelSystemTrouble
Foreignmate&l in fuel (A)
Wrongfuel (A)
Badfuelpump (G,D)
Fuelshutoff attank (A)
Arestrictioninairfilter system(A)
Badinjectionnozzles(D)
Arestrictioninfuelfilter(A)
Carburetorproblem(G,L,N)
AmsIrictionin chokelinkage(G)
EiectricaiSystemTrouble
Dirtyor loosebatteryconnections(A)
Bador loosewiring(A)
Weakbattery(A)
Badkey switch(A)
Badsafety startswitches
Badignitionsystem(G,L, N)
EngineDoesNot RunEvenly
PrimaryEngineProblem
Wrongvalveclearance(A)
A leakin cylinderheadgasket(A)
Valvesburned(A)
Wornorbrokenpistontings (A)
Lowcompression(A)
Wrongtiming(A)
Coolanttemperammbelownormal(A)
Enginetempemmreabovenormal(A)
FuelSystemProblem
LOW
fuelsupply(A)
Arestrictioninfuel linesorfiltets (A)
Badfuelpump (G,D)
Badinjectionpump (D)
Badinjectionnozzles(D)
Exhaustsystemrestriction(A)
Carbumtoradjustedwrong(G,L, N)
Leaks in carburetor or intake manifold gaskets
(G,L,N)
EngineDoesNotRunEvenly
PrimaryEngineProblem
Worncamshaftlobes(A)
Weakvalvesprings(A)
Wrongvalveclearance(A)
Bumed valves(A)
Lowcompression(A)
Wrongtiming(A)
Enginetempera&mabovenormal(A)
Bad governor(A)
FuelSystemProblem
Airinfuel (G,D)
Badinjectionnozzles(D)
Badinjectionpump (D)
Waterinfuel(G,D)
Wrongfuelmixture(A)
Badfuelpump (G,D)
Badcarburetor(G,L, NI
ElectricalSystemProblem
Wrong sparkplugs (G, L N)
Leaksinwiring(G,L,N)
Badignitionsystem(G,L, N>
A Lossof Power
PrimaryEngineProblem
Brokencylinder-headgasket(A)
Worncam&aftlobes(A)
Wrongvalveclearance(A)
Bumedvalves(A)
Weakvalvesprings(A)
Wrongtiming(A)
Low compression(A)
Wrongoilviscosity(A)
Coolanttemperatumwrong(A)
Enginetempemtureabovenormal(A)
Wrongthrottlelinkage(G,L, N)
Governornotadjustedcorrectly(A)
00-l-2 l EngineTroubleshooting SM 591, Aug ‘93