Clark GPH 50 Forklift Service Repair Manual

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

Pictorial Group Index Group 20 Drive Axle Group 34 uprights a_ Group 32 lilt Cylinders Group 23 Braklng/lnchlng Group 21 Prop Shaft Group 06 Transmlsslon Group 29/30 Hydraulic Group 00 Group 02 Fuel Group26/26 -!I - Group 01 Cooling - Group 22 Wheels and Tires Using the Pictorial Group Index and Table of Contents Clakinangespartsandserviceproceduresby~~ Gro~~~s.MostoftheGroupsarereprewWabove.AllGmups are listed in the Table of Contents beginning on the next page. The group number and section number listed in the Table of Contents combine with a page number to provide a unique identifier that is printed on the lower outside comer of each page. For example, “00-1-2” on the lower comer of the page indicates Group 00, Section 1, Page 2. 0 Copyright Clark Materlal Handling 1993 SM 591, Aug ‘93

CONTENTS Table of Contents Section# Group# Group/Section Name INTRODUCTION Safety PlannedMaintenance 00 00 al 00 00 00 ENGINES Engine Troubleshooting Perkins Diesel Engine Workshop Manual GM “Detroit” Diesel EngineWorkshop Manual Ford Gas/LPG BngineWorkshop Manu Engine Removal 01 01 01 01 01 COOL ING SYSTEM Cooling System Troubleshooting Cooling System Testing and Maintenance Fan Belt Replacement Radiator Removal and Replacement 02 02 02 02 02 FUEL SYSTEM Fuel System Troubleshooting Air Induction System The IMPCO Fuel System Removal of IMPCO Vaporizing System 06 06 06 06 06 06 TRANSMISSION Transmission Maintenance and Service Manual Transmission Removal and Installation Transmission Drain and Refill Transmission Oil Cooler Checks Neutral Start Switch 14 14 14 14 14 ELECTRICAL SYSTEM wiring C&r C5de.s ElectricalDiagrzns BlectlicalChecks StarterandAltemator 20 20 20 20 20 20 20 20 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

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

CONTENTS Section# Group # Group/Section Name 34 34 34 34 34 34 34 34 UPRIGHTS Troubleshooting and Visual Iqection OpltiOIldChtXkS Carriage Check and Adjustment Upright Check and Adjustment Cylinder Repair Lift ChainMaintenance Upright Removal and Replacement 38 38 COUNTERWEIGHTS Counterweight Removal and Replacement 1 SPEClFICATIONS Namplates andDecals GxxEralspecifications PM and Driver’s Daily Inqection Forms Lubricants and Shop Supplies Special Tools Lubrication charts and Intervals 40 40 40 40 40 40 40 1 2 3 4 5 6 SM 591, Aug ‘93 C43ntents-3

Emw Introduction Planned Maintenance The Importance of Planned Maintenance ......................................................... 2 2 PM Intervals ......................................................................................................... PM Procedures ..................................................................................................... 3 PM Report F orm ................................................................................................................ Precautions ........................................................................................................................ Visual Inspection ............................................................................................................... Decals, Fasteners, and Leaks ................................................................................................... Carriage and Upright ................................................................................................................ Overhead Guard ....................................................................................................................... Forks ........................................................................................................................................ Wheels and Tires ...................................................................................................................... Brake and Inching Pedal Freeplay ........................................................................................... Functional Tests ................................................................................................................ Starting System ........................................................................................................................ Gauges, Meters, and Indicators ................................................................................................ Accelerator, Brake/Inching System, and Parking Brake .......................................................... 7 Lift Mechanisms and Controls ................................................................................................. Auxiliary Controls ................................................................................................................... Steering System ....................................................................................................................... Shift Control and Brakes .......................................................................................................... Under the Hood ................................................................................................................. Belts and Hoses ........................................................................................................................ Engine Air Cleaner .................................................................................................................. Battery ...................................................................................................................................... Engine Cooling System ............................................................................................................ Engine Gil .............................................................................................................................. Engine Oil and Filter Change ................................................................................................. Hydraulic Sump Tank ............................................................................................................ Hydraulic Fluid and Filter Change ......................................................................................... SumpTankBreather .............................................................................................................. Transmission Fluid Check ..................................................................................................... Drive Axle Fluid Check ......................................................................................................... Air Cleaning the Truck .................................................................................................... Critical Fastener Torque Checks ..................................................................................... Truck Chassis Inspection and Lubrication ...................................................................... 12 Upright and Tilt Cylinder Lubrication ............................................................................ 13 Lift Chain Maintenance ................................................................................................... Lift Chain Adjustment Check ................................................................................................ Lift Chain Inspection and Measurement ................................................................................ Lift Chain Replacement ......................................................................................................... Lift Chain Lubrication ........................................................................................................... ; 3 3 4 4 4 5 : 5 6 7 8 8 ; 9 9 9 9 10 10 11 11 11 11 11 12 12 13 13 14 14 14 Planned Maintenance-1 SM 591, Aug ‘93

Introduction cl!!mK The Importance of 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 intervals 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, ence CLARK has found to be convenient and suitable under normal operation. The operating condition classifications are: and ate based on experi- 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 the lift 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 are highly generalized and should be applied as actual conditions dictate. “*Air restriction indicator may determine interval. Planned Maintenance-2 SM 591, Aug ‘93

Introduction PM Procedures Daily checks and periodic maintenance should be performed according to the following procedures. Visual Inspection 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. PM Report Form 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 required 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 inspection and truck condition. Please note the special codingsystemforindicatingtheimportanceofneeded repairs and/or adjustments. 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 damaged or missing decals and name- plates. Replace them immediately. They contain important iuformatio~~ The periodic maintenance procedures outlined in thismanualateintendedtobeusedwiththePM report form. They are arranged in groupings of maintenance work that are done in a logical and efficient sequence. Inspect the truck before and after starting engine for any signs of extemal leakage: fuel, engine oil or coolant, transmission fluid, etc. 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 maintenance. Check for hydraulic oil leaks and loose fittings. DO NOT USE BARE HANDS TO CHECK. Oil may be hot or under pressure. Precautions A CAUTION /\ ! ! CAUTION Do not make repairs or adjustments unless authorized to do so. HYDRAULIC FLUID PREssuRE. Do not use your hands to check for hydraulic leakage. Fluid under pres- surecaupenetrateyourskinandcause serious injury. Disconnect the battery ground cable (-) from the engine or frame before working on electrical components. Always wear safety glasses. Wear a safety (hard) hat in industrial plants and in special areas where protection is necessary or required Remove all jewehy (watch rings, bracelets, etc.) before working on the truck SM 591, Aug ‘93 Planned Maintenance-3

Introduction el!!mK Overhead Guard Forks Be sure that the driver’s overhead guard and any other safety devices are in place, undamaged and attached securely. Inspect the load forks for cracks, breaks, bending and wear. The fork top surface should be level and even with each other. The height difference between both fork tips should be no more that l/16 inch per foot of fork length. 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. 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. Puta2”thick Check the overhead guard for damage. Be sure that it is properly positioned and all mounting fasteners are in place and tight. Carriage and 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 fasteners and locking means are in place and tight If the fork blades ate obviously bent or damaged, they mustbetepairedorreplacedbefore put into operation. the track is Inspect the fork locking pins for damage. Reinsert them and note whether they fit properly. Besureallsafetyguardsandchainretainersamin place and not damaged. Jnspect the carriage stops and cylinder retainer bolts. Check all welded connections. 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. Planned Maintenance-rl SM 591, Aug ‘93

Introduction Wheels and Tires Brake and Inching Pedal Freeplay 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”. Pxessdownonthebrakepedalwithyourhandto check for &play. The freeplay should be approximately 0.31 inch (8mm). Adjust fieeplay as described in Group 23, if necessary. checkinchingpedalfreeplayaswiththebrakepedal, and adjust if necessary. Functional Tests Besurethat: ? Parking brake is applied. ? 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. Check all wheel lug nuts or bolts to be sure none 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.) Press the horn button to check horn function. If the horn or any other part does not operate, report the faihu-e and 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 position. Starter must not engage until dim&ion control lever is movedtoNEUTRALposition. A WARNING Check tire pressure from a position facing the tread of the tire, not the side. Use a 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 removal and repair. Incorrect (low) tire pressure can reduce stability of your lift truck. See Group 40, Section 2, T@ecification,” for proper inflation Pm 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 start engine, rotate the key clockwise. Release to “run” position when engine starts. The “anti- Planned Maintenance-5 SM 591, Aug ‘93

Introduction lx!mu restart” fm 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. requims that the key be returned to Oil Pressure Gauge Micaks engine oil pressure. Oil pressure should be be- tween3Opsi(207kPa)and 60 psi (414 kPa) at normal engine operating At idle, pressure should not fall below 20- 25 psi (138 kPa). If pressure is low or erratic, shut downtheengineandlocatetheprob 1enL Gauges, Meters, and Indicators speeds. 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. Ammeter Indicatesrateofbatterycharge or discharge. With the engine running, the gauge shouldmadslightlytothe “+” side of 0. If the ammeter shows a continu- ous high rate of charge or discharge, or reads errati- tally, troubleshoot the battery charging system. Water Temperature Gauge Indicates t.czqem gine coolant water in degrees,lOO-280°F (3%138°C). Water temperanne should be about 180°F (82°C) after 10 of operation. Ifthe indicator registers in the ‘hot” zone, turn off the engine and troubleshoot the cooling system. of en- minutes 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 troubleshoot the transmission. 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. (Not used onLPGl CNG.) Air Restriction Indicator Located on the seat deck of diesel models, this indicator shows red when it is time to change the air filter element. NOTICE The electrically-operated gauges register correctly when the key switch is in the ON position. When the key switch is OFF, the indicator needle willnotnecessarilgre~toanygiven position. SM 591, Aug ‘93 Planned Maintenance-5

Introduction Hour Meter Lift Mechanisms and Controls Indicates total engine operating time in hours and tenths. The indicated hoursareusedforplanned maintenance. Record the hours on the PM Report FolnL 1. Check the function of the lift system and controls with the hydraulic pump (engine) running. 2. 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. Accelerator, Brake/Inching System, and Parking Brake Be sure that tbere is adeqnate overhead clearance before raising the up right. 1. 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. 3. Pullbackontheliftcontrolleverandraisethe fork carriage to full height. Watch the upright 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 looseness; the chains should have equal tension and move smoothly without noticeable wobble. Release the lever. 2. Make sure the truck accelerates smoothly. 3. Depress the inching (left) pedal and depress the accelerator to see if the transmission dis- engages properly. 4. Check the function of the parking brake. Apply and then put truck in gear and accelerate 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 Do not operate a lift truck if tbe service or parking brakes are not operating properly. 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. 4. Push forward on the lift control lever. Watch the upright as it lowers. When the forks reach the floor, release the lever. SM 591, Aug ‘93 Planned Maintenance-7

Introduction EmI5 Auxiliary Controls If the truck is equipped with an attachment, test the control lever for correct function and briefly operate the attachment. Shift Control and Brakes Check and make sure that the travel ama is clear in front of the truck. 1. 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. Steering System The steetig system, steer axle 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 a need for inspection or ser- vicing. 2. Remove your right foot from the brake pedal and put 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* II - 3. 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. 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 components should operate smoothly when the steering wheel is turned Never operate a truck which has a steering system fault. A WARNING Fasten your seat belt before the truck. When you have completed the operational tests, park and leave truck according to standard shutdown procedures. Be sure to make a record of all maintenance and operating problems you find. driving Planned Maintenance-9 SM 591, Aug ‘93

Cl!!lRK Introduction Under the Hood Battery Inspect the battery for any damage, cracks, leaking condition, etc. If the terminals are corroded clean and protect them with CLARKBattery Saver (available from your Clark dealer). If the battery has removable cell caps, check to be sure the cells are all filled. Ifnecessary, refill with distilled water. Check fluid levels and other components within the engine compartment. Unlatch and open the hood to access the engine compartment. A ! CAUTION To avoid the possibility of personal injury, never work in engine compartment with engine running except when absolutely necessary to check or makeadjustments. Takeextremecare to keep face, hands, tools, loose clothing,etc.awayfromfananddrivebelts. Also, remove rings. Engine Cooling System Check radiator coolant level (on a daily basis in highcycle applications): 1. Remove the radiator cap, only when the engine 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. watches, bracelets, and Belts and Hoses CAUTION A ! Inspect the engine coolant hoses and fan belt(s). Look for leaking and obvious damage, worn (frayed) condition, breaks, etc. that could cause faihrre during operation. STEAM. Do not remove the radiator cap when the radiator is hot. Steam from the radiator will cause severe burns. Engine Air Cleaner 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. Check the engine air cleaner for damage and contamination (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. Change or service the air cleaner element every 50 to 250 operating hours, depending upon your application. Air cleaner service intervals may also be determined by the air restriction indicator. 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 of the radiator 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 Planned Maintenance-9

Introduction m!!mK Engine Oil 3. The correct PULL level is the bottom edge of the filler neck. 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. Fill Level If level is low, add a 50/50 mixture of specified 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. It is normal to add some oil between oil changes. Keep the oil level above the ADD mark on the dipstick by adding oil as m@red. DO NOT OVER- PILL. Use the correct oil as specified under Lubri- cant specifications. Inspect the coolant\ condition. Look for excessive contamination or rust or oil in the coolant solution. Check the PM time interval for need to change coolant. 4. Engine Oil and Filter Change It is recommended to: 5. Check condition of radiator cap rubber seal and radiator filler neck for damage. Be sure they are clean. Check overflow hose for clogging or damage. Drain and replace the engine crankcase oil every 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 Your lift truck cooling system is fiued with a factory-installed solution of 50% water and 50% permanent-type anti-freeze containing rust and corrosion 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 system. With only water in the system do not let the engine run hot. Do not use alcohol or methanol antifreeze. NOTICE The time interval for changing engine oil will depend upon your application and operating tinditions. To determine the correct schedule for your truck it is qgested periodically submit engine oil samples to a commercial laboratory for analy sis of the condition of the oil. that you Planned Maintenance-1 0 SM 591, Aug ‘93

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 improved fuel economy. 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. For diesel engines, 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. (Severe service or adverse conditions may require mom frequent fluid change). Replace the hydraulic oil filter elements every 1000 hours 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 hydraulic line connections at the filter adapter are tightened correctly. Sump Tank Breather Remove the sump tank fill cap/breather and inspect for excessive (obvious) contammation and damage. Clean or replace the fill cap/breather, per recommended PM schedule or as required by opemting conditions. Hydraulic Sump Tank 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. Transmission Fluid Check 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- Hydraulic fluid expands as its temperanne rises. Therefore, it is preferable to check the fluid level at operating temperamre (after approximately 30 minutes 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. 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. Drive Axle Fluid Check Check the condition of the hydraulic fluid (age, color or clarity, contamination). Change (replace) the oil asnecessary. The drive axle fluid should be checked every PM (typically 50-250 hours). Change fluid every 1000 hours. Hydraulic Fluid and Filter Change Drain and replace the hydraulic sump fluid every 2000 operating hours. Planned Maintenance-l 1 SM 591, Aug ‘93

CLRRK Introduction Air Cleaning the Truck Critical Fastener Torque Checks 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 prevent fires. A clean truck will run cooler. 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: 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. does not remove heavy deposits of grease, oil, etc., it maybenecessaryto usesteam orliquidspmy Drive axle mounting Drive and steer wheel mounting Counterweight mounting Overhead guard mounting Tilt cylinder mounting and yokes Upright mounting and components. Jfairpressure cleaner. Truck Chassis Inspection and Lubrication LIFT TRUCKS SHOULD BE AJR CLEANED AT EVERY PM INTERVAL AND OTHERWISE AS OFTEN AS NECESSARY. Lubrication requirements are given in Group 40 in Section 4, “Lubricant Recommendations,” and in Section 5, ‘2ubrication Jntervals.” 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). Lubrication and inspection of truck chassis components includes steer wheels, steer axle linkage, steering 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. A ! CAUTION Check for play in wheel bearings by attempting to move the wheel side to side and up and down, by hand Wear suitable eye protection and pro- tective clothing. Inspect the steering cylinder piston rods, seal, and fastenersfordamageandleaks, andlooseness. Check for leaks at the steering gear. 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. 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 excess grease from all points afterlubricating.Lubricatemiscellaneouslinkageas needed, Planned Maintenance-1 2 SM 591, Aug ‘93

CldlRK Introduction Upright and Tilt Cylinder Lubrication Clean the fittings and 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. Lift Chain Adjustment Check Lift chains am correctly adjusted if the lower carriage rollers reach their end (lowest) position approximately 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 adjusted. Lift Chain Maintenance On trucks with attachments without forks, raise the carriage to a 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 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 are a result of poor maintenance. need periodic maintenance to give maximum service life. A WARNING Donotattempttorepairawornchai~. Chains Chains. Adjust lift chains by loosening or tightening of the chain anchor nuts. Replace worn or damaged chains. 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. Planned Maintenance-13 SM 591, Aug ‘93

Introduction cl!mK Lii Chain Lubrication Lift Chain Inspection and Measurement Lift chain lubrication is an important part of your maintenance program. The lift chains operate under heavy loadings and will function more safely and have longer life if they are regularly and correctly lubricated. Clark chain lubricant is mcom- mended; itiseasily sprayedonandprovidessuperior lubrication. Heavymotoroilmayalsobeusedasa lubricant and corrosion inhibitor. 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: ? Rust and corrosion ? Crackedplates 4aisedoltllmedpiils ? Tight joints Lubricate the entire length of the upright rail lift and caniage chains with Clark Chain and Cable Lube. ? Wear, wom pins or holes. When the pins or holes become worn the chain becomes longer. When a section of chain is 3% longer than a section of new chain, the chain is worn and must be discarded. 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. 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. Chderreplacementchainsl?omyourCLARKdealer. Replaceallchainsasaset. Do not remove factory lubrication or paint new Chains. Clark provides a chain tool, part number 59-960- 9908, (shown below) that serves as a handy guide for inspecting a variety of chain types. 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. Clark chain tool, part number 59-960-9908 Planned Maintenance-14 SM 591, Aug ‘93

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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.. ... ..Sectio n 3 Perkins G4.236 Engine Workshop Manual ....... Section 4 Engine Removal and Replacement ................................... Section 5 SM 591, Aug ‘93 Group 00

Group 00, Engines Section 1. Engine Troubleshooting Engine Will Not Start ..“..“...“......“..““....“....“....”.”.................“......”.....““........“.“...--.“..” .. 2 .. 2 Engine Does Not Run Evenly .. ..-..“““..““...m.....““~..“““...””....”””.”..-~.....“-“-.-..”..” 2 Engine Does Not Run Evenly .~m..~.......“.““.~..~.“..““~...””””..~..”.~~.”.-...~~..~.~. .” 2 A Loss of Power .“““““..~.~“.H”“.“~......“““.....~..”....~.”..~-................-.“.~“..“.~~.” - 3 Engine Temperature above Normal “..m....W”..~“......~....~~“..~~..~.......~~”-”~~- Oil Consumption above Normal ....... .._............“.““..“.“.....“...”..”~.._””..”...__.“._“..~ .... 3 Black Exhaust Smoke .“.“...“...........“..“.“.....“........”...._..““_“....~.”.”.............“_.“..“.“_” ” 3 ” 3 White Exhaust Smoke “~““....“...“.U”..“.“..“._.“.........”.”...”..”....................““..“.....“....“..“” ._ _“..o.....U”““. 4 .“.“_..““..“.....“..“...“...““~“..”............“__.......” . Truck Slow to Accelerate Timing Wrong ..................................... .._.“......“...“......................”..”._”.....““......”...”~..“.” .” 4 Engine Causes a Loud Noise ..“..“““...““.......................................“............................-“...“-~ . 4 . ...” 4 Engine Noises . General ..... ..“._.._H....“..“.........““.“.................~.....“...................“....““...” ” 4 Other Types of Engine Noises . ..“....““.m.““..........“........-..”...”..”.””.....“...-”-”....-“.- Cylinder Head, Valves, and Rocker Arms ....... .._““....“..“.......“.....““..“......”...........“...“” . ...” 5 5 Cylinder Block, Liners, Pistons, and Rods .“.--.-.....“.-“..~“.“..........”......”.....-”-““.“. Crankshaft, Main Bearings, and Plywheel ....... ..U_......“....“..........““.._.”..”..._””....”._” - 6 Cooling System .~.““...........H........“.......””.........~~..-..“..“..........““.........~...“.“...“...~”~ .- 6 ... 7 Fuel System .“.H.U.........“............“.““.....”..””.....-.........”....”....“....-.“......-“.“-...“....-.- Charging the Circuit .... ..““........U..“.“.“.....“......._............~....“““_.“....”.....““....““._._.“” .... 8 NOTE This troubleshooting chart lists engine problems followed by causes. Each cause is followed by a code indicating whether it pertams to w gasoline(G),dieSel@),LIX%),ornaturaiOOengine. (A) or only to a Additional troubleshooting information may be found in the B m located in Section 2,3, or 4 of Group 00. Engine Troubleshooting . 00-l -1 SM 591, Aug ‘93

Group 00, Engines CmK Engine Does Not Run Evenly Engine Will Not Start Primary Engine Problem Worn camshaft lobes (A) Weak valve springs (A) Wrong valve clearance (A) Bumed valves (A) Low compression (A) Wrong timing (A) Engine tempera&m above normal (A) Bad governor (A) Fuel System Trouble Foreign mate&l in fuel (A) Wrong fuel (A) Bad fuel pump (G, D) Fuel shut off at tank (A) A restriction in air filter system (A) Bad injection nozzles (D) A restriction in fuel filter (A) Carburetor problem (G, L, N) A msIriction in choke linkage (G) Fuel System Problem Air in fuel (G, D) Bad injection nozzles (D) Bad injection pump (D) Water in fuel (G, D) Wrong fuel mixture (A) Bad fuel pump (G, D) Bad carburetor (G, L, NI Eiectricai System Trouble Dirty or loose battery connections (A) Bad or loose wiring (A) Weak battery (A) Bad key switch (A) Badsafety startswitches Bad ignition system (G, L, N) Electrical System Problem Engine Does Not Run Evenly Wrong spark plugs (G, L N) Leaksinwiring(G,L,N) Bad ignition system (G, L, N> Primary Engine Problem Wrong valve clearance (A) A leak in cylinder head gasket (A) Valves burned (A) Wornorbrokenpistontings (A) Low compression (A) Wrong timing (A) Coolant temperamm below normal (A) Engine tempemmre above normal (A) A Loss of Power Primary Engine Problem Broken cylinder-head gasket (A) Worn cam&aft lobes (A) Wrong valve clearance (A) Bumed valves (A) Weak valve springs (A) Wrong timing (A) Low compression (A) Wrong oil viscosity (A) Coolant temperatum wrong (A) Engine tempemture above normal (A) Wrong throttle linkage (G, L, N) Governor not adjusted correctly (A) Fuel System Problem LOW fuel supply (A) Arestrictioninfuel lines orfiltets (A) Bad fuel pump (G, D) Bad injection pump (D) Bad injection nozzles (D) Exhaust system restriction (A) Carbumtor adjusted wrong (G, L, N) Leaks in carburetor or intake manifold gaskets (G,L,N) SM 591, Aug ‘93 ? Engine Troubleshooting 00-l-2

Clark GPH 50 Forklift Service Repair Manual