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Clark GPS Standard Forklift Service Repair Manual

service repair manual

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Clark GPS Standard Forklift Service Repair Manual

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  1. SM-520R GCS/GCS Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

  2. Foreword This service publication provides information covering normal service, maintenance and repair of the Clark lift trucks noted on the cover. It has been specifically prepared to help owners and service personnel maintain these lift trucks in efficient and safe operating condition. Regular, correct maintenance and care of lift trucks is not only important for long and efficient truck life; it is essential for safe operation. The importance of proper maintenance through planned service, inspection and qualified repairs cannot be emphasized too strongly. To assist in keeping lift trucks in good operating condition, this manual includes preventive maintenance procedures to be performed at regular intervals. These are essential to the service life and safe operation of all fork lift trucks. Instructions for safety inspections, operational checks, cleaning, and lubrication are provided for reference in setting-up and conducting a recommended periodic Planned Maintenance (PM) program. Refer to the Operator’s Manual, located on the truck, for additional information on the operation, care and maintenance of your truck. Genuine Clark replacement parts should be used for all service and repair requirements. Substitute parts from other sources may be different than original parts and may not meet OSHA or other safety requirements. Any reference to brand names other than Clark in this manual is made simply as an example of the type of tools and materials recommended for use and, as such, should not be considered as an endorsement. Equivalents, if available, may be used. For more information on maintenance and repair of these trucks, contact your authorized Clark dealer. NOTICE - The descriptions and specifications included in this manual were in effect at the time of printing. C/ark Equipment Company reserves the right to discontinue models at any time, or make improvements and changes in specifications or design without notice and without incurring obligation. Specifications, torques, pressures, measurements, adjustments, illustrations and other items may change at any time. Contact your authorized CLARK dealer for information on possible updates or revisions. 0 1989 Clark Equipment Company 1211 I89 SM520 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute ii

  3. Contents Part Subject 1 General Information ........................................................................... 2 Specifications ........................................................................................ Planned Maintenance ....................................................................... 3 Engine (Group 00) .................................................................................... 4 5 Fuel System (GROUPS 02,03) ................................................................. 6 Electrical System (Groups 11-15) ........................................................ 7 Transaxle (stops 06,07,20) ................................................................. 8 Brakes and Inching System (GIOUPS 22,23) ................................... 9 Steering System (Groups 25,26) ......................................................... IO Hydraulic System (Groups 28-33) ..................................................... 11 Wheels and Tires (Groups 22,23) .................................................... Counterweight and Chassis (Group 38) ...................................... 12 Uprights (Group 34). ............................................................................. 1 3 14 Index.. .................................................................................................... 212719 SM520 1 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute . . . III

  4. About This Manual This manual is intended for use by persons who are trained and authorized to do lift truck maintenance. It is designed to provide essential information about the correct and safe service maintenance and repair of the lift truck by trained mechanics of service technicians. The information is organized into 14 major Parts of related components or topics as outlined by the Table of Contents at the front of the manual: . 1 General information including precautions and safe maintenance practices. ? 2 Service specifications and reference information including lubricants, capacities, pressures, etc. ? 3 Planned Maintenance (PM) service procedures. ? 4-13 Adjustment, service and repair procedures for truck components. In Parts 4-13, the detailed service and repair procedures are arranged in Sections for each procedure, component or subsystem. Some Sections include explanations that cover service procedures common to several components or subsystems. In general, each Section is written to show and describe the general arrangement, adjustment, removal, disassembly, inspection, repair, and assembly steps that are normally required to service the component. Component specifications (as applicable), information notes and safety messages are included within those procedures. In most cases, specifications are shown in Section 2, Service Specifications, for convenience of reference. Each Section includes Parts GROUP number(s) at the bottom of each page for cross reference. The Parts GROUP numbers are the same as the component group in the Master Parts Book and Service Parts Book. They are parts system reference numbers; use only the appropriate Parts Manual for ordering parts. Do not order parts from numbers shown in this manual. The Table of Contents lists major headings of Parts of the manual. Additional content listings are placed at the beginning of each Section of the manual, subsection or component heading to simplify reference to multiple topics or procedures covering optional equipment, such as engines and transaxles. If you cannot find a topic in the respective Table of Contents, check the Alphabetical Subject Index at the back of the manual. This manual has been made easier to use by providing only specific steps and instructions necessary to explain the activity, component, assembly, or process being worked on. The technician is expected to include obvious additional steps of standard procedure for removal, disassembly, cleaning, inspection, reassembly, installation, etc., as needed. To be better prepared to do the necessary service work, take time to completely read the entire procedure, including any special instructions, before doing any work. The technician is cautioned and expected to always work in a safe manner by using the correct procedure. Do not take chances which may result in injuries. 12/l/89 SM520 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute -v

  5. 1 General Information 1 .O-2 Safe Maintenance Practices.. ................................................ 1 .O-4 Safety Signs and Messages.. ................................................. 1 .o-5 General Precautions ............................................................. 1 .O-6 Product identification.. .......................................................... 1 .O-6 Model Nomenclature ......................................................... 1 .O-7 Model Designations.. ......................................................... 1 .O-7 Model Serial Number Code.. .............................................. .l .O-8 Vehicle and Upright Identification.. ..................................... .I .O-9 Product Visual Identification .............................................. 12/l/89 SM520 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute l.O- 1

  6. 1 .O General Information Safe Maintenance Practices The following instructions have been prepared from current industry and government safety standards applicable to industrial truck operation and maintenance. conditions, 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. understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please contact your local CLARK dealer. These recommended procedures specify Carefully read and engine until there is no more fuel in the system and engine stops running. If engine will not run, close LP- tank valve and vent fuel slowly in a safe area. 1. Powered industrial trucks can become hazardous if maintenance is neglected. maintenance facilities, procedures must be provided. Therefore, suitable trained personnel, and 10. Operation of the truck to check performance must be conducted in an authorized, safe, clear area. 2. industrial trucks shall be done in conformance with the manufacturer’s recommendations. Maintenance and inspection of all powered 11. Before Starting To Drive Truck: a) Be in operating position. b) Disengage clutch on manual transmissions, or apply brake on trucks with powershift transmission and electric trucks. c) Put directional control in neutral. d) Start engine or turn on power. e) Check functioning of lift and tilt systems, directional and speed controls, steering, brakes, warning devices, and attachments. 3. A scheduled planned maintenance, lubrication, and inspection program shall be followed. 4. Only trained and authorized personnel should be permitted to maintain, repair, adjust, and inspect industrial trucks, and in accordance manufacturer’s specifications. with the 5. Properly ventilate work area, vent exhaust fumes, and keep shop dean and floor dry. any load handling 6. equipment present in the work area. Do not use an open flame to check for level, or leakage of fuel, electrolyte, or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. Avoid fire hazards and have fire protection 12. Before Leaving The Truck: a) Stop truck. b) Fully lower the load engaging means: upright, carriage, forks, or attachments. c) Put directional control in neutral. d) Apply the parking brake. e) Stop the engine or turn off power. f) Turn off the control or ignition circuit. g) Put blocks at the wheels, if truck is on an incline. h) Remove the ignition key (OSHA regulation) 7. Before Starting Work On Truck: a) Raise drive wheels off of floor or disconnect power source and use blocks or other positive truck- positioning devices. b) Put blocks under the upright rails and carriage, innermast( or chassis before working on them. c) Disconnect battery before working on the electrical system. 13. Handle LP-gas cylinders with care. such as dents, scrapes, or gouges may dangerously weaken the tank and make it unsafe for use. Damage 8. Before working on engine fuel system of gasoline powered trucks with gravity-feed fuel systems, be sure fuel shutoff valve is closed. 14. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, lift overload devices, guards and safety devices, lift and tilt mechanisms, articulating axle stops, and frame members must be carefully and regularly inspected and maintained in a safe operating condition. 9. Before working on engine fuel system of LP-gas powered trucks, close LP-gas cylinder valve and run 12/l/89 SM520 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute 1. 0- 2

  7. 1 .O General Information 24. Care must be taken to assure that all replace- ment parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment. including tires, are to be installed manufacturer’s procedures. CLARK or CLARK-approved parts. Special trucks or devices designed and 15. approved for hazardous-area operation must receive special attention to ensure preserves the original, approved safe operating features. that maintenance Parts, per the Always use genuine 16. Fuel systems must be checked for leaks and condition of parts. Extra special consideration 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. 25. practices. completely prior to removal. Following assembly of tires on multi-piece rims, use a safety cage or restraining device while inflating. When removing tires, follow industry safety Most important, deflate pneumatic tires 17. All hydraulic sytems must be regularly inspected and maintained in conformance with good practice. Tilt and lift cylinders, valves, and other similar parts must be checked to assure that “drift” or leakage has not developed to the extent that it would create a hazard. 26. components from the truck, such as counterweight, upright, engine, transaxle, etc. properly blocked, truck may become unstable. Be sure that lifting and handling equipment is of the correct capacity and in good condition. Use special care when removing heavy - If not WARNlNG 18. When working on hydraulic system, be sure the engine is turned off or battery disconnected electric trucks, upright is in its fully-lowered position, and hydraulic pressure relieved in hoses and tubing. WARNING - Always put blocks under the carriage and upright rails when necessary to work with upright in an elevated position. on 27. Before any truck is returned to service it must be safety checked to insure safe operation. NOTICE - Additional operating and maintenance safety instructions are contained in the following publications: 19. Batteries, motors, controllers, limit switches, protective devices, electrical connections must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of electrical insulation. conductors and ANSVASME B56.1 - 1983: Safety Standard for Low Lift and High Lift Trucks (Safety Code For Powered Industrial Trucks). Published by: Sociei of Mechanical Engineers, United Engineering Center, 345 E. 47th Street, New York, N.Y. 10017. 20. To avoid injury to personnel or damage to the equipment, consult the manufacturer’s procedures in replacing contacts on any battery connection. NFPA 5051982: Fire Safety Standard for Powered Industrial Trucks: Type Designations, Areas of Use, Maintenance and Operation. Available from: National Fire Protection Assoc., Inc., Batterymarch Park, Quincy, MA 02269. 21. condition to minimize fire hazards and help to detect loose or defective parts. Industrial trucks must he kept in a clean 22. The truck manufacturers and maintenance instruction plates, tags, or decals must be maintained in legible condition. capacity, operation General Industry Standards, OSHA 2206: OSHA Safety and Health Standards (29 CFR 1910), Subpart N-Materials Handling and Storage, Section 1910.178 Powered Industrial Trucks. For sale by: Superintendent of Documents, U.S. Government Printing Office, Washington, D.C 20402. 23. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturers prior written approval. Capacity, operation and maintenance instruction plates, tags or decals must be changed accordingly. Using other than Clark parts may nullify the truck rating. Note - 12/l/89 SM520 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute 1.0 - 3

  8. 1 .O General Information Safety Signs and Messages SAFETY SIGNS and MESSAGES are placed in conspicuous places throughout this manual and also on the lift truck to provide instructions and to call attention to specific areas where potential hazards exist and special precautions should be taken. Be sure to know and understand the meaning of these instructions, signs and messages. Each one is there for a specific purpose. Damage to the truck or death or serious injury to personnel may result if these messages are not followed. NOTICE This message is used when special information, instructions or identification is required relating to procedures, equipment, tools, pressures, capacities and other special data. IMPORTANT This message is used when special precautions should be taken to ensure a correct action or to avoid damage to or malfunction of the truck or a component. CAUTION This message is used as a reminder of safety hazards which can result in personal injury if proper precautions are not taken. WARNING This message is used when a hazard exists which can result in injury or death if proper precautions are not taken. DANGER This message is used when an extreme hazard exists which will result in death or serious injury if proper precautions are not taken. These labels identify hazards which may not otherwise be apparent to a trained mechanic. There are many potential hazards for an untrained mechanic and there is no way to label the truck or service manual against all such hazards. Clark Equipment Company cannot anticipate every possible circumstance that might involve a potential hazard. The safety signs and warning messages in this manual are therefore not all inclusive. If a procedure, tool, device or work method not specifically noted or recommended by Clark is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the lift truck or its components will not be damaged or made unsafe by the procedures you choose. 12/l I89 SM520 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute 1.0 - 4

  9. 1 .O General Information I --1 IMPORTANT SAFETY NOTICE Read and understand all safety precautions and warnings before performing repairs on lift trucks. Appropriate service methods and proper repair procedures are essential to the safe, reliable operation of industrial trucks as well as the personal safety of the individual doing the work. This Service Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure successful repair and reliable truck operation. There are numerous variations in procedures, techniques, tools, and parts for servicing industrial trucks, as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or precautions as to each. Accordingly, anyone departing from the instructions provided in this manual through procedures used or choice of tools, materials, and parts may jeopardize his or her personal safety and/or the safety of the vehicle user. Improper or careless techniques cause accidents. Don’t take chances with incorrect or damaged equipment. Read and understand the procedures for safe operation and maintenance outlined in this manual. STAY ALERT! Follow safety rules, regulations and procedures. Accidents can be avoided by recognizing dangerous procedures or situations before they occur. DRIVE AND WORK SAFELY and follow the safety signs and their messages displayed on the truck and in this manual. General Precautions The following list contains general precautions that should be followed when working on a lift truck: ? Use safety stands whenever a procedure requires you to be under the vehicle. . Always wear safety glasses for eye protection. ? Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. ? Remove rings, watches, loose jewelry and open clothing before working on a vehicle, to avoid serious injury. ? Keep hands and other objects clear of the fan belt and fan blades if it is necessary to work in the engine compartment. ? Do not smoke while working on a vehicle. ? Keep yourself and your clothing away from all moving parts, especially the fan and belts, when the engine is running. ? Put ignition switch in the OFF position, unless otherwise required by the procedure. ? Avoid contact with hot metal parts such as the radiator, exhaust manifold, exhaust pipe and muffler to prevent serious burns. ? Set the parking brake. Place wheel chocks or wood blocks of 4” x 4” size or larger to the front and rear surfaces of the tires to provide further restraint from inadvertent vehicle movement. SM520 1211189 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute l.O- 5

  10. 1 .O General Information Product Identification Model Nomenclature Pneumatic Tire Models G PX 20/22/25/27/30 G PS 20/22/25/27/30 GPS 20/22/25/27/30 DPS 20/22/25/27/30 Cushion fire Models GCX 20/22/25/27/30 GCS 20/22/25/27/30 GCS 17/20/22/25/27/30 DCS 17/20/22/25/27/30 -, C M B MC,WC,I I -,C MB MC,WC,I I @ 24 inch [500 mm] Load Center Rated Load Capacity* 27 30 17 20 22 25 Model Basic Capacity 5500 [ 27501 6000 [3000] 3500 4000 [2000] 4500 [2250] 5000 [2500] Ibs t&Is1 ww *This is the basic capacity of the truck chassis. The actual capacity of the truck may be less due to the use of high lift uprights and/or attachments. SM520 2/27/g 1 1.0 - 6 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

  11. 1 .O General Information Product Identification Model Designation by Engine and Transaxle Application Serial No. Prefix I . 010 GP138 I I I I I 1 - Lot 5521 thru 7157 2 - Lot 7158 and above 3 - Lot 6200 and above 4 - Lot 6200 and above 5 - Lot 5510 thru 6086 Notes: 6 - Lot 5536 thru 7169 7 - Lot 7170 and above 8 - Lot 5525 thru 6091 9 - Lot 6205 and above 10 - Lot 6205 and above ? HR500 and TA18 transaxles incorporate full-floating straight drive axles with drum-and-shoe brakes. ? HR600 transaxles incorporate pre-reduction enclosed oil-cooled disc brakes & offset drive axles. Model Serial Number Code Cushion Tire Trucks Model Designation Plant of Mfr Sequence No. Lot No. Plant of Manufacture -xXxX -xXxX -XX GX 230 GX 230C G138 MB G138 MC G138 WC G138 I None . . . . . . . . Battle Creek, Ml FA . . . . . . . . . . . Georgetown, FB. . . . . . . . . . .Lexington, KOF. . . . . . . . . Republic of Korea I= -xXxX -xXxX -xXxX 1% -XX -XX -XX I= -xXxX -xXxX -xXxX KY KY Pneumatic Tire Trucks Model Designation Plant of Mfr Sequence No. Lot No. Plant of Manufacture GPX 230 GPX 230C GP138 MB GP138 MC GP138 WC GP138 I -XXXX -XxXX -xXxX -xXxX -xXxX -XXXX -xXxX -xXxX -xXxX -xXxX -xXxX -xXxX -XX -XX -xx -XX -XX -XX See above SM520 2127191 1.0 - 7 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

  12. 4 Engine 4.3 Engine Tune-Up Gasoline/LPG & Diesel .4.3-l .4.3-2 .4.3-5 Tune-Up Preparation.. ............................................................. l-Preliminary Checks.. ............................................................. 2-Tune-Up Procedures.. .......................................................... Engine Tune-Up consists of: I)- preliminary checks to be sure that all engine systems are functioning correct/y, and 2) tune-up procedures, which include performing tests, making minor adjustments and replacing minor components as necessary to bring an engine up to its peak level of performance. Also refer to Section 4.2, Engine Troubieshooting Tune-Up Preparation CAUTION Open and remove both side doors, and raise the seat deck. Be sure the seat deck support is securely latched. To perform this service procedure, it is recommended that you: ? Put blocks under the upright rails. . Raise the drive wheels off the floor. ? Return all controls to neutral, apply the parking brake, and turn key switch OFF, except as noted. 1 WARNING Stop engine before checking battery terminals or electrical connections. Do not hold ignition wires with bare hands since shocks or other injuries can result. LPG (propane), sparks or flames near a battery could cause an explosion or fire. Battery acid can cause corrosive burns. Always wear eye protection. Use of jumper cables or battery charging should be done only as directed by manufacturer’s safety instructions. -1 Minimum Tools Required: ? Tachometer ? Voltmeter ? Timing light ? Torque wrenches 9 Vacuum gauge ? Jumper wire WARNING LPG Fuel Note - The following pages describe general engine tune-up procedures illustrated with typical views of the subject activity. Please check your engine model for specific component arrangement corresponding service requirement. Park truck in a well-ventilated or perform maintenance sources of ignition. when exhaust manifold is excessively is highly flammable. area. Do not smoke near open flame or other Do not disconnect any lines and hot. LP Gas Lubricate threads on spark plugs used in SM520 Parts GROUP 00,Ol 12/I 189 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute 4.3 - 1

  13. 4.3 Engine Tune-Up 1 -Preliminary Checks Note - The following quick, simple checks should always be made to make sure that basic and easy to find troubles are not the cause of poor engine performance. have eliminated these items you can check into the other possible causes of poor engine performance. 1. Check engine oil and coolant levels. 2) Breather hoses from oil separator to oil pan and from oil separator to air horn on carburetor. separator is not serviceable. NOTICE - The oil separator model 4654 engines. Carefully inspect rocker cover side nipple hole (orifice) and intake manifold nipple hole for clogging. Oil has been eliminated on later Once you TM(D)27 [2.7L] Engine 1 2. Check engine air filter. A clogged filter will cause engine power loss. Replace, as needed. Note - On engines equipped with Cyclopac air cleaner, do not service filter until indicated by restriction indicator. TMD27 diesel shown. TM27 gasoline/LPG similar. Blow-by circulates into intake manifold maintaining crankcase pressure within a narrow range regardless of operating speed or load. Servicing of the PCV system is usually confined to cleaning PCV orifice and/or valve along with cleaning the air inlet, where applicable. All connections must be air tight. Check condition of the hoses and connections. Repair or replace as required. IMPORTANT - Be careful when inspecting or replacing the air filter element to prevent dirt from entering the engine air intake housing. 3. Check air intake tubes for signs of filter leakage. 4. Check crankcase breather system to be sure it is functioning correctly. Check the following and, if necessary, clean or replace faulty parts: 1) Breather hoses for damage, cracks, and clogging. 2) Rocker cover and intake manifold fitting holes for clogging. D176GA [2.9L] Engine 4654 [2.6L] Engine Check crankcase breather or PCV system to be sure it is clean (opening or hoses not plugged with dirt or grease). There are 2 sections of engine ventilation system: 1) Breather (PCV) hose from rocker cover to intake manifold (shown). 12/l/89 SM520 4.3 - 2 Parts GROUP 00,Ol Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

  14. 4.3 Enaine Tune-Up ““ON . j-~- . For safety when checking or removing battery connectrons, always first drsconnect the negative battery cable at the engine ground connection. If crankcase breather opening or PCV valve is plugged with dirt and oil accumulation, remove and clean with an approved solvent or replace, as required. 7. Check battery for damage and cleanliness of terminals. Remove the boot covers to expose terminal connections. Clean battery terminals and cable connections if they are dirty and corroded. Check battery terminal tightness. Replace boots over terminals inspection. If necessary, wash battery with a mild solution of baking soda and water. First, make sure that cell vent caps are tight to ensure that soda solution contaminate battery electrolyte. cable connections for after does not NOTICE - For side-mounted attached to terminal terminal. When tightening torque value to prevent terminal damage, while assuring a good connection. Do not overtighten. terminals, each battery cable is by a bolt which threads the bolt, use recommended into the 5. Gasoline engines only. Check choke control linkage to carburetor to be sure it fully closes opens the choke. and and .’ 8. Be sure battery negative securely connected to engine block. Check engine starter cable connections. (ground) cable is 6. Check coil polarity to be sure that primary wire from point-type distributors is connected to negative terminal on coil (black wire to coil, white wire to 12 volts at bottom of ballast resistor). Note - On electronic ignition systems there are two wires coming distributor and both are connected engine coil does not have external ballast resistor. from the D176GA to the coil. SM520 P arts G RO U P 12/l/89 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute 00,O l 4.3 - 3

  15. 4.3 Engine Tune-Up Cranking Test 13. If there is indication of a faulty battery, or if engine cranking speed is slow, perform a cranking test, as follows: 1) LPG fuel system. Shut off LPG service valve. 9. Start the engine. 10. With engine running, look at the battery charge indicator. The light should not be illuminated, indicating voltage output from the alternator. 11. Check fuel gauge to be sure fuel level is adequate, to ensure that low fuel level will not affect other tests of engine performance. 2) Ground the ignition system. coil wire from the distributor cap, clip a jumper lead onto the coil wire and ground it on engine block. Disconnect high tension Spark Test WARNING Electrical Shock I Do not hold ignition wires with bare hands since shocks or other injuries can result. High ignition voltage or the reaction from electrical shock can cause severe personal injury. 3) Then, terminals. the throttle and obtain higher compression) engine for 15 seconds. connect Now push accelerator a voltmeter across the battery pedal fully down (to open and crank the 4) During cranking the battery voltage should exceed 9.6 volts. Battery voltage of less than 9.4-9.6 volts indicates trouble in the battery, cables, or starter. 5) Immediately should be 12 volts, minimum. quick response. voltmeter has a sluggish response battery problem. after cranking, battery no-load voltage The voltmeter should show a If the voltage is less than 12 volts or the it is an indication of a 12. Perform a spark test with each spark plug wire, or use a spark indicator, to check coil and spark plug wires to be sure coil is producing adequate voltage to all plugs. At the same time, check all spark plug wire connections for tightness. 6) If battery immediately (e.g., 8 volts), the problem is in the cables or starter. inspect the cables for connections. Then, remove Rebuild or replace, as required. no-load voltage returns to 12 volts after cranking but there is low cranking voltage First, loose and burned teminal and check the starter. If there is indication refer to Section 6.3, Ignition System Maintenance. of a problem in the ignition system, 7) Remove distributor cap and start and accelerate speed of 1800-2000 the jumper lead, connect the coil wire to engine to a steady rpm. 8) Charging system output voltage should be between 12.5-13.5 volts. SM520 00,07 12/l I89 4.3 - 4 Parts G RO U P Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

  16. 4.3 Engine Tune-Up 4G64 [2.6L] Engine. Install the vacuum gauge at the breather hose leading from the valve cover to the intake manifold. Use a nipple or an adapter to connect to the vacuum hose. TM27 [2.7L] Engine. Attach vacuum gauge to PCV fitting on intake manifold. 14. If the battery (discharging) check the alternator circuit and battery. See cranking test above. Refer to Section 6.8, Alternator Maintenance. has been down” “running or if engine cranking speed is low, 3. Start the engine, and let it warm up. While doing this, look for excessive exhaust smoke and listen for any unusual engine noise. - Blue exhaust smoke consumption caused by faulty seating of piston rings, dirt, or worn engine components pistons, or valve guides. Black smoke indicates excessive fuel consumption caused by faulty carburetor problem (gasoline engines only). NOTICE - The above preliminary tests show whether the basic engine sytems are functioning and that charging and cranking systems are okay or in need of repair. Remove the voltmeter after these tests are made. indicates excessive oil Note Fuel Supply System Gasoline engines 1. Check if there is a fuel system problem by accelerating engine with the choke knob in and the tilt lever fully forward (or back) to put hydraulic system in bypass to load engine. 2. If engine operation is erratic, pull choke knob out and again accelerate under hydraulic by-pass load. If engine smooths out there is a problem in the fuel system due to insufficient fuel flow to engine. 1) Check in-line fuel filter. Replace, as necessary. 2) Check fuel pump flow and pressure. Repair or replace fuel pump, as required. 3) Check carburetor. Repair, clean or replace. LPG engines For LPG trucks, refer to Section 5.2, LPG Fuel System. such as rings, cylinders, or choke 1. Stall Test 1. First, perform a stall test to determine engine condition and whether engine and other compo- nents are functioning correctly. 1) Idle speed and vacuum 2) No-load governed speed and vacuum 3) Speed and vacuum in hydraulic (tilt) bypass 4) Engine stall speed and vacuum Refer to Section 4.7, RPM, Vacuum & Stall Tests, for procedures and analysis of test results. Also see Section 2.7, Service Specifications. Check: NOTICE - A stall test is perhaps the most important and useful test for quickly determining tests should be a part of all engine tune-ups and must be carefully conducted and analyzed problems. Stall tests must include RPM, vacuum pressure measurements to accurately problem areas. For this reason, stall testing is described in a separate, detailed section noted above. Engine speed and vacuum checks with engine under load, are made to also determine whether major components or systems other than the engine are causing problems. Note - lf stall speed is low, do not automatically torque converter. Carefully Frequently an obstruction, e.g., carbon plugging, in the air intake or exhaust system is the problem. Z-Tune-Up Procedures 1. Connect a tachometer, instrument such as the Clark Dynamic Engine Analyzer, Part No. 1802047, to the engine. 2. Install a vacuum gauge. The pick-up location to install a vacuum gauge will vary between engines. Find a location where the vacuum gauge may be connected to measure intake manifold vacuum. engine condition. Stall to pinpoint specific or combination test and hydraulic diagnose specific blame the condition. check engine 2. Idle Speed 1. Check engine idle speed and adjust carburetor idle setting if idle speed is not correct. Refer to Section 4.10 for Carburetor Idle Adjustment. 4654 Engine 650 rpm (600-700 rpm) TM(D)27 Engine 650 rpm (600-700 rpm) D176GA [2.9L] Engine. Install vacuum gauge at the plug fitting in the intake manifold (shown). Reference Section 2. I, Service Specifications. SM520 Parts GROUP 00,Ol 12/l/89 4.3 - 5 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

  17. 4.3 Engine Tune-Up 3. Ignition System Refer to Section additional procedures. 1 -Distributor, Coil and Wiring 2. TM27 [2.7L] & D 176GA [2.9L] engines. 1. Inspect electronic ignition unit. Check air gap. Refer to Section 6.5, Ignition System - TM27 Engine. Refer to Section 6.6, Ignition System - D 176GA Engine. 6.3, Ignition System Maintenance, for Lubricatiotl Refer to Section 6.4, ignition System-4G54 Note - TM27 [2.7L] and D176GA {2.9L] engine distributors do not require periodic lubrication. [2,6L] Engine. coil 1. Ignition coils do not normally require any service except keeping all terminals and connections clean and tight. The coil should be kept reasonably clean; however, it must not be subjected to steam cleaning or similar cleaning methods that may cause moisture to enter the coil. 2. Check the ignition coil tower for tracking and obvious damage. Be sure the tower is clean and dry. Check coil boot nipple for correct sealing and insulating qualities. If flashover occurs here, the engine probably won’t start. 3. Check primary circuit wires for tight connections and correct polarity. When the ignition coil is wired up incorrectly with the distributor, it can cause high speed missing with loss of power and performance under heavy loads. 4. Check the coil to distributor cap high-tension (secondary) cable. Check the fit of the boot on the coil and distributor cap towers. A high voltage leak at this point will cause the engine not to start. 5. Test the Coil When Necessary. suspected of being faulty, remove and check its operation on a coil tester and replace it if inoperative. 1. First, check the distributor, coil and ignition wiring (4G54 engine shown). 2. Remove the distributor condition for: ? cracks ? carbon tracking or flashover burn marks ? corrosion, rusting or damage of terminals ? burned center terminal or side inserts ? dirt inside and outside ? moisture It is very important for the cap to be clean. Moisture and dirt make a good path for flashover. Once a carbon track has started, the cap must be replaced. cap and check its 3. Clean the distributor cap and terminals, or replace, as needed. 4. Remove the spark plug wires (cables) from the distributor cap. Inspect the cable socket terminals in the cap for corrosion and burn damage. Clean the towers and terminals, as needed. 5. Remove the rotor and inspect it for: ? cracks ? carbon tracking or flashover burn marks ? burned, pitted , bent or worn terminal tip . moisture, contamination and dirt buildup Clean or replace the rotor, as needed. 6. Check centrifugal advance governor. Install the rotor. Turn (rotate) the rotor in the direction of rotation and release it to confirm that the rotor returns to the original position smoothly. If the coil is Spark Plug wires 1. Check spark plug cables and boots for cuts, cracking, brittleness, burns or excessive corrosion of the terminals on both ends, and general deteriora- tion. If the cables are three years old or more, replace them. 2. To install new cables, remove one old wire at a time and match it to a new one. Use all looms and separators and route the wires exactly as the old ones. NOTICE - Dielectric Grease. The use of a dielectric silicone grease at high-voltage connecting points such as coil and distributor cap towers and spark plugs is recommended to ensure good electrical connection and prevent corrosion. Adjust or Replace Ignition Points 1. 4654 [2_6L] engine only. 1. Inspect the ignition points for wear condition, etc. 2. Inspect condenser and condition of installation. 3. Replace ignition points and condenser, as needed. 4. Lubricate distributor cam and pivots (see below). 5. Check point gap setting (see Ignition Timing below). 6. Check electronic ignition unit, as appljcable. Refer to Section 6.4, Ignition System - 4G54 Engine. 2-Spark Plugs 1. Use an air nozzle to blow dirt and contamination out of the spark plug wells, before and after loosening the plugs. SM520 12/l/89 4.3 - 6 Parts GROUP 00,Ol Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

  18. 4.3 Engine Tune-Up 2. Adjust idle speed to 500 rpm. 3. Disconnect vacuum advance hose at distributor (as applicable) and plug or clamp the open end. 4. Install a timing light. IMPORTANT Do not allow dirt and contaminants to enter spark plug openings when the plugs are removed. 2. Remove and check the spark plugs and clean, adjust or replace, as necessary. 3. As each plug is removed, keep it in cylinder order and examine it carefully. burned electrodes, wear, carbon deposits and gap setting. Inspect closely for cracked insulators. 4. If the edges of the plug’s inner and outer electrodes are noticeably Generally, spark plugs used with breaker-point ignition should be replaced per recommended schedule. With electronic ignition, check each plug for excessive wear. 5. It may be necessary to periodically clean the plugs with a plug cleaner and to reset the gaps to correct specifications. Check the gap of the plugs with a wire gauge, using the tool at the end of the gauge to bend the outer electrode to change the gap. 6. Spark plugs must be correctly installed in order to obtain good performance from them. spark plug seat in the cylinder head. Use new seat gaskets and screw plug in by hand. Tighten all plugs to correct torque with socket wrench of correct size. Wipe insulators clean before installing the boots and cables. Refer to Section 6.3, Ignition additional spark plug maintenance procedures. CAUTION Enaine Fan Be careful of rotating fan blades when using a timing light. Check spark plugs for 5. With engine running at 500 rpm idle speed and vacuum advance disconnected, aim the timing light at the crankshaft pulley and timing indicator. eroded, replace it. Clean the 6. Check the initial (basic) timing by alignment of timing notch on crank pulley with mark on timing indicator (4654 engine shown). Adjust timing, as necessary. Refer to Section 4.4, Ignition Timing Procedures. See also Section 2.7, Service Specifications. System Maintenance, for Mgnition Timing and Advance IMPORTANT - Correct ignition timing is vital to the proper and efficient operation of the engine. result in engine overheating, and valve life, and lowered fuel economy. It is important that the ignition (electronic ignition) is set correctly adjusting the timing. Checking timing is counter-productive set to specification. Timing is set using a timing light. The light flashes when the “points” open. the wrong time, the timing marks are seen at the wrong time. And therefore, based incorrectly. To insure accuracy, the points must be set using a dwell meter. Using a feeler gauge to set points can be very inaccurate due to variations in judgment of “feel” as well as other mechanical variations. points. Refer to Section 4.4, Ignition Timing Procedures. 1. Using a dwell meter, check and adjust point gap or air gap (electronic ignition) first and then check ignition timing and advance. See Section 2.7, Service Specifications, 7. Check spark advance mechanism(s). Accelerate the engine speed slowly to determine smooth spark advance. This will be indicated by the notch on crankshaft pulley, which will appear to move away from the initial timing point and, generally, truck. Run engine at steady Temporarily connect the vacuum advance hose and check for correct advance. If there is no advance or if it is erratic, the distributor advance inspected and repaired or replaced. etc., or replace advance diaphragm. Refer to Part 6, Ignition System Maintenance for your engine. if there is a steady and Incorrect timing can with resultant reduced piston upwards, as viewed in point gap or air gap before checking and 1600-1800 rpm. 8. if the point gap is not mechanisms Check for hose leaks, must be If the points open at on this, the timing is set procedures 9. Reconnect vacuum advance and set idle speed to specification. 4. Readjust Idle Speed 1. After replacement or adjustment components or other engine parts, recheck and adjust the carburetor idle speed to specification and adjust idle air-fuel ratio. 2. Adjust idle air-fuel ratio to obtain low carbon monoxide (use CO meter). Use a dwell meter to set of ignition for your engine. SM520 falts GROUf OU,U7 12/l I89 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute 4.3 - 7

  19. 4.3 Enaine Tune-M in the water pump and alternator can be damaged. 6. Check the exhaust pipe to be sure that exhaust is not blowing into the radiator (except GS, LPS, DS construction with piccolo tube). 7. As a final step, if necessary: 1) pressure test the cooling system. 2) pressure test the radiator cap. 3) check the thermostat. 4) check the coolant for freeze protection level. 5) check overflow reservoir and hoses. 5. Compression Check 1. If the stall speed reading is not in the correct range or the engine runs erratically, perform an engine compression check. This will check the condition of the piston rings and engine valves. Refer to Section 4.6, Engine Cylinder Compression See Section 2.1, Service Specifications. Test. 6. Valve Clearance Settings 1. If the engine compression test indicates a valve problem, or valve train is noisy, check and adjust valve (tappet) clearances, as necessary. 8. TMD27 [2.9L] Diesel Engine Refer to Section 4.5, Valve Tappet Clearance Adjustment. Valve Clearance Settings: Specifications See Section 2.1, Service 7. Cooling System Refer to Section information. 1. If there is an indication of engine overheating, perform a complete check of the engine cooling system. 2. Inspect the radiator for damage and clogging from dirt contamination. Air clean the radiator, if it has not already been cleaned as part of the PM procedure. 4.8, Cooling System for additional J 1. Check glow plugs and inspect glow plug wiring. Repair or replace, as needed. 2. Inspect fuel lines for leaks. Adjust fuel control linkage, and accelerator pedal linkage to allow for full travel of arm on fuel injection pump, as necessary. Refer to Section 5.3. Diesel Fuel System for additional information. 9. Recheck Engine Performance 1. Stall Test. Run a stall test to check engine performance after tune-up. Remove the tachometer, vacuum gauge and timing light. 3. Check to be sure that the fan blades are not loose or damaged and that the fan is installed correctly (fan installed badwards is a wmmon problem.) Tune-Up Completion When you have systematically procedures you should have been successful in restoring the engine to its peak level of performance, determined the need for additional of the engine. 1. Lower and latch the seat deck. Be sure seat deck is correct/y latched. Install and close the side doors. Lower the drive wheels to the floor and remove any blocking, if used. 2. Test drive the truck. 3. Clean up any loose dirt and spills. Wipe off the truck. completed these tune-up NOTfCE - The fan is designed as a “pusher-type” to push air through the radiator. installed with their curve to push air into the radiator as they turn in the direction of right-hand engine rotation. fan, i.e., The fan blades should be or otherwise or repair maintenance - Fan blades should engage l/3 of the depth IMPORTANT of the radiator shroud. 4. On optional models with viscous fan drive, check the fan drive (speed control) assembly. 5. Check the fan drive belt for proper tension and adjust, as necessary. If tension is low, the belt will slip. If belt tension is too high the bearings and seals SM520 mfa9 4.3 - 8 Parts GROUP 00,Ol Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

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  21. 4 Engine Engine Ignition 4.4 Ignition Timing Procedures 4.4-l .4.4-3 .4.4-4 4.4-4 .4.4-5 .4.4-6 General Procedures.. ............................................................... Checking Ignition Timing.. ....................................................... Initial (Basic) Ignition Timing.. .................................................... Ignition Timing Adjustment.. ..................................................... Checking Spark Advance.. ....................................................... Emergency Timing Method.. .................................................... Engine Ignition Timing procedures include: I) checking the point gap (air gap on electronic ignition) and initial (basic) timing of the distributor to the engine, 2) adjusting the timing when timing is found to be incorrect, and 3) checking spark advance. Normally Clark industrial engines with distributor- ignition are timed to have the distributor points open (or electronic breaker trigger) when the #1 cylinder is on compression stroke and the crankshaft crankshaft pulley) mark lines up with the pointer or timing indicator on the engine. (or 1. Open and remove either the right hand (4654 & TM27 engine) or left hand side door (D176GA engine), and raise the seat deck. Be sure the seat deck support is securely latched. The general timing procedures are the same for all G(P)X, GCS/GPS 77-30 engine models, whether equipped with contact breaker-point distributor or electronic ignition distributor. Both types of ignition utilize a typical distributor mounted and driven in the conventional manner. Individual differences components and procedures are noted or shown where applicable. NOTICE - 4654 [2.6L] Engine Air Filter in Note - The following pages d8SCfib8 general ignition timing pfOC8dUf8S i/iustrated with typical views of the subject activity. f/ease check your engine model for specific component arrangement service requirement. engine and corresponding Refer to Part 6, Ignition System maintenance engine model. for your General Procedures For best access to the distributor indicator, it is recommended to remove the air filter housing from the truck. If you are unfamiliar with this procedure, please refer to Section 4.9, Air Filter. and timing Be careful of rotating fan blades when There are two methods of checking ignition timing: with or without a timing light. Timing without a light is an emergency method which is outlined at the end of this section. The preferred method is to use a timing light as described in the folio wing procedures. SM520 Parts GROUP 11 12/l/89 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute 4.4 - 1

  22. 4.4 Ignition Timing General Procedures (Cont’d) 7. Disconnect vacuum hose from vacuum advance on distributor (as applicable). Plug or clamp the open end of vacuum hose to carburetor or manifold. - D176GA [2.9L] engine does not have vacuum advance. 8. Lower the engine speed by adjusting carburetor idle screw to obtain 500 tpm idle speed. 2. Install a tachometer, or a combination test instru- ment, such as the Clark Dynamic Engine Analyzer, Part No. 1802047. Note - Tachometer nected directly to battery terminals suitable). must be con- (other ground Note not the Refer to Section 4.10, Engine Adjustments, information on idle adjustment. 9. Run engine at 500 rpm idle speed (unless otherwise noted), so the automatic advance of the distributor is not operating. for additional Note - lt is standard practice to check engine initial (basic) timing with engine running at 500 rpm idle speed setting, so that the automatic advance completely retarded and not affecting VERY IMPORTANT TO OBTAIN CORRECT TIMING. of the distributor timing. is THIS IS NOTICE - Correct ignition’timing is vital to the proper and efficient operation of the engine. timing can result in engine overheating, resultant reduced piston and valve life, and lowered fuel economy. It is important that the ignition point gap (or air gap on electronic ignition) is set correctly before checking and adjusting the timing. Checking timing is counter-productive gap is not set to specification. Timing is set using a timing light. The light f/ashes when the “points” open. If the points open at the wrong time, the timing marks are seen at the wrong time. therefore, based on this, the timing is set incorrect/y. To insure accuracy, the points must be set using a dwell meter. Using a feeler gauge to set points can be inaccurate due to variations in judgment of “fee/” as well as other mechanical variations. Always use a dwell meter to set points. 3. Install a timing light. Incorrect Note - An ignition timing light, Clark Part No. 1801971, or equivalent, with inductive spark pickup is recommended. Install per manufacturer recommendations. 4. Clean the timing pointer or indicator and timing mark or notch on the crank pulley to make the mark more legible under the timing light. 5. Start the engine and warm it up until it runs smoothly. 6. Check and adjust ignition point gap or air gap (electronic ignition), as applicable, with a dwell meter. IMPORTANT - To insure accuracy, always use a dwell meter to check and adjust point gap setting. See NOTICE at right. with if the point And Refer to Part 6, Ignition engine model for ignition point or air gap S8tkgS. System Maintenance for your SM520 12/l/89 Parts GROUP 11 4.4 - 2 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

  23. 4.4 Ignition Timing Checking Ignition Timing - Distributors with vacuum advance. IMPORTANT Before ignition timing can be checked or adjusted, disconnect vacuum advance line from distributor and plug or clamp the open end of line leading to the manifold to prevent loss of vacuum. 4054 [2.6L] Engine 2. With engine running at the noted idle speed, aim the timing light at the crankshaft pulley and timing indicator. Note timing marks as light flashes. (4G54 [2.6L] engine shown.) TM27 [2.7L] Engine 1. The timing indicator is located near crankshaft pulley similar to the 4G54 [2.6L] engine and may be seen from right-hand side of truck. CAUTION D176GA [2.9L] Engine Enaine Fan to hold the timing light in a position to avoid being too close to the rotating fan blades. Be careful to stay away from the fan when leaning over to see the timing marks. 1. Stand at left side of truck and point timing light down in a vertical direction between the fan and alternator. CAUTtON Engine Fan 1. The 4654 engine timing indicator (1) is located near the crankshaft pulley (2) and may be seen from the right-hand side of the truck. Be sure to hold the timing light in a position above the top of the alternator (or radiator) to avoid being too close to the rotating fan blades. stay away from the fan when leaning over to see the timing marks. Be careful to I SM520 Parts GROUP 11 12/l/89 Copyrighted Material Intended for CLARK dealers only Do not sell or distribute 4.4 - 3

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