Clark GPX 30 Forklift Service Repair Manual

SM-593 GPX/DPX 30/55

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

Service Manual SM 593

G PXlDPX

Copyrighted Material Intended for CLARK dealers only Do not sell or distribute

30/35/40/405/50/55

Pictorial Index Group23 -

Group 34

- Group 32 c

Group 25

!-

Group 20

Group 22

Group 06

Group 29 Group 38l

Group 30

Group 40

+-z)

Group 14

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SM 593, JAN ‘93

CONTENTS

Contents of this Manual Group

Section

Description INTRODUCTION Safety Planned Maintenance

00 00 00 00

1 2 3

01 01

ENGINES Engine Removal Diesel Workshop Manual Gas/LPG Workshop Manual

01 01 01

COOLING SYSTEM Troubleshooting Cooling System Testing and Maintenance Fan Belt Replacement Radiator Removal

02 02 02 02 02 02

FUEL SYSTEM Fuel Pump Pressure .Test The IMPCO Fuel System Carburetor Overhaul Velocity Governor Overhaul Removal of IMPCO Vaporizing System

06 06 06 06 06

TRANSMISSION Transmission Checks Draining and Refill Transmission Removal Transmission Overhaul

14 14 14 14

1 2 2

DRIVE AXLE Axle End Lubrication Axle End Removal Axle Ends Overhaul Differential Overhaul

20 20 20 20 20 22 22 22

ELECTRICAL SYSTEM Wiring Color Code Wiring Diagrams Electrical Checks

1 2

WHEELS AND TIRES Lifting, Jacking, and Blocking Wheels and Tires Mounting (continued on next page)

SM 593, JAN ‘93

0 Clark Material Handling Copyrighted MaterialCompany 1993 Intended for CLARK dealers only Do not sell or distribute

Contents-l

Group

Section

BRAKING/INCHING

23 23 23 23 23 23 23 23 25 25 25 25

STEERING COLUMN AND GEAR

1 2 3

Steer Axle Removal Steer Axle Overhaul Steering System Adjustment Steer Cylinder Removal Steer Axle Wheel Bearings Steer Cylinder Overhaul HYDRAULIC SUMP, FILTERS, AND PUMP

1 2

40 40 40 40 40 40

Contents-2

Hydraulic Sump and Filters Hydraulic Pump Troubleshooting & Overhaul (Vane Type) HYDRAULIC VALVE/LIFT CIRCUIT

Hydraulic System Pressure Check Hydraulic Valve Overhaul Hydraulic Valves Hydraulic Schematic TILT CYLINDERS

1 2 3

Tilt Cylinder Removal Tilt Cylinder Overhaul Tilt Lock Valve UPRIGHTS

34 34 34 34 34 34 34 34 38 38

Troubleshooting Steering Column and Gear Removal Char-Lynn Steering Control Unit (Steering gear) STEER AXLE

30 30 30 30 30 32 32 32 32

SYSTEM

System Description/Troubleshooting Brake and Inching System Bleeding Brake and Inching Pedals Adjustment Master Cylinder Overhaul Power Booster Overhaul Brake Caliper Overhaul Parking Brake

26 26 26 26 26 26 26 29 29 29

Description

Troubleshooting and Visual Inspection Operational Checks Carriage Check and Adjsutment Upright Check and Adjustment Cylinder Repair Lift Chain Maintenance Upright Removal and Replacement COUNTERWEIGHTS

1

Counterweight Removal and Installation SPECIFICATIONS

Namplates/Decals General Specifications PM Inspection and Drivers Daily Inspection Forms Recommended Lubricants & Lubricant Specifications Lubrication Intervals

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SM 593, JAN ‘93

INTRODUCTION

INTRODUCTION

Safety ................................................................................. Section 1 Planned Maintenance ........................................................ Section 2

SM 593, JAN ‘93

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Introduction

Introduction

ElfIRK

Safety Safety Signs and Messages ...................................................................................

2

Practices ........................................................................

2

User Safe Maintenance

SM 593, Jan ‘93

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Safety-l

Introduction

Cl!mK

Safety Signs and Messages Safety signs and messages are placed in this manual and also on the lift truck to provide instructions and to identify specific areas where potential hazards exist and special precautions should be taken. Be sure you know and understand the meaning of these instructions, signs, and messages. Damage to the truck, death, or serious injury to you or other persons may result if these messages are not followed.

NOTICE This message is used when special 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.

A!

CAUTION

This message is used as a reminder of safety hazards which can result in personal injury if proper precautions are not taken.

A

WARNING

This message is used when a hazard exists which can result in injury or death if proper precautions are not taken.

A

DANGER

This message is used when an extreme hazard exists which can result in injury or death. or serious injury if proper precautions are not taken.

NOTE: The above terms have been adopted by Clark Material Handling Company. The same terms may be used in different context in service literature supplied directly or indirectly by vendors of truck components.

User Safe Maintenance Practices The following instructions have been prepared from current industry and government safety standards applicable to industrial truck operation and maintenance. These recommended procedures specify 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. Carefully read and 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.

1. Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities, trained personnel, and procedures must be provided.

2. Maintenance and inspection of all powered industrial trucks shall be done in conformance with the manufacturer’s recommendations.

3. A scheduled planned maintenance, lubrication, and inspection program shall be followed.

Safety-2

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SM 593, Jan ‘93

Cl!YRK

Introduction

4. Only trained and authorized personnel shall be permitted to maintain, repair, adjust, and inspect industrial trucks. Work should be performed in accordance with the manufacturer’s specifications.

5. Properly ventilate work area, vent exhaust fumes, and keep shop clean and floor dry.

6. Avoid fire hazards and have fire protection 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.

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.

Disconnect battery before working on the electrical system.

8. Before working on engine fuel system of gasoline- or diesel-powered trucks, be sure the fuel shut-off valve is closed.

9. Operation of the truck to check performance must be conducted in an authorized, safe, clear area.

10. Before starting to drive truck: a.

Be in operating position.

b.

Be sure parking brake is engaged.

C.

Put direction control in neutral.

d.

Start engine.

e.

Check functioning of direction and speed controls, steering, brakes, warning devices, and any load handling attachments.

Stop the engine by turning off the ignition circuit.

e.

Put blocks at the wheels if truck is on an incline.

12. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, guards, safety devices, and frame members must be carefully and regularly inspected and maintained in a safe operating condition.

13. Special trucks or devices designed and approved for hazardous area operation must receive special attention to ensure that maintenance preserves the original, approved, safeoperating features.

14. 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. capacity, opera15. The truck manufacturer’s tion, and maintenance instruction plates, tags, or decals must be maintained in legible condition.

16. Batteries, motors, controllers, limit switches, protective devices, electrical conductors, and connections must be inspected and maintained in conformance with good practice.

Special attention must be paid to the condition of electrical insulation.

17. To avoid injury to personnel or damage to the equipment, consult the manufacturer’s procedures in replacing contacts on any battery connection.

18. Industrial trucks must be kept in a clean condition to minimize fire hazards and help in the detection of loose or defective parts.

11. Before leaving ttruck a.

Stop truck.

b.

Put directional

c.

Apply the parking brake.

SM 593, Jan ‘93

d.

control in neutral.

19. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturer’s prior written approval. Capacity, operation and main-

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Safety-3

Introduction tenance instruction plates, tags, or decals must be changed accordingly.

20. 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. Parts, including tires, are to be installed per the manufacturer’s procedures.

Always use genuine CLARK or CLARKapproved parts.

21. Use special care when removing

heavy components from the truck, such as counterweight, seat deck, upright, etc. Be sure that lifting and handling equipment is of the correct capacity and in good condition.

NOTICE You should also be familiar with additional operating and maintenance safety instructions contained in the following publications:

ANSI/ASME B56.1 - 1988 Operator Control-Industrial Tow Tractors (Safety Standard For Powered Industrial Trucks). Published by: Society of Mechanical Engineers, United Engineering Center, 345 E. 47th Street, New York, NY 10017.

NFPA 505- 1982: Fire Safety Standard for Powered Industrial Trucks: Type Designations, Areas of Use, Maintenance and Operation. Available from: National Fire Protection Assoc., Inc., Batterymarch Park, Quincy, MA 02269.

General Industrial 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, DC 20402.

Safety-4

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SM 593, Jan ‘93

Group 06, Transmission

CLRRK

Transmission Removal The transmission removal process described below requires that you first remove the uprights, disconnect all connections to the transmission, and “drop” the transmission. The engine remains in the truck.

The procedure is as follows:

8. Drain transmission oil.

9. Remove pin(s) from shift bellcrank on transmission.

linkage(s)

at

1. Block the wheels to prevent roll. Then put the

direction control in neutral.

2. Using a safety-inspected and approved hoist or other lifting device of adequate capacity, raise truck 12-18 inches (305-457 mm) off floor, as described in Group 22, Section 1, “Lifting, Jacking, and Blocking.” Put wheel cradles of adequate capacity under rear wheels.

3. Put metal or narrow blocks under front frame.

Also block under counterweight so that the truck will not tip backward after the upright and transmission are removed.

10. Remove the parking brake yoke pin at the transmission. Remove fasteners attaching parking brake cable to transmission case.

4. Remove the uprights as described in Group 34, Section 8, “Upright Removal.”

11. At the transmission inching control valve, disconnect the inching line that comes from the selector valve.

5. Remove the drive wheels.

6. Unlatch and swing back the hood. Disconnect the battery cables.

7. Remove the floor plate.

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Transmission Removal

Inching Line Disconnect

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SM 593, Jan ‘93

c19Ru=

Group 06, Transmission

12. At the brake line tee (on top of the transmission) that connects the wheel caliper lines to the selector valve line, disconnect the line that goes to the selector valve.

Brake Line Disconnect,

15. Remove the electric wire leads to the transmission.

16. Remove the transmission inspection cover so that you can see the bolts that mount the torque converter drive plate to the engine flywheel.

Inspection Cover

Access Port

13. Remove the accelerator cable bracket fasteners from the accelerator pedal attaching bracket and move the accelerator linkage to one side as an assembly.

17. Remove the plug from the drive plate access port in the transmission case, for best access to the bolts that mount the torque converter drive plate to the engine flywheel.

18. Rotate the flywheel so that a torque converter drive plate mounting bolt lines up with the access port. With an extension through the access port, unscrew the bolt from the flywheel. Repeat for each bolt.

Bracket Fastener

14. Disconnect two transmission oil cooling lines: At the transmission control cover, disconnect the line that goes to the radiator. At the tee on the transmission, disconnect the line that goes to the oil filter.

NOTICE Do not pry on the torque converter.

Nicks and scratches on the convertor housing could lead to fatigue of the metal and eventual leaks.

Disconnect

Disconnect

SM 593, Jan ‘93

/

Bolt to ’ Engine Flywheel

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Transmission Removal

l

06-3-3

Group 06, Transmission 19.

Use a lift truck or safety-inspected and approved lifting device to support the transmission and use a jack to support the engine bell

housing.

20. Remove bolts that attach transmission to engine bell housing. (See illustration in step 22.)

21. Remove bolts attaching transmission and differential to frame.

Transmission Installation The following is a continuation of the process, described above, by which the transmission was “dropped” from the truck with the engine left in. The instructions below first cover installation of the torque converter into the transmission, then installation of the transmission into the truck.

1. Make sure truck blocking is secure and correctly positioned, raising truck 12-18 inches (305-457 mm) off floor.

Transmission Mounting Bolt

2. Make sure transmission is secure on the lifting device and that the insertion area beneath the truck is clear of obstacles and blocking.

3. Remove the transmission inspection cover so that you can see inside to mount the torque converter drive plate to the engine flywheel.

Also remove the access port plug. You will bolt the torque converter drive plate to the engine flywheel through this port.

CAUTION

Make sure blocking is not disturbed when the transmission is removed.

22. Gradually pull the transmission from the engine and lower it. Make sure that all connections to the transmission are free as you lower.

NOTICE

Keep inspection opening covered with a clean shop rag to prevent foreign material from getting inside transmission case.

4. Make sure the torque converter drive plate is bolted to the torque converter. (See illustration in step 1 l-c.) Fastener torque is 28-32 lbf-ft (37.9-43.4 Nmm).

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Transmission Removal

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SM 593, Jan ‘93

Group 06, Transmission

Cl!!mK 5. Lubricate the seal and bearing surface of the transmission stator support to let the tang drive of the convertor slide into the convertor pump drive gear tangs.

11. Bolt the torque converter drive plate to the engine flywheel as follows: a.

Rotate the torque converter drive plate so that a mounting bolt hole lines up with the access port.

b.

Rotate the engine flywheel so that a mounting bolt hole lines up with the access port.

NOTICE

Gear

6. Vlake sure the convertor pump drive gear is :orrectly positioned on the stator support.

Do not pry on the torque converter.

Nicks and scratches on the convertor housing could lead to fatigue of the metal and eventual leaks.

Place a mounting bolt with washer in an appropriate magnetic socket so that the rounded-edge side of the washer will contact the torque converter drive plate.

c.

7. Carefully insert the torque convertor drive shaft into the stator support. Rotate the transmission gearing to align the tangs on the convertor shaft; and push the convertor so its tangs drop into the gear tangs.

8. Replace the gasket, and carefully insert trans1mission assembly into position with the engine.

Housing Mounting

\

6 Flywheel

SM 593, Jan ‘93

Washer (Rounded Edges against Plate)

d.

With the socket on an extension, insert the mounting bolt through the access port and through the torque converter drive plate.

Start the bolt into the engine flywheel.

e.

Repeat for each mounting bolt. Tighten the bolts gradually, making several rotations of the drive plate/flywheel. Final torque for each bolt should be 19-21 lbf-ft (25.8-28.5 Nom).

9. Check that the torque converter is free to rotate with the flywheel.

10. Insert the bolts joining the transmission housing to the engine bell housing. Tighten the fasteners to a torque of (33-37 Nom) 24-27 lbf-ft.

\

NOTICE

If a drive plate mounting bolt falls into the transmission case, it must be removed to avoid eventual destruction of the transmission.

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Transmission

Removal

l

06-3-5

Group 06, Transmission

El!!WK

12. Replace the inspection cover on the transmission and tighten the fasteners to a torque of 2427 lbf-ft. (33-37 Nom).

13. Replace the inspection port plug.

14. Remove the jack or blocking supporting the engine bell housing.

15. Align center hole on each side of frame and differential housing. Install one bolt and lockwasher on each side and tighten to “finger tight” torque.

19. Install hoist on front of engine.

20. Raise engine until all 10 transmission mounting bolts freeplay out of bolt holes.

21. Add shims (flat washers) under front engine mounts, if necessary, and loosely reinstall the engine mounting bolts.

22. Let down hoist.

23. Torque all transmission mounting bolts to (550 Nom) 405-515 lbf-ft. Torque both engine mounting bolts to 23-27 lbf-ft (32-36 Nom).

24. Replace the electric wire leads to the transmission.

25. Connect two transmission oil cooling lines: At the transmission control cover, connect the line that goes to the radiator. At the tee on the transmission, connect the line that goes to the oil filter. Be sure of correct assembly. Tighten connectors to a torque of (25-27 Nom) 18-20 lbf-ft.

Connect -----

16. Add shims to right and left side side to fill void.

17. Start all 10 transmission mounting bolts (with lockwashers), but do not tighten.

18. Loosen two front engine mounting bolts.

26. At the transmission inching control valve, connect the inching line that comes from the selector valve.

Engine , Mounting Bolt

Inching Line Connection

Washer/Shim -

06-3-6

l

Transmission

Removal

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SM 593, Jan ‘93

CMRK

Group 06, Transmission

27. At the brake line tee (on top of the transmission) that connects the wheel caliper lines to the selector valve line, connect the line that goes to the selector valve.

30. Install the connecting pin(s) in shift linkage yoke(s) at bellcrank on transmission. Insert cotter pin(s) and bend legs on cotter pin(s).

Brake Line Disconnect.

28. Move the accelerator linkage into position and install the accelerator cable bracket fasteners into the accelerator pedal attaching bracket.

Torque fasteners to 83-94 lbf-in (9-l 1 N=m).

31. Replace the upright as described in Group 34, Section 8, “Upright Removal.”

32. Fill transmission with correct fluid.

33. Fill hydraulic sump tank to correct level with proper fluid.

34. Install battery and tighten battery terminal nuts to a torque of 170-191 lbf-in (19-22 Nom).

Make sure terminal boots are fnmly in place.

35. Start truck, allow fluids to circulate, and shut off truck.

Bracket Fastener

29. Replace fasteners attaching parking brake cable to transmission case. Replace the parking brake yoke pin and cotter pin. Spread cotter pin ends.

36. Recheck fluid transmission and hydraulic fluid levels.

37. Bleed the inching lines and bleed the brake lines from the wheel caliper to the power boosters, as described in Group 23, Section 2, “Brake and Inching System Bleeding.”

38. Install the floor plate and tighten the fasteners.

39. Mount drive wheels on axle ends. Tighten wheel nuts to a torque of 450-500 lbf-ft (610-678N.m).

40. Carefully raise truck using approved equipment of adequate capacity and remove blocking.

Yoke Pin

SM 593, Jan ‘93

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Transmission Removal

l

06-3-7

Group 06, Transmission

Cl!ARK

40. Make sure all warning decals are in place.

41. Carefully check all operating controls in accor-

dance with operator manual.

42. Check for any binding in control linkages and

make sure all controls return to position when released.

47. Operate truck slowly and listen for any unusual

noise in transmission. Make sure truck responds correctly to forward/reverse shifts, and to low/ high shifts if 2-speed.

06-3-8

l

Transmission Removal

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SM 593, Jan ‘93

Group 06, Transmission

Cl!!YRK

HYDRATORK TRANSMISSION SINGLE SPEED AND TWO SPEED FWD AND REV MODELS HZ00 THRU H213: When the Hydratork transmission is disassembled, the following steps must be carefully followed for correct operation of the transmission.

The arrow shows the location of the model and part numbers.

1. Remove the torque convertor.

2.

Remove all fasteners from the axle adaptor to transmission.

Separate the adaptor from the transmission by using jackscrews.

Remove the axle adaptor assembly.

3.

Remove the axle adaptor adjustment shim(s) and the O-ring seal.

1 n772

06-4-2

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Transmission Overhaul

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SM 593, Jan ‘93

CMRK 4.

Group 06, Transmission

Remove the convertor pump from the transmission assembly.

10224 5.

Remove the control cover assembly and gasket.

10225 6.

Install the control cover capscrews into the oil sleeves. After the capscrews are in place, lift up on the capscrews (while holding the oil tubes) to prevent damage to the tubes.

10226 7.

Remove the forward and reverse oil tubes.

SM 593, Jan ‘93

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Transmission Overhaul

l

06-4-3

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EL’YRK

Group 06, Transmission

8.

Remove the high and low oil tubes.

NOTE Single speed speed transmission does not have hi and lo clutches as shown in photo.

10228 9.

Remove the speed selector oil distributor retainer ring.

10234 10.

Remove the speed selector oil distributor by pulling out from the transmission.

10235 11.

Use soft brass stock to keep the gears from moving.

10236

06-4-4

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Transmission Overhaul

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SM 593, Jan ‘93

Group 06, Transmission

Cl!lRK 12. Remove the output shaft retainer.

Fig. 10383 13. Use a soft brass bar to remove the output shaft from the converter end toward the axle adaptor end.

Fig. 10237 14. After the shaft has been moved toward the axle adaptor end, remove the gear, spacer and thrust washer. Continue to move the shaft until the shaft assembly is away from the clutch pack.

Fig. 10238

SM 593, Jan ‘93

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Transmission Overhaul

l

06-4-5

Group 06, Transmission

Fig. 10244 (Output Shaft Assembly)

15. Remove the transmission input shaft cap on the axle adaptor end of the transmission.

Later model transmissions do not have this o-ring seal (a).

Fig. 10229

06-4-6

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Transmission Overhaul

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SM 593, Jan ‘93