CLARK FORKLIFT IClOO Cooling and Exhaust Systems TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

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CLARK FORKLIFT IClOO Cooling and Exhaust Systems TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

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CLARK FORKLIFT IClOO Cooling and Exhaust Systems TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

• The cooling and exhaust systems play a vital role in the proper functioning of the internal combustion engine. Because the sources of problems with these systems are hard to determine, this class will teach you the theories behind the components of the cooling and exhaust systems and show you how to troubleshoot each system.
• The engine runs because of the energy and heat created in the combustion chamber when the spark plug ignites the fuel. However, only a small amount of this heat is turned into useful mechanical work.
• For the engine to function properly, the excess heat must be removed. The cooling system’s main function is to control the operating temperature of the engine. It removes excess heat in the cylinder block by transfen’ing the heat to a coolant solution in the engine water jacket.
• The heated coolant leaves the cylinder block and enters the radiator where air blown through the radiator core removes the heat from the coolant and expels it from the system.
• The exhaust system has two p1’imary functions. To reduce noise and to direct exhaust away from the operator and engine. When you have finished this class and passed the w1’itten test, you will have learned three things: 1. You will know how the components of the cooling and exhaust systems work.
• 2. You will be familiar with the problems associated with these components. 3. You will know how to troubleshoot these systems. After you have finished this class, you can use this manual as a handy reference guide.

Table Of Contents:

CLARK FORKLIFT IClOO Cooling and Exhaust Systems TECHNICAL TRAINING MANUAL – PDF DOWNLOAD

About this class .. . . . .. .. . .. .. .. … …… .. . . .. … .. … . .. .. .. . . … .. …… …. … .. .. ….. ……. …… .. 3
About safety .. …. .. … . .. . .. . .. .. …. … . .. . . . . . . .. . . .. .. . . .. .. . . …. .. .. .. .. . .. . . . … . . . . . .. . … . … . . . 4
Section 1. The Cooling System . .. . .. . . . . . .. . . . . . . . . . . .. .. . . .. . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . .. . . 5
The Cooling System . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Coolant ……………………………………………………………………………………. 5
Water Pump ……………………………………………………………………………. 6
Thermostat . . .. . . … . . . . … . … .. … . .. . . . .. . . . . . .. . .. .. .. . .. . . … .. . … . … . . .. . . . . . … … .. . .. …. 7
Radiator Core . .. . . …. . . .. .. .. . … . … … .. … ……. … .. … . . .. … .. …. …….. …. . …. .. .. . . . 8
Transmission Oil Cooler ……………………………………………………………. 10
Radiator Pressure Cap . . . . . .. . .. . .. . .. . . .. . . .. … . .. . . .. . . .. . . . .. . .. .. . .. . .. . .. .. . … .. .. . . .. . 11
Overflow Pipe and Coolant Recovery Bottle .. .. ……. …. ….. .. . … … … …. . 12
Hoses and Clamps . . . . . . . . .. . . .. . . .. . . . . . . . . .. . . . .. . .. . . . . . . .. . . .. .. . . . .. . . .. .. . . . .. . . .. . . . . . . . .. 13
Cooling Fan ……………………………………………………………………………… 14
Fan Shroud . . …… .. . .. . .. …. ….. … .. . . … .. .. .. .. .. ……. .. …. …. …….. …… …… .. …. .. 15
Fan Belt ………………………………………………………………………………….. 15
Fan Belt Adjustment………………………………………………………………….. 15
Sender and Gauge ……………………………………………………………………. 16
Viscous Fan Drive . . . ……. .. .. . … .. . .. .. . ….. .. . . .. . … . … .. . … . ….. .. . .. . . … ….. .. . … . 17
Section 3. Troubleshooting the Cooling System …………………………………. 19
Five Basic Steps to Troubleshooting……………………………………………. 19
Physical Inspection with the Engine Off ……………………………………. 19
Physical Inspection with the Engine Running .. . .. .. . . . .. .. . .. .. .. . . . . . . .. . .. . . 22
Pressure Testing the Cooling System………………………………………….. 22
Testing the Thermostat ……………………………………………………………. 23
Checking the Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Checking the Viscous Fan Drive . . . .. . . . .. . . .. . .. . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. 24
Using the Cooling System Analyzer ………………………………………….. 24
Reverse Flow Flushing … .. … … . . … . . .. .. …. .. . …. .. …… … . .. … .. … . … ….. … .. .. 26
Reverse Flow Flushing the Radiator …………………………………………. 26
Reverse Flow Flushing the Engine Jacket …………………………………. 26
Section 4. The Exhaust System ……………………………………………………….. 28
Exhaust Manifold . . . … .. . ……. .. .. . . . … . . . … . .. . . .. . … . ….. .. . … .. .. . . . .. . .. . … … .. . . .. 28
Exhaust Pipe . .. .. .. …… ….. .. . . .. … . . … … … . .. .. . .. . . .. . . . .. .. …… .. .. . .. … …. ……. .. . 29
Muffler ……………………………………………………………………………………. 29
Tail Pipe . . … . .. . …. .. ….. .. .. …. .. .. … . … … . …… .. .. … . . …. … .. .. . … .. . .. .. . ……. .. .. … 30
Catalytic Converter (Optional) ………………………………………………….. 31
Piccolo Tube Tail Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 31
Section 5. Troubleshooting the Exhaust System …. .. .. .. . .. .. .. . .. .. . .. .. … .. .. …. . 32
Troubleshooting the Exhaust System . .. .. . . …. … . . ….. ….. … . . … .. ….. … . .. . 32
Section 6. Easy Reference Troubleshooting … .. .. .. . . .. . . .. ……… .. . . . .. .. .. . … .. … 33
Easy Reference Troubleshooting .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . .. . 33
Engine Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Engine Runs Cold .. …. .. … .. .. .. . . . … .. …. .. … … . . . .. … . ……… .. . . . . . . . . . . . …. … . .. . . 35
Water Pump :Leaks ………………………………………………………………….. 35
Water Pump Makes Noise ………………………………………………………… 35
Oil in Coolant .. .. .. …… .. ……. .. … . .. .. .. …. .. …… … .. .. … ….. … . . . . … ….. … …… .. 36
Copyrighted Material IC 100 page 1
Intended for CLARK dealers only

Please Note:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]
  

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