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CLARK FORKLIFT SM- 606 GPX 3540503 SERVICE MANUAL
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CLARK FORKLIFT SM-606 GPX 3540503 SERVICE MANUAL – PDF DOWNLOAD
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CLARK FORKLIFT SM-606 GPX 3540503 SERVICE MANUAL – PDF DOWNLOAD
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CLARK FORKLIFT SM-606 GPX 3540503 SERVICE MANUAL – PDF DOWNLOAD
- 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. 2. 3. Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities, trained personnel, and procedures must be provided. Maintenance and inspection of all powered industrial trucks shall be done in conformance with the manufacturer’s recommendations. A scheduled planned maintenance, lubrication, and inspection program shall be followed. Safety-2 SM 593, Jan ‘93 CMRK 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. 11. Before leaving ttruck a. Stop truck. b. Put directional control in neutral. c. Apply the parking brake. 12. 13. 14. 15. 16. 17. 18. 19. d. Stop the engine by turning off the ignition circuit. e. Put blocks at the wheels if truck is on an incline. 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.
- 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. 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. The truck manufacturer’s capacity, operation, andmaintenance instruction plates, tags, or decals must be maintained in legible condition.
- 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. To avoid injury to personnel or damage to the equipment, consult the manufacturer’s procedures in replacing contacts on any battery connection.
- Industrial trucks must be kept in a clean condition to minimize fire hazards and help in the detection of loose or defective parts. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturer’s prior written approval.
Table Of Contents:
CLARK FORKLIFT SM-606 GPX 3540503 SERVICE MANUAL – PDF DOWNLOAD
CONTENTS ................................................................. 4 INTRODUCTION ............................................................. 6 Safety................................................................ 8 Safety Signs and Messages......................................... 8 User Safe Maintenance Practices................................... 8 Planned Maintenance................................................... 11 PM Report Form.................................................... 12 Visual Inspection................................................. 12 Forks......................................................... 13 Wheels and Tires.............................................. 14 Brake and Inching Pedal Freeplay.............................. 14 Functional Tests.................................................. 14 Key/Start Switch ............................................. 14 Battery Light ................................................ 15 Fuel Light ................................................... 15 Engine Oil Pressure Light..................................... 15 Coolant Temperature Light..................................... 15 Brake Malfunction Light ...................................... 15 Air Filter Restriction Light ................................. 15 Transmission Temperature Light................................ 15 Hydraulic Filter Restriction Light............................ 15 Parking Brake Light........................................... 15 Hour Meter.................................................... 16 Accelerator, Service Brake, Parking Brake, and Inching .... 16 Lift Mechanisms and Controls ................................. 16 Auxiliary Controls............................................ 17 Steering System .............................................. 17 Shift Control and Brakes ..................................... 17 Under the Hood.................................................... 18 Belts and Hoses .............................................. 18 Engine Air Cleaner ........................................... 18 Battery ...................................................... 18 Engine Cooling System ........................................ 18 Engine Oil ................................................... 19 Engine Oil and Filter Change ................................. 20 Hydraulic Sump Tank .......................................... 20 Hydraulic Fluid and Filter Change ............................ 20 Sump Tank Breather ........................................... 20 Transmission Fluid Check ..................................... 20 Truck Chassis Inspection and Lubrication.......................... 21 Air Cleaning...................................................... 21 Upright and Tilt Cylinder Lubrication............................. 21 Critical Fastner Torque Checks.................................... 22 Lift Chain Maintenance............................................ 22 Lift Chain Adjustment Check................................... 22 Lift Chain Inspection and Measurement ........................ 23 Lift Chain Lubrication ....................................... 23 Lift Chain Replacement ....................................... 23 00 ENGINES .............................................................. 24 00-01 Engine Removal and Replacement................................. 25 Engine Removal.................................................... 26 Engine Replacement .............................................. 30 00-02 Vortec V-6 GM Engine Repair Procedures......................... 35 General Description............................................... 38 General Information............................................... 45 Disassembly of the Engine......................................... 46 Cleaning, Inspection, and Repair.................................. 53 Assembly of the Engine............................................ 72 00-02A Delco Distributor ............................................ 89 01 COOLING SYSTEM ....................................................... 92 01-01 Troubleshooting ............................................... 93 01-02 Cooling System Testing and Maintenance ........................ 95 Engine Coolant Check.............................................. 96 Cooling System Inspection......................................... 96 Cooling System Pressure Tests..................................... 97 Testing the Radiator Cap...................................... 97 Testing Radiator and Cooling System........................... 98 Testing the Thermostat........................................ 98 Flushing the Cooling System....................................... 98 Cooling System Drain and Refill................................... 99 01-03 Fan Belt Replacement ..........................................100 01-04 Radiator Removal ..............................................101 02 FUEL SYSTEM ..........................................................102 02-01 Fuel Pump Pressure Test (Gas Only) ........................103 02-02 The IMPCO LPG Fuel System ...................................105 02-03 Carburetor Overhaul ..........................................121 02-04 Velocity Governor Overhaul ..................................127 02-05 Removal of IMPCO Vaporizing System .........................129 06 TRANSMISSION .........................................................130 06-01 Transmission Checks ...........................................131 Tools Required ...................................................132 General Checks....................................................132 Stall RPM Checks..................................................132 Pressure Checks ..................................................134 Inching Pressure..............................................134 Clutch Pack Pressures.........................................134 Converter Pressure............................................134 Neutral Start Switch..........................................134 Transmission Cooling System Checks ...............................135 Fluid Aeration Checks ...........................................136 Fluid Leakage Checks ............................................136 06-02 Transmission Drain and Refill .................................137 06-03 Transmission Removal ..........................................139 06-04 Transmission Overhaul .........................................147 14 ELECTRICAL SYSTEM ....................................................182 14-01 Wiring Color Codes ............................................183 14-02 Wiring Diagrams ...............................................186 14-03 Electrical Checks .............................................189 Battery Load Test.................................................190 Positive Post Volt Drop Test......................................191 Negative Post Volt Drop Test......................................192 Positive Cable Volt Drop Test.....................................193 Negative Cable Volt Drop Test.....................................194 Starter Ground Test...............................................195 Solenoid Disc Contact Volt Drop Test..............................196 Solenoid Circuit Volt Drop Test...................................197 20 DRIVE AXLE ..........................................................198 20-01 Axle End Lubrication...........................................199 20-02 Axle End Removal...............................................201 20-03 Axle Ends Overhaul ............................................206 20-04 Differential Overhaul .........................................213 22 WHEELS AND TIRES .....................................................221 22-01 Lifting, Jacking, and Blocking ................................222 Lifting and Blocking .............................................223 Jacking and Blocking .............................................224 22-02 Wheels and Tires Mounting .....................................226 Safe Handling of Split Rim Wheels ................................227 Filling Tires with Air ...........................................232 23 BRAKING/INCHING SYSTEM ..............................................233 23-01 Braking/Inching System Description and Troubleshooting ........234 Braking/Inching Description ......................................235 Braking.......................................................235 Inching.......................................................235 Service Brake Troubleshooting ...................................237 Inching System Troubleshooting ..................................238 23-02 System Brake and Inching Bleeding .............................240 Manual Bleeding Procedure ........................................241 Power Bleeding Procedure .........................................244 23-03 Brake and Inching Pedal Adjustment ............................248 23-04 Master Cylinder Overhaul ......................................249 23-05 Power Booster Assembly Overhaul ...............................253 23-06 Caliper and Disk Inspection and Overhaul ......................254 Inspection........................................................255 Axle End Removal..................................................255 Piston Replacement................................................255 Caliper Replacement...............................................256 Disk Lining Renewal...............................................256 Reassembly and Bleeding...........................................256 23-07 Parking Brake .................................................257 25 STEERING COLUMN AND GEAR .............................................258 25-01 Troubleshooting ...............................................259 25-02 Steering Column and Gear Removal ..............................260 25-03 Char-Lynn Steering Control Unit (Steering Gear) ..............262 Trouble Shooting Information......................................263 Repair Information................................................267 Parts Information.................................................277 26 STEER AXLE ...........................................................283 26-01 Steer Axle Removal and Replacement ............................284 26-02 Steer Axle Overhaul ...........................................287 26-03 Steering System Adjustment ....................................297 26-04 Steer Cylinder Removal and Replacement ........................298 26-05 Steer Axle Wheel Bearings .....................................301 26-06 Steer Cylinder Overhaul .......................................303 29 HYDRAULIC SUMP, FILTERS, AND PUMP ....................................305 29-01 Hydraulic Sump and Filters ....................................306 29-02 Hydraulic Pump (Vane Type) Troubleshooting and Overhaul .......308 30 HYDRAULIC VALVE/LIFT CIRCUIT .........................................314 30-01 Hydraulic System Pressure Check ...............................315 30-02 Hydraulic Valve Troubleshooting and Overhaul ..................316 30-03 Hydraulic Valves .............................................323 Priority Valve and Flow Divider Assembly .........................324 Priority Valve................................................324 Flow Divider..................................................324 Main Hydraulic Valve (Control Valve) .............................325 Control Valve Linkage.............................................326 30-04 Hydraulic Schematic ..........................................327 32 TILT CYLINDERS .......................................................329 32-01 Tilt Cylinder Removal and Replacement .........................330 32-02 Tilt Cylinder Overhaul ........................................333 32-03 Tilt Lock Valve ...............................................337 34 UPRIGHTS .............................................................338 34-01 Troubleshooting and Visual Inspection .........................339 34-02 Operational Checks ............................................344 Lift Chain Checks ................................................345 Fork Checks ......................................................347 Upright Checks ...................................................348 Roller Patterns...............................................348 Upright Racking...............................................348 Load Test.....................................................349 Hydraulic Cylinder Checks ........................................350 Cylinder Seal Checks..........................................350 Drift Test....................................................350 34-03 Carriage Check and Adjustment .................................352 Carriage Roller Check ............................................353 Carriage Removal and Reinstallation ..............................354 Carriage Removal..............................................354 Shimming the Carriage Rollers.................................355 Carriage Reinstallation.......................................355 34-04 Upright Check and Adjustment ..................................357 Roller Clearance Checks .........................................358 Roller Bearing Replacement Procedures ............................360 Upright Reassembly ...............................................364 34-05 Cylinder Repair ...............................................366 34-06 Lift Chain Maintenance ........................................369 Lift Chain Inspection.............................................370 Lift Chain Lubrication............................................373 Lift Chain Replacement............................................375 Check List........................................................375 34-07 Upright Removal and Replacement ...............................379 38 COUNTERWEIGHTS .......................................................382 38-01 Counterweight Removal .........................................383 40 SPECIFICATIONS .......................................................386 40-01 Nameplate and Decals ..........................................387 40-02 GPX 30/50E General Specifications .............................388 Capacities........................................................389 Service Weights...................................................389 Axle Weights......................................................389 Maximum Gradeability..............................................389 Parking Brake Test................................................390 Drawbar Pull......................................................390 Travel Speeds.....................................................390 Turning Radius....................................................390 Wheels & Tires....................................................391 Drift: Lift and Tilt..............................................391 Lift Speeds, Upright..............................................392 Lowering Speeds, Upright..........................................392 Drive Axle........................................................393 Service Brakes....................................................393 Parking Brake.....................................................393 Cooling System....................................................393 Electrical........................................................393 Gasoline/LPG Engine Specifications................................394 Engine Fuel Specifications........................................395 Engine Tune-Up (Gas/LPG)..........................................394 Hydraulic System..................................................396 Critical Fastener Torque Specifications...........................396 Transmission......................................................397 40-03 PM Inspection and Driver’s Daily Inspection Forms .............398 40-04 Lubricants and Shop Supplies ..................................401 Lubricants........................................................402 Sealants..........................................................405 Gasket Materials..................................................406 Threadlocks and Threadsealers.....................................407 Adhesives.........................................................407 Cleaners..........................................................408 Miscellaneous Shop Supplies.......................................410 40-05 Lubrication Intervals .........................................411
Please Note:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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