Description
This Clark GCS 20-30 GCX GPS GPX Forklift Service Manual is the complete workshop publication for Clark cushion-tire and pneumatic-tire lift trucks in the 17 through 30 series. Published under document number SM-520R, it covers every major system on these trucks, from engine and fuel delivery through transaxle, brakes, steering, hydraulics, and upright service. Whether you are maintaining a GCS 20, diagnosing a GPX 30, or rebuilding a TA18 transaxle, this service manual provides the procedures, specifications, and torque values needed to complete the job correctly.
File Details
- Manual Type: Service Manual
- Brand: Clark
- Document Number: SM-520R
- Language: English
- Page Count: 900+ pages
- File Format: PDF
- Coverage: Clark GCS, GCX, GPS, GPX, DCS, and DPS series lift trucks
- Revision: Revised through 1991
Models and Engines Covered
This Clark forklift service manual covers the following models and engine configurations:
- Cushion Tire Models: GCX 20, 22, 25, 27, 30; GCS 20, 22, 25, 27, 30; GCS 17; DCS 17, 20, 22, 25, 27, 30
- Pneumatic Tire Models: GPX 20, 22, 25, 27, 30; GPS 20, 22, 25, 27, 30; DPS 20, 22, 25, 27, 30
- Mitsubishi 4G54 [2.6L] Gas/LPG Engine: 4-cylinder inline, 4-cycle, water-cooled, 156 cu in displacement, used in MB, MC, GX, and GPX models
- Continental TM27 [2.7L] Gas/LPG and TMD27 [2.7L] Diesel Engines: 4-cylinder, 164 cu in displacement, used in I, GX-C, and GPX-C models
- Waukesha D176GA [2.9L] Gas/LPG Engine: 4-cylinder, 176 cu in displacement, used in WC models
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Clark GCS 20-30 GCX GPS GPX Forklift Service Manual – SM-520R” are as follows:
Title Pagep. 1
Forewordp. 2
Contentsp. 3
About This Manualp. 4
+Part 1 General Informationp. 5
Safe Maintenance Practicesp. 6
Safety Signs and Messagesp. 8
General Precautionsp. 9
+Product Identificationp. 10
Model Nomenclaturep. 10
Model Designation by Engine and Transaxle Applicationp. 11
Model Serial Number Codep. 11
Machine Serial Number Uright Deck Numberp. 12
Truck Model Visual Identificationp. 13
Truck Systems by Parts GROUP Numberp. 14
+Part 2 Specificationsp. 15
+2.1 Service Specificationsp. 18
Frame/Chassisp. 18
Cooling Systemp. 18
Electrical Systemp. 18
Fuel Systemp. 19
Drive & Steer Tiresp. 19
+Engine Applications and Specificationsp. 20
MITSUBISHI 4G54 [2.6 L]p. 20
CONTINENTAL TM27 & TMD27 [2.7L]p. 21
WAUKESHA D176GA [2.9 L]p. 22
+Transaxle Applications and Specificationsp. 23
CLARK TAI 8p. 23
CLARK HR510 & HI3511p. 23
CLARK HR600p. 24
+Model Specificationsp. 24
HR610p. 24
HR611p. 24
HR612p. 24
HR620p. 24
HR621p. 24
Brakesp. 25
Brake-Inching Control Systemp. 25
+Steering Systemp. 26
Power Steering System – All Modelsp. 26
Steer Axle & Steering Cylinderp. 26
Main Hydraulic Systemp. 27
Lift Speedsp. 28
Maximum Fork Driftp. 28
Tilt Cylindersp. 29
Truck Weightsp. 29
Counterweight Weightsp. 29
Fill Capacitiesp. 30
Fluid Recommendationsp. 30
Lubricant Specificationsp. 31
+Torque Specificationsp. 32
Critical Fastener Torque Specificationsp. 32
Truck Chassis – Generalp. 32
4G54 [2.6L] Enginep. 33
TM27/TMD27 [2.7L] Enginesp. 33
D176GA [2.9L] Enginep. 34
Truck Data Plate and Decal Specificationsp. 35
Data Plate and Decal Location Specificationsp. 36
Product Specification Changesp. 16
+Part 3 Planned Maintenancep. 37
+3.1 PM Schedulesp. 38
Planned Maintenance (PM)p. 38
+PM Service Intervalsp. 39
Typical Operating Conditionsp. 39
Recommended PM Intervalsp. 39
Safety and Operational Checksp. 40
Recommended Planned Maintenance and Lubrication Schedulep. 41
+3.2 Planned Maintenance Procedures PM Programp. 42
+Visual Inspectionp. 42
Overhead Guard, Load Backrest, Fork Retainersp. 43
Upright and Lift Chainsp. 43
Forksp. 44
Wheels and Tiresp. 45
Engine & Accessoriesp. 46
+Functional Testsp. 47
Safety Equipmentp. 47
Hourmeterp. 47
Enginep. 48
Brake and Hydraulic Controlsp. 48
Steering Systemp. 48
Lift Mechanism and Controlsp. 49
Auxiliary Function Controlp. 49
Operational Tests – Test Drivep. 50
+Lubrication, Fluids and Filtersp. 50
Engine Cooling Systemp. 50
Checking Coolantp. 51
Engine Coolant Changep. 51
Engine Oil Level Checkp. 52
Engine Oil and Filter Changep. 52
Engine Fuel Systemp. 53
Master Cylinder Reservoirp. 53
Hydraulic Sumpp. 53
Hydraulic Oil Filterp. 54
Transaxle Fluidp. 54
Transaxle Oil Filter Changep. 55
Truck Chassis Inspection and Lubricationp. 55
Upright and Tilt Cylinder Lubricationp. 55
Lift Chainsp. 55
Air Cleaningp. 56
Critical Fastener Torque Checksp. 57
+3.3 Machine Jacking and Blockingp. 60
Raising Drive Wheels Off Floorp. 60
Blocking The Upright In Raised Positionp. 60
Raising Rear of Truckp. 61
Raising Entire Truckp. 61
Raising Truck With A Hoistp. 62
Lifting and Jacking Pointsp. 63
Shipping Tie-Down Instructionsp. 63
+Part 4 Enginep. 64
+4.1 Engine Maintenance – Oil and Filter Changep. 65
Oil Change Frequencyp. 65
Engine Oil Level Checkp. 65
Engine Oil & Filter Changep. 66
+4.2 Engine Troubleshooting Gasoline/LPG and Dieselp. 67
Gasoline/LPG Engine Troubleshooting Guidep. 68
Diesel Engine Troubleshooting Guidep. 74
+4.3 Engine Tune-Up Gasoline/LPG &n Dieselp. 79
Tune-Up Preparationp. 79
Minimum Tools Required:p. 79
+1 -Preliminary Checksp. 80
4654 [2.6L] Enginep. 80
TM(D)27 [2.7L] Enginep. 80
D176GA [2.9L] Enginep. 80
Spark Testp. 82
Cranking Testp. 82
Batteryp. 83
Fuel Supply System Gasoline Enginesp. 83
+2-Tune-Up Proceduresp. 83
1. Stall Testp. 83
2. Idle Speedp. 83
3. Ignition Systemp. 84
4. Readjust Idle Speedp. 85
5. Compression Checkp. 86
6. Valve Clearance Settingsp. 86
7. Cooling Systemp. 86
8. TMD27 [2.9L] Diesel Enginep. 86
9. Recheck Engine Performancep. 86
Tune-Up Completionp. 86
+4.4 Ignition Timing Proceduresp. 87
General Proceduresp. 87
Checking Ignition Timingp. 89
Initial (Basic) Ignition Timingp. 90
Checking Spark Advancep. 91
Ignition Timing Completionp. 91
Emergency Method Distributor Ignition Timing Without Timing Lightp. 92
+4.5 Engine Valve Clearance Adjustmentp. 93
Valve Tappet Clearance Adjustmentp. 93
Minimum Tools Requiredp. 93
Preliminary Service Preparationp. 93
+General Proceduresp. 94
Valve Clearance Checkp. 94
Valve Clearance Adjustmentp. 94
TM(D)27 [2.7L] Engine Proceduresp. 95
4654 [2.6L] Engine Proceduresp. 96
D176GA [2.9L] Engine Proceduresp. 98
Valve Adjustment Completionp. 99
+4.6 Engine Compression Pressure Test – (Gasoline/LPG & Diesel)p. 100
Gasoline/LPG Engines – Typical Compression Test Procedurep. 100
Analysis of Pressure Readingsp. 102
Compression Test Completionp. 103
Diesel Engine – Typical Compression Test Procedurep. 103
Analysis of Diesel Compression Readingsp. 104
Test Completionp. 105
+4.7 Engine RPM, Vacuum & Stall Testsp. 106
1. Engine RPM at Idlep. 107
Engine Troubleshooting With Intake Manifold Vacuum Test at Idlep. 108
2. Intake Manifold Vacuum at Idlep. 108
3. Engine RPM at Max No-Load Governed Speedp. 109
4. Engine Vacuum at Max No-Load Governed RPMp. 109
5. Engine RPM & Vacuum at Hydraulic By-Passp. 110
+6. Full Throttle Engine Stall RPM & VAcuump. 110
Full Throttle Stall Speed Chart Gasolinep. 111
Analysis of Stall Testp. 112
7. Transmission Pressure Checksp. 112
8. Test Completionp. 113
+4.8 Cooling Systemp. 114
Cooling System Troubleshootingp. 114
Coolant Specificationp. 115
Engine Coolant Level Checkp. 115
Cooling System Inspectionp. 116
+Cooling System Pressure Testsp. 117
Radiator and Cooling Systemp. 117
Radiator Capp. 117
Thermostatp. 117
+Engine Coolant Changep. 118
Draining Radiator & Cooling Systemp. 118
Cleaning & Flushing Cooling Systemp. 118
Fan Drive Specifications Tempatrol Viscous Drivep. 119
Fan Drive Troubleshootingp. 120
Cooling Fan lnstallation – Without Viscous Fan Drivep. 121
Fan Beltp. 121
Fan Belt Tensioningp. 121
Fan Belt Tension Specificationp. 121
Cooling System G(P)X, MB, MC, I Modelsp. 122
Cooling System WC Models – D176GA [2.9L] Enginep. 123
Cooling System – Without Overflow Reservoir MB Models – 4654 [2.6L] Enginep. 124
Transmission Cooling Linesp. 125
+4.9 Engine Air Cleanerp. 127
Air Cleaner Maintenancep. 127
Air Cleaner With Integral Door on Housing Early Truck Modelsp. 128
Air Cleaner With foam seal on engine compartment door GC(P)X, MB, MC Models – 4654 [2.6L] Enginep. 129
Air Cleaner With foam seal on engine compartment door I Models – TM(D)27 [2.7L] Enginep. 130
Air Cleaner I, G(P)X-C Models-Dieselp. 131
Air Cleaner Assembly I, G( P)X-C Models-Dieselp. 132
Air Filter Element Replacementp. 133
Air Cleaner Removalp. 134
Canister Dry Air Filter Servicep. 134
+4.10 Engine Adjustmentsp. 135
+1 -Carburetor Idle Speed Adjustmentp. 135
4654 [2.6L] Enginep. 136
TM(D)27 [2.7L] Enginep. 137
D176GA [2.9L] Enginep. 137
Accelerator Pedal and Linkage, Control G(P)X, MB, MC Models – 4G54 [2.6L] Enginep. 138
Accelerator Pedal and Linkage, Choke Control I Model – TM27[2.7L] Enginep. 139
Accelerator Pedal and Linkage, Choke Control WC Model – D176GA [2.9L] Enginep. 140
Accelerator Pedal and Linkage G(P)X-C Models – TM27 (2.7L) Enginep. 141
Idle Speed 4G54 [2.6L] Enginep. 136
Idle Speed TM(D)27 [2.7L] Enginep. 137
Idle Speed D176GA [2.9L] Enginep. 137
Accelerator Pedal and Linkage, Choke Control G(P)X, MB, MC Models – 4G54 [2.6L] Enginep. 138
Accelerator Pedal and Linkage, Choke Control I Model – TM27[2.7L] Enginep. 138
Accelerator Pedal and Linkage, Choke Control WC Model – D176GA [2.9L] Enginep. 139
Accelerator Pedal and Linkage G(P)X-C Models – TM27 (2.7L) Enginep. 141
2-Choke Control Adjustmentp. 142
3-Throttle Linkage Adjustmentp. 143
+4-Governor Adjustmentp. 146
4654 [2.6L] Enginep. 147
TM27 [2.7L] Enginep. 149
TM27 [2.7L] Engine TMD27 [2.7L] Diesel Enginep. 150
D176GA [2.9L] Enginep. 151
+4.11 Engine Removalp. 154
Truck Preparationp. 154
ENGINE REMOVAL CHECK LISTp. 154
Engine Mounts GC(P)X, MB, MC Models – 4654 [2.6L] Enginep. 155
Engine Mounts I Models – TM(D)27 [2.7L] Enginep. 156
Engine Mounts G(P)X-C Models – TM(D)27 [2/7L] Enginep. 157
Engine Mounts WC Models – D176GA [2.9L] Enginep. 158
Engine Removal Proceduresp. 159
Engine Removalp. 163
Truck Preparationp. 159
+Engine Installationp. 164
ENGINE INSTALLATION CHECK LISTp. 164
+4.12 Engine Components GC(P)X, MB, MC Models – 4G54 [2.6L] Enginep. 165
Oil Pumpp. 165
Water Pump, Thermostat Housing, Starterp. 166
Oil Pump, Oil Filter, LPG Carburetor, Governor, Distributorp. 167
Oil Pump, Oil Filter, Gasoline Carburetor, Fuel Pump, Governor, Distributorp. 168
Rocker Cover, Cylinder Head & Gasketp. 169
Front End Cover, Oil Pan & Gasketp. 170
Intake Manifold, Exhaust Manifold, Gasketsp. 171
Exhaust Systemp. 172
+4.13 Engine Components G(P)X-C, I Models – TM(D)27 [2.7L] Enginep. 173
Water Pump Assemblyp. 173
Water Pump, Thermostat Housing, Gasoline Carburetor, Starterp. 174
Distributor, Ignition Coil, Fuel Pumpp. 175
Crankcase Ventilation, Oil Filterp. 176
Rocker C over, Cylinder Head & Gasketp. 177
Oil Pump, Oil Panp. 178
Intake and Exhaust Manifolds, Gasketsp. 179
Exhaust Systemp. 180
+4.14 Engine Components WC Models – D176GA [2.9L] Enginep. 181
Water Pump Assemblyp. 181
Water Pump, Thermostat Housing, Gasoline Carburetor, Fuel Pump, Distributor, Governor, Oil Pumpp. 182
Engine Oil Filter and Linesp. 183
Rocker Cover, Cylinder Head & Gasketp. 184
Cylinder Head, Rocker Arms, Valves Assemblyp. 185
Oil Pan & Gasket, Oil Pumpp. 186
Intake and Exhaust Manifolds, Gasketsp. 187
Exhaust Systemp. 188
+Part 5 Fuel Systemp. 189
Fuel Tank Installation – Gasoline/Dieselp. 190
+5.1 Fuel Systems Maintenancep. 191
General Proceduresp. 191
Fuel Tank – Gasoline & Dieselp. 191
Gasoline Fuel Systemp. 191
Fuel Lines GC(P)X, MB, MC Models -4G54 [2.6L] Enginep. 192
Fuel Lines I Models – TM(D)27 [2.7L] Gas and Diesel Enginep. 193
Fuel Lines WC Model – D176GA [2.9L] Enginep. 194
Fuel Lines G(P)X-C Model – TMD27 [2.7L] Diesel Enginep. 195
+5.2 LPG Fuel Systemp. 196
Description and Operationp. 196
LPG Tankp. 197
LPG Tank Maintenancep. 197
LPG Fuel Linesp. 198
Vacuum and Coolant Linesp. 199
Hydrostatic Relief Valvep. 199
Fuel Lock-Off Valve and Filterp. 199
Vaporizer-Regulatorp. 200
Maintenancep. 200
LPG Carburetorp. 201
LPG Carburetor Maintenancep. 202
+LPG Troubleshootingp. 203
Before Working On Truckp. 203
Checking IMPCO LPG Systemp. 203
Troubleshooting Guidep. 204
LPG Fuel Lines GC(P)X, MB, MC Models – 4654 [2.6L] LPG Enginep. 205
LPG Fuel Lines I Model – TM27 [2.7L] LPG Enginep. 206
LPG Fuel Lines WC Model – D176GA [2.9L] LPG Enginep. 207
LPG Fuel Lines G(P)X-C, I Models – TM27 [2.7L] Enginep. 208
LPG Fuel Lines G(P)X, MC Models – 4654 [2.6L] LPG Enginep. 209
+5.3 Diesel Fuel Injection System TMD27 [2.7L] Diesel Enginep. 210
Description and Operationp. 210
Engine Fuel Lines – I Model – TMD27 [2.7L] Diesel Enginep. 211
Engine Fuel Lines – G(P)X-C, I Models – TMD27 [2.7L] Enginep. 212
Engine Fuel Lines – TMD27 [2.7L] Enginep. 213
Fuel Injection System – TMD27 [2.7L] Diesel Enginep. 214
Fuel Supply (Transfer) Pumpp. 215
Fuel Pump Troubleshootingp. 215
Priming The Fuel Systemp. 215
Fuel Filtersp. 216
Fuel Filter Replacementp. 216
Fuel Injectorsp. 216
Fuel Injector Testingp. 217
Injection Pumpp. 218
Injection Pump Overhaulp. 218
Timing Of Injection Pump To The Enginep. 218
Reinstalling and Timing The Original Fuel Injection Pumpp. 219
Installing and Timing A New Fuel Injection Pumpp. 220
+5.4 Carburetor Gasoline – 4654 [2.6L] Enginep. 221
Carburetor Adjustmentp. 221
+Description and Operationp. 222
1. Air Svstemp. 223
2. Float Systemp. 223
3. Low-speed Systemp. 223
4. Main Metering Systemp. 224
5. Enrichment Systemp. 225
Carburetor – 4G54 [2.6L] Gasoline Engine Downdraft, Certified Low-Emissionp. 226
+Carburetor Overhaulp. 227
Precautionsp. 227
Cleaningp. 227
Inspectionp. 227
Reassembly Notesp. 227
Carburetor Disassemblyp. 228
Caburator Disassembled Viewp. 229
Reassemblyp. 232
+5.5 Carburetor Overhaul Gasoline – TM27 [2.7L] Enginep. 235
Cleaningp. 235
Inspectionp. 235
Adjustmentp. 235
Description and Operationp. 236
Carburator Disassembled Viewp. 240
Disassemblyp. 241
Parts Nomenclaturep. 242
Reassemblyp. 243
+5.6 Carburetor Overhaul Gasoline – D176GA [2.9L] Enginep. 245
Cleaningp. 245
Inspectionp. 245
Adjustmentp. 245
Parts Nomenclaturep. 246
Throttle Body Overhaulp. 247
Bowl Assembly Overhaulp. 249
Carburetor Reassembly Completep. 251
+5.7 LPG Carburetor IMPCO Model CA1 00 Carburetor Assembliesp. 252
Descriptionp. 252
Operationp. 252
Carburetor Adjustmentp. 253
LPG Carburetor Maintenance Removal and Installationp. 254
Parts Nomenclature Carburetor – 4654 [2.6L] LPG Enginep. 255
LPG Tankp. 256
Carburetor Removalp. 256
Carburetor Overhaul 4G54 [2.6L], D176GA [2.9L] Engines IMPCO Model CA1p. 256
+Parts Nomenclature Carburetor – D176GA [2.9L] LPG Enginep. 257
Disassemblyp. 258
Cleaning and Inspectionp. 258
Carburetor Reassemblyp. 260
Bench Adjustmentsp. 261
Carburetor Installationp. 261
+5.8 LPG Carburetor IMPCO Model CA50 Carburetor Assemblyp. 262
Description and Operationp. 262
Carburetor Adjustmentp. 262
Carburetor Overhaul TM27 [2.7L] Engine – IMPCO Model CA50p. 262
Disassemblyp. 262
Parts Nomenclature Carburetor – TM27 [2.7L] LPG Enginep. 263
Cleaning and Inspectionp. 264
Carburetor Reassemblyp. 265
Carburetor Installationp. 266
+5.9 LPG Vaporizer-Regulator IMPCO Model J Converterp. 267
Description and Operationp. 267
LPG Vaporizer Maintenance Removal and Installationp. 268
LPG Tankp. 269
Vaporizer-Regulator Removalp. 269
Installationp. 269
Parts Nomenclature Vaporizer-Regulator – LPG Vaporizer-Regulator – LPGp. 270
+Vaporizer-Regulator Overhaulp. 271
Disassemblyp. 271
Cleaninag and Inspectionp. 272
Reassemblyp. 273
Bench Tests After Reassemblyp. 276
+5.10 LPG Fuel Lock-Off Valve IMPCO Model VFF 30p. 277
Description and Operationp. 277
Lock-Off Valve & Filter Maintenance Removal and Installation Notesp. 278
LPG Tankp. 279
Lock-Off Valve Removalp. 279
Installationp. 279
Parts Nomenclature Lock-Off Valve – LPG IMPCO Model VFF30p. 280
+Lock-Off Valve Overhaulp. 281
Disassemblyp. 281
Cleaning and Inspectionp. 283
Reassemblyp. 283
Installationp. 286
+Part 6 Electrical Systemp. 287
+6.1 Electrical System Wiringp. 298
Engine Wiring G(P)X, MB, MC Models – 4G54 [2.6L] Enginep. 299
Truck Wiring MB, MC Models – 4G54 [2.6L] Enginep. 300
Engine Wiring I Models – TM(D)27 [2.7L] Enginep. 301
Truck Wiring I Models – TM(D)27 [2.7L] Enginep. 302
Engine Wiring WC Models – D176GA [2.9L] Enginep. 303
Truck Wiring WC Models – D176GA [2.9L] Enginep. 304
Truck Wiring G( P)X-C – TM( D)27 [2.7L] Enginep. 305
Truck Wiring G(P)X-C Models – TM(D)27 [2.7L] Enginep. 306
Truck Wiring G(P)X – 4654 [2.6L] Enginep. 307
Electrical Assemblies Mounting G(P)X, MB, MC Models – 4G54 [2.6L] Enginep. 308
Electrical Assemblies Mounting I Models – TM(D)27 [2.7L] Enginep. 309
Electrical Assemblies Mounting WC Models – D176GA [2.9L] Enginep. 310
+6.2 Ignition System Troubleshootingp. 311
When engine cranks, but does not startp. 311
When engine runs, but does not run smoothlyp. 312
+6.3 Ignition System Maintenancep. 313
Ignition System Componentsp. 313
+Operationp. 314
Ignition Spark Advancep. 314
Vacuum Advance.p. 314
Breaker Point Ignition Systemp. 314
Electronic Ignition Systemp. 314
+On-Vehicle Troubleshootingp. 315
Spark Testp. 316
Insulation Test of Distributor Cap and Rotorp. 316
Spark Plug Testp. 316
+Distributorp. 317
Adjust or Replace Ignition Pointsp. 317
Distributor Lubricationp. 317
Check Centrifugal Advance Governorp. 317
+Ignition Coilp. 317
Spark Plug Wiresp. 318
Spark Plugsp. 319
Ignition Timing and Advancep. 319
Spark Plug Maintenancep. 320
+6.4 Ignition System 4G54 [2.6L] Enginep. 321
Troubleshooting Testsp. 321
+(Type I)-Contact Breaker Point Distributorp. 322
Descriptionp. 323
Distributor Maintenancep. 323
Ignition Pointsp. 323
Point Gap Settingp. 323
Breaker Arm Springp. 323
Condenserp. 324
Centrifugal Advance Governor Mechanismp. 324
Vacuum Advance Control and Linep. 324
Lubricationp. 324
Replacing Ignition Pointsp. 324
Distributor Reassemblyp. 325
Checking Dwell Anglep. 325
Checking Ignition Timingp. 325
Adjusting Ignition Timingp. 325
Checking Spark Advancep. 326
Ignition Coilp. 327
Distributor Removalp. 327
Distributor Installationp. 328
+(Type 2) – CEI* Electronic Ignition Distributorp. 329
Descriptionp. 330
Operationp. 330
+Distributor Maintenance Inspection, Rotor and Capp. 331
Vacuum Advance Control and Linep. 331
Lubricationp. 331
Air Gap Settingp. 331
Replacement of Ignition Module Disassembly of lgnitorp. 332
Inspection of Spark Plug Wiring, Ignition Timing and Adjustment, Checking Spark Advancep. 332
Ignition Coilp. 332
Distributor Removal/Installationp. 332
+6.5 Ignition System TM27 [2.7L] Enginep. 333
General Troubleshooting Testsp. 333
TM27 [2.7L] Engine Gas/LPG Distributorp. 334
Descriptionp. 335
Operationp. 335
Troubleshootingp. 336
Distributor Maintenancep. 336
Distributor Inspectionp. 337
Ignition Module Replacementp. 337
Distributor Reassemblyp. 338
Checking Ignition Timingp. 338
Adjusting Ignition Timingp. 338
Checking Spark Advancep. 338
Ignition Coil Inspecting and Testing The Coilp. 338
Inspect Spark Plugs and Wiresp. 338
Distributor Removalp. 339
Distributor Installationp. 339
+6.6 Ignition System D176GA [2.9L] Enginep. 340
General Troubleshooting Testsp. 340
D176GA [2.9L] Engine Distributorp. 341
Descriptionp. 342
Operationp. 342
+Distributor Maintenance Rotor and Capp. 343
Lubricationp. 343
Sensor Air Gap Settingp. 343
Replacing The Electronic Ignition Modulep. 343
Check Centrifugal Advance Governor Mechanismp. 345
Distributor Reassemblyp. 345
Checking Dwell Anglep. 345
Checking Ignition Timingp. 345
Adjusting Ignition Timingp. 346
Ignition Spark Advancep. 346
Ignition Coilp. 347
Inspect Spark Plugs and Wiresp. 347
Distributor Removalp. 347
Distributor Installationp. 347
+6.7 Electronic Ignition Conversion Per-Lux /gnito@ for D176GA [2.9L] Enginep. 349
General Troubleshooting Testsp. 349
Parts Nomenclature Electronic Ignition System-D1 76GA [2.9L] Enginep. 350
Description and Operationp. 351
Distributor Maintenancep. 351
Ignition Module Replacementp. 351
Troubleshootingp. 352
Distributor Inspectionp. 352
Centrifugal Advance Mechanismp. 352
Checking and Adjusting Ignition Timingp. 352
Ignition Spark Advancep. 352
Ignition Coilp. 352
Distributor Removal and Installationp. 352
+6.8 Alternator Maintenancep. 353
Troubleshooting Guidep. 353
Alternator Maintenance Precautionsp. 354
Alternator Inspectionp. 354
Troubleshooting Proceduresp. 354
A. Abnormal Charge Indicator Lamp Operationp. 355
B. Abnormal Charging System Operationp. 355
Delco 1 OSI Alternatorp. 356
Alternator Installationp. 357
Alternator Drive (Fan) Beltp. 357
Fan Belt Tensioningp. 357
Fan Belt Tension Specificationp. 357
Alternator Mounting Parts G(P)X, MB, MC Models – 4654 [2.6L] Enginep. 358
Alternator Mounting Parts G(P)X-C, I Models – TM(D)27 [2.7L] Enginep. 359
Alternator Mounting Parts WC Model – D176GA [2.9L] Enginep. 360
+6.9 Alternator – Delco 103p. 361
Specificationsp. 361
Maintenancep. 361
Alternator Operating Principlesp. 362
Inspection and Troubleshooting Proceduresp. 362
Parts Nomenclature Delco 1 OSI Alternatorp. 363
+6.10 Alternator – Motorola 9DBp. 364
Specificationsp. 364
Inspection and Troubleshooting Proceduresp. 364
Description and Operationp. 364
Maintenancep. 365
Through-Bolt Removalp. 365
Voltage Regulator and Brush Assembly Removalp. 366
Parts Nomenclature Motorola 9DB Alternatorp. 367
+6.11 Starting System Troubleshootingp. 368
Troubleshooting Notesp. 368
Troubleshooting Proceduresp. 369
Starting System Mechanical Checksp. 369
Starting System Electrical Checksp. 370
On-Vehicle Troubleshootingp. 370
Volt Drop Testsp. 374
+6.12 Starter Motor Troubleshootingp. 376
On-Vehicle Troubleshootingp. 376
Starter Motor Testsp. 376
Starter Solenoid Volt Drop Testp. 376
Disc Contact Test:p. 377
Solenoid Circuit Test:p. 377
Starter Motor Inspectionp. 378
Starter No-Load Bench Testp. 378
Diagnosis of No-Load Test Resultsp. 379
Starter Disassemblyp. 379
+6.13 Starter Maintenance – Delco WC Model, D176GA [2.9L] Enginep. 380
Specificationsp. 380
Parts Nomenclature Starter Motor Assembly – Delco l0MTp. 381
+6.14 Starter Maintenance Direct-Drive (Type 1) – 4G54 [2.6L] Enginep. 382
Specificationsp. 382
Descriptionp. 382
Starter Motor Assembly – Standard Direct-Drive (Type 1) MB, MC Models, 4654 [2.6L] Enginep. 383
Before-Disassembly Testsp. 384
Starting Circuit Troubleshootingp. 384
Starter Removalp. 385
Starter Overhaul Disassemblyp. 385
Parts Inspectionp. 386
Reassemblyp. 388
Testingp. 389
Starter Installationp. 389
+6.15 Starter Maintenance Reduction-Type (Type 2) – 4654 [2.6L] Enginep. 390
Descriptionp. 390
Specificationsp. 390
Removal/Installation of Starterp. 390
Starter Motor Assembly – Reduction Type (Type 2) MB, MC Models, 4654 [2.6L] Enginep. 391
BeforeDisassembly Testsp. 392
Starter Overhaul Disassemblyp. 392
Parts inspectionp. 392
Starter Reassemblyp. 394
Testingp. 394
+6.16 Starter Maintenance G( P)X-C, I Models, TM(D)27 [2.7L] Enginep. 395
Descriptionp. 395
Specificationsp. 395
Starter Motor Assembly – Reduction type I Model, TM27 [2.7L] Gasoline/LPG Enginep. 396
Starter Motor Assembly – Reduction typeG(P)X-C, I Models – TMD27 [2.7L] Diesel Enginep. 397
Before-Disassembly Testsp. 398
Starting Circuit Troubleshootingp. 398
No-Load Testp. 398
Starter Removalp. 398
Starter Overhaul Disassemblyp. 399
Cleaningp. 400
Reassemblyp. 400
Testingp. 400
+Part 7 Transaxlep. 401
SPIRAL BEVEL AND HYPOID TOOTH BEARING CONTACT CHARTp. 402
+7.1 Transaxle Maintenance – Fluid and Filter Changep. 403
Access To Transaxle Service Pointsp. 403
HR500 Service Pointsp. 404
HR600 Service Pointsp. 404
TA18 Service Pointsp. 405
Transaxle Fluid Level Checkp. 405
+TRANSAXLE FLUID AND FILTER CHANGE: Drain and Refillp. 406
Draining The Transaxlep. 406
Transmission Sump Oil Strainer Screen Service (HR500 and HR600)p. 407
Transaxle Oil Filter Changep. 407
Refilling The Transaxlep. 408
+7.2 Transmission Troubleshootingp. 409
Troubleshooting Techniquesp. 409
Powershift Transmissionsp. 409
Troubleshooting Guidep. 409
Troubleshooting Proceduresp. 410
Fluid Level Checkp. 410
Transmission Pressure Checksp. 410
Mechanical Checksp. 410
+7.3 Transmission Pressure Checksp. 411
Test Preparationp. 411
Pressure Test Procedurep. 411
Pressure Specificationsp. 411
Pressure Check Pointsp. 411
HR600 Series Transmission Pressure Specificationsp. 412
HR600 Oil Circuit Diagramp. 412
HR600 Transmission Pressure Check Pointsp. 413
HR500 Transmission Pressure Specificationsp. 414
HR!500 Oil Circuit Diagramp. 414
HR500 Transmission Pressure Check Pointsp. 415
TA18 Transmission Pressure Specificationsp. 416
TAI 8 Transmission Pressure Check Pointsp. 416
+7.4 Transaxle Mounting Removal/Installationp. 417
Transmission Fasteners MC, WC, I Models – HR600 Transaxlep. 418
Transaxle Mounting Parts MC, WC, I Models – HR600 Transaxlep. 419
Transaxle Mounting Parts MB, G(P)X and G(P)X-C Models – HR500, TA18 Transaxlep. 420
Transaxle Removalp. 421
Transaxle Installationp. 427
+7.5 Transaxle Overhaul General Proceduresp. 431
Disassemblyp. 431
Cleaningp. 431
Inspectionp. 432
Repair and Replacementp. 432
Reassemblyp. 434
+7.6 TAI 8 Transaxlep. 435
Description and Operationp. 435
Specificationsp. 436
Service Informationp. 438
TAI 8 Service Maintenancep. 438
TAI 8 Transmission Pressure Specificationsp. 439
TAI 8 Transmission Pressure Check Pointsp. 439
General Arrangementp. 440
+Parts Nomenclaturep. 441
Parts Nomenclature Converter Housing, Adapter Plate, Transmission Case, Oil Linesp. 441
Torque Converter, Charging Pump, Oil Filter, Stator Support, Reverse Idler Gear & Shaft, Pump Idler Gear, Control Coverp. 442
Forward & Reverse Clutch Packp. 443
Output Gear, Ring & Pinion, Differentialp. 444
Drive Axle Wheel End Housings, Axle Shaft, Wheel Hub & Brake, Mounting Bracketp. 445
Brake Assembly LHp. 446
Brake Assembly RHp. 447
Control Coverp. 448
+Disassemblyp. 449
Remove Auxiliary Subassembliesp. 449
Wheel End Disassemblyp. 450
Brake Assembly Removalp. 451
Separation of Converter Housing and Adaptor Platep. 452
Stator Support Removal From Adaptor Platep. 452
Clutch Assembly, Idler Gear & Pinion Shaft Removalp. 453
Clutch Disassemblyp. 454
Differential Disassemblyp. 454
+Transaxle Reassemblyp. 455
Differential Assemblyp. 456
Trial Wheel End Assembly for Differential Bearing Preload Checkp. 457
Pinion Gear Shimmingp. 458
Pinion Gear Installationp. 459
Trial Wheel End Assembly for Ring & Pinion Gear Contact and Backlash Checkp. 460
Wheel End Final Assemblyp. 461
Wheel hub assemblyp. 462
Clutch Assemblyp. 463
Stator Support Assemblyp. 464
Transmission Assemblyp. 464
+Service Brake Adjustmentp. 467
Adjustment thru Backing Platep. 467
Adjustment thru Wheel Hubp. 468
+7.7 HR500 Transaxle 11FHR510/511 l-Speedp. 469
Description and Operationp. 469
Specifications – HR510, HR511p. 470
+HR500 Service Maintenancep. 470
Fluid Level Checkp. 470
Fluid and Filter Changep. 470
Refilling The Transaxlep. 470
HR500 Transmission Pressure Specificationsp. 471
HR500 Oil Circuit Diagramp. 471
+Parts Nomenclaturep. 472
Parts Nomenclature General Arrangement – HR500 Transaxle Assemblyp. 472
Torque Converter, Stator Support, Turbine Shaftp. 473
Converter Pump Drivesp. 474
Converter Housing, Transmission Case, Control Cover (Valve) Assemblyp. 475
Forward Clutch Packp. 476
Reverse Clutch Packp. 477
Output Gear, Drive Axle Ring & Pinion, Differentialp. 478
Drive Axle Housing, Axle Shaft, Wheel Hub & Brakep. 479
Brake Assembly LHp. 480
Brake Assembly RHp. 481
Transmission Control Coverp. 482
+Transaxle Disassemblyp. 483
Remove Auxiliary Subassembliesp. 483
Converter Housing Removalp. 484
Converter Housing Disassemblyp. 484
Torque Converter Removalp. 487
Converter Impeller Hub Removal and reassemblyp. 487
Oil Baffle Removalp. 488
Oil Baffle Installationp. 488
Converter Oil Baffle Oil Seal Replacementp. 489
Pump Drive Chain inspectionp. 490
Pump Drive Chain and Charging Pump Sprocket Removalp. 490
Pump Drive Sprocket Disassemblyp. 490
Removal/Disassembly of Reverse Idler Gear and Bearing Assemblyp. 490
Turbine Shaft Removalp. 492
Stator Support Removalp. 493
Transmission & Drive Axle Disassemblyp. 493
Axle Shaft Removalp. 495
Brake Assembly Removalp. 497
Axle Housing Removalp. 498
Differential Disassemblyp. 499
Reverse Clutch Disassemblyp. 500
Forward Clutch Disassemblyp. 502
+Transaxle Reassemblyp. 504
Assembly Notes:p. 504
Forward Clutch Reassemblyp. 505
Reverse Clutch Reassemblyp. 509
Differential Reassemblyp. 512
Trial Assembly for Pinion Bearing Preload Checkp. 513
Remove Pinion Shaft for Differential Bearing Preload Checkp. 514
Trial Assembly for Differential Bearing Preload Checkp. 514
Pinion Final Assemblyp. 515
Output Gear 81 Reverse Clutch Installationp. 515
Axle Assemblyp. 516
Converter Parts Reassemblyp. 522
Converter Housing Reassemblyp. 525
Pump Drive Chain Installationp. 526
Charge Pump Sprocket Installationp. 526
Converter Oil Baffle Installationp. 526
Torque Converter Installationp. 527
Aux Pump Drive Sprocket Installationp. 527
Forward Clutch Installationp. 528
Transmission Final Assemblyp. 528
Converter Housing to Transmission Assemblyp. 529
Install Aux Subassembliesp. 529
Control Cover Removal and Installationp. 530
Transmission Control Coverp. 531
Control Coverp. 530
+Brake Adjustmentp. 532
Service Brake Adjustmentp. 532
Adjustment Thru Backing Platep. 532
Adjustment Thru Wheel Hubp. 533
+7.8 HR600 Transaxles 11 FHR61 O/61 l/61 2 1 -Speed 11 FH R620/621 2-Speedp. 534
Description and Operationp. 534
Basic Specifications – HR600p. 535
+HR600 Service Maintenancep. 535
Fluid Level Checkp. 535
Fluid and Filter Changep. 535
Refilling The Transaxlep. 535
HR600 Series Transmission Pressure Specificationsp. 536
HR600 Oil Circuit Diagramp. 536
General Arrangement 11 FHR61 O/61 l/61 2 1 -Speed Transmissionp. 537
General Arrangement 11 FHR620/H621 2-Speed Transmissionp. 538
+Parts Nomenclaturep. 539
Torque Converter, Control Cover, Oil Strainerp. 539
Pump Drives, Charging Pump, Stator Support, Reverse Idlerp. 540
Turbine Shaft, Clutches, Differential Bearing Carrier MC, WC, I Models – HR610/61 l/61 2 l-speed transaxlep. 541
Clutch Pack Assemblies – Forward/Reverse MC, WC, I Models – HR610/61 l/612 l-speed transaxlep. 542
Turbine Shaft, Clutches, Differential Bearing Carrier, Pinion Gear WC, I Models – HR620/621 2-speed transaxlep. 543
Clutch Pack Assemblies – Forward/Low, Reverse/High WC, I Models – HR620/621 2-speed transaxlep. 544
Transmission Case, Accumulator Valvep. 545
Drive Axle Adaptor and Differentialp. 546
Axle End and Brake Assembly – LHp. 547
Axle End and Brake Assembly – RHp. 548
Control Cover (Valve) Control Cover (Valve)p. 549
Control Cover (Valve) WC, I Models – HR620/621 2-speed transaxlep. 550
Transmission Accumulatorp. 551
+Control Cover Overhaulp. 552
Removalp. 552
Disassemblyp. 552
Parts Inspectionp. 554
Control Cover Reassemblyp. 555
Installationp. 557
+Accumulator Valve Overhaulp. 558
Removalp. 558
Disassemblyp. 558
Parts Inspectionp. 559
Reassemblyp. 560
Installationp. 561
+7.9 HR620 Transmission Overhaul 11 FHR620/621 2-speed transaxle (*)p. 562
+Torque Converter Disassemblyp. 562
Remove Aux Subassembliesp. 562
Torque Converter Removal and Replacementp. 564
Converter Oil Baffle Installationp. 570
Transmission Disassemblyp. 572
Disassemble Transmission from Drive Axlep. 572
Converter Housing Separation from Transmission Casep. 572
Converter Housing Disassemblyp. 573
Transmission Case Disassemblyp. 577
Clutch Packsp. 580
+Cleaning and Inspection of Partsp. 586
+Transmission Reassemblyp. 588
Inspectionp. 586
Repair and Replacementp. 587
+Reassemblyp. 587
Assembly Notes:p. 588
Clutch Packsp. 589
Transmission Case Reassemblyp. 600
Converter Parts Reassemblyp. 603
Converter Housing Reassemblyp. 605
Transmission Final Assemblyp. 606
Install Aux. Subassembliesp. 610
Assemble Transmission to Drive Axlep. 610
To Check Ring & Pinion Gear Backlashp. 611
To Check Ring & Pinion Gear Tooth Bearing Contact Patternp. 611
+7.10 HR610 Transmission Overhaul 11FHR610/611/612 l-speed transaxlep. 612
Assembly Notes:p. 612
+Parts Nomenclaturep. 613
Turbine Shaft, Clutches, Differential Bearing Carrier MC, WC, I Models – HR610/61 l/61 2 l-speed transaxlep. 613
Clutch Pack Assemblies – Forward/Reverse MC, WC, I Models – HR61 O/61 l/61 2 1 -speed transaxlep. 614
+Transmission Disassemblyp. 615
Converter Housing Separation from Transmission Casep. 615
Transmission Case Disassemblyp. 615
+Transmission Reassemblyp. 615
Forward Clutch & Shaft Assemblyp. 615
Reverse Clutch & Pinion Shaftp. 615
Reverse Clutch & Pinion Shaft Assemblyp. 616
Reverse Clutch Assemblyp. 616
Converter Housing Reassemblyp. 616
Transmission Case Reassemblyp. 616
Converter Housing to Transmission Case Reassemblyp. 617
Axle Housing Pilot Adaptorp. 618
Trial Installationp. 618
+7.11 Drive Axle Overhaul HR600 Series Transaxlesp. 619
+Parts Nomenclaturep. 620
Axle End and Brake Assembly – LHp. 620
Axle End and Brake Assembly – RHp. 621
+Drive Axle Disassemblyp. 623
Axle Endp. 623
Brake Disc Housing Disassemblyp. 624
Axle End Housing Disassemblyp. 627
Axle Adaptor & Differential Housing Disassemblyp. 629
Parts Inspectionp. 630
+Drive Axle Reassemblyp. 631
Assembly Notes:p. 631
Axle Adaptor & Differential Housing Reassemblyp. 632
Axle End Housing Reassemblyp. 635
Brake Disc Housing Reassemblyp. 637
Internal Gear Hub Assemblyp. 640
Brake line fittings and bleeder screwp. 642
After final assembly of transaxle:p. 642
+7.12 Directional Control Linkage Transmission Shift Controlsp. 643
Directional Control G(P)X, G(P)X-C Models – TAI 8Transaxlep. 643
+Parts Nomenclaturep. 644
Directional Control Linkage MB Model – HR500 Transaxlep. 644
Directional Control Linkage MC, WC, I Models – HR600 Transaxle l-Speedp. 645
Directional Control Linkage WC, I Models – HR600 Transaxle 2-Speedp. 646
+Part 8 Brakesp. 647
+8.1 Service Brake & Inching Systemsp. 648
Description and Operationp. 648
Type I – Single master cylinderp. 648
Type 2- Dual master cylindersp. 648
GCX, GPX Model Trucksp. 649
MC, WC and I Model Trucksp. 649
Inching Control Systemp. 649
Parking Brake Linkage Installation G(P)X, G(P)X-C Models – TA18 Transaxle MB Models – HR500 Transaxlep. 650
Parking Brake Linkage Installation MC, WC, I Models – HR600 Transaxlep. 651
+8.2 Brake & Inching System Type 1 – Single Master Cylinderp. 652
Description and Operationp. 652
Parts Nomenclature Brake Pedal Linkage & Master Cylinder Installation Type 1 – MB, MC, WC, I Modelsp. 653
Brake & Inching Pedal Adjustmentp. 654
Parking Brake Adjustmentp. 656
Parts Nomenclature Brake Master Cylinder Assembly MB Modes – HR500 Transaxlep. 657
Brake Master Cylinder Check MB Models – HR500 Transaxlep. 658
Parts Nomenclature Brake Master Cylinder Assembly MC, WC, I Models – HR600 Transaxlep. 659
Brake Master Cylinder Check MC, WC, I Models – HR600 Transaxlep. 660
Brake Disc Wear Thickness Check MC, WC, I Models – HR600 Transaxlep. 661
+Parts Nomenclaturep. 663
Hydraulic Brake & Inching Lines MB Model – HR500 Transaxlep. 663
Hydraulic Brake & Inching Lines MC, WC, I Models – HR600 Transaxlep. 664
Hydraulic Brake & Inching Lines MC, WC, I Models – HR600 Transaxlep. 665
+8.3 Brake Bleeding Procedures Type 1 – Single Master Cylinderp. 666
Brake & Inching Circuit Bleedingp. 666
Hydraulic Brake Fluid and Bleeding Precautionsp. 667
Bleeding Procedures Type 1 – Single Master Cylinder Service Brake Circuitp. 668
Bleeding Procedures Type 1 – Single Master Cylinder Inching Circuitp. 670
+8.4 Brake & Inching Systemp. 671
Description and Operationp. 671
Parts Nomenclature Brake Pedal & Linkage – Type 2 G(P)X, G(P)X-C Models, TA18 Transaxlep. 672
Parts Nomenclature Hydraulic Brake & Inching Lines – Type 2 G(P)X, G(P)X-C Models, TA18 Transaxlep. 673
Inching Troubleshooting Guidep. 674
Brake & Inching Pedal Adjustment Type 2 – Dual Master Cylindersp. 676
Service Brake Adjustment TAI 8 Transaxlep. 678
Parts Nomenclature Parking Brake Linkage – Type 2 G(P)X Model, TA18 Transaxlep. 680
+8.5 Brake Bleeding Type 2 – Dual Master Cylinders TA18 Transaxlep. 681
Brake & Inching Circuit Bleedingp. 681
Hydraulic Brake Fluid and Bleeding Precautionsp. 682
Bleeding Procedures – Service Brake & Inching Circuitp. 682
Brake & Inching Circuit TAl8 Transaxlep. 683
Pressure Bleeding Procedurep. 683
Optional Procedure Manual Brake Bleedingp. 684
Brake Bleeding Procedure Service Brake Circuitp. 684
+Brake Bleeding Procedure Type 2 – Dual Master Cylinders inching Circuitp. 685
Manual Bleeding Methodp. 685
+Part 9 Steering Systemp. 686
Power Steering Lines Installation MB, MC, WC, I Models -(Type 1/7A) Steer Axlep. 687
Steering System/Main Hydraulic Lines – HR500 & HR600 Transaxlep. 688
Power Steering Lines Installation G(P)X, G(P)X-C, MC, I Models -(Type 2) Steer Axlep. 689
+9.1 Power Steering System Relief Pressure Settingp. 690
Description and Operationp. 690
Steering System Relief Pressure Setting:p. 690
Relief Pressure Setting Checkp. 690
+9.2 Steering Column and Valve (Steering Gear)p. 692
Description and Operationp. 692
Troubleshooting Guidep. 692
Parts Nomenclature Steering Column & Valve Mountingp. 693
+9.3 Steering Column Removal/Installationp. 694
Horn Button and Steering Wheel Disassemblyp. 694
Steering Column and Valve Removalp. 695
Installation Steering Column and Valve Reassemblyp. 696
Horn Button and Steering Wheel Reassemblyp. 698
Parts Nomenclature Steering Control Valvep. 699
+9.4 Steering Valve Overhaul (Steering Control Unit)p. 700
Disassemblyp. 700
Meter (Gerotor) Endp. 700
Control Endp. 701
Parts Inspectionp. 702
+Reassemblyp. 702
Control Endp. 702
Meter (Gerotor) Endp. 704
+9.5 Steer Axlesp. 706
Backgroundp. 706
Steer Axle Type Specificationsp. 706
Mountingp. 706
Steer Axle – (Type 1)p. 707
Steer Axle (Type 1A)p. 708
Steer Axle (Type 2)p. 709
+9.6 Steer Axle Wheel Bearing Maintenancep. 710
Steer Wheel Bearing Checkp. 710
+Wheel Bearing Adjustmentp. 710
With self-locking nutp. 711
With slotted nut and cotter pinp. 711
+Wheel Bearing Lubrication (Clean, repack and adjust bearings)p. 712
GPS Pneumatic Tired Trucksp. 712
With self-locking spindle nutp. 713
With slotted nut and cotter pinp. 713
+9.7 Steer Axle Removal/Installationp. 714
Removalp. 714
Steer Axle Mounting Partsp. 715
Steer Axle Mounting Parts Variationsp. 716
Installationp. 718
+9.8 Steer Axle Overhaul Type 1)p. 720
(Type 7) Steer Axlep. 720
Preparation For Disassemblyp. 720
Parts Nomenclature Steer Axle – (Type I)p. 721
+Disassemblyp. 722
Wheel Hub Disassemblyp. 722
Power Steering Cylinder and Tie Rod Assembly Removalp. 724
Steering Cylinder Disassemblyp. 725
Steering Knuckle, Kingpin & Bearing Disassemblyp. 725
+Parts Inspectionp. 727
+Steer Axle Reassemblyp. 728
Steering Knuckle, Kingpin Bearing Reassemblyp. 728
Steering Cylinder Reassemblyp. 729
Steering Cylinder and Tie Rod Reassemblyp. 729
STEERING LINKAGE ADJUSTMENT PROCEDUREp. 730
Steering Cylinder and Tie Rod Assembly Installationp. 730
Wheel Hub Assemblyp. 731
+9.9 Steering Cylinder Overhaul (Type 1 & IA, Style 7,2 & 3)p. 734
Style 7 & 2 Steering Cylinderp. 734
Preparation For Disassemblyp. 734
Parts Nomenclature Power Steering Cylinder – (Type 1, Sty/e 7 & 2)p. 735
Parts Nomenclature Power Steering Cylinder – (Type 7A, Sty/e 3)p. 736
Disassemblvp. 737
Inspectionp. 738
Reassemblyp. 738
Bench Testp. 739
+9.10 Steer Axle Overhaul (Type 1A)p. 740
(Type IA) Steer Axlep. 740
Preparation For Disassemblyp. 740
Parts Nomenclature Steer Axle – (Type IA)p. 741
+Disassemblyp. 742
Wheel Hub Disassemblyp. 742
Power Steering Cylinder and Tie Rod Links Removalp. 744
Steering Cylinder Disassemblyp. 744
Steering Knuckle, Kingpin & Bearing Disassemblyp. 745
Parts Inspectionp. 746
Steer Axle Reassemblyp. 747
+9.11 Steering Cylinder Overhaul (Type IA, Style 4)p. 751
Style 4 Steering Cylinderp. 751
Preparation For Disassemblyp. 751
Parts Nomenclature Power Steering Cybkr – (Type 7A, Sty/e 4)p. 752
Disassemblyp. 753
Parts Inspectionp. 753
Reassemblyp. 754
Bench Testp. 754
Steering Knuckle, Kingpin & Bearing Reassemblyp. 747
Steering Cylinder Reassemblyp. 748
Steering Cylinder and Tie Rod Link Installationp. 748
Wheel Hub Assemblyp. 749
+9.12 Steer Axle Overhaul (Type 2)p. 755
(Type 2) Steer Axlep. 755
Preparation For Disassemblyp. 755
Parts Nomenclature Steer Axle – (Type 2) Pneumatic-Tire Version Shownp. 756
+Disassemblyp. 757
Wheel Hub Disassemblyp. 757
Power Steering Cylinder and Tie Rod Arms Removalp. 759
Steering Cylinder Disassemblyp. 759
Steering Knuckle 81 Knuckle Pin Bearings Disassemblyp. 760
+Steer Axle Reassemblyp. 761
Steering Knuckle & Knuckle Pinp. 761
Steering Cylinder Reassemblyp. 762
Steering Cylinder and Tie Rod Arm Installationp. 762
Wheel Hub Assemblyp. 763
+9.13 Steering Cylinder Overhaul (Type 2 Steer Axle)p. 764
(Type 2 Axle) Steering Cylinderp. 764
Preparation For Disassemblyp. 764
Parts Nomenclature Power Steering Cylinder – (Type 2 SteerAxle)p. 765
Disassemblyp. 766
Inspectionp. 766
Reassemblyp. 766
Bench Testp. 766
+Part 10 Hydraulic Systemp. 767
Hydraulic System Schematic Diagram GC(P)X, GCS/GPS 17-30p. 768
Main Hydraulic Systemp. 769
Description and Operationp. 769
Parts Nomenclature Steering Priority Demand (Flow Control) Valvep. 769
Parts Nomenclature Main Hydraulic Lines G(P)X, G(P)X-C Models – TA18 Transaxlep. 770
Parts Nomenclature Main Hydraulic/Steering Lines G(P)X, G(P)X-C Models – TA18 Transaxlep. 771
Parts Nomenclature Main Hydraulic Lines MB, MC, WC, I Models – HR500,HR600Transaxlep. 772
Parts Nomenclature Main Hydraulic Lines MB, MC, WC, I Models – HR500, HR600 Transaxlep. 773
Parts Nomenclature Lift and Tilt Linesp. 774
+10.1 Hydraulic Sump – Fluid and Filter Changep. 775
Hydraulic Sump and Filter Installationp. 775
Hydraulic Sump Fluid Level Checkp. 776
Sump Tank Breather Maintenancep. 776
Oil Filter Maintenancep. 776
+Fluid and Filter Changep. 777
METHOD I- Fluid Changep. 777
METHOD 2 – Fluid Changep. 778
Check Operation of Hydraulic Systemp. 779
Hydraulic Oil Filter and Base Assembly Partsp. 780
+10.2 Hydraulic System Relief Pressure Check & Adjustmentp. 781
Relief Pressure Check and Adjustment Procedurep. 781
and Adjustment Procedurep. 781
Hydraulic System Relief Pressure Specificationsp. 782
+10.3 Main Hydraulic Pump Removal/Installationp. 783
Pump Specificationsp. 783
Pump Troubleshootingp. 783
+Main Pump Mounting Installation MB, MC, WC, I Models – HR500 & HR600 Transaxlep. 784
Pump Removalp. 784
Pump Installationp. 784
+Main Pump Mounting Installation G(P)X, G(P)X-C Models – TA18 Transaxlep. 785
Pump Removalp. 785
Pump Installationp. 785
+10.4 Main Hydraulic Pump Overhaulp. 786
Preparation For Disassemblyp. 786
Disassemblyp. 786
Parts Nomenclature Main Hydraulic Pumpp. 787
Parts Inspectionp. 789
Reassemblyp. 790
Break-h and Test Procedurep. 791
+10.5 Main Hydraulic Control Valve Removal/Installationp. 792
Description and Operationp. 792
Main Hydraulic Valve Mounting and Control Lever Linkage (Typical)p. 793
+Removalp. 794
Valve Control Linkage Disassemblyp. 794
Installationp. 795
Troubleshooting Guidep. 796
+10.6 Main Hydraulic Valve Overhaulp. 797
Preparation For Disassemblyp. 797
Disassemblyp. 797
Main Hydraulic Valve Assembly Parts (Basic Lift-Tilt Valve shown)p. 798
Cleaning, Inspection and Repairp. 801
+Reassemblyp. 802
Hydraulic Valve Relief Pressure Settingsp. 802
+10.7 Tilt Cylinder Maintenancep. 803
Tilt Cylinder Drift Testp. 803
Tilt Cylinder Adjustmentp. 804
Tilt Cylinder Removalp. 805
Tilt Cylinder Mounting Installationp. 806
Tilt Cylinder Assembly Partsp. 808
+Tilt Cylinder Overhaulp. 809
Inspectionp. 810
Reassemblyp. 811
Tilt Cylinder Installationp. 812
+Part 11 Wheels & Tiresp. 813
Cushion Tire Nomenclaturep. 814
Pneumatic Tire Nomenclaturep. 815
Pneumatic Tire Nomenclaturep. 816
+11.1 Cushion Tire and Wheel Maintenancep. 817
General Maintenancep. 817
Drive Wheel Removal/Installationp. 817
+Steer Wheel Removal/Installationp. 818
Removalp. 818
Installationp. 818
Cushion Tire Replacement Removal/Installationp. 819
+11.2 Pneumatic Tire and Wheel Maintenancep. 820
Pneumatic Tire Maintenance Precautionsp. 821
General Maintenancep. 822
Wheel Disassembly and Tire Removalp. 823
Tire Installation and Wheel Reassemblyp. 826
Filling Tires With Airp. 828
Filling Tires With Nitrogenp. 830
Procedure For Adding Air Pressure To Mounted Tire and Wheel Assembliesp. 831
Split-Rim Wheel Assembliesp. 832
Directional-Tread Tiresp. 833
+Part 12 Counterweight & Chassisp. 834
+12.1 Counterweight Maintenancep. 835
Maintenance-Generalp. 835
Counterweight Removalp. 835
Counterweight Mountingp. 836
Removal Using a Hoist or Overhead Cranep. 837
Removal Using Another Lift Truck As a Hoistp. 839
Counterweight Inspectionp. 840
Counterweight Installationp. 841
+12.2 Chassis Componentsp. 843
Overhead Guardp. 843
Parts Nomenclature Sheet Metalp. 844
Parts Nomenclature Sheet Metal and Trimp. 845
Parts Nomenclature Seat Mountingp. 846
Parts Nomenclature Seat Assemblyp. 847
Parts Nomenclature Top Hood and Mountingp. 848
Parts Nomenclature Instrument Panelp. 849
Parts Nomenclature Parts Nomenclaturep. 850
+Part 13 Uprightsp. 851
+13.1 Upright Maintenancep. 852
Upright Down Drift (Fork Drift) Testp. 852
Upright Maintenancep. 853
+Lift Chain Maintenancep. 853
Lift Chain Lubricationp. 853
Lift Chain (Fork Height) Adjustmentp. 854
Lift Chain Inspection and Measurement for Wearp. 854
Lift Chain Inspection and Wear Criteriap. 855
Lift Chain Replacementp. 855
Fork Removalp. 856
Carriage Removalp. 856
Upright Removalp. 858
Parts Nomenclature Upright Mountingp. 859
Upright Installationp. 861
+13.2 High Visibility Standard Upright (HIVIS Std)p. 862
Parts Nomenclature HIVIS Standard Upright Assemblyp. 863
Parts Nomenclature Lift Cylinder – HIVIS Std Uprightp. 864
Parts Nomenclature Lift Cylinder Piping – HIVIS Std Uprightp. 865
Parts Nomenclature Lift Chain – HIVIS Std Uprightp. 866
+13.3 Triple Stage Upright (TSU)p. 867
Parts Nomenclature Tripple Stage Upright Assemblyp. 868
Parts Nomenclature Primary Lift Cylinder – TSU Uprightp. 869
Parts Nomenclature Final Lift Cylinder – TSU Uprightp. 870
Parts Nomenclature Lift Cylinder Piping – TSU Uprightp. 871
Parts Nomenclature Lift Chain – TSU Uprightp. 872
+Part 14 Indexp. 873
+14.1 Listing by Section Contentsp. 874
3 Planned Maintenancep. 874
4 Enginep. 874
5 Fuel Systemp. 876
6 Electrical Systemp. 878
7 Transaxlep. 880
8 Brakesp. 882
9 Steering Systemp. 882
10 Hydraulic Systemp. 884
11 Wheel & Tiresp. 885
I2 Counterweight & Chassisp. 885
13 Uprightsp. 886
14.2 Subject Indexp. 887
Chapters Covered
- General Information – Safe Maintenance Practices, Safety Signs, Product Identification, Model Nomenclature, Serial Number Codes
- Specifications – Service Specifications, Engine Applications, Transaxle Specifications, Brake Specifications, Steering System Specifications, Hydraulic System Specifications, Torque Specifications, Fluid Recommendations
- Planned Maintenance – PM Schedules, Service Intervals, Safety and Operational Checks, PM and Lubrication Schedule, Visual Inspection, Functional Tests, Lubrication, Fluid and Filter Service, Critical Fastener Torque Checks
- Engine – Oil and Filter Change, Troubleshooting, Tune-Up, Ignition Timing, Valve Tappet Clearance, Compression Testing, RPM/Vacuum/Stall Tests, Cooling System, Air Cleaner, Adjustments, Removal and Installation, Engine Components for 4G54, TM27/TMD27, and D176GA engines
- Fuel System – Gasoline Fuel System, LPG Fuel System, Diesel Fuel Injection System, Carburetor Overhaul (4G54, TM27, D176GA), LPG Carburetor (IMPCO CA100 and CA50), LPG Vaporizer-Regulator (IMPCO Model J), LPG Lock-Off Valve (IMPCO VFF30)
- Electrical System – Wiring Diagrams, Ignition System Troubleshooting and Maintenance, Ignition Systems for each engine, Electronic Ignition Conversion, Alternator Maintenance (Delco 10SI and Motorola 9DB), Starting System Troubleshooting, Starter Motor Maintenance
- Transaxle – Transaxle Maintenance, Transmission Troubleshooting, Pressure Checks, Removal and Installation, Overhaul General Procedures, TA18, HR500, HR600, HR620 2-Speed, HR610 1-Speed, Drive Axle Overhaul, Directional Control Linkage
- Brakes – Service Brake and Inching Systems, Type 1 Single Master Cylinder, Type 2 Dual Master Cylinders, Brake Bleeding Procedures for both types
- Steering System – Power Steering Relief Pressure Check, Steering Gear Troubleshooting, Steering Column Removal and Installation, Steering Valve Overhaul, Steer Axle Types 1, 1A, and 2, Wheel Bearing Maintenance, Steering Cylinder Overhaul
- Hydraulic System – System Schematic, Main Hydraulic System Description, Hydraulic Sump and Filter, Relief Pressure Check and Adjustment, Main Hydraulic Pump Removal and Overhaul, Main Hydraulic Control Valve Removal and Overhaul, Tilt Cylinder Maintenance and Overhaul
- Wheels and Tires – Cushion Tire and Wheel Maintenance, Pneumatic Tire and Wheel Maintenance
- Counterweight and Chassis – Counterweight Maintenance, Overhead Guard, Sheet Metal, Seat Mounting, Top Hood, Instrument Panel
- Uprights – Upright Maintenance, Lift Chain Maintenance, Fork and Carriage Removal, Upright Removal and Installation, HIVIS Standard Upright, TSU Triple Stage Upright
- Index – Section Contents Listing, Subject Index
What This Clark Forklift Service Manual Gives You
The SM-520R manual is far more than a simple maintenance guide. It is a full workshop reference covering the complete service life of these Clark lift trucks. The engine section alone walks through tune-up procedures, ignition timing, valve clearance adjustment, compression testing, and complete removal and installation for all three engine families used in these trucks. The transaxle section covers the TA18, HR500, HR600, HR610, and HR620 units with detailed disassembly, inspection, reassembly, and pressure testing procedures. The hydraulic section includes the schematic diagram, pump overhaul, valve overhaul, and tilt cylinder service. Brake, steering, and upright sections round out the major systems.
For technicians and fleet owners working with Clark GCS 20-30 or GCX GPS GPX models, this manual provides the exact torque specifications, fluid capacities, pressure settings, and service limits needed to maintain these trucks correctly. The detailed illustrations and exploded views help identify components and their assembly relationships, while the troubleshooting guides help diagnose problems before they become major failures.
Why This Manual Matters
Clark lift trucks in the 17-30 series are durable machines, but they require correct maintenance and repair procedures to stay safe and productive. The Clark GCS 20-30 service manual gives you the manufacturer’s own procedures for every major repair task. From adjusting the parking brake to overhauling a transaxle, you get the step-by-step guidance that prevents costly mistakes. The specifications section alone justifies the cost, with torque values, fluid recommendations, and service limits that are often difficult to find elsewhere.
Whether you are a professional technician, a fleet maintenance manager, or an owner-operator who prefers to handle repairs in-house, having the Clark SM-520R service manual at hand means you can approach any job with confidence. The manual covers both cushion-tire and pneumatic-tire models, all engine options, and every transaxle variant used in these trucks.
Instant PDF Delivery
This Clark forklift repair manual is delivered as an instant PDF download. No shipping, no waiting for a physical book. Once your order is complete, you can download the manual immediately and access it on any device – laptop, tablet, or smartphone. The PDF format means you can print specific pages for use in the workshop, search for the information you need, and keep the entire manual organized on your computer or in the cloud.
With over 900 pages of technical content covering every system on the GCS, GCX, GPS, and GPX series trucks, this is the most complete reference available for these Clark forklift models. Get your copy today and have the full service manual ready for your next maintenance or repair job.
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