Clark Sm 591 Service Manual

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Service
Manual
SM 591

GPH/DPH 50/60/70/75

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Intended for CLARK dealers only
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 Main Table of Contents

Pictorial Group Index

Group 20
a_

Group 34
Drive Axle uprights

Group 32
lilt Cylinders

Group 23
Group 21 Braklng/lnchlng
Prop Shaft

Group 06
Transmlsslon

Group29/30
Hydraulic

Group 00
Group 02
Fuel

Group26/26 - Group 01
-!I Cooling

- Group 22
Wheels and Tires

Using the PictorialGroup Index and Table of Contents

Clakinangespartsandserviceproceduresby~~ Contents combine with a page number to provide a unique
Gro~~~s.MostoftheGroupsarereprewWabove.AllGmups identifierthat is printed on the lower outside comer of each
are listed in the Table of Contentsbeginningon the next page. page. For example,“00-1-2”on the lower comer of the page
The group number and section number listed in the Table of indicatesGroup 00, Section 1, Page 2.

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 CONTENTS

Table of Contents
Group# Section# Group/Section Name

INTRODUCTION
Safety
PlannedMaintenance

00 ENGINES
00 Engine Troubleshooting
al Perkins Diesel Engine Workshop Manual
00 GM “Detroit” Diesel EngineWorkshop Manual
00 Ford Gas/LPG BngineWorkshop Manu
00 Engine Removal

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

02 FUEL SYSTEM
02 Fuel System Troubleshooting
02 Air Induction System
02 The IMPCO Fuel System
02 Removal of IMPCO Vaporizing System

06 TRANSMISSION
06 Transmission Maintenance and Service Manual
06 Transmission Removal and Installation
06 Transmission Drain and Refill
06 Transmission Oil Cooler Checks
06 Neutral Start Switch

14 ELECTRICAL SYSTEM
14 wiring C&r C5de.s
14 ElectricalDiagrzns
14 BlectlicalChecks
14 StarterandAltemator

20 DRIVEAXLE
20 Drive Axle Description
20 Drive Axle Dissassembly
20 Drive Axle Assembly
20 Drive Axle Adjustment and Fastener Torque Values
20 Drive Axle Ends Disassembly and Assembly
20 Drive Axle Removal and Installation
20 Drive Axle Lubrication

(continued on next page)

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 Main Table of Contents

Group# section# Group/Section Name

21 PROP !sHAFr
21 1 Prop Shaf&Troubleshooting, Removal, and Service

22 WHEELSANDTIRES
22 Lifting, Jacking, and Blocking
22 Tire Removal and Mounting
22 Wheel Mounting
22 Towing

23 BRAKING/lNCHINGSYSTEM
23 System Description and Troubleshooting
23 Brake and Inching Pedal Adjustment
23 Brake and Inching System Bleeding
23 ServiceBrakeInqxctionandOverhaul
23 MasterCylin~
23 Hydrovac Overhaul
23 Parking Brake Adjustment

25 STEERING COLUMN AND GEAR

25 1 Steering SystemTroubleshooting
25 2 Steering Column and Gear Removal
25 3 Hydraguide Steering Control Unit

26 STEER AXLE
26 Steering System Checks and Adjustments
26 SteerAxle WheelBearings
26 Steer Axle Removal and Replacement
26 Steer Cylinder Removal and Replacement
26 SteerCylinder Overhaul

29 HYDRAuLIcsuMP,FJLTERs,ANDPuMP
29 1 Hydraulic Filters and Fluid Replacement
29 2 Hydraulic Pump Troubleshooting
29 3 HydraulicPumpOverhaul

30 HYDRAuLIccoNTRoLvALvE/LlFTcIRcurr
30 Hydraulic System Troubleshooting
30 Hydraulic SystemPressureQxck
30 Hydraulic Valve Owrhanl
30 Hydraulic Control Valve Linkage
30 Hydraulic Schematic

32 TILT CYLINDERS
32 1 Tilt Cylinder Removal and Replacement
32 2 Tilt Cylinder Overhaul
32 3 Tilt Lock Valve

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 Main Table of Contents

CONTENTS

Group # Section# Group/Section Name

34 UPRIGHTS
34 Troubleshooting and Visual Iqection
34 OpltiOIldChtXkS
34 CarriageCheck and Adjustment
34 Upright Check andAdjustment
34 Cylinder Repair
34 Lift ChainMaintenance
34 Upright Removal and Replacement

38 COUNTERWEIGHTS
38 1 Counterweight Removal and Replacement

40 SPEClFICATIONS
40 1 Namplates andDecals
40 2 GxxEralspecifications
40 3 PM and Driver’s Daily Inqection Forms
40 4 Lubricants and Shop Supplies
40 5 Special Tools
40 6 Lubrication charts and Intervals

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 Main Table of Contents

Emw Introduction

Planned Maintenance

The Importance of Planned Maintenance ......................................................... 2

PM Intervals ......................................................................................................... 2

PM Procedures ..................................................................................................... 3
PM Report Form................................................................................................................
Precautions ........................................................................................................................ ;
Visual Inspection ............................................................................................................... 3
Decals, Fasteners, and Leaks ................................................................................................... 3
Carriage and Upright ................................................................................................................ 4
Overhead Guard ....................................................................................................................... 4
Forks 4
........................................................................................................................................
Wheels and Tires ...................................................................................................................... 5
Brake and Inching Pedal Freeplay ...........................................................................................
Functional Tests ................................................................................................................ :
Starting System ........................................................................................................................ 5
Gauges, Meters, and Indicators ................................................................................................ 6
Accelerator, Brake/Inching System, and Parking Brake .......................................................... 7
Lift Mechanisms and Controls 7
.................................................................................................
Auxiliary Controls ................................................................................................................... 8
Steering System 8
.......................................................................................................................
Shift Control and Brakes ..........................................................................................................
Under the Hood ................................................................................................................. ;
Belts and Hoses ........................................................................................................................ 9
Engine Air Cleaner 9
..................................................................................................................
9
Battery ......................................................................................................................................
Engine Cooling System 9
............................................................................................................
Engine Gil 10
..............................................................................................................................
Engine Oil and Filter Change ................................................................................................. 10
Hydraulic Sump Tank 11
............................................................................................................
Hydraulic Fluid and Filter Change ......................................................................................... 11
SumpTankBreather 11
..............................................................................................................
Transmission Fluid Check 11
.....................................................................................................
Drive Axle Fluid Check ......................................................................................................... 11
Air CleaningtheTruck .................................................................................................... 12
Critical Fastener Torque Checks ..................................................................................... 12
Truck Chassis Inspection and Lubrication ...................................................................... 12
Upright and Tilt Cylinder Lubrication ............................................................................ 13
Lift Chain Maintenance ................................................................................................... 13
Lift Chain Adjustment Check ................................................................................................ 13
Lift Chain Inspection and Measurement ................................................................................ 14
Lift Chain Replacement 14
.........................................................................................................
Lift Chain Lubrication 14
...........................................................................................................

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 Main Table of Contents

Introduction cl!!mK

The Importance of Planned

Maintenance
A planned maintenance (PM) program of regular,
routine inspections and lubrication is important for
long life and trouble-free operation of your lift truck.
Make and keep records of your inspections. Use
these records to help establish the correct PM inter-
vals for your application and to indicate maintenance
required to prevent major problems from occurring
during operation.

PM Intervals
Time intervals on the following charts and elsewhere
in this Section relate to truck operating hours as
recorded on the hometer, and ate based on experi-
ence CLARK has found to be convenient and suit-
able under normal operation. The operating condition
classifications are:
Normal Operation: Eight-hour material handling,
mostly in buikiings or in clean, open air on clean
paved surfaces.
Severe Operation: Prolonged operating hours or
constantusage.
Extreme Operation:

Jn sandy or dusty locations, such as cement

plants,lumbermills,andcoaldustorstonecrush-
ing sites.
H&h-temperature locations, such as steel mills
and foundries.
Sudden temperature changes, such as constant
trips from buildings into the open air, or in re-
frigeration plants.
If thelift truck is used in severe or extreme operating
conditions, the maintenance intervals shouldbe short-
ened accordingly.

NOTICE

Siucethe operating environment of lift

trucksvarieswidely,theabovedescrip-
tions are highly generalized and should
be applied as actual conditions dictate.
“*Air restriction indicator may determine interval.

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Introduction

PM Procedures Visual Inspection

Daily checks and periodic maintenance should be First, perform a visual inspection of the lift truck and
performed according to the following procedures. its components. Walk around the truck and take note
of any obvious damage andmaintenance problems.
PM Report Form
A planned maintenance program of regular, routine
inspections and lubrication is important for long life
and trouble-free operation of your lift truck. Make
and keep records of your inspections. Use these
records to help establish the correct PM intervals for
your application and to indicate maintenance re-
quired to prevent major problems from occuning
during operation.
As an aid in performing and documenting your PM
inspections, Clark has prepared a “Gas, LPG or
Diesel Planned Maintenance Report” form. Copies Decals, Fasteners, and Leaks
of this form may be obtained from your authorized Check for loose fasteners and fittings.
Clark dealer. We recommend that you use this form
as a checklist and to make a record of your inspec- Check to be sure all capacity, safety, and warning
tion and truck condition. Please note the special plates and decals are attached and legible.
codingsystemforindicatingtheimportanceofneeded
NOTICE
repairs and/or adjustments.
The periodic maintenance procedures outlined in Do not operate a lift truck with dam-
thismanualateintendedtobeusedwiththePM aged or missing decals and name-
report form. They are arranged in groupings of main- plates. Replace them immediately.
tenance work that are done in a logical and efficient They contain important iuformatio~~
sequence. Inspect the truck before and after starting engine for
When you have finished the PM inspections, be sure any signs of extemal leakage: fuel, engine oil or
to give a copy of the report to the designated author- coolant, transmission fluid, etc.
ity or the person responsible for lift truck mainte- Check for hydraulic oil leaks and loose fittings. DO
nance. NOT USE BARE HANDS TO CHECK. Oil may
be hot or under pressure.
Precautions

/\ ! CAUTION
A! CAUTION
Do not make repairs or adjustments
HYDRAULIC FLUID PREssuRE.
unless authorized to do so.
Do not use your hands to check for
Disconnect the battery ground cable (-) from the hydraulic leakage. Fluid under pres-
engine or frame before working on electrical com- surecaupenetrateyourskinandcause
ponents. Always wear safety glasses. Wear a safety serious injury.
(hard) hat in industrial plants and in special areas
where protection is necessary or required Remove
all jewehy (watch rings, bracelets, etc.) before work-
ing on the truck
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Introduction el!!mK
Overhead Guard Forks
Be sure that the driver’s overhead guard and any Inspect the load forks for cracks, breaks, bending
other safety devices are in place, undamaged and wear. The fork top surface should be level and
and attached securely. even with each other. The height difference be-
tween both fork tips should be no more that l/16
inch per foot of fork length.

A WARNING

If the fork blade at the heel is worn

down by more than 10 percent, the
load capacity is reduced and the fork
must be replaced.
Inspecttheforksfortwistsandbends. Puta2”thick
metal block, at least 4” wide by 24” long on the
blade of the fork with the 4” surface against the
Check the overhead guard for damage. Be sure that
blade. Put a 24” carpenter’s square on the top of the
it is properly positioned and all mounting fasteners
block and against the shank. Check the fork 20”
are in place and tight.
above the blade to make sure it is not bent more than
1” maximum.
Carriageand Upright
Inspectthe welds on the carriage and upright for
cracks. Report any cracks noted immediately. Be
sum that the mounting fasteners are in place and
tight.
Inspect the upright assembly: rails, carriage rollers,
lift chains, and lift and tilt cylinders. Look for
obvious wear and maintenance problems, damaged
or missing parts. Check for any loose parts or
fittings. Check for leaks, any damaged or loose
rollers and rail wear (metal flaking). Carefully check
the lift chains for wear, rust and corrosion, cracked
or broken links, stretching, etc. Check that the hft If the fork blades ate obviously bent or damaged,
and carriage chains are cornxtly adjusted to have they mustbetepairedorreplacedbefore the track is
equal tension. Check that the lift chain anchor fas- put into operation.
teners and locking means are in place and tight Inspect the fork locking pins for damage. Reinsert
Besureallsafetyguardsandchainretainersamin them and note whether they fit properly.
place and not damaged. Jnspect the carriage stops
and cylinder retainer bolts. Check all welded con-
nections.
Jnspect all lift line hydraulic connections for leaks.
Check the lift cylinder rods for wear marks, grooves
and scratches. Check the cylinder seals for leaks.

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 Main Table of Contents
Wheels and Tires
Check the condition of the drive and steer wheels
and tires. Remove objects that ate embedded in the
tread. Inspect the tires for excessive wear or breaks
or “chunking out”.
Check all wheel lug nuts or bolts to be sure none are
loose or missing. Have missing bolts or lug nuts
replaced and tightened to correct torque before
opemting truck (See ‘Torque Specifications” in
Group 40.)
A WARNING
Check tire pressure from a position
facing the tread of the tire, not the side.
Usea long handled gauge to keep your
body away from the side. If tires are
low, do not add air. Check with a
mechanic. The tire may require re-
moval and repair. Incorrect (low) tire
pressure can reduce stability of your
lift truck. See Group 40, Section 2,
T@ecification,” for proper inflation
Pm
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Introduction
Brake and Inching Pedal Freeplay
Pxessdownonthebrakepedalwithyourhandto
check for &play. The freeplay should be approxi-
mately 0.31 inch (8mm). Adjust fieeplay as de-
scribed in Group 23, if necessary.
checkinchingpedalfreeplayaswiththebrakepedal,
and adjust if necessary.
FunctionalTests
Besurethat:
l Parking brake is applied.
l Directional control is in ‘W’ (neutral).
Test the horn, lights and all other safety equipment
and accessories. Be sure they are properly mounted
and working correctly.
Press the horn button to check horn function. If the
horn or any other part does not operate, report the
faihu-e and have it repaired before the truck is put in
operation.
Now prepare to start the truck so that you can test
gauges, accelerator service and parking brakes, all
hydraulic controls, directional controls, and steering
system. All controls must operate freely and return
to neutral properly.
Starting System
A 3position starter switch is standard equipment.
Check the operation of the
neutral start switch by plac-
ing direction control lever in
forwardorreverseandturning
key switch to START posi-
tion. Starter must not engage
until dim&ion control lever is
movedtoNEUTRALposition.
As you start the engine, check the instrument panel.
The oil pressure gauge and ammeter should register
when the key reaches the on position. The other
gauges should register as the engine cranks over.
To start engine, rotate the key clockwise. Release to
“run” position when engine starts. The “anti-
PlannedMaintenance-5
 Main Table of Contents

Introduction lx!mu

restart” fm requims that the key be returned to Oil Pressure Gauge

the “off’ position before it can again be turned to
Micaks engine oil pressure.
“start” If engine does not start on the first attempt,
Oil pressure should be be-
do not reengage the starter until engine comes to a
tween3Opsi(207kPa)and
complete stop (approximately 5 seconds). After the
60 psi (414 kPa) at nor-
engine starts, let it warm up until it runs evenly.
mal engine operating
Gauges, Meters, and Indicators speeds. At idle, pressure
should not fall below 20-
The gauges, hour meter, and indicator light in the 25 psi (138 kPa). If pres-
instrument panel tell you many important things sure is low or erratic, shut
about the performance of your lift truck FamGrizc downtheengineandlocatetheprob
you&f with their location and purpose and make it 1enL
a practice to scan the instrument panel as you start
the engine, after it starts, and periodically as you Ammeter
operate the tmck. Indicatesrateofbatterycharge
or discharge. With the en-
Water Temperature Gauge gine running, the gauge
shouldmadslightlytothe
Indicates t.czqem of en- “+” side of 0. If the am-
gine coolant water in de- meter shows a continu-
grees,lOO-280°F ous high rate of charge or
(3%138°C). Water tem- discharge, or reads errati-
peranne should be about tally, troubleshoot the bat-
180°F (82°C) after 10 tery charging system.
minutes of operation. Ifthe
indicator registers in the
‘hot” zone, turn off the en-
Transmission Temperature tight
gine and troubleshoot the cooling sys-
tem. This light comes on when oil temperature in the
torque converter is too high. Shift to a lower range.
Fuel Gauge If light stays on, shut the truck down and trouble-
shoot the transmission.
Indicates quantity of fuel re-
maininginthetanki&ac- Air Restriction Indicator
tions of the whole. Fuel
level should be checked Located on the seat deck of diesel models, this
at the beginning of each indicator shows red when it is time to change the air
shift. The tank should be filter element.
fullatthebeginningof
each shift. (Notused onLPGl NOTICE
CNG.)
The electrically-operated gauges reg-
ister correctly when the key switch is
in the ON position. When the key
switch is OFF, the indicator needle
willnotnecessarilgre~toanygiven
position.

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 Main Table of Contents

Introduction

Hour Meter Lift Mechanisms and Controls

Indicatestotal engine oper-
ating time in hours and 1. Check the function of the lift system and
tenths. The indicated controls with the hydraulic pump (engine)
hoursareusedforplanned running.
maintenance. Record the 2. Pull back on the tilt control lever and hold
hours on the PM Report until the upright reaches the full back tilt
FolnL position. Push forward on the lever to return
the upright to the vertical position. Release
the lever.

Accelerator, Brake/Inching System, and

Parking Brake Be sure that tbere isadeqnate over-
head clearance before raising the up
1. Push the brake (right) pedal down fully and right.
hold. The brakes should apply before the
pedal reaches the floor-plate. If the pedal 3. Pullbackontheliftcontrolleverandraisethe
continues to creep downwards, report ‘the fork carriage to full height. Watch the up-
failure immediately. DO NOT OPERATE right assembly as it rises. All movements of
THE TRUCKUNTILTHEBRAKESARE the upright, fork carriage, and lift chains
REPAIRED. must be even and smooth, without binding or
jerking. Watch for chain wobble or loose-
2. Make sure the truck accelerates smoothly.
ness; the chains should have equal tension
3. Depress the inching (left) pedal and depress and move smoothly without noticeable
the accelerator to see if the transmission dis- wobble. Release the lever.
engages properly.
4. Check the function of the parking brake.
Apply and then put truck in gear and acceler-
ate to insure that brake holds. Park the truck
on a grade and apply the parking brake. The
parking brake should hold a lift truck with
rated load on a 15% grade.

A! CAUTION
Do not operate a lift truck if tbe ser-
vice or parking brakes are not operat- If the maximum fork height is not reached,
ing properly. this indicates there is an inadequate (low) oil
level in the hydraulic sump tank or severe
binding within the upright.
4. Push forward on the lift control lever. Watch
the upright as it lowers. Whentheforks reach
the floor, release the lever.

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 Main Table of Contents

Introduction EmI5

Auxiliary Controls Shift Controland Brakes

If the truck is equipped with an attachment, test the Check and make sure that the travel ama is clear in
control lever for correct function and briefly operate front of the truck.
the attachment.
1. Push firmly on the brake (right) pedal. Re-
SteeringSystem lease the parking brake. Move the directional
control lever from “N” (neutral) to FOR-
The steetig system,steeraxle and steering linkage
WARD travel position.
shouldbeinspectedperiodically forabnormalloose-
ness and damage, leaking seals, etc. Also, be alert 2. Remove your right foot from the brake pedal
for any changes in steering andput it on the acceleratorpedal. Push down
action: Hard steering, e; until the truck moves slowly forward. Re-
cessive freeplay (looseness) move your foot from the accelerator pedal
or unusual sound when turn- and push down on the brake pedal to stop the
ingormaneuveringindicates II - truck. The brakes should apply smoothly and
a need for inspection or ser- ePallY*
vicing.
3. Be sure the travel area is clear behind the
Check the steering system by moving the steering truck. Put the directional control lever in the
handwheel in a full right turn and then in a full left REVERSE travel position. Push down on the
turn. Return the handwheel (steer wheels) to the accelerator pedal until the truck moves slowly
straight-ahead position. The steering system com-
in the reverse direction. Remove your foot
ponents should operate smoothly when the steering
from the accelerator pedal and push down on
wheel is turned
the brake pedal to stop the truck. The brakes
Never operate a truck which has a steering sys- should apply smoothly and equally.
tem fault.

A WARNING
When you have completed the operational tests,
park and leave truck according to standard shut-
Fastenyour seatbelt before driving
down procedures. Be sure to make a record of all
the truck. maintenance and operating problems you find.

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 Main Table of Contents
Cl!!lRK
Under the Hood
Check fluid levels and other components within the
engine compartment. Unlatch and open the hood to
access the engine compartment.
A! CAUTION
To avoid the possibility of personal
injury, never work in engine com-
partment with engine running except
when absolutely necessary to check or
makeadjustments. Takeextremecare
to keep face, hands, tools, loose cloth-
ing,etc.awayfromfananddrivebelts.
Also, remove watches, bracelets, and
rings.
Belts and Hoses
Inspect the engine coolant hoses and fan belt(s).
Look for leaking and obvious damage, worn (frayed)
condition, breaks, etc. that could cause faihrre dur-
ing operation.
Engine Air Cleaner
Check the engine air cleaner for damage and con-
tamination (excessive dirt buildup and clogging).
Check for correct mounting attachments of the air
cleaner. Be sure that the air cleaner hose is securely
connected (not loose or leaking). Fan or cone shaped
dust deposits on tube or hose surfaces indicate a
leak.
Changeor service the air cleaner element every 50
to 250 operating hours, depending upon your appli-
cation. Air cleaner service intervals may also be
determined by the airrestriction indicator.
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Introduction
Battery
Inspectthe battery for any damage, cracks, leaking
condition, etc. If the terminals are corroded clean
and protect them with CLARKBattery Saver (avail-
able from your Clark dealer). If the battery has
removable cell caps, check to be sure the cells are all
filled. Ifnecessary, refill with distilled water.
Engine Cooling System
Check radiator coolant level (on a daily basis in
highcycle applications):
1. Remove the radiator cap, only when the en-
gine is cold First turn the cap slowly to
release pressure that may be in the radiator.
Then push the cap down fully and turn to
release and remove the cap.
A! CAUTION
STEAM. Do not remove the radiator
cap when the radiator is hot. Steam
from the radiator will cause severe
burns.
Never remove the radiator cap while the engine is
running. Stop the engine and wait until it has cooled.
Even then, use extreme care when removing the cap
i?omtheradiator. Itisgoodsafetypmcticetousea
shop cloth to cover the radiator cap while it is being
removed. Wrap the cloth around the cap and turn it
slowly to the first stop. Step back while the pressure
is released from the cooling system.
2. When you are sure all the pressure has been
released, press down on the cap, with the
cloth in place, turn and remove it. Stand clear
of theradiator opening; hot coolant may splash
out. Failure to follow these instructions could
result in serious personal injury from hot
coolant or steam blowout and/or damage to
the cooling system or engine.
PlannedMaintenance-9
 Main Table of Contents
Introduction
3. The correct PULL level is the bottom edge of
the filler neck.
Fill
Level
If level is low, add a 50/50 mixture of speci-
fied coolant and water to the correct fii level.
If you have to add coolant more than once a
month or if you have to add more than one
quart at a time, check the cooling system for
leaks.
4. Inspect the coolant\ condition. Look for ex-
cessive contamination or rust or oil in the
coolant solution. Check the PM time interval
for need to change coolant.
5. Check condition of radiator cap rubber seal
and radiator filler neck for damage. Be sure
they are clean. Check overflow hose for clog-
ging or damage.
NOTICE
Your lift truck coolingsystem is fiued
with a factory-installed solution of
50% water and 50% permanent-type
anti-freeze containing rust and corro-
sion inhibitors. You should leave it in
yeararound. Plainwatermaybeused
only in an emergency, but replace it
with the specified coolant as soon as
possible to avoid damage to the sys-
tem. With only water in the system
do not let the engine run hot. Do not
use alcohol or methanol antifreeze.
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m!!mK
Engine Oil
With the truck level and the engine shutdown for at
least 2 minutes, check the engine oil level.
Locate the engine oil dipstick. Pull the dipstick out,
wipeitwith acleanwiperandrGnsertitfu.llyintothe
dipstick tube. Remove the dipstick and check oil
level.
It is normal to add some oil between oil changes.
Keep the oil level above the ADD mark on the
dipstick by adding oil as m@red. DO NOT OVER-
PILL. Use the correct oil as specified under Lubri-
cant specifications.
Engine Oil and Filter Change
It is recommended to:
Drain and replace the engine crankcase oil ev-
ery 50 to 250 operating hours. See NOTICE
below.
Replace the engine oil filter every oil change.
Remove the oil pan drain plug to drain old oil,
after truck has been in operation and engine
(oil) is hot (at operating temperature).
NOTICE
The time interval for changing en-
gine oil will depend upon your appli-
cation and operating tinditions. To
determine the correct schedule for
your truck it is qgested that you
periodically submit engine oil samples
to a commercial laboratory for analy
sis of the condition of the oil.
SM 591, Aug ‘93
 Main Table of Contents
ELclRK
Oil performance designation: To help achieve
proper engine performance and durability, use only
engine lubricating oils of the proper quality. These
oils also help promote engine efficiency which re-
sults in improvedfuel economy. A symbol has been
developed by the API (American Petroleum Insti-
tute) to help you select the proper engine oil. It
should be included on the oil container you pur-
chase. For dieselengines, CLARK recommends that
you use motor oil that meets API Service Classilica-
tion CR/SF. CC/CD or CD/SF oils can be used in
areas where CE oil is not available. See “Lubrication
Specifications in Group 40.
HydraulicSump Tank
Check the hydraulic sump tank fluid level. Correct
fluid level is important for proper system operation.
Low fluid level can cause pump damage. Overfill-
ing can cause loss of fluid or lift system malfunction.
Hydraulic fluid expands as its temperanne rises.
Therefore, it is preferable to check the fluid level at
operating temperamre (after approximately 30 min-
utes of tmck operation). To check the fluid level,
first park the truck on a level surface and apply the
parking brake. Put the upright in a vertical position
and lower the fork carriage fully down. Pull the
dipstick out, (attached to the sump breather) wipe it
with a clean wiper and reinsert it. Remove dipstick
and check oil level. Keep the oil level above the
LOW mark on the dipstick by adding recommended
hydraulic fluid only, as required DO NOT OVER-
FLL.
Check the condition of the hydraulic fluid (age, color
or clarity, contamination). Change (replace) the oil
asnecessary.
HydraulicFluid and Filter Change
Drainand replace the hydraulic sump fluid every
2000 operating hours.
Copyrighted Material
SM 591, Aug ‘93 Intended for CLARK dealers only
Do not sell or distribute
Introduction
(Severe service or adverse conditions may require
mom frequent fluid change). Replace the hydraulic
oil filter elements every 1000 hours and at every oil
change. Remove, clean, and reinstall the hydraulic
and steer system suction line screens a.tfirstPMand
every 500 hours thereafter. Check for leaks after
installation of the filters. Also, check that the hy-
draulic line connections at the filter adapter are tight-
ened correctly.
Sump Tank Breather
Remove the sump tank fill cap/breather and inspect
for excessive (obvious) contammation and damage.
Clean or replace the fill cap/breather, per recom-
mended PM schedule or as required by opemting
conditions.
TransmissionFluid Check
Before making check, run engine until unit is at
operating temperature. This is important as tmns-
mission oil temperature should be 200 degrees F and
the engine water jacket should be at opemting tem-
Apply parking brake. With the engine operating at
idle and the tmmmission in NEUTRAL, check the
fluid on the dipstick. Fill if necessary to the FULL
mark on the dipstick using “Amoco looo” (Clark
ti776236; 1 gal. can). Change fluid every 1000
hours.
Drive Axle Fluid Check
The drive axle fluid should be checked every PM
(typically 50-250 hours). Change fluid every 1000
hours.
PlannedMaintenance-l1
 Main Table of Contents
Introduction
Air Cleaningthe Truck
Always maintain a lift truck in a clean condition. Do
not allow dirt, dust, lint or other contaminants to
accumulate on the truck. Keep the truck fIee from
leaking oil and grease. Wipe up ah oil or fuel spills.
Keep the controls and floorboards clean dry, and
safe. A clean truck makes it easier to see leakage,
loose, missing, or damaged parts, and will help pre-
vent fires. A clean truck will run cooler.
The environment in which a lift truck operates will
determine how often and to what extent cleaning is
necessary. For example, trucks operating in manu-
facturing plants which have a high level of dirt, dust
or lint, (e.g. cotton fibers, paper dust, etc.) in the air
or on the floor or ground will require more frequent
cleaning. The radiator, especially, may require daily
aircleaningtoensurecorlectcooling. Jfairpressure
does not remove heavy deposits of grease, oil, etc., it
maybenecessaryto usesteam orliquidspmy cleaner.
LIFT TRUCKS SHOULD BE AJR CLEANED AT
EVERY PM INTERVAL AND OTHERWISE AS
OFTEN AS NECESSARY.
Air cleaning should be done using an air hose with
special adapter or extension having a control valve
and nozzle to direct the air properly. Use clean, dry,
low-pressumcompressedair. Restrictairpressureto
30 psi (207 kPa), maximum. (OSHA mquirement).
A! CAUTION
Wear suitable eye protection and pro-
tective clothing.
Air clean: upright assembly, drive axle, radiator,
from both counterweight and engine side, engine
and accessories, driveline and related components,
steer axle and steer cylinder.
Copyrighted Material
PlannedMaintenance-12 Intended for CLARK dealers only
Do not sell or distribute
CLRRK
Critical FastenerTorque Checks
Fasteners in highly loaded (critical) components can
quickly fail if they become loosened; also, loose
fasteners can cause damage or failure of the compo-
nent. For safety it is important that the correct torque
be maintained on all critical fasteners of components
which directly support, handle or control the load
and protect the operator.
Check torque of critical items, including:
Drive axlemounting
Drive and steer wheel mounting
Counterweight mounting
Overhead guard mounting
Tilt cylinder mounting and yokes
Upright mounting and components.
Truck Chassis Inspectionand
Lubrication
Lubrication requirements are given in Group 40 in
Section 4, “Lubricant Recommendations,” and in
Section 5, ‘2ubrication Jntervals.”
Lubrication and inspection of truck chassis compo-
nents includes steer wheels, steer axle linkage, steer-
ing cylinder, and wheel bearings. To check these
items, the truck must be properly raised and blocked
as described in “Lifting, Jacking, and Blocking” in
Croup 22, section 1.
Check for play in wheel bearings by attempting to
move the wheel side to side and up and down, by
hand
Inspect the steering cylinder piston rods, seal, and
fastenersfordamageandleaks, andlooseness. Check
for leaks at the steering gear.
Check linkages by observing whether the steer
wheels lag when you turn the handwheel.
Lubricate the steer axle linkage rod ends and pivot
points. Be sure to clean the gmase fittings before
lubricating. Remove the excess grease from all points
afterlubricating.Lubricatemiscellaneouslinkageas
needed,
SM 591, Aug ‘93
 Main Table of Contents
CldlRK
Uprightand Tilt Cylinder Lubrication
Clean
the fittings and lubricate the tilt cylinder rod
end bushings (forward end). Clean the fittings and
lubricate the tilt cylinder base rod end bushings
(rear end). Clean and lubricate the upright trunnion
bushings.
Lift Chain Maintenance
Lift chains are very important components of fork
lift trucks. The chain system on your upright was
designed for safe, efficient and reliable transmission
of lifting force from hydraulic cylinder to the forks.
Safe use of your truck with nrinimurn down-time
depends on the correct cam and maintenance of the
lift chains. Most complaints of unacceptable chain
pzrRnmance are a result of poor maintenance. Chains
need periodic maintenance to give maximum ser-
vice life.
A WARNING
Donotattempttorepairawornchai~.
Replace worn or damaged chains.
Copyrighted Material
SM 591, Aug ‘93 Intended for CLARK dealers only
Do not sell or distribute
Introduction
Lift Chain Adjustment Check
Lift chains am correctly adjusted if the lower car-
riage rollers reach their end (lowest) position ap-
proximately 0.50 inch (13mm) from the lower edge
of the inner rail.
On trucks with forks, measure the height of the
fork from the floor, which should be approximately
0.50 (13mrn) when the lift chain is corm&y ad-
justed.
On trucks with attachments without forks, raise
the carriageto a height that exposes several inches of
the inner rail at the roller path. Apply a light layer of
grease to the roller path on the inner rail. Lower the
carriage and pick up a rated capacity load, (tilt the
upright back slightly) and raise the load until the
carriage rollers have passed over the greased area.
Lower the load completely and remove the load
from the forks. Raise the carriage again to expose the
inner rail. Now check the track the roller left in the
grease and determine the correct adjustment of the
Chains.
Adjust lift chains by loosening or tightening of the
chain anchor nuts.
On trucks with triple stage uprights, adjust back
chains so that the inner rail top is 0.125 inch (3.2
mm) above the intermediate rail. Adjust chains for
even tension.
NOTICE
Itisimportanttomaketheliftchain
adjustment check with a rated load to
makesurethatthechainsarestretched
to their maximumlength.
PlannedMaintenance-13
 Main Table of Contents

Introduction cl!mK

Lift Chain Inspection and Measurement Lii Chain Lubrication

Inspeztand lubricate the lift chains every truck PM
(50-250 hours). When operating in corrosive envi-
ronments, inspect the chains every 50 hours. During
the impection, check for the following conditions:
l Rust and corrosion
l Crackedplates
4aisedoltllmedpiils
l Tight joints
l Wear, wom pins or holes.
When the pins or holes become worn the chain
becomes longer. When a sectionof chain is 3%
longer than a section of new chain, the chain is
worn and must be discarded.
Chainwearcanbemeasumdbyusingachainscale
or a steel tape measure. When checking chain wear,
be sure to measure a segment of chain that moves
over a sheave. Do not repair chains by cutting out
the worn section and joining in a new piece. If part
of a chain is wom, replace all the chains on a truck.
Clark provides a chain tool, part number 59-960-
9908, (shown below) that serves as a handy guide for
inspecting a variety of chain types.
Lift chain lubrication is an important part of your
maintenance program. The lift chains operate un-
der heavy loadings and will function more safely
and have longer life if they are regularly and cor-
rectly lubricated. Clark chain lubricant is mcom-
mended; itiseasily sprayedonandprovidessuperior
lubrication. Heavymotoroilmayalsobeusedasa
lubricant and corrosion inhibitor.
Lubricate the entire length of the upright rail lift
and caniage chains with Clark Chain and Cable
Lube.
Lii Chain Replacement
All chains must be replaced if any strand has wear
of 3% or more, or if any of the damaged conditions
noted are found during inspection.
Chderreplacementchainsl?omyourCLARKdealer.
Replaceallchainsasaset.
Do not remove factory lubrication or paint new
Chains.
Replace anchor pins and worn or broken anchors
when instalhng new chains.
Adjust tension on new chains.
Lubricate chains when they are installed on the
upright.

Clark chain tool,part number 59-960-9908

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Planned Maintenance-14 Intended for CLARK dealers only SM591, Aug ‘93
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Clark Sm 591 Service Manual
Main Table of Contents
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GROUP 00, ENGINES

GROUP 00

ENGINES

Engine Troubleshooting..................................................... section 1

Perkins 4.248.2 Diesel Engine Workshop Manual ............ Section 2

GM 3-53N Detroit Diesel Engine Workshop Manual.. ... ..Sectio n 3

Perkins G4.236 Engine Workshop Manual ....... Section 4

Engine Removal and Replacement ................................... Section 5

Perkins G4.236 Engine Workshop Manual

Copyrighted Material
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Do not sell or distribute
This is the cut pages sample. Download all 794 page(s) at: ManualPlace.com