Main Table of Contents

SM498S
CGC, CGP, CDP 20-30
Shop Manual
VOLUME 1 OF 2, GROUPS 00 - 03
 Main Table of Contents

Truck Models Covered by this Manual

This manual consists of a “base” module that pertains to
ail Genesis models and other modules that pertain only to
specific models. Manuals shipped with the truck contain
the base module and the modules specific to the purchased
truck.
You may, however, purchase specific modules and expand
your manual to fully cover multiple models. To do so,
order the desired modules as you would any other Clark
part.

Arrangement and Use of this Manual

Clark armuges parts and service procedures by standard- You can quickly locate a specific point in the manual by
ized Groups. In this manual, Groups are similar to “chap- using the headers and footers that appear on every Section
ters.” Groups are listed in the indexes on the next page. page. The following illustration points out these areas.
Each Group begins with a table of contents that shows the
Sections contained within the Group. Lengthy Sections
also begin with a table of contents.
Each Group and Section has an identifying name and
number, or “ID.”
Each page also has a unique ID The page ID consists of ns In
three numbers separated by hyphens. The three numbers
/
represent the Group number, the Section number, and the
page number. For example, “00-1-2” on the lower comer
Section ID Mania,
ID
\
Section ID

of the page indicates Group 00, Section 1, Page 2.

The Group number sometimes has a letter or letters added
to it in parentheses if one or more variations of the Group
exist. For example, if the truck has a standard transaxle,
Group 06 is expressed as “06(S);” if the truck has a hydro-
static transmission, Group 06 is expressed as “06(H).”
This manual is intended for the use of trained service
personnel. Please read Group SA, “Safe Maintenance,”
and the Operator’s Manual before working on or operat-
ing the truck.

0 Copyright Clark Material Handling 1994 SM 598,Oct ‘94

 CONTENTS
Contents of this Manual
Group Index
Group SA. Safe Maintenance Group 22. Wheels and Tires
Group PS. Periodic Service Group 23. Brake System
Group 00. Engines Group 25. Steering Column and Gear
Group 01. Cooling System Group 26. Steer Axle
Groupo2.Fuel System Group 29. Hydraulic Pump, Sump, and Filters
Group 03. Air Induction System Group 30. Hydraulic Control Valve/Lii Circuit
Group 06. Transmission Group 32. Tilt Cylinders
Group 12. Ignition System Group 34. uprights
Group w. Instrument Pod Group 38. Counterweight, Sheet Metal, & Chassis
Group 14. Electrical System Group 40. Specifications

Alphabetical Index
(SEE NEXT PAGE)

Pictorial Index
Group 34. Uprights
Y
\ n n /Group 06. Transmission

Group 32. Tilt Cylinders

II / Group 23. Brake/Inching System

SM 598, Apr ‘96 Contents-l

 Main Table of Contents

GROUP SA

GROUP SA

SAFE MAINTENANCE

Safety ............................................................................... Section 1

Lifting, Jacking, and Blocking the Truck ..................... Section 2

Towing .............................................................................. Section 2

SM 598, OCT ‘94 Safe Maintenance

 Main Table of Contents
CMRK
Section 1. Safety
Safety Signs and Messages
Safety signs and messages in this manual and on the lii
truck provide instructions and identify specific areas where
potential hazards exist and special precautions should be
taken. Be sure you know and understand the meaning of
these instructions, signs, and messages. Damage to the
truck, death, or serious injury to you or other persons may
result if these messages are not followed.
NOTE
This message is used when special informa-
tion, instructions or identification is re-
quired relating to procedures, equipment,
tools, pressures, capacities, and other spe-
cial data.
IMPORTANT
This message is used when special precau-
tions should be taken to ensure a correct
action or to avoid damage to, or malfunc-
tion of, the truck or a component.
A CAUTION
This message is used as a reminder of safety
hazards that can result in personal injury
if proper precautions are not taken.
A WARNING
This message is used when a hazard exists
that can result in injury or death if proper
precautions are not taken.
A DANGER
This message is used when an extreme haz-
ard exists that can result in injury or death
or serious injury if proper precautions are
not taken.
The above terms have been adopted by Clark Material
Handling Company. The same terms may be used in differ-
ent context in service literature supplied directly or indi-
rectly by vendors of truck components.
SM 598,Oct ‘94
Group SA, Safe Maintenance
Safe Maintenance Practices
The following instructions have been prepared from cur-
rent industry and government safety standards applicable
to industrial truck operation and maintenance. These rec-
ommended procedures specify conditions, methods, and
accepted practices that aid in the safe maintenance of in-
dustrial trucks. They are listed here for the reference and
safety of all workers during maintenance operations. Care-
fully read and understand these instructions and the spe-
cific maintenance procedures before attempting to do any
repair work.
When in doubt of any maintenance procedure, please con-
tact your local Clark dealer.
1. Powered industrial trucks can become hazardous if
maintenance is neglected. Therefore, suitable mainte-
nance facilities, trained personnel, and procedures
must be provided
2. Maintenance and inspection of all powered industrial
trucks shall be done in conformance with the
manufacturer’s recommendations.
3. A scheduled planned maintenance, lubrication, and
inspection program shah be followed.
4. Only trained and authorized personnel shah be permit-
ted to maintain, repair, adjust, and inspect industrial
trucks. Work should be performed in accordance with
the manufacturer’s specifications.
5. Properly ventilate work area vent exhaust fumes, and
keep shop clean and floor dry.
6. Avoid fire hazards and have fire protection equipment
present in the work area Do not use an open flame to
check for level or leakage of fuel, electrolyte, or
coolant. Do not use open pans of fuel or flammable
cleaning fluids for cleaning parts.
7. Before starting work on truck:
a. Raise drive wheels off of floor or disconnect
power source and use blocks or other positive
truck positioning devices.
b. Disconnect battery before working on the electri-
cal system.
8. Before working on engine fuel system of gasoline- or
diesel-powered trucks, be sure the fuel shut-off valve
is closed.
Safety l SA-l-1
 Main Table of Contents
Group SA, Safe Maintenance
9. Operation of the truck to check performance must be
conducted in an authorized, safe, clear area.
10. Before starting to drive truck:
a. Be in operating position.
b. Be sure parking brake is engaged.
c. Put direction control in neutral.
d. Start engine.
e. Check functioning of direction and speed con-
trols, steering, brakes, warning devices, and any
load handling attachments.
11. Before leaving truck
a. Stop truck.
b. Put directional control in neutral.
c. Apply the parking brake.
d. Stop the engine by turning off the ignition circuit.
e. Put blocks at the wheels if truck is on an incline.
12. Brakes, steering mechanisms, control mechanisms,
warning devices, lights, governors, guards, safety de-
vices, and frame members must be carefully and regu-
larly inspected and maintained in a safe operating
condition.
13. Special trucks or devices designed and approved for
hazardous area operation must receive special atten-
tion to ensure that maintenance preserves the original,
approved, safe-operating features.
14. Fuel systems must be checked for leaks and condition
of parts. Extra special consideration must be given in
the case of a leak in the fuel system. Action must be
taken to prevent the use of the truck until the leak has
been corrected.
15. The truck manufacturer’s capacity, operation, and
maintenance instruction plates, tags, or decals must be
maintained in legible condition.
16. Batteries, motors, controllers, limit switches, protec-
tive devices, electrical conductors, and connections
must be inspected and maintained in conformance
with good practice. Special attention must be paid to
the condition of electrical insulation.
17. To avoid injury to personnel or damage to the equip-
ment, consult the manufacturer’s procedures in replac-
ing contacts on any battery connection.
18. Industrial trucks must be kept in a clean condition to
minimize fire hazards and help in the detection of loose
or defective parts.
SA-1-2 l Safety
EUIRK
19. Modifications and additions that affect capacity and
safe truck operation must not be done without the
manufacturer’s prior written approval. Capacity, op-
eration and maintenance instruction plates, tags, or
decals must be changed accordingly. This is an OSHA
requirement.
20. Care must be taken to assure that all replacement parts,
including tires, are interchangeable with the original
parts and of a quality at least equal to that provided in
the original equipment. Parts, including tires, are to be
installed per the manufacturer’s procedures. Always
use genuine CLARK or CLARK-approved parts.
21. Use special care when removing heavy components
from the truck, such as counterweight, seat deck,
upright, etc. Be sure that lifting and handling equip-
ment is of the correct capacity and in good condition.
Also, this removal may upset the stability of the truck.
The frame must always be safely blocked for major
component removal.
NOTE
You should also be familiar with additional
operating and maintenance safety instruc-
tions contained in the following publica-
tions:
ANSVASME B56.1- 1988 Operator Control-Industrial Tow
Tractors (Safety Standard For Powered Industrial Trucks).
Published by: Society of Mechanical Engineers, United
Engineering Center, 345 E. 47th Street, New York, NY
10017.
NFPA 505-1982: Fire Safety Standard for Powered Indus-
trial Trucks: Type Designations, Areas of Use, Mainte-
nance and Operation. Available from: National Fire
Protection Assoc., Inc., Batterymarch Park, Quincy, MA
02269.
General Industrial Standards, OSHA 2206: OSHA Safety
and Health Standards (29 CFR 1910), Subpart N-Materials
Handling and Storage, Section 1910.178 Powered Indus-
trial Trucks. For sale by: Superintendent of Documents,
U.S. Government Printing Office, Washington, DC 20402.
SM 598,Oct ‘94
 Main Table of Contents

CMRK Group SA, Safe Maintenance

Section 2.

Lifting, Jacking, and Blocking

3
Safe Parking ...................................................................................................................................
.&

2
Lifting, Jacking, and Blocking Points ..........................................................................................

Raising Drive Wheels Off Floor ....................................................................................................

2

3
Raising Truck with A Hoist ..........................................................................................................

4
Blocking the Upright in Raised Position ......................................................................................

4
Raising Rear of Truck ...................................................................................................................

Raising Entire Truck ..................................................................................................................... 5

Shipping Tie-Down Instructions .................. ................................................................................. 6

WARNING A
Lifting or jacking any large piece of equipment such as your fork truck presents
obvious hazards. It must be done with great care and forethought. Consult the
truck weight tabulations in Group 40, “Specifications” to ensure that your
lifting equipment is of adequate capacity.

SM 598,Oct ‘94 Lifting, Jacking, and Blocking l SA-2-1

 Main Table of Contents

Group SA, Safe Maintenance CUlRK

Safe Parking RaisingDrive Wheels Off Floor
Before working on truck: This procedure uses the upright as a lever to lift the drive
1. Park truck on a hard, level, and solid surface, such as wheels off the floor and prevent accidents due to inadvert-
a concrete floor with no gaps or breaks. ent powering of the drive wheels.

2. Put upright in vertical position and fully lower the Park truck safely as described in “Safe Parking.” Block
forks or attachment. steer wheels.

3. Put all controls in neutral. Turn key switch OFF and Be sure upright trunnion bolts are tight. Bolt torques
remove key. must be 75-80 Nom (55-59 ft-lb).

4. Apply the parking brake and block the wheels. Start the engine. Tilt the upright fully back. Adjust
upright height as necessary to put blocking underneath
A WARNING
Defective equipment can cause accidents.
the lower end of the upright.
Put a solid 100 x 100 mm (4 x 4 in) hardwood block
All tools and lifting equipment must be in under the front section of each upright rail. Put a 3-6
good condition, meet the load capacity re- mm (.125-.250 in) steel plate on top of each block.
quirements and have OSHA labels when
required. Tools with defects can have fail-
ures causing severe injury or death.

Lifting, Blocking,and JackingPoints

Use the following illustration to locate general lifting, block-
ing, and jacking points on the truck. Read the procedures
for raising, blocking, or jacking specific components of the
truck to make sure you understand the correct, safe proce-
dures.

5. Tilt upright fully forward. This raises the drive wheels

off the floor. Release the tilt control lever and turn
engine OFF.

‘hnder Steer \L Under Frame L Under Upright

Axle Frame
Mount

AWARNING
Do not attempt to lift the truck by the over-
head guard or the counterweight. Severe
injury may result and the truck can be
damaged.

SA-2-2 . Lifting, Jacking, and Blocking SM 598,Oct ‘94

 Main Table of Contents

ClRRK Group SA, Safe Maintenance

6. Insert blocking under the frame behind the drive 3. To raise the front of the truck using the upright, spread
wheels or slip wheel cradles under the drive wheels. If two chains on the outer rail tiebar of the upright.
using blocking, check for safe clearance between drive
wheels and floor and blocks.

NOTE

When forks are raised as in illustration
above, use shop rags, paper, or bright tape
on fork tips to signal the danger of trip-
ping.
7. Check for stable condition of the truck. Be sure that the
blocks are located securely under the truck frame
before operating the drive or working on truck.
8. Lower the drive wheels to the floor and remove the
blocks by reversing the above procedure.
A
WARNING
Chain and hoist used to lift truck should be
checked to make sure they are of safe Iift-
ing capacity. See the truck data plate for
information.
4. Slowly lift truck and lower drive wheels onto the
cradles or place blocking under frame prop points.

Raising Truck with A Hoist

When suitable equipment is available, the front of the truck
may be raised by means of a hoist, with wheel cradles
placed under the wheels or blocking placed under the frame.

n ! CAUTION
When lifting the front of the truck watch
truck for signs of lateral instability. It may
tip sideways. You may have to support or
guide the side of the truck or overhead
guard to prevent tipping.

1. Park truck safely as described in “Safe Parking.” Block

rear steer wheels.
5. When maintenance work is completed, lower the truck
2. Check trunnion bolts to make sure they are tightened to to the floor by reversing the lifting procedure. Check to
correct torque. Bolt torques must be 75-80N.m (55-59 be sure no tools or equipment are under the truck or
ft-lb). wheels.

SM 598,Oct ‘94 Lifting, Jacking, and Blocking l SA-2-3

 Main Table of Contents

Group SA, Safe Maintenance ClmK

Blocking the Upright In Raised Position

.*II I
This procedure is used to safely provide clearance for
access from the front of truck to components on or near the II II ” /II/l
Al e Carriage
drive axle. Illustrations show upright with forks removed
however, fork removal is not necessary
Outer
1. Park truck safely as described in “Safe Parking.” Rail
2. Put blocks in front of and behind drive wheels.
3. Put wooden support blocks conveniently near upright
rails before raising the upright. Use two 100 x 100 mm
(4 x 4 in) hardwood blocks or equal, of about 300 x 300
mm (12 in) and 600 x 600 mm (24 in) length.
NOTE
For standard uprights, block may need Short
length cut to suit. For triple stage uprights, Block
the carriage may be blocked up, as shown.

4. Start engine and raise the upright carriage.

5. Hold the taller block against inner rail and lower the
upright until carriage rests on block. 7. Reverse the procedure to remove blocking.

Raising Rear of Truck

The truck may be raised at the rear by jacking and blocking
under the center of the frame member at either the front or
Outer rear steer axle mounting, or under the center section of the
Rail steer axle.
Refer to truck data plate for truck weights.

A WARNING
An incorrectly installed counterweight can
move or fall unexpectedly. Never lift or
block a truck using the counterweight. Fail-
ure to follow procedures outlined in this
manual can result in injury or death.

1. Park truck safely as described in “Safe Parking.” Put

blocks at front and rear of drive wheels.

6. Hold the shorter block against the outer rail and lower
the upright until inner rail rests on the block.

SA-2-4 l Lifting, Jacking, and Blocking SM 598,Oct ‘94

 Main Table of Contents
ClRRK
2. Put a floor jack under the steer axle mounting frame
member, centered between the two wheels.
A WARNING
Never lift the truck by the counterweight.
Refer to truck data plate for truck weights.
NOTE
If there is insufftcient clearance under
frame for your jack, the truck may fmt be
driven onto shims, such as 25 x 150 x 300
mm (1 x 6 x 12 in) pieces of board, to
increase the truck frame underclearance.
3. Raisethetruckonlyashighasnecessary toperformthe
maintenance work
4. Put blocks at both sides of the truck, fully under the
frame main side structure. Put the blocks in front of but
close to the counterweight and steer wheels for best
truck stability.
Put equal blocks under each side of the truck to provide
a level working position.
5. Lower the truck onto the blocks and remove the jack.
n ! CAUTION
Before performing any maintenance, check
the truck for stabilitY on the blocks.
SM 598, Apr ‘96
Group SA, Safe Maintenance
6. When maintenance work is completed, lower the rear
of truck to the floor by reversing the above procedure
and lowering each side of the truck 50 mm (2 in) at a
time:
l Put jack under frame and raise truck
l Carefully remove blocks and lower truck.
l Remove jack and blocks from drive wheels.
Raising EntireTruck
1. Park truck safely as described in “Safe Parking.”
Lower upright fully.
2. If necessary, drive truck onto boards to increase
undercLearance.
A WARNING
SIDE-TO-SIDE TIPOVER. When jacking
side of truck, be sure upright is lowered
fully and do not raise one side of the truck
more than about 50 mm (2 in) higher than
the other, to avoid tipping truck over later-
ails*
END-TO-END TIPOVER. If the upright
and &ansaxle are removed while the truck
is blocked up, the truck will tip backwards
due to the heavy counterweight. Both up-
right and counterweight must be removed
before attempting to raise the truck for
transaxle removal. The back of the truck
must be supported by blocking under the
steer axle to prevent movement.
The reverse is also true. If the counter-
weight is removed while the truck is up on
blocks, the weight of the upright and
transaxle will cause the truck to tip on the
front blocks and fall forward.
Lifting, Jacking, and Blocking l SA-2-5
 Main Table of Contents

Group SA, Safe Maintenance emu

3. Put the jack under side frame near the center of the
truck. 0! CAUTION
Before performing any maintenance work,
check the truck for stable condition on the
blocking.

When maintenance work is completed, lower the en-

tire truck to the floor by reversing the lifting procedure.
Lower the truck one side at a time, while carefully
removing the blocks. Check to be sure no tools or
equipment are under the truck or wheels.
NOTE
Depending on jack height, shims under the
tires may be needed for clearance to allow
removal of jack.

Shipping Tie-Down Instructions

Front of Truck
IMPORTANT
a. With Upright and Carriage Installed
Be sure to put the jack squarely and fully
under the main side structure of the frame. l Lower the carriage fully.
Do not put the jack under the outer covers l Put a tie down (e.g., chain) between the carriage
which enclose the fuel and hydraulic sump fork bars.
tanks.

4. Carefully raise the truck one side at a time, only as high

as necessary to do the maintenance work and not more
than a maximum of 150 mm (6 in) total.
5. Put blocks under the side frame, at each side of the jack.
Spread the blocks close to the steer and drive wheels
for maximum stability.

b. Without an Upright and Carriage Installed

Rear of Truck
6. If using one jack, lower the truck onto the blocks and
move the jack to the opposite side. Repeat the lifting
procedure.
7. Put the same size blocks under each side of the truck so
it will be level.
l Put a chain across the truck floor plate. Protect
truck from chain damage by using covered chain
or protective material under the chain at contact
points.
l Attach the tie down to pocket in bottom of coun-
terweight.

SA-2-6 l Lifting, Jacking, and Blocking SM 598,Oct ‘94

 Main Table of Contents
ClRRK
Section 3.
Towing
If your truck is disabled but can be moved freely on its own
wheels without further damage, use the following proce-
dures to tow the truck safely to a repair area.
A WARNING
It is important for your safety and to the
care of your lift truck to use the proper
equipment and carefully follow these rec-
ommendations for safe towing.
Do not tow a lift truck if there is a problem
with the brakes or tires, or if the steering
cannot be operated.
Do not tow the disabled truck up or down
ramps or steep inclines.
Do not attempt to tow the disabled truck if
traction or weather conditions are poor.
Be sure to apply the parking brake or block the drive
wheels on the disabled truck while working around it.
When possible, raise the carriage (forks) on the dis-
abled truck 300 mm (12 in) from the floor or ground.
Secure the carriage on the upright with a chain.
Use a truck for towing that is of equal or larger capacity
than the disabled truck. Carry a partial load on the tow
truck for improved traction.
Direction of towing for distances of
300 meters (325 yards) or less.
Disabled truck with
driver in place to steer.
SM 598,Oct ‘94
Group SA, Safe Maintenenance
4. Check that the counterweight bolts on both trucks are
in place and properly torqued to 340-380 Wm (250-
280 ft-lb). These bolts are made of special, high-tensile
steel and are not commercially available. When neces-
sary, replace these bolts only with a genuine Clark
replacement part.
5. Use an approved, solid metal tow bar with towing
couplers that connect to the towing pins in the counter-
weights.
NOTE
DOT-approved towing equipment is avail-
able from your Clark dealer.
6. Release the parking brake on the towed vehicle. Place
directional control lever in neutral.
7. Tow the disabled truck backwards. An operator must
be on the disabled truck.
/\ ! CAUTION
The power steering wiI1 not operate on the
disabled truck when the, engine is not run-
ning. The steering handwheel will be dif’fi-
cult to turn.
8. Tow the truck slowly. Careful towing is necessary to
prevent injury to personnel or damage to the disabled
truck. The truck should be towed at a speed of less than
8 kph (5 mph, or a moderate walking speed) with a
driver in place and steering the disabled truck.
Tow truck moving at 8 kilome-
ters-per-hour (5 mph) or less.
Towing l SA-3-1
 Main Table of Contents
Group SA, Safe Maintenance CMRK
IMPORTANT
Do not lift the disabled truck or any wheels A WARNING
Always engage the parking brake when
off the floor while the truck is being towed.
parking a lift truck. The truck can roll and
9. Park the disabled truck in authorized areas only. Fully cause injury or death to personnel near it.
lower the forks on the floor, leave the directional
control in neutral, turn the ignition switch to OFF, and
engage the parking brake. Remove the ignition key
and, when necessary, block the wheels to prevent the
truck from rolling.

LIFTTRUCK PARKING

SA-3-2 l Towing SM 599,Oct ‘94

 Main Table of Contents

GROUP PS

PERIODIC SERVICE

Maintenance Schedules .................................................. Section 1

The Planned Maintenance Program ............................. Section 2

The PM Inspection Form ............................................... Section 3

SM 598, Apr ‘96 Periodic Service

 Main Table of Contents

ElHRK Group PS, Periodic Service

Section 1.
Maintenance Schedules

“PeriodicService” and “Planned DeterminingMaintenanceIntervals

Maintenance” Time intervals on the charts on the next four pages and
elsewhere in this manual relate to truck operating hours as
The term “periodic service” includes all maintenance tasks
recorded on the hourmeter, and are based on experience
that should be performed on a regularly scheduled basis.
Clark has found to be convenient and suitable under nor-
The term “Planned Maintenance” indicates a formalized mal operation. Standard operating condition classifications
program of basic inspections, adjustments, and lubrications are:
that the Clark service organization provides customers at a
Normal Operation: Eight-hour material handling, mostly
prescribed interval, usually 50-250 hours. The recommended
in buildings or in clean, open air on clean, paved surfaces.
basic “Planned Maintenance” procedure is given in Section
2 of this Group. Severe Operation: Prolonged operating hours or constant
usage.
The current Section,“Maintenance Schedules,” specifies
all maintenance tasks-including Planned Maintenance Extreme Operation:
tasks-that should be performed periodically, and suggests In sandy or dusty locations, such as cement plants,
intervals at which they should be performed. lumber mills, and coal dust or stone crushing sites.
High-temperature locations, such as steel mills and
foundries.
Sudden temperature changes, such as constant trips
from buildings into the open air, or in refrigeration
plants.
If the lift truck is used in severe or extreme operating
conditions, the maintenance intervals should be shortened
accordingly.

IMPORTANT
MAINTENANCE INTERVALS. If the lift
truck is used in severe or extreme operat-
ing conditions, the maintenance intervals
should be shortened accordingly.
Since the operating environments of lift
trucks vary widely, the above descriptions
are highly generalized and should be ap-
plied as actual conditions dictate.

SM 598,Oct ‘94 Maintenance Schedules l PS-l-l

 Main Table of Contents

Group PS, Periodic Service ClmK

Service Chart/Lubrication Points

A decal, similar to the illustration below, is located on the
underside of the truck’s engine cover. This decal is a basic
guide to periodic maintenance intervals and tasks. A more
detailed &art is supplied on the next page.

Every 8 - 10 hours or daily

____---- Every 50 - 250 hours or monthly
------~---------_-_

0 Check/ Lubrimte l Change / Replace n Clean /Air Clean

Drain /Flush Check MonitorIndicator Lights

0 0 @ and Service as Required

A - Diesel Engine Oil: 15W40 B - HydraulicFluid C - EngineCoolant D - MP Grease E - Transaxle fluid

API, CC, CD I SG, SF
GadLPG Engine Oil: 1OW30
API, CC, CD / SG, SF
Clark# 1802155 50 I50 Mixture NLG#2 Clark # 2778236 used in
standard transaxle.
Hydrostatictransmission
shares hydraulicsystem
fluid(note B).

PS-l-2 l Maintenance Schedules SM 598, Apr ‘96

 Main Table of Contents

ClmK Group PS, Periodic Service

Recommended Periodic Service Schedule

This chart lists maintenance tasks that should be done appropriate for diesel, gas, and LPG trucks. Refer to
periodically,
the suggested time intervals, and the service Operator’s Manual for Daily Checks.
manual Group in which the task is covered. Apply as

TASKS
PS - Periodic Muintenunce

Stall rpm - check on standard .

transaxletruck
Tune up - determine if needed by stal; .
check and/or functional test
Valve tappet adjustment - diesel .
engine I I I I I
Group 01 - Cooling System
Coolant level / condition - .
check/sample
Coolant protection level - .
hydrometer test
Coolant change - dram & flush .
Coolant hoses - inspect/replace . .
Fan blades - inspect loose/damaged .
Fan belt(s) - check tension, wear . .
Radiator cap_ - inspect/test
- .
.
I

Thermostat - testh@a= I I I I I I
Water pump - check leaks/wear I I . I I I
Group 02 - Fuel System
Carburetor idle/air - check/adjust I I . I I I
CO level - check/adjust I I I I I .
Diesel injectors/lines - clean/inspect .
Filler cap/screen - clean/inspect .
Fuel filter, diesel - replace .
b
Fuel filter, gas - replace I .
L.PG lock-off valve filter - .
inspect/replace I I I I I
LPG tank mounting/mmrd
__ - insnect I
I I
. I I I

LX tank shut-off valve - I I . I I I I

inspect/test
LPG vaporizer/regulator/hoses - .
inspect
Throttle linkage - check/adjust .

* Oil change interval may be determined by laboratory analysis

SM 598, Apr ‘96 Maintenance Schedules l PS-l-3

 Main Table of Contents

Group PS, Periodic Service Emu

&erg 450- Every 900- Every 2000

berg 500 Holus 1000 Hours Houis
TASKS 1st 50 Hours SO-250 I-bus (or3 months) (or6 months) (or 1 year)
Group 02 - Air Intake & Exhaust
Air filter element - replace I I I l (Diesel) l (Gas/LPG)
Air hoses/clamps - inspect .
I I I I I
Exhaust .uipe/muffier
. - insnect .
I I I I I

Group 06 - Transaxle
Air vent - inspect, clean or replace .
on standard transaxle I
Axle end lube - clean/repack During brake repairs
Axle mounting bolts - .
inspect/tighten
Charging pump - stall test standard .
transaxle
Clutch pack operation - stall test .
standard transaxle
Pressure checks .
Fluid change - drain/fill .
Fluid filter - replace . .
Fluid level/condition - check/sample
Inching operation - check/test
Oil cooler / lines - inspect
Transmission strainer - clean on .
standard transaxle I I
Group I2 - Ignition and Starting System
Diesel cold starting plug - test I I I I I .
Distributor cap/rotor - inspect .
Electronic ignition - test .
Ignition timing - check/adjust .
Ignition wiring- - inspect
.
.
L -
Neutral start - check .
Parking brake interlock - check .
Spark plugs - regap/replace .
Starter motor - inspect/test .
.
I I

Starter solenoid - inspect/test I I I I I

Group Z3 - Gauges, Zndicators
Hourmeter - check I I . I I I

Wiring harness - inspect I I I I . I

Group 14 - Electrical: Alternator, Regulator, Battery
Alternator - inspect/test I I I I .
Alternator drive belts - . . I
Alternator output - test .
Battery electrolyte level - check/add .
Battery condition - cranking voltage .
test I I I I I
Battery terminals/cables - .
cleanjtighten I I I I I
Group 22 - Wheels And Tires
Wheel mounting bolts - tighten I . I . I I I
Tire pressure/condition - check . .

PS-l-4 l Maintenance Schedules SM 598,Oct ‘94

 Main Table of Contents

EmK Group PS, Periodic Service

inspect/tighten
Upright lift cylinder downdrift - test
Upright rollers - check
Upright trunnion bolts - tighten

SM 598, Apr ‘96 Maintenance Schedules . PS-1-5

 Main Table of Contents

EmK Group PS, Periodic Service

Section 2.
The Planned Maintenance Program

This Section defines a set of basic service procedures, known as the “Planned
Maintenance Program,” and describes a systematic approach for performing them.

Introduction to Planned Maintenance .......... ..“..................................~.........~ ............................ 2

PM Intervals ..................................................................................................................................... 2
The PM Form ................................................................................................................................... 2

The Basic PM Procedures .................................................................................. ..~~............~_._ - 2

The Recommended PM Task Chart ................................................................................................. 3
Visual Inspection ............................................................................................................................. 4
Decals, Fasteners, and Leaks .................................................................................................... 4
Overhead Guard ........................................................................................................................ 4
Carriage, Load Backrest_ and Upright ..................................................................................... -4
Forks ......................................................................................................................................... 4
Brake and Inching Pedal Freeplay ............................................................................................ 5
Wheels and Tires ...................................................................................................................... 5
Functional Tests ............................................................................................................................... 5
Starting System ......................................................................................................................... 5
Engine Shut Down Mode .......................................................................................................... 5
Parking Brake Interlock ............................................................................................................ 5
Accelerator, Brake/Inching System, Direction Control, and Parking Brake ............................ 6
Steering System ........................................................................................................................ 6
Lift Mechanisms and Controls.. ................................................................................................ 7
Auxiliary Controls .................................................................................................................... 7
Air Cleaning the Truck .................................................................................................................... 7
Truck Chassis Inspection and Lubrication ....................................................................................... 8
Lift Chain Lubrication ..................................................................................................................... 8
Upright and Tilt Cylinder Lubrication ............................................................................................. 8
Under-the-Hood Inspection ............................................................................................................. 8
General Checks ......................................................................................................................... 8
Engine Aii Cleaner ................................................................................................................... 8
Fluid Checks .................................................................................................................................... 8
Battery ....................................................................................................................................... 8
Engine Cooling System ............................................................................................................ 9
Engine Oil Check ...................................................................................................................... 9
Hydraulic Fluid Level ............................................................................................................... 9
Transaxle Fluid Level ............................................................................................................... 9
Stall Tests ......................................................................................................................................... 9
Cranking Voltage Test ..................................................................................................................... 9
Critical Fastener Torque Checks ...................................................................................................... 9

SM 598,Oct ‘94 Planned Maintenance l PS-2-l

 Main Table of Contents
Group PS, Periodic Service
introduction to Planned Maintenance
A program of regular, routine inspections, lubrication, and
other service tasks is important for the long life and trouble-
free operation of the lift truck.
The Clark service organization offers customers a formal-
ized program-called Planned Maintenance, or PM-for
performing these tasks.
PM Intervals
The PM inspections, adjustments, and lubrications are typi-
cally performed on each covered truck at 50-250 hour
intervals. (See Section 1, in this Group about defining
service intervals.)
The PM Form
As an aid to service technicians performing and document-
ing PM inspections, Clark has prepared a “Gas, LPG or
Diesel Planned Maintenance Report” form. A black-and-
white copy of this form is inserted in Section 3 of this
Group.
We recommend that you use this form as a checklist and to
make a record of your inspection and truck condition. This
record can be used to inform the owner of needed repairs
and help establish the optimal PM intervals.
When you have finished the PM inspections, be sure to give
a copy of the report to the person responsible for lift truck
maintenance.
PS-2-2 l Planned Maintenance
Llmu
The Basic PM Procedures
The chart on the next page lists the basic PM tasks. The
actual PM program may be modified to meet the spe-
cific needs of the truck application.
The procedures beginning on page 4 outline a systematic
approach to performing the PM tasks. These procedures
consist of:
External visual checks you make as you walk around
the truck with it turned off.
Operational checks you make while operating the
truck.
Tests, adjustments, and lubrication you perform
with the covers removed.
A! CAUTION
l Do not make repairs or adjustments un-
less authorized to do so.
l Disconnect the battery ground cable (-)
from the engine or frame before work-
ing on electrical components.
l Always wear safety glasses.
l Wear a safety (hard) hat in industrial
plants and in special areas where protec-
tion is necessary or required.
l Remove all jewelry (watch, rings, brace-
lets, etc.) before working on the truck.
SM 598,Oct ‘94
 Main Table of Contents

EmK Group PS, Periodic Service

The Recommended PM Task Chart

Listed by Service Manual Group

Group PS - The Basic PM Procedures Group 14 - Alternator, Battery, Starter

Visual inspection Alternator - inspect/test
Functional performance check-test drive Alternator drive belts - inspect/adjust
I
Air cleaning of truck Alternator output - test
I
Lubrication, filters, and fluid levels checks Battery condition - performance load test
1 Critical fasteners torque check Battery electrolyte level - check/add
I
I G~OUD 00 - Rnhze I Battery terminals/cables - clean/tighten
Exhaust smoke (blue-oil; black-fuel) Neutral start - check
Idle RPM - check/adjust Starter cranking voltage - test
Max no-load gov’d RPM - check/adjust Group 22 - Wheels And Tires
Mounts / brackets - inspect/tighten Tie pressure/condition - check
Oil filler cap & seal - clean/check Group 23 - Brakes
Oil level I condition - check Brake lines - check
1 Stall RPM - check Check oneration
I
Group 01 - Cooling System
Coolant hoses - inspect/replace
Coolant level / condition - check/sample

Fan blades - inspect loose/damaged

Fan speed control - inspect
Group 02 - Fuel System & Exhaust
Air hoses/clamps - inspect Group 29 - Hydraulic Fluid
Exhaust pipe/muffler - inspect Hydraulic fluid level/condition - check/sample
LPG tank mounting/guard - inspect
LPG tank shut-off valve - inspect/test
LPG vaoorizer/reeulator/hoses - inspect
Throttle linkage - check/adjust
I

SM 598,Oct ‘94 Planned Maintenance l PS-2-3

 Main Table of Contents
Group PS, Periodic Service
Visual Inspection
First, perform a visual inspection of the lift truck and its
components. Walk around the truck and take note of any
obvious damage and maintenance problems.
Decals, Fasteners, and Leaks
Check for loose fasteners and fittings.
Check to be sure all capacity, safety, and warning plates
and decals are attached and legible.
NOTICE
Do not operate a lift truck with damaged
or missing decals and nameplates. Replace
them immediately. They contain important
information. See Group 40 for decal loca-
tions.
Inspect the truck before and after starting engine for any
signs of external leakage: fuel, engine oil or coolant, trans-
mission fluid, etc.
Check for hydraulic oil leaks and loose fittings. DO NOT
USE BABE HANDS TO CHECK.
A! CAUTION
HYDRAULIC FLUID PRESSURE. Do not
use your hands to check for hydraulic leak-
age. Oil may be hot or under pressure.
Fluid under pressure can penetrate your
skin and cause serious injury.
Overhead Guard
Be sure that the overhead guard and any other safety de-
vices are in place, undamaged, and attached securely. In-
spect welds and structural members for cracks or other
damage. Also check for loose or missing fasteners.
PS-2-4 l Planned Maintenance
Emu
Carriage, Load Backrest, and Upright
(See Group 34 for detailed inspection procedure.)
Inspect the welds on the carriage, load backrest, and up-
right for cracks. Be sure that the mounting fasteners are in
place and tight.
Inspect the upright assembly: rails, carriage rollers, car-
riage fork bars, lift chains, and lift and tilt cylinders. Look
for obvious wear and maintenance problems and 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 lift and carriage chains are correctly ad-
justed to have equal tension. Check that the lift chain
anchor fasteners and locking means are in place and tight.
Be sure all safety guards and chain retainers are in place
and not damaged. Inspect the carriage stops and cylinder
retainer bolts. Check all welded connections.
Inspect all lift line hydraulic connections for leaks. Check
the lift cylinder rods for wear marks, grooves and scratches.
Check the cylinder seals for leaks.
Forks
Inspect the load forks for cracks, breaks, bending and wear
as described in Group 34.
A WARNING
HEEL WEAR. 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. See Group 34 for inspection
procedures.
SM 598,Oct ‘94
 Main Table of Contents
Inspect the fork latches to ensure that they are in good
condition, operate freely, and lock correctly.
Wheels and Tires
Check the condition of the drive and steer wheels and tires.
Remove objects that are 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 as explained in Group 22.
A
WARNING
Check tire pressure from a position facing the
tread of the tire, not the side. Use a long
handled gauge to keep your body away. If
tires are low, the tire may require removal
and repair. Incorrect (low) tire pressure can
reduce truck stability. See “Specifications” in
Group 22 for proper inflation pressure.
Brake and Inching Pedal Freeplay
There should be no inching or braking pedal freeplay. Both
pedals should be at same the height. Adjust as described in
Group 23.
SM 598,Oct ‘94
Group PS, Periodic Service
Functional Tests
Be sure that:
l Parking brake is applied
l Directional control is in “N” (neutral).
Test the horn, lights, and all other safety equipment. Be
sure they are properly mounted and working correctly. Test
all controls to ensure that they operate freely and return to
neutral properly.
Now prepare to start the truck and test its operation.
Starting System
A 3-position starter switch is standard equipment.
Check the neutral start function by placing the direction
control lever in forward or reverse and turning key switch
to “start” position. The starter must not engage until the
direction control lever is moved to “neutral” position.
As you start the engine, check the instrument display. All
indicator lights should come on for a 2-second lamp check.
The seat belt prompt light should remain on for 4 seconds,
accompanied by a buzzer sound. The parking brake light
should remain on if the brake is set. If the truck has a diesel
‘%<‘.,. engine, the glow plug preheat light
,,,.. 7,,
’ ‘., ,,, .,. should remain on for 6 seconds. If
,:, <,;,, ‘...
‘,, ‘1,
.,
,,,,
Z,‘Z. ,:. the lights do not operate as described,
.‘,’ ‘.Z,, ‘;, ,,. % .:.
::....., refer to Group 13 to diagnose the
‘/.
problem.
@
Engine Shut Down Mode
If the truck’s fault protection system detects low engine oil
pressure, excessive transmission oil temperature, or exces-
sive engine coolant temperature, the truck will go into
“shutdown mode”-a buzzer will sound for 30 seconds,
after which the truck will shut itself off. The truck may be
restarted, but if the fault condition still exists, the engine
will again shutdown in 30 seconds.
Parking Brake Interlock
The transmission should disengage when the parking brake
is on and reengage when the parking brake is released.
1. Apply the parking brake.
2. Start the engine, if it is not already running.
3. Place the direction control in forward or reverse. Make
sure the path is clear in the chosen direction.
4. Accelerate briefly. The truck should not move or put any
strain on the parking brake if the interlock system is OK_
5. Release the parking brake (and service brake). Truck
should move slowly in selected direction. (On hydro-
static truck, depress accelerator pedal slightly.)
Planned Maintenance l PS-2-5
 Main Table of Contents
Group PS, Periodic Service
Accelerator, Brake/Inching System, Direction Control,
and Parking Brake
A
WARNING
Fasten your seat belt before driving the
truck.
Make sure that you on a level surface, the travel area is
clear in front of the truck, the parking brake is release, and
the truck is running..
1. Push the brake (right) pedal down fully and hold. The
brakes should apply before the pedal reaches the
floorplate. If the pedal continues to creep downward,
report the failure immediately. Do not operate the
truck until the brakes are repaired.
2. Move the direction control lever fromneutral to forward.
3. For standard transaxle trucks: Release the brake pedal
and let the truck travel slowly forward. Then push
down on the brake pedal to stop the truck. The brakes
should apply smoothly and equally.
4. For hydrostatic transmission trucks:
a. Release the brake pedal. The transmission should
not engage and the truck should not move.
b. Accelerate briefly, then release the accelerator
pedal. Do not depress the brake pedal. The truck
should decelerate to a stop briefly after the accel-
erator pedal is released.
c. Depress the brake pedal and depress the accelera-
tor pedal slightly, the truck should not move.
5. Be sure the travel areais clear behind the truck. Repeat
steps 2 through 4 in the reverse direction.
Direction
Control
Parking Brake
Inching Pedal
Operator’s Controls. Standard arrangment shown.
PS-2-6 l Planned Maintenance
CUIRK
Drive the truck and check that it accelerates and
decelerates smoothly and stops properly.
Depress the inching (left) pedal and depress the accel-
erator to see if the transmission disengages properly.
Check the function of the parking brake. 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.
n ! CAUTION
If the service brake, parking brake, or in-
terlock is not operating properly, take the
truck out of service until it is repaired.
Steering System
Check the steering system by moving the steering handwheel
in a full right turn and then in a full left turn. Return the
steer wheels to the straight-ahead position. The steering
system components should operate smoothly when the steer-
ing handwheel is turned. Hard steering, excessive play
(looseness), or unusual sounds when turning or maneuver-
ing indicates a need for inspection or servicing.
If the truck has a steering system fault, take the truck
out of service until it is repaired.
Lift Lever
Tilt Lever
Aux Lever
Brake Pedal
Accelerator
SM 598,Oct ‘94
 Main Table of Contents

EMRK Group PS, Periodic Service

Lift Mechanisms and Controls
(See Group 34 for detailed test procedure.)
1. Check the function of the lift system and controls with
the engine running.
2. Pull back on the tilt control lever and hold until the
upright reaches the full back tilt position. Push for-
ward on the lever to return the upright to the vertical
position. Release the lever.
If there is excessive play between rails and channels,
upright adjustment is required If there is racking,
adjustment of the cylinder rod yokes is required
A CAUTION
Be sure that there is adequate overhead
clearance before raising the upright.
3. Pull back on the lift control lever and raise the fork
carriage to full height. Watch the upright assembly as
it rises. All movements of the upright, fork carriage,
and lift chains must be even and smooth, without
binding or jerking. Watch for chain wobble or loose-
ness; the chains should have equal tension and move
smoothly without noticeable wobble. Release the
lever.
When you have completed the operational tests, park
and leave truck according to standard shutdown proce-
dures. Be sure to make a record of all maintenance and
operating problems you find.
Air Cleaning the Truck
A CAUTION
Wear suitable eye protection and protec-
tive clothing.
Open the hood and remove the floor-plate. Then air clean
the following: upright assembly, drive axle, radiator from
both counterweight and engine sides, engine and accesso-
ries, driveline and related components, and steer axle and
steer cylinder.
Use an air hose with special adapter or extension that has a
control valve and nozzle to direct the air properly. Use
clean, dry, low-pressure compressed air. Restrict air pres-
sure to 30 psi (207 kPa), maximum. (OSHA requirement).
It is important to maintain a lift truck in a clean condition.
Do not allow dirt, dust, lint or other contaminants to accu-
mulate on the truck. Keep the truck free from leaking oil
and grease. Wipe up all 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 prevent fires. A clean truck will run cooler.
The environment in which a lift truck operates determines
how often and to what extent cleaning is necessary. For
example, trucks operating in manufacturing 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, require
more frequent cleaning. The radiator, especially, may re-
quire daily air cleaning to ensure correct cooling. If air
pressure does not remove heavy deposits of grease, oil, etc.,
it may be necessary to use steam or liquid spray cleaner.

If the maximum fork height cannot be reached, this

indicates there is low oil level in the hydraulic sump
or severe binding within the upright.
4. Push forward on the lift control lever. Watch the
upright as it lowers. If you suspect a problem with
lifting or lowering speeds, refer to Group 34 to diag-
nose the problem.

Auxiliary Controls
If the truck is equipped with an attachment, test the control
lever for correct function and operate the attachment to
check its function

SM 598,Oct ‘94 Planned Maintenance l PS-2-7

 Main Table of Contents
Group PS, Periodic Service
Truck Chassis Inspection and Lubrication
Lubrication requirements are given in the “Service Chart/
Lubrication Points” chart in Section 1 of this Group. Also
see Lubricants and Shop Supplies” in Group 40 for parts
information, and “General Specifications” in Group 40 for
lubricant specifications.
Lubrication and inspection of truck chassis components
includes steer wheels, steer axle linkages, and steer wheel
bearings, and drive wheel bearings. To check these items,
the truck must be properly raised and blocked as described
in “Lifting, Jacking, and Blocking” in Group SA.
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 fasteners
for damage and leaks, and looseness.
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 grease fittings before lubricating.
Remove the excess grease from all points after lubricating.
Lubricate miscellaneous linkage as needed.
Upright and 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 Lubrication
Lubricate the lift chains as described in Group 34.
PS-2-8 l Planned Maintenance
URIC
Under-the-Hood inspection
General Checks
Check all fluid levels and make sure that the following
items are clean, secure, and in good condition:
Hoses, lines, clamps, and fittings
Wires, cables, and connectors
Distributor, distributor cap, and rotor, coil, and plug
wires (gas/LPG/CNG engine only)
Control linkages, pedals, and levers
Engine mounts
Fan and fan belts
Oil filler cap
Steering gear (check for leaks).
A CAUTION
To avoid the possibility of personal injury,
never work in engine compartment with
engine running except when absolutely nec-
essary to check or make adjustments. Take
extreme care to keep face, hands, tools,
loose clothing, etc., away from fan and drive
belts. Also, remove watches, bracelets, and
rings. Do not smoke.
Engine Air Cleaner
Do not open the air cleaner to check the filter element. The
filter element should be replaced only at the specified
service interval or when the air filter light indicates that it is
dirty.
Fluid Checks
Battery
Inspect the battery for any damage, cracks, leaking condi-
tion, etc. If the terminals are corroded, clean and protect
them with CLARK Battery Saver (available from your
Clark dealer). If the battery has removable cell caps. check
to be sure the cells are all filled. If necessary, refill with
distilled water.
SM 598,Oct ‘94
 Main Table of Contents

Group PS, Periodic Service

Engine Cooling System
Check coolant level in the coolant recovery bottle and in
the radiator as described in Group 0 1.
Fill the oil level above the LOW mark on the dipstick by
adding only the hydraulic fluid prescribed in Group 29.
DO NOT OVERFILL.

A! CAUTION
STEAM. Do not remove the radiator cap
when the radiator is hot. Steam from the
radiator will cause severe burns.
Transaxle Fluid Level
Coolant should be checked on a daily basis in high-cycle
applications. Check the transaxle fluid level with the engine running, as
explained in Group 06.
Engine Oil Fill to the FULL mark on the dipstick, using the transaxle
fluid specified in Group 06.
Oil Level: With the truck level and the engine shutdown
for at least 5 minutes, check the engine oil level.
Locate the engine oil dipstick. Pull the dipstick out, wipe it
with a clean wiper and reinsert it fully into the dipstick
tube. Remove the dipstick and check oil level.
Low Full

Stall Test
On standard transaxle trucks, perform the stall test de-
scribed in Group 00 to determine engine and transaxle
condition.
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 required. Use only the oil specified in Group 00. Cranking Voltage Test
Oil Change: Change oil as described in Group 00. To determine battery condition, check the cranking voltage
as described in Group 14.
Diesel Engine Oil Filter: Replace as described in Group
00. Critical Fastener Torque Checks
Hydraulic Fluid Level For safety it is important that the correct torque be main-
tained on all critical fasteners of components which directly
Check the hydraulic sump tank fluid level as described in support, handle or control the load and protect the operator.
Group 29. Correct fluid level is important for proper sys-
tem operation. Low fluid level can cause pump damage. Check torque of critical items, including:
Overfilling can cause fluid leakage. Drive axle mounting
Hydraulic fluid expands as its temperature rises. Therefore, Drive and steer wheel mounting
it is preferable to check the fluid level at operating tempera- Counterweight mounting
ture (after approximately 30 minutes of truck operation).
Overhead guard mounting
Gperator’s cell mounting
Tilt cylinder mounting and yokes
Upright mounting and components.
Critical fastener torque specifications are given in the gen-
eral specifications Section of Group 40.

SM 598,Oct ‘94 Planned Maintenance l PS-2-9

CWRK GAS LPG or DIESEL ,/ O.K.
x = Adjust(notP.M.)
CUSTOMER PLANNED MAINTENANCE REPORT r = Repairor replace
s = Requiresshoprepair

I
MODEL&SERIAL NO CUST P.O. NO.
ATTACHMENT NO

I I
AUTHORIZED SIGNATURE INSPECTOR SPECIAL INSTRUCTIONS

l SEE MAINTENANCE INTERVAL IN P.M.A. MANUAL

5%760.0566/l MAR52
 Main Table of Contents

GROUP 00 (D)

GROUP 00 (D)

S4S DIESEL ENGINE

Engine Specifications and Description ................. (See Section 6)

Engine Troubleshooting ........................................ (See Section 6)

Engine Oil and Filters Maintenance ............................. Section 1

Throttle Linkage Checks and Adjustment ................... Section 2

Fuel Supply System ..............*......................................... Section 3

Engine RPM Settings and Stall Tests ............................ Section 4

Engine Compression Checks ................... ............. (See Section 6)

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

S4S Diesel Engine Service Manual* .............................. Section 6

S4S Diesel Engine Balancer Supplement ...................... Section 7

*NOTE
The MITSUBISHI S4S SERVICE MANUAL is copied
into Section 6. This manual includes:
l Engine specifications
l Engine troubleshooting
l Compression tests
l Valve tappet adjustment
l Injector inspection and cleaning
l Injection pump timing
l Fuel filter draining and inspection
l Engine overhaul.
The engine shown in the S4S manual does not have
balancers. These are covered in Section 7.
Disregard information about the 4DQ7 engine that
also appears in the Mitsubishi manual.

SM 598,Oct ‘94 Group 00(D)

 Main Table of Contents
CMRK
Section 1.
Engine Oil and Filter
(S4S Diesel Engine)
Engine Oil Requirements
Engine oil does not “wear out.” However, the lubricating
oil in internal combustion engines becomes contaminated
from the by-products of combustion: dirt, water, unburned
fuel entering the crankcase, and the detergents holding the
carbon particles in suspension in the crankcase.
Motor oils used for internal-combustion engine lubrication
perform many useful functions including:
l Dissipating heat
l Sealing piston rings
l Preventing metal-to-metal contact wear
l Reducing power loss through friction.
Lubricating oil recommendations are based upon engine
design, type of service, and the ambient temperature in
which the engine is operating. High-quality oils are re-
quired to assure maximum performance, long engine life,
and minimum cost of operation.
The schedule for changing oil is directly dependent upon
the operational environment. An extremely clean operation
could go 150-250 hours while a dirty operation (foundry or
cement factory) could be 50 hours or less.
NOTE
Oil changes should be scheduled every SO-
250 hours, monthly, or more frequently if
necessary. The time interval for changing
engine oil will depend upon your appiica-
lion and operating conditions. To deter-
mine the correct schedule for your truck, it
is suggested that you periodically submit
engine oil samples to a commercial labora-
tory for analysis of the condition of the oil.
SM 598,Oct ‘94
Group 00(D), Engine (Diesel)
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 results in
improved fuel economy. A symbol has been developed by
the API (American Petroleum Institute), SAE, and ASTM
to help you select the proper engine oil. It should be in-
cluded on the oil container you purchase.
IMPORTANT
Use 15W40, API CC, CD/SG, SF engine
oil.
Engine Oil Level Check
The engine oil level should be checked every 8 operating
hours.
Check the oil level with engine stopped. Allow 5
minutes for the oil level to stabilize. Pull the dipstick
out, wipe it with a clean wiper, and reinsert it fully into
the dipstick tube. Remove the dipstick and check the
oil level.
Oil level should be at the FULL level marking on the
dipstick. Add recommended oil as needed. Wait 5
minutes after adding oil and check the oil level again.
Do not overfill.
FULL
ADO I I
NOTE
It is normal to add some oil between oil
changes. Keep the oil level above the ADD
mark on the dipstick . Do not overfill. Use
the correct oil as specified above.
4. Check the periodic service schedule (operating hours),
or the condition of the oil to determine ifit needs to be
changed.
Diesel Engine Oil and Filter l 00(D)-1-l
 Main Table of Contents
Group 00(D), Engine (Diesel)
IMPORTANT
Use lSW40, API, CC, CD&G, SF engine
oil. Sump capacity is 10 L (2.6 gal; 10.4 qt).
Diesel Engine Oil and Filter Change
Recommended service intervals and procedures:
Drain and replace the engine crankcase oil every 50 to
250 operating hours, or sooner as explained on the
previous page.
Replace engine oil filter at every oil change.
Drain and replace engine oil in a new or rebuilt engine
after the first 50 hours of operation.
Drain oil after engine is at operating temperature.
To change the engine oil and oil ftiter:
1. Safely park the truck and put an oil drain pan under the
truck.
2. Remove drain pfi~~.at bottom of engine oil pan and
drain the oil com@tely.
NOTE
Raise and block up the truck under the
frame to give easier access to the engine
drain plug. Refer to “Lifting, Jacking, and
Blocking” in Group SA.
Engine Side View
00(D)-1-2 . Diesel Engine Oil and Filter
ClRRK
3. Remove the engine oil ftiter. If necessary, use a stan-
dard filter wrench.
4. Install new oil filter. Follow installation instructions
printed on the outside surface of the filter. Check that
the oil seal is lubricated and correctly in place.
IMPORTANT
Always use genuine CLARK parts.
5. Clean and inspect the oil drain plug and seal. Replace
the drain plug and/or seal if damaged.
6. Install drain plug. Remove oil drain pan.
7. Remove and inspect the condition of the engine oil
filler cap located on top of the engine valve cover.
Replace cap if it is damaged or the seal is broken.
8. Refill the crankcase with fresh engine oil through the
rocker cover oil filler opening.
Sump capacity is 10 L (2.6 gai, 10.4 qt).
9. Wait several minutes after adding oil to check the oil
level. Add oil if necessary.
10. Start the engine and allow it to run at idle for several
minutes. Checkthe oil filter and drain plug for leakage.
11. Check the engine oil level with the engine stopped for
5 minutes. Add oil as necessary.
Dipstick
Oil Filter
Drain Plug
SM 590,Oct ‘94
 Main Table of Contents

elm6 Group 00(D), Engine (Diesel)

Section 2.

Throttle Linkage Checks and Adjustment

(S4S Diesel Engine)

IMPORTANT
HYDROSTATIC TRANSMISSION TRUCKS. The throttle linkage for the
standard transaxle truck is covered in this Section. If you are servicing a
hydrostatic transmission truck, refer to the control system Section in Group
06(H) for information about the throttle linkage.

SM 598,Oct ‘94 Diesel Engine Throttle Linkage l 00(D)-2-1

 Main Table of Contents

Group 00(D), Engine (Diesel) CIRRK

Linkage Check Accelerator Cable Adjustment
1. Turn off the engine and safely park the truck. With the floorboard still offz
2. Check accelerator pedal travel: Move the accelera- 1. Loosen the jam nut at the accelerator cable bracket.
tor pedal to the fullydown position. If the pedal
2. Adjust the set nut so that the pedal roller and lever
stops before it hits the floorplate, the accelerator
assembly bottoms out just as the throttle lever reaches
cable is adjusted too short.
the wide-open position.
3. Raise the operator’s seat deck and remove the
3. Retighten the jam nut.
floorplate.
4. Perform the check procedure.
4. Depress the accelerator pedal roller and check for
free movement of the entire throttle linkage. Lubri-
cate and repair as needed. NOTE
5. Check throttle lever travel: Hold the pedal roller Make sure no hoses or other items bind
fully down and check the throttle lever at the injec- against the throttle linkage.
tion pump. If the throttle lever is not pivoted to the
wide-open position, the cable is adjusted too long.

Throttle Lever
(on Injection
Pedal Pump)
/
\

. Accelerator
Cable

L Bracket

Accelerator Pedal Mounting. No adjustment. Linkage at Injection Pump. Adjust with set nut.

Accelerator Cable

Lever

Linkage at Accelerator Pedal. Pedal rests on roller. No adjustment.

00(D)-2-2 . Diesel Engine Throttle Linkage SM 598,Oct ‘94

 Main Table of Contents

ClRRK Group 00(D), Engine (Diesel)

Section 3.

. Fuel Supply System (S4S Diesel Engine)

NOTE
FUEL FILTER SERVICE. See the Mitsubishi S4S
Service Manual in Section 6 for filter service informa-
tion.

Fuel Level Sender

Connection \__?

Fuel Level Sender

Clean before reassembly.

i
\.

SM 598, Apr ‘96 OO(D)+l . Diesel Fuel Supply System

 Main Table of Contents

CUlRK Group 00(D), Engine (Diesel)

Section 4.

RPM Settings and Stall Tests

(S4S Diesel Engine)

The tests in this Section check :

l Engine speed settings
l Overall engine performance
l Whether major components or systems other than the
engine have problems or are causing problems.
Tests include:
l Engine idle speed
l Engine maximum no-load governed speed
l Engine stall speed.

NOTE
HYDROSTATIC TRANSMISSION trucks
are m covered by the stall check proce-
dure.

SM 590,Oct ‘94 Diesel Engine RPM Settings and Stall Tests l 00(D)-4-l
 Main Table of Contents
Group 00(D), Engine (Diesel)
Test Procedures
Perform the tests in the order given here.
PreliminaryProcedures
1. Safely parktruck,apply parkingbrake,and place con-
trols in neutral.
2 connect a tachometer.
3. Check all throttle control linkage for complete and free
movement
4. Startthe engine and let it warm up until it mns evenly and
acceleratessmoothly.
Allow the engine to warm up to operating temperamre before
putting it under any load conditions.
EngineRPMat Idle
Check the engine idle speed. If idle speed is not 650-700
rpm, adjust the idle setting screw on the injection pump.
Engine RPM at Maximum No-Load
Governed Speed
the speed to which the governor limits the engine: (On
check
hydrostaticttansmissiontrncks, it is necessary to disco~ect the
electronic govemor controL described in Group 06(B), before
performingthispr=dm=)
1. Push the accelerator pedal slowly to the floor.
2. When the engine speed stabilizes, mad the maximum
no-load governed speed on the tachometer.
If the no-load govemed speed is not 2550-2650rpm for standard
tmnsaxletracks (and2950-3050rpm for hydrostatictrammission
tracks), adjust screw at top of injection pump. On hydrostatic
trammission tmck it is necessary to disconnect the electronic
govemor controk described in Group 06(-B),before performing
this adjustment
EngineRPMat Stall
NOTE
HYDROSTATIC TRANSMISSION trucks
are &covered by this procedure.
Be sure that trawxle fluid level has been checked and is
correct(seeGroupo6),andthatbrakingandinchingpedalsare
adjusted correctly (see Group 23) before you run a stall test
n ! CAUTION
Performstalltestswith the parkingbrake off
and the truck placed against a solid barrier
(such as a wall or another lift truck) to prevent
movement. Make sure that the truck cannot
move and that the solid barrier is capable of
withstandingthe force before you begin.
00(D)-%2 l Diesel Engine RPM Settings and Stall Tests
GMRK
1. Add load on forks to increase weight and prevent
inadvertent drive wheel spin
2. Place truck against the immovable barrier described in
the CAUT’lONnotice directly above.
3. Put the directional control lever in forward (orreveme,
depending upon truck position to barrier).
NOTE
Use of the POWER SERVICE BRARES or
STEERING HANDWHEEL can affect en-
giue rpm. Do not touch either during the
test.
4. Release the parkingbrake.
5. Slowly push the accelerator pedal fully down and hold
it there while you read the tachometer.
IMPORTANT
Do not rnn engine and converter at stall
longer than necessary to take the rpm read-
ing, or longer than 30 seconds at one time.
Then, shift transmission into neutral for 15
seconds and ruu the engine at one-half speed
for 1-2 minutes to cool torque converter
oil. Excessive temperature, 1u)” C (25oOF)
maximum, will overheat the converter and
cause damage to converter, seals, and fluid.
To test both clutch packs in the transmission, check stall
speed with transaxle in forward and reverse.
Analysis of Diesel EngineStall Test
Normal stall speed (2150-2250 rpm):
- Engine performanceis good.
- Torque converteris operating correctly.
- Transmissionclutch packs areoperatingcorrectly (not
slipping).
Below normal stall speed (1900-2000 rpm):
Engine performance is poor (needs tune-up or repair).
Use the engine compression checks in the “Work-
shop Theory” section of the Mistubushi S4S Service
Manual, which is inserted into this Group (Group
OOD),to further check the engine condition.
Transmission and torque converter am OK.
Very low stall speed (1300-1400 rpm):
- Torque converter stator is slipping. Repair of torque
converteris required.See tmnsaxletroubleshooting in
Group 06.
High stall speed (more than 2400 mm):
- Transaxleclutch or converterproblems.See tmnsaxle
troubleshooting in Group 06.
SM 598, Apr ‘96
 Main Table of Contents

CIRRK Group 00(D), Engine (Diesel)

Section 5.

Engine Removal and Replacement

(S4S Diesel Engine)

Engine Removal ............................................................................................................................. 2

Engine Replacement ..“....................” ............................................................................................ 4

SM 598,Oct ‘94 Diesel Engine Removal and Replacement l OO(D)-5-1

 Main Table of Contents

Group 00(D), Engine (Diesel) CIRRK

EngineRemoval 5. Disconnect the battery and remove it from the engine

compartment. Disconnect negative cable first.
n! CAUTION
SAF’EPARRING. Before working on truck:
1. Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks
2. Put upright in vertical position and fully
lower the forks or attachment.
3. Put all controls in neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the
wheels.
To remove the engine:
1. Tilt the steering column fully forward
2. Raise the seat deck.
3. Lift out the operator’s compartment floor plate and
remove the seat deck as explained in Group 38.
4. Remove the overhead guard from the operator’s cell.

Overhead 6. Disconnect and remove the air cleaner and hoses as

Guard described in Group 03, “Air Induction System.”
7. Disconnect and remove the exhaust pipe between the
engine exhaust manifold and the muffler pipe. See
Group 03, Section 4.

Muffler Pipe

Operator’s
cell

NOTE
Remove the overhead guard only ifan over-
head hoist is used to lift the engine out. If 8. Label and disconnect all wiring from the engine to
an engine hoist or another fork lift truck components that will remain in the truck frame. See
will be used to lift out the engine, removal Group 14 for wiring configurations.
of the overhead guard is not necessary.

00(D)-5-2 l Diesel Engine Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents
ClRRK
9. On the standard transaxle truck, disconnect the accel-
erator cable at the clevis. On the hydrostatic transmis-
sion truck, disconnect the electrical connection and
remove the linkage actuator and linkage with the engine.
/CL
&
,/,/
injection Pump
Lever
Cable Bracket
10. Disconnect and cap the fuel lines at the fuel tank.
11. Drain the coolant from the engine and radiator, and
disconnect the radiator hoses from the engine thermo-
stat and water pump, as explained in Group 01.
12. Disconnect and remove the radiator upper shroud, fan
ring, and venturi ( as explained in Group 01) to allow
for engine front-to-back movement.
13. Unbolt the engine mounting bolts.
SM 598,Oct ‘94 Diesel Engine Removal and Replacement
Group 00(D), Engine (Diesel)
14. Disconnect the engine from the transaxle (or hydro-
static transmission pump) as explained in Group 06.
15. Using a hoist and chains or engine stand of adequate
capacity, hook the chains to the engine. Use the lift
hooks on the front and rear of the engine to hoist.
Remove slack from the chains.
A ! CAUTION
Do not attempt to move the engine with
your hands as it is being disconnected from
the transmission or hoisted from the truck.
Always use a prybar to gently clear the
engine from the transmission or the truck
frame.
6. Slowly hoist the engine out of the frame.
IMPORTANT
Do not allow the engine and fan to swing
forward to bump the radiator during re-
moval. Damage to the fan and/or radiator
will result. Slip a sturdy piece of cardboard
in front of the radiator core to protect the
tins.
l W(D)+3
 Main Table of Contents

Group 00(D), Engine (Diesel) CMRU

Engine Replacement
Before beginning engine replacement, make sure the truck
parked with the parking brake applied and wheels chocked.
To replace the diesel engine:
6. Set the engine onto the mounting isolators. Set mount-
ing bolts in place but do not tighten. The engine may
have to be shifted to line up with the transmission.

1. Make sure the hoist and chains or engine stand you are
using is of adequate capacity to safely lift the engine.
2. Hook the hoist chains to the engine lifting eyes.

7. Connect the engine to the transaxle (or hydrostatic

Slowly lift the engine and move it into place over the
truck frame.
Make sure there are no wires, cables, hoses, or other
equipment in the way of lowering the engine into the
frame.
Slowly begin lowering the engine into the frame.
transmission pump) as explained in Group 06.
8. Torque engine mounting bolts to 170-190 Nom (125-
140 f&lb).
9. Align and connect the exhaust pipe to the engine
exhaust manifold using a new gasket for reassembly.
Torque bolts to 40-45 Nom (30-33 f&lb). Replace the
V-band coupling and torque the bolt to 9- 10 N-m (8 l-
91 in-lb; 6.75-7.5 e-lb).

A WARNING
Never use your hands to move the engine Exhaust
V-Band
Coupling
Pipe
in the frame. Always use a pry bar to gen-
tly shift or hold the engine in place. After
the engine is in place, keep the hoist chains Muffler
attached and keep slack out of the chains. Pipe
Remove the chains only when the engine is
securely mounted in the truck frame and
remounted with the transmission.

New
Gasket

00(D)-5-4 l Diesel Engine Removal and Replacement std 598, act $94
 Main Table of Contents

CIRRK Group 00(D), Engine (Diesel)

10. Replace the upper radiator shroud and venturi as de- 15. Replace the engine air cleaner and hoses. See Group 3
scribed in Group 01. for complete details. Set the canister and hoses in place
and align before tightening clamps and mounting nuts.
11. Reconnect the radiator hoses between the radiator and
Torque the base-mounting nuts to 20-25 Nom (14.8-
the water pump and the thermostat of the engine, as
18.5 ft-lb); torque hose-to-engine clamp to 1.9-2.9
described in Group 01. Before reinstallation, check
N*m (1.4-2.1 f&lb).
that hoses are in good condition with no drying, crack-
ing, or splitting. 16. Replace the battery and reconnect the cables to the
battery posts and to the starter and ground.
12. Uncap and reconnect the fuel line at the fuel tank.
Make sure the hose is in good condition with no drying,
cracking, or splitting evident. Torque band clamp to
0.8- 1.ON*m (0.6-0.73 ft-lb).

Groundedto

13. Reconnect the wiring. See Group 14 for drawings that

show the wiring harness and component connection
points on the engine.
14. On the standard transaxle truck, reconnect the accel-
erator linkage and adjust length using the adjustment
nuts. See Section 2 for throttle linkage adjustments.
Torquetheterminalnutsatthebatterypoststo 14
20 N*m (10.3-14.8 ft-lb).
Torque the nut on the starter terminal to lo-12
Nom (90-l 10 in-lb; 7.5-9.1 ft-lb).
Install covers over cable ends after assembly.

On the hydrostatic transmission truck, reconnect the 17. Replace the seat deck according to the procedures in
electrical connection to the linkage actuator. (Actuator Group 38.
and liiage not removed from engine.)

Cable Bracket

SM 598, act ‘94 Diesel Engine Removal and Replacement . 00(D)-5-5

 Main Table of Contents

Group 00(D), Engine (Diesel) CWIRK

18. Install the driver overhead guard. Torque the bolts to
70-75 Nom (52-55 f&lb).

Operator’s
cell

19. Close engine drain valve and fill radiator according to

the procedures presented in “Engine Cooling System
Testing and Maintenance” in Group 01. Check inlet
and outlet hoses for leaks.
20. Restart the engine and check all truck electrical, hy-
draulic, and mechanical components for proper opera-
tion before returning the truck to service.

OO(D>s-6 l Diesel Engine Removal and Replacement SM 698,Oct ‘94

 Main Table of Contents

EmK Group 00(D), Engine (Diesel)

Section 6.
S4S Diesel Engine Service Manual
The Mitsubishi S4S Diesel Engine Service Manual is copied into the following pages of this
Section. The manual’s contents are as follows.

GENERAL ... ...... ..... ..“. ........ . .......... “.... ...“. ......... . ...... ..“..“.... ... ...................
. .
..... “..” ..I.. ... .. . 5
6
SPECIFICATIONS .........................................................................................................................................
SECTIONAL VIEWS ..................................................................................................................................... 9
PERFORMANCECURVES ........................................................................................................................ 13
MAINTENANCE STANDARDS ..... .” ... .......I.. .... ... .” ... ......“..“..“......... .. ......““l..“..“........ ... ..... . ... 17
MAINTENANCE STANDARDS ................................................................................................................ 16
25
TIGHTENING TORQUE .............................................................................................................................
SEALANT APPLICATION DATA ............................................................................................................. 29
SPECIAL. TOOLS .U..“..“..“..“..“““......“..“““.~...”..~..~..~”~..“..“..“..-..~..~..“..~.-.....-..-..“..“.-..”” . 31
32
SPECIAL TOOL LIST .................................................................................................................................
ENGINE PROPER ..“..I ..“. .........“........I”............ ..“. .........“. .....“. .....U......“................““..“..................“. 35
CYLINDER HEAD AND VALVE MECHANISM ..................................................................................... 36
TIMING GEARS, CAMSHAFT AND OIL PAN ........................................................................................ 51
FLYWHEEL .................................................................................................................................................
64
PISTONS, CONNECTING RODS, CRANKSHAFT AND CRANKCASE .............................................. 70

INLET AND EXHAUST SYSTEMS ... ... ......“......“......I ..“....... ......“......... . ... ........... ..”... ..... . . ... . 95
DESCRlPTION ............................................................................................................................................. 96
EXHAUST MANFOLD .............................................................................................................................. 96
LUBRICATION SYSTEM “. ......... ..“. ................... “I.. ...... “..” ..I.. ....” ..“. .....“................“....“......“......”. 97
DESCRIPTION ............................................................................................................................................. 98
OIL PUMP .................................................................................................................................................... 99
OIL PILTER ............................................................................................................................................... 104
RELIEFVALVE ......................................................................................................................................... 105

COOLING SYSTEM ..“..“._U..“..U..“.....~..“..“.“.”~.~..~.”..~.”.~....-..“......~..-“-..“.~..~.” - 107

108
DESCRIPTION ...........................................................................................................................................
109
WATER PUMP ...........................................................................................................................................
110
THERMOSTAT ..........................................................................................................................................
FUEL SYSTEM ~....I..“..““_._.........“..“..“..”..”..”..~.~.~..“.~..“..”..”..~.~.......~“..“.““.“..“.~“”..” . 111
112
DESCRIPTION ...........................................................................................................................................
116
FvELFILTER ............................................................................................................................................
INJECTION NOZZLES ............................................................................................................................. 117
INJECTION PUMP .................................................................................................................................... 121
ELECTRICAL SYSTEM .._.....“..“..“.._.““....“..~..“..”..”..”..”..”..~..~..~.”..”.-”~~“~.~..~..~.~.” . 125
126
STARTER ...................................................................................................................................................
134
ALTERNATOR ..........................................................................................................................................
HEATER PLUGS ............................................................................. 139
..........................................................
WORKSHOP THEORY ..“......“............“” ...+......“. ........... I...“““........““.. .. ...... “................“......” .. 141
SUGGESTIONS ON DISASSEMBLY AND REASSEMBLY ................................................................. 142
TESTING THE COMPRESSION PRESSURE ......................................................................................... 145

TROUBLESHOOTING ..“......“.._.~......““~.~...“.“.~.”..”.....~~”..““~.“..~..~..~.-~~~.~~ .. 147

148
TROUBLESHOOTING CHART (1) ..........................................................................................................
152
‘IROUBLJZSHOOTING CHART (2) ..........................................................................................................

NOTE NOTE
4DQ7 ENGINE INFORMATION is also in the BALANCERS are not shown in the S4S Diesel
Mitsubishi manual. DISREGARD this infor- Engine Service Man uaI. This information is cov-
mation. ered in Section 7, “Balancer Supplement.”

SM 598, Apr ‘96 S4S Diesel Engine Service Manual . 00(D)-6-l

 Main Table of Contents

Group 00(D), Engine (Diesel) ClmK

SCOPE HOW TO USE THIS MANUAL

This Service Manual describes, group by 1. The parts read in the texts or shown
group, the specifications, maintenance in the illustrations are numbered in
standards, adjustments, disassembly , the disassembly sequence prescribed
inspection and repair, and reassembly of for each system or assembly.
the 4DQ7 and S4S diesel engines.
‘2. The item to be inspected during
The groups and their contents will be disassembly are indicated in 1-1
found in GROUP INDEX and the contents in the disassembled view.
of each group in the first page of the
group* 3. The maintenance standards to be
referred to for inspection and repairs
For ope‘ration and periodic maintenance, are indicated in easy-to-refer passages
refer to OPERATION & MAINTENANCE of the texts and also in GROUP No. 2
MANUAL. For component parts and in a tabulated form.
ordering of service parts, refer to PARTS
LISTS. For construction and function of 4. The sequence in which the parts are
each group or system, refer to training to be reassembled are shown in the
manuals. form of, for example, @-@+@+O_~
below the assembled view.

5. Marks are used in this manual. to

emphasize important and critical
instructions as shown below:

6. Tightening torque in “wet” condition is

indicated as xwet]. Unless indicated
as such, .- the torque is to be
considered in rrdryrt condition.

NOTES, CAUTIONS.AND WARNINGS

NOTES, CAUTIONS and WARNINGS are used in this manual to emphasize

important and critical instructions. They are used for the following
conditions:

[E] . . . . . . . . . . ,. . . . . . . . . . . An operating procedure, condition, etc.,

which is essential to highlight.

[m] ............... Operating procedures, practices, etc.,

which if not strictly observed, will result
in damage to or destruction of engine.

............. Operating procedures, practices, etc.,

which if not correctly followed, will result
in personal injury or loss of life.

00(D)-6-2 l S4S Diesel Engine Service Manual SM 598,Oct ‘94-

 Main Table of Contents

ClClRK Group 00(D), Engine (Diesel)

DEFINITION OF TERMS

In this manual, the foliowing terms are used in the dimensional and other
specifications:

NOMINAL VALUE .. .... . .... Indicates the standard dimension of a

part.

ASSEMBLY STANDARD . .... Indicates the dimension of a part, the

dimension to be attained at the time of
reassembly or the standard performance.
Its value is rounded to the nearest whole
number needed for inspection and is
different from the design value.

STANDARD CLEARANCE .. .. Indicates the clearance to be

obtained between mating parts at the time
of reassembly.

REPAIR LIMIT ............. A part which has reached this limit must
be repaired.

SERVICE LIMIT ............ A part which has reached this limit must
be replaced.

SM598,Oct‘94 S4S Diesel Engine Servlce Manual 9 00(D)-6-3

 Main Table of Contents

CmK Group 00(D), Engine (Diesel)

GENERAL

1. SPECIFICATIONS ................................................................................................................... 6

2. SECTIONAL VIEWS ............................................................................................................... 9

2.1 4DQ7 longitudinal sectional view .............................................................................. 9
2.2 4DQ7 transverse sectional view ................................................................................ 10
2.3 S4S longitudinal sectional view ................................................................................ 11
2.4 S4S transverse sectional view ................................... ................................................ 12

3. PERFORMANCE CURVES .................................................................................................. 13

3.1 4DQ7 ............................................................................................................ ............. 13
3.2 S4S .......................................................*.................................................................... 14

SM 598, Apr ‘96 S4S Diesel Engine Service Manual l OO(D)+S

 Main Table of Contents

Group 00(D), Engine (Diesel) CWIRK

GENERAL

1. SPECIFICATIONS

Model designation I 4DQ7 I s4s I

We Water-cooled, Cstroke cycle, diesel
No.of cylinders - arrangement 4 - m-line
Type of combustion chamber I Swirl I
Valve arrangement Overhead
Bore x stroke, mm (in.) 88 k 94 (3.46 x 3.70) 94 x 120 (3.70 x 4.72)
Piston displacement, liter (cu in.) 2286 (139503) 333 1 (203274)
Compression .ratio 22 : 1
Firing order (injection sequence) l-342
Direction of rotation Counterclockwise as seen from timing gear side
Fuel (ASTM specification) Grade No. 2-D diesel fuel
Engine oil CC (API service classification)
Overall length, mm (in.) 666 (26.2) ,647 (25.5)
Dimensions Overall width, mm (in.) 533 (2 1.O) 552 (21.7)
Overall height, mm (in.) , 654 (25.7) 7 12 (28.0)
195 (430) 235 (520)
Bated output, PS (kW)/rpm I 40 (29)/2200 I 60 (44)/2200 I
Maximum torque, kgf-m (lbf-ft) [N-ml/r-pm 1 13.9 (101) [136]/1600 1 20.5 (148) [201]/1400 1
Compression pressure, kgf/cms (psi) @Pa] 27 (384) [2648 J , 33 (469) [3236],
(at 150 to 200 rpm) I minimum I minimum I
Minimum no-load speed, rpm 650 to 700
Maximum no-load speed, rpm 2350 f 20
Type of cylinder Dry (integral)

No.of Compression ring 2

piston rings oil ring 1 (w/spring expander)
Open 30” B.T.D.C.
Inlet valves
Close 50” A.B.D.C.
Valve timing
open 74’ B.B.D.C.
Exhaust valves
Close 30” A.T.D.C.
,
Valve Inlet valves, mm (in.)
0.25 (O.Ol), cold
clearance Exhaust valves, mm (in.)
starting system Electric starter

00(0)-S-6 l S4S Diesel EngineService Manual SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 00(D), Engine (Diesel)

r Model designation 4DQ7 I S4S I

Engine oil Oil pan liter (U.S. gal) 6 (1.6) 9 (2.4)

capacity Overall, liter (U.S. gal) 6.7 (1.8) 10 (2.6)
Nom-ml
run,
3to5(43to71)[294to4903
oil pressure kgf/cn? (psi) [kPa]
Idling, kgf/cma (psi) [kPa] 1.O (14) [98] , minimum
Tme Trochoid
Speed ratio to crankshaft 0.50 0.74
Delivery capacity,
Oil pump liter (U.S. galb/mir@m
(oil temp: 50 C(122 F), 10.5 (2.8)/1250 26 (6.9)/2230
- pressure: 3 kgf/cm2
(43 psi) [294 kPa])
Oil filter 1 Type Paper element (spin-on type)

1 We Piston valve

(43 f 3) (50 + 4)
Relief valve [294
3.0 2+20]
0.2 [343
3.5 2f 291
0.3 I
oil bypass 0.8 to 1.2 (11 to 17) [78 to 1181
valve
Capacity (engine water jacket), liter (US. gal) 1 4.1 (1.1) I 5.5 (1.5) I
a

I Tee Centrifugal
Water Speed ratio to crankshaft 1.31 : 1 1.38 : 1
pump _
Delivery capacity,
liter (U.S. gal)/min/rpm 100 (26)/3000 - 150 (40)/3000

Fan belt I Type I Low-edge cog A type V-belt, 1 piece I

I Type Wax pellet
Valve opening temperature, 76.5 + 2 76.5 + 1.5
Thermostat “C (“F) (170 + 3.6) I (170 2 2.7) I
V?a$eET ?90°C (194’F), 9 (0.35), 8 W1),
minimum I minimum I
Type - manufacturer Distributor (DPK) - Mikuni Precision
Injection
_....._ Diameter of plunger, mm (in.) 6.5 (0.256) 7 (0.276)
Cam lift, mm (in.) 1.5 (0.06)
Injection timing, B.T.D.C. lSO 20”
1 Type - manufacturer Throttle-Nippon Denso
Type of nozzle holder Bosch KCAl7SD
E
6
z Type of nozzle tip Bosch DNOPDZ 1 Bosch DNI 5PD6
2
5
Diameter of spray hole,
1.oo (0.039)
z Injection
mm (in.)
nozzles Spray angle 0” 15”

12o+‘i 140+::
Valve 0 ening pressure,
kgf/cm B(psi) UW
(1706+‘42,) (1991 +t;; )
[l 1768+g80,] [13729+2;;]

Fuel filter Type Paper element with water separator (spin-on type)
I

SM 598,Oct
‘94 S4S Diesel Engine Service Manual 9 00(D)-6-7
 Main Table of Contents

Group 00(D), Engine (Diesel) CMRK

r Model designation I 4DQ7 I S4S

Voltage - polarity, V 12 V - negative ground
Standard: M002T6227 1
Model M002T62271 Cold weather:
M003T6767 1

Starter Type - manufacturer Lever-shift type - Mitsubishi Electric

Standard: 12 - 2.2
Output, V - kW 12 - 2.2
Cold weather: 12 - 3.0
No.of pinion teeth/ lOI 113 101 122
No. of ring gear teeth
Dry clutch models: AOOlT25070
Model
Wet clutch models: A005T22570
Type - manufacturer 3-phase, w/IC regulator - Mitsubishi Electric
Dry clutch models: 12 - 35
Output, V - A
Wet clutch models: I2 - 50
Rated speed, rpm 5000
Alternator Working speed, rpm Dry clutch models: 1000 to 13500
Wet clutchmodels: Up to 10000
Dry clutchmodels: 15000/0.5
Maximum speed, rpm/min
Wet clutchmodels: 12000/0.5
Dry clutch models: 1.97 Dry clutch models: 2.29
Speed ratio to crankshaft
Wet clutch models: 2.00 Wet clutch models: 2.00
1 Regulator type. IC (integrated circuit)
Regulated voltage, V -14.4 +-0.3

- Type _ Sheathed
Heater plugs Rated output, V - A 10.5 - 9.7
1 Resistance at room temn.. $2 1 0.16
L

00(D)-6=8 ’ S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CMRU Group 00(D), Engine (Diesel)

2. SECTIONAL VIEWS
_...
2.1 4DQ7 longitudinal sectional view

-11 12 13 14 15 /16

1 Thermostat 8 Crankshaft gear 15 Rocker bracket

2 Piston 9 Crankshaft pulley 16 Rocker shaft
3 Piston pin 10 Timing gear case 17 Cylinder head
4 Connecting rod 11 Exhaust valve 18 Pushrod
5 Water pump 12 Inlet valve 19 Tappet
6 Water pump pulley 13 Valve spring 20 Camshaft
7 Camshaft gear 14 Rocker arm 21 Crankshaft

SM 598,Oct‘94 545 Diesel Engine Service Manual l 00(D)-6-9

 Main Table of Contents

Group 00(D), Engine (Diesel) CMRK

2.2 4DQ7 transverse sectional view

405726

Rocker cover 7 Crankcase 13 Second ring

Rocker arm 8 Oil pump 14 Oil ring
Cylinder head 9 Oil strainer 15 Piston
Pushrod 10 Heater plug 16 Connecting rod
Tappet 11 Injection nozzle 17 Crankshaft
Camshaft 12 Top. ring

OO(D)+lO l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 00(D), Engine (Diesel)

2.3 S4S longitudinal sectional view

505727

1 Thermostat case 8 Crankshaft pulley 15 Rocker bracket

2 Piston 9 Crankshaft gear 16 Rocker shaft
3 Piston pin 10 Timing gear case 17 Cylinder head
4 Water pump 11 Inlet valve 18 Pushrod
5 Water pump pulley 12 Exhaust valve 19 Tappet
6 Idler gear 13 Valve spring 20 Camshaft
7 Connecting rod 14 Rocker arm 21 Crankshaft

SM 598,Oct ‘94 S4S Diesel Engine Service Manual l 00( D)-6-11

 Main Table of Contents

Group 00(D), Engine (Diesel) CIRRK

2.4 S4S transverse sectional view

17 405728

1 Rocker cover 7 Crankcase 13 Piston

2 Rocker arm 8 Heater plug 14 Connecting rod
3 Cylinder head 9 Injection nozzle 15 ,‘Crankshaft
4 Pushrod 10 Top ring 16 Oil pump
5 Tappet 11 Second ring 17 Oil strainer
___ _
6 Camshaft 12 Oil ring

00(D)-6.12 9 S4S DieselEngineService Manual SM 598,Oct ‘94

 Main Table of Contents

CUIRK I Group 00(D), Engine (Diesel)

3. PERFORMANCE CURVES

3.1 4DQ7

Complete with alternator and air cleaner,

corrected to standard conditions ‘specified
by Japanese Industrial Standard

7
14 (101) [137] ,-”
13 (94) [127] $5
12 (87) [118] z%
g 5

200 (7.0)
190 (6.7)
180 (6.3)
170 (6.0)

1000 1250 1500 1750 2000 2250 2500

Speed, rpm

405731

SM 598,Oct
‘94 . S4S Diesel Engine Service Manual l 00(D)-6-13
 Main Table of Contents

Group 00(D), Engine (Diesel) EIARK

GENERAL

3.2 s4s

Complete with alternator and air cleaner,

corrected to standard conditions specified
by Japanese Industrial Standard

f
22 (159) [216] ;_
20 (145) [196] $$
18 (130) [I771 z;
mi
s r”

r”
Oh
‘3 +
200 (7.0) ;g
1‘80 (6.3) 55
‘160 (5.6) if
LL%
1500 1750 2000 2250 2500

Speed, rpm

405732

00(D)-6-14 l S4S Diesel Enghe Service Manual SM 596,Oct ‘94

 Main Table of Contents

ClmK Group 00(D), Engine (Diesel)

MAINTENANCE STANDARDS

1. -ANCE STANDARDS .......................................................................................... 16

2. TIGHTENING TORQUE ....................................................................................................... 25

2.1 Importantbolts and nuts............................................................................................ 25
2.2 Standardbolts ............................................................................................................ 27
2.3 Standardstuds ........................................................................................................... 27
2.4 Standardplugs ........................................................................................................... 27
2.5 Tightening torques for major components ................................................................ 28

3. SEALANT APPLICATION DATA ....................................................................................... 29

SM 598, Apr ‘96 S4S Diesel Engine Service Manual l 00( D)-6-15
 Main Table of Contents

Group 00(D), Engine (Diesel)

‘1. MAINTENANCE STANDARDS

1.0 (14) [98], minimum at 1500 rpm

Inlet valves open 30” B.T.D.C.

Inlet valves close 50’ A.B.D.C.
Valve timing Exhaust valves open 74’ B.B.D.C.
Exhaust valves close 30’ A.T.D.C.
13’ (crank angle)

Fuel injection 4DQ7 18’ B.TD.C. I

1
timing . s4s 20” B.T.D.C. I
,
22
E~ Warpage of gasketed 0.05 (0.0020), 0.20 / Begrind if warpage
~~ surface- maximum (0.0079) i 1sminor.
/
88.000 to 88.035 88.700 1
Inside 4DQ7 (386) (3.46456 to 3.46594) (38:7%) (3.49212) j Refd to
0+0.25 (+OXlO98) or
diameter 94 000 to 94.035
S4s +o 50 (+0 0197)
z (39;O) (3.70078 to 3.70216) (%:5) (39%:4) ov&e oi_nominal
u
c value by honing and
0.01 (0.0004),
3 Out ofround use the same over&f
maximum
. pistons and piston
0.015 (0.00059), rings.
Taper maximum
$ If repair limit is
z reached, replace
% bearings. If it is
5 (0.035 to 0.100) exceeded, regrind
4DQ7 (2?6) ((0.00138 to 0.00394)) journals and use
undersize bearings:
(0.20)
P Undersize bearings:
r: -0.25 (-0.0098)
1 Clearance -0.50 (-0.0197)
0 on journal wear:
E at journal -0.75 (-0.0295)
(0.03)
(1) Crankcase and
g ((0.0012)) bearing caps to
(0.050 to 0.110) be used in
S4S combination.
(3Z7) ((0.00197 to 0.00433)) .
(2) Upper shell of
bearing has oil
groove.

00(D)-6-16S4S Diesel Engine Service Manual

l SM596,Oct‘94
 Main Table of Contents

CIRRIC Group 00(D), Engine (Diesel)

Unit: mm (in.)
Repair Service
Nominal Assembly standard . . .
roup Inspection point Remarks
value (standard clearance) (cleEice) (cleF..&e)

E! 0 to 0.04 Load: 500 kgf

‘E 4DQ7 (1103 Ibf)[4903 N]
(0 to 0.0016)
; Crush
.s 0.040 to 0.080 Load: 600 kgf
S4S
(0.00157 to 0.00315) (1323 Ibf)[5884 N!
E
22.000 to 22.033 22.100
Inside 4DQ7 (0%) (0.86614 to 0.86744) (0.87008)
14.000 to 14.018
5 diameter S4S (O!&F2) 1
s (0!:5) (0.55118 to 0.55189)
s
(0.035 to 0.098) (0.12)
2 4DQ7 If repair limit is
c Clearance ((0.00138 to 0.00386)) ((0.0047))
reached, replace
on tappet (0.016 to 0.052) (0.08) tappets.
0) S4S
E ((0.00063 to 0.00205)) ((0.0031))

2 (O& to 0.11) If repair limit is

Clearance 4DQ7
6 ((0.0024 to 0.0043)) (0.15) reached, bore
oncamshaft crankcase and use
(0.07 to 0.11) ((0.0059))
journal ~4s bushings.
((0.0028 to 0.0043))
.E I
B 54.02 to 54.05
c ,I:: : (2%) (2.1268 to 2.1279)
r” P’ 53.02 to 53.05
z - No- 3 (2?9) (2.0874 to 2.0886)
Inside
’ diameter No. 1 54.03 to 54.05
No. 2 (2?3) (2.1272 to 2.1279)
-%
VY 53.03 to 53.05
No- 3 (25;) (2.0878 to 2.0886)
Warpage of gasket 0.05 (0.0020), 0.20 Regrind if warpage
‘0, contact surface maximum (0.0079) is minor.
2
b 1.3 to 1.4
4DQ7
z Thickness (0.051 to 0.055)
3 ofgasket 1.15 to 1.25
S4S
(0.045 to 0.049)
Inlet 7.940 to 7.955 7.900
Diameter valves (0.31260 to 0.31319) (0.31102)
of valve
stem Em- (0% 7.920 to 7.940 7.850
u valves (0.31181 to 0.31260) (030905)
z
s
5 Inlet (0.055 to 0.085)
a & valves 8 ((0.00217 to 0.00335)) (0.15)
2 P
d Exhaust (O-31) (0.070 to 0.105) ((0.0059))
u” 5 Stem If repair limit is
valves ((0.00276 to 0.00413))
I. clearance _ reached, replace
$ inguide inlet (0.065 to 0.095) guides.
(A valves ((0.00256 to 0.00374)) (0.200)
=: &&al& (Oil) (0.080 to 0.115) ((0.00787))
valves ((0.00315 to 0.00453))
1.20
Thickness of 4DQ7 (01~~~9) (0.047)
head (valve
margin) 1.83
S4s (0%9) (0.072)

SM 598,Oct
‘94 S4S Diesel Engine Service Manual l 00( D)-6-17
 Main Table of Contents

Group 00(D), Engine (Diesel) ElfIRK

Unit: mm (in.
l-
Repair Service
Nominal Assembly standard . . .
;roup , Inspection point Remarks
value (standard clearance) (cIeEice) (cllF&e)

0.6 to 1.0
4DQ7
(0%) , (0.024 to 0.039) (0.K)
Valve Inlet 0.2 to 0.6
5 sinkage ties (OpdT6) (0.008 to 0.024)
%. (O.‘d!9)
>” m Exhaust 0.5 0.3 to 0.7
valves (0.020) (0.012 to 0.028)
Squareness (face 0.03 (0.0012),
runout) of valve face maximum
17.6 to 18.3
Height to top 4DQ7 (O!& (0.697 to 0.720)
of vaIve guide 13.7 to 14.3
S4S
(0545) (0.539 to 0.563)

Ansle 3o”
5rn 1.0 to 1.4
4DQ7 (O!G7) (0.039 to 0.055) (O.‘dZ,)
2 Width
2 1.26 to 1.54
S4S (O.Zl)
(O.%) (0.050 to 0.061)
48.85 47.60
Free length (1.87)
(1.92)
E”
-rc Test force/length 18to20 15 (33)
2 under test force, (40 to 44)
Al4711
jj ~O&ffPJl/ w; ;; $1 I 44(1.73)

Squareness l.S”, maximum

VaIve clearance
.. ..
-
Inside 18.000 to 18.061
diameter 4DQ7 (O!;l) (0.70866 to 0.71106)
of rocker 19.010 to 19.030
bushing S4S
(O!& (0.74842 to 0.74921)
17.966 to 17.984
z
Y
Diameter 4DQ7 (O!;l) (0.70732 to 0.70803)
8
of rocker
d shaft 18.980 to 19.000
S4S
(O!& (0.74724 to 0.74803)
(0.016 to 0.077) (0.10) If repair Iimit is
Clearance 4DQ7 reached, replace
((0.00063 to 0.00303)) ((0.0039))
of bushing bushings. If it is
on shaft (0.010 to 0.050) 0.07 exceeded, replace
S4S
((0.00039 to 0.00197)), ((0.0028)) , , shafts.
-
0.4 (O-016), Runout measured
B 4DQ7
Runout maximum with pushrod sup
g (bend) OL),nnl?\
.J \“.“ILJ.
I I ported at centerline:
S4S of its spherical ends
rriaximum
-

~~~
00(D)-6-18 l S4S Dtesei Engine Service Manual SM 598,Oct ‘94
 Main Table of Contents

CIRRK Group 00(D), Engine (Diesel)

unit: mm (in 2
Repair Service
Nominal Assembly standard . . .
koup Inspection point Remarks
value (standard clearance) (cleF$e) (cllzce)

Measure with both

Runout 0.02 (O.OOOS), 0.05 ends supported.
(bend) maximum (0.0020) Straighten or
replace.
64.965 to 64.985
Diameter 4DQ7 (2626) (2.55767 to 2.55846) (Z%!!l$ (2p:;3%)
of journal 77.955 to 77.970
S4S
(37:7) (3.06909 to 3.06968) &%%) (3%?3)
Out of round of 0.01 (0.0004), 0.03
journal maximum (0.0012)
0.01 (0.0004), 0.03
Taper of journal
maximum (0.0012)
57.945 to 57.965
4DQ7
Diameter (2.28129 to 2.28208) 57.800
of crankpin s4s &I 57.955 to 57.970 . (2.27559)
(2.28169 to 2.28228)
Out of round 0.01 (0.0004), 0.03
of crankpin maximum (0.0012)
0.01 (0.0004), 0.03
Taper of crankpin
maximum (0.0012)
Fillet radius of
20.2
journal and
(0.:2) - (kO.008)
crankpin
(0.100 to 0.189)
4DQ7
((0.00394 to 0.00744)) (0.300)
End play
(0.100 to 0.264) ((o.o1181))
S4S
((0.00394 to 0.01039))

Vertical to piston
pins

SM 598,Oct ‘94 S4S Diesel Engine Service Manual . OO(II)-6-l

9
 Main Table of Contents

Group 00(D), Engine (Diesel) CIRRK

unit: mm (in.

Nominal Assembly standard Repair

. . Service
. .
;roup Inspection point Remarks
value (standard clearance) (cleF!&e) (clep&e)

(0.385 to 0.450)
4DQ7
Top ((0.01516 to 0.01772)) ((6~;~!;))
land
(0.435 to 0.500)
@ S4S
((0.01713 to 0.01969)) ((%%))
2
v
.5 (0.341 to 0.396)
3 Second 4DQ7 ((0.01343 to 0.01559)) ((%ZL))
0 land .
(0.384 to 0.439)
((0.01512 to 0.01728)) (&%)) 1
f
s m(j 4DQ7 (0.311 to 0.366)
P ((0.01224 to 0.01441)) ((;pd;;%))
(0.335 to 0.390)
((0.01319 to 0.01535)) ((ZLZ))
g
z
E PE 4DQ7 (0.015 to 0.070)
((0.00059 to 0.00276)) (&%%))
G S4s

4DQ7 0.35 to 0.75

Projection (0.0137 to 0.0295)
above Check bearing
CrankcaSe -0.25 to 0.15 clearance.
S4S
(-0.0098 to 0.0059)
Max. permissible
v) difference between
r average weight of Pg(O.2 oz),
z all pistons in one maximum
z engine
‘5
z End gap (0.3 to 0.5) (1.5)
.s ((0.012 to 0.020)) ((0.059))
z If repair limit is
(0.059 to 0.099) reached, replace
4DQ7
((0.00232 to 0.00390)) piston rings.
Top (0.20) If repair limit is
ring ((0.0079)) exceeded, replace
(0.07 to 0.11) piston. .
S4S (1) Ring groove
((0.0028 to 0.0043))
Measure side
clearance with
2 ring kept flush
‘Z 8 (0.025 to 0.060) with second
C
4DQ7
((0.00098 to 0.00236))
g I! Second land.
b jg - (0.15)
E 0 mg ((0.0059))
% (0.045 to 0.085)
S4S ’
rn ((0.00177 to 0.00335)) 0

(0.025 to 0.060) @ Compression ring

4DQ7
((0.00098 to 0.00236)) @ straightedge
Qil (0.15) 8 Piston
ring ((0.0059)) (2) Oil ring to be
(0.025 to 0.065) replaced as a set
S4S ((0.00098 to 0.00256)) including ex-
pander spring.

00(D)-6-20 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ClRRK Group 00(D), Engine (Diesel)

Unit: mm (in

Group Inspection point Remarks

If repair limits is
(0 to 0.016) (0.05) reached, replace pin
piston ((0 to 0.00063)) (0.0020) If it is exceeded,
replace piston.
Clearance in Replace pm or
connecting rod bushing. Ream if
bushing necessary.

Inside 4DQ7
diameter of
bushing S4s

0.05/100

4-A
4DQ7 (0.0020/3.9),
maximum 0.15
Twist/bend
0.10/100 (O.OOS9)
S4S (0.0039/3.9),
maximum
If repair limit is
reached, replace
- 4DQ7 (0.035 to 0.100) bearings. If it is
((0.00138 to 0.00394)) exceeded, regrind
Crankpin crankpins and use
clearance in undersize bearings.
connecting (1) Rod and cap to
rod bearing be used in com-
bination.
S4S (0.030 to 0.090) (2) Marks of cap
((0.00118 to 0.00354)) and rod to be
on the same
side.
Load
crush of 4DQ7: 500 kgf
(0.020 to 0.060)
connecting rod (sfirso36;)$.;03 NJ
bearing ((0.00079 to 0.00236))
(1323 Ibf)[5884 N]
Replace connecting
End play
rod.
Max. permissible
difference between 10 g (0.4 oz),
average weight of maximum
all connecting rods
in one engine
Flatness 0.15 (0.0059) 0.50 Grind or replace.
Face runout maximum (0.020) Replace flywheel.
I I

SM 598,Oct
‘94 S4S Diesel Engine Service Manual 9 00( D)-6-21
 Main Table of Contents

Group 00(D), Engine (Diesel) ElfIRK

Unit: mm (in
Repair Service
Nominal Assembly standard . . .
Group Inspection point Remarks
value (standard clearance) (clepGce) (cl~~lce)

0.02 (O.OOOS), 0.05 Straighten by cold

Runout
maximum (0.0020) working or replace.
A-B
Inlet 46$16 = 6.684
0 (1.84708) (0.263 15)
z A-B
g
4DQ7 45.&4 = 7.344
c i Ex- (1.80882) (0.28913)
2 u haust A-B
z S4S 46.:80 = 6.720 Replace camshaft.
d (1.84567) (0.26457)
v, No.1 53.94 to 53.96 53.90
E$ No. 2 (2%) (2.1236 to 2.1244) (2.1220)
52.94 to 52 96 52.90
35 No. 3
(2?9) (2.0842 to 2.d850) (2.0827)
..
(0.10 to 0.25)’
End play Replace thrust platl
((0.0039 to 0.0098))
36.000 to 36.025
Inside 4DQ7 (13:2) (1.41732 to 1.41830)
diameter of
bushing 40.000 to 40.025
MS
(14:7) (1.57480 to 1.57578)
:: -0.025 (-0.00098)
z Chrtside 4DQ7 ($2) -0.050 (-0.00197)
M diameter of
M
.r shaft -0.009 (-0.00035)
S4S
E (1%) -0.025 (-0.00098)
?
4DQ7 (0.025 to 0.075)
shaft ((0.00098 to .0.00295))
clearance in (0.100)
Replace bushing.
Z bushing ~4s (0.009 to 0.050) ((0.00394))
& ((0.00035 to 0.00197))
s
(0.05 to 0.20) (0.35)
= End play
((0.0020 to 0.0079)) ((0.0138))
Length of thrust
(0.05 to 0.20)
journal of shaft Replace thrust plan
(1%2) ((0.0020 to 0.0079)) ((%))
and boss
(0.039T to 0.076T)
Fit (inter- 4DQ7 ((0.00154T to
ference) of 0.00299T))
shaft in (lYf8) (0 035T to 0 076T)
crankcase S4S ‘((0.00138T to
bore 0.00299T))

4DQ7 (0.05 to 0.15) (0.25)

((0.0020 to 0.0059)) ((0.0098))
=
2 Idle gear and . (0.06 to 0.24) (0.30)
3 oil pump gear ((0.0024 to 0.0094)) . ((0.012))
u VJ
a 3 Idle gear and Replace gears.
(0.05 to 0.17) (0.25)
injection pump
((0.0020 to 0.0067)) ((0.0098))
gear

00(D)-6-22 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 00(D), Engine (Diesel)

Unit: mm (in.)

T-
Lroup Inspection point
Nominal
value
Assembly standard
(standard clearance)
Repair
limit
(clearance)
Service
liit
(clearance)
Remarks

Idle gear and 1

I (0.04to 0.18) . ..
camshaft gear __
((0.0016 t 0 0.007 1)) 0.25
$ n-place gears.
v, Crankshaft gear (0.05 td0.18) ((0.0098)) ne
and idle gear ((0.0020 to 0.0071))
Clearance between (0.13 to 0.15)
outer rotor and ((0.0051 to 0.0059))
inner rotor I I!
End play of (0.04 to 0.09) (0.15) Refinish case cover
rotors ((0.0016 to 0.0035)) ((0.0059)) or pump case.

Clearance (0.200 to 0.275)

4DQ7 ((A?%!&).
between ((0.00787 to 0.01083))
outer rotor (0.20 to 0.30)
and pump s4S ((0.0079 to 0.1181)) (&%))
case
15.985 to 16.000
~tygf;f s4s (0!:3) (0.62933 to 0.62992)
Clearance
between 0.032 to 0.074 (0.150). Replace pump case
shaftand S4s (OJJO126 to 0.00291) ((0.0059 1)) or pump assembly.
pump case
3.0 i 0.2 kgf/cm’
4DQ7 - (43 * 3 psi)
1294 -+20 kPa]
Setting 0.6 mm (0.024 in.)
kgf/cm2 - thickness (one
(psi) Wal s4s 3.5 f 0.3 kgf/cm2 piece) of shim will
(50 * 4 psi) vary settint by
[343 + 29 kPa] 0.5 kgf/cm (7 psi)
[49 kPa].
..

Warpage of flanges (0.;:8)

maximuh

Runout of 0.05 0.10

commutator (0.0020) (0.004)
Diameter of 31.4
commutator (1%) (1.236)
Depth of commutator 0.4 to 0.6
mold (0.016 to 0.024) (O%S)
Length of brush 18 (0.71) 11 (0.43)
Pressure of brush 3.1 to 3.9
spring, (6.8 to 8.6) (24)
kgf Uhf) PI [30.4 to 38.21 [ 19.61
Thrust gap of 0.5 (0.020), Below 0 not
pinion shaft maximum permissable.
0.5 to 2.0
Pinion gap
(0.020 to 0.079)

No-load 4500,
11 130
characteristics minimum

SM 598, ml’94 S4S Diesel Engine Service Manual . 00(D)-&23

 Main Table of Contents

Group 00(D), Engine (Diesel) CMRK

Unit: mm (in
Repair Service
Nominal Assembly standard . . .
Group , Inspection point value (standard clearance) (cleygce) (cliz&e)
Remarks

Brush length 18.5 (0.73) 7 (0.28)

Pressure of brush 310 to 430 210
spring, gf (02) (11 to 15) (7)
8 Diameter of 32.4
z spring (1.276) .
E
: z&h 3.4 St
Resistance models
between At 20°C (68’F)
slip rings wet
clutch 2:4 Sz
Imodels I I

Temp. at 76.5 + 2°C

!
4DQ7 (169.7 + 3.6”F)
z which valve
5 starts 76.5 + 1.5’C
opeas S4S
E (169.7 f 2.7”F)
8
s 4DQ7 9 (0.35), minimum
Valve lift ; At 90°C (194’F)
5% 8 (0.31), minimum i
$ Tension 12 (O-47), Under thumb
s (deflection) approx. pressure

00(D)-6-24 9 S4S Diesel Engine Service Manual SM 596,Oct ‘94

 Main Table of Contents

CUlRK Group 00(D), Engine (Diesel)

2. TIGHTENING TORQUE

2.1 Important bolts and nuts

C4DQ71

Thread Width Tightening torque

Secured part or component dia. x pitch across flats
bd (mm> kgf-m lbf.ft N-m
I I

Cylinder head Ml2 x 1.75 19 12.0 + 0.5 87 24 118 25

..- I I
1 Rocker shaft bracket. j M8 x 1.25 1 12 1 1.5~0.5 1 11 +4 1 155

r Main bearing cap 1 Ml2 x 1.75 / 12 / 8.5kO.5 1 61 24 1 83+5

Connecting rod cap Ml0 x 1.25 14 5.5 + 0.5 4024 54+5

Flywheel -. -. Ml2 x 1.25 17 8.5 + 0.5 61+4 83 f5

/--Camshaft thrust plate. 1 M8x1.25 ) 12 / l-820.5 ( 1324 / 1825

Front plate M8 x 1.25 12 1.020.5 724 1025

Timing gear case, cover M8 i 1.25 12 1.o 20.5 , 724 i 1025

I--Crankshaft pulley M24 x 1.5 I 36 40 + 1 / 289*8 /392210

I Idle gear thrust plate 1 MlOx 1.25 1 14 1 3.5 20.5 i 25 ?4 / 34 +5

rOilpan 1 M8x1.25 1 12 / 0.7 1 St4 1 755

I-Oil drain plug Ml4 x 1.5 I 22 I 420.5 j 2924 / 3925

Oil filter / 1 x 12UNF 1 1 1.5 to 2.0 1 11 to 14 1 15 to 20

Injection nozzle M20 x 1.5 21 621 43 t 8 59210

Fuel leak-off pipe nut Ml2 x 15 17 2.0 to 2.5 14to 18 ) 15 to25

r Injection pump gear Ml4 x 1.5 I 22 1 8.320.5 / 6024 / 81 25

IalB 1 M8 x 1.25 1 12 1 1.oto1.2 j 7to9 1 10to12

Heater plug (body) Ml0 x 1.25 12 ’ 1.5 to2.0 15 to 20

(terminal) M4 x 0.7 8 0.10 to 0.15 1 to 1.5

I Exhaust manifold M8 x 1.25 12 1 3.420.5 1 2524 ) 33+5

Injection pipe nut Ml2 x 1.5 19 2.5 to 3.5 18 to 25 25 to 34

SM 598,Oct
‘94 S4S Diesel Engine Service Manual 9 00(D)-6-25
 Main Table of Contents

Group 00(D), Engine (Diesel) CmK

B4Sl

Secured part or component

Fuel return pipe nut Ml0 x 1.25 14 1A to 2.4 12 to 17 16to24

00(D)-6-26 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CIARK Group 00(D), Engine (Diesel)

2.2 Standard bolts

2.3 Standard studs

Drive torque
Studs driven in aluminum Studs driven in steel
kgf-m 1 lbf-ft Nern kgf-m / lbf-ft N-m

M8 x 1.25 0.75 5.4 7.4 1.3 9 13

Ml0 x 1.5 1.4 10 14 2.4 17 24

.
2.4 Standard plugs :
Tightening torque
Thread
dia. x pitch Studs driven in aluminum Studs driven in steel
b-4 1
kgf-m ibf-ft N-m kgfem 1 lbf.ft N-m

(PTR1/8
l/8) I*’ 7 10 1.8 13 * 18

RI/4
(PT l/4) 2.5 18 25 4.0 29 39

Remarks: 1) Use these torques for bolts and nuts with spring washers.
2) The tolerance of these torques is +lO%.
3) Do not coat threads with oil.

SM 598,Oct
‘94 545 DieselEngineServiceManual 9 00(D)-6-27
 Main Table of Contents

Group 00(D), Engine (Diesel) CMRK

2.5 Tightening torques for major components

Rocker shaft bracket bolts Cylinder head bolts Unit: ,kgf.m (Ibf-ft) [N-m ]
1.5 * 0.5 12.0 f 0.5
t;; 2 ;;) (87 + 3.6)
f
\ / [118t5]

Crankshaft pulley nut T Flywheel bolts .

4DQ7: 40*1 8.5 2 0.5
(289 f 7) t;; f :p’
[392 f lo] +
S4S: 50 i 1
(362 f 7)
[490+1b] /
Timing gear case bolts 405725
4DQ7 : 1.O + 0.5
Main bearing cap bolts 2
(723.6)
4DQ7: 8.5 *OS
[lo ?5]
(61 23.6)
s4s: 1.0 to 1.3 .i83
. 251 ’
a

(7 to 9) S4s: 10.5 +0.5

[lo to 133 (76 f 3.6)

,oilpan bolts
4DQ7 : 0.7 (5) [71
s4s: l.Oto 1.3 ’
(7 to 9)
[lo to 131 .

405726
Connecting rod
5.5 r 0.5 Plug
7 L\

00(D)-6-28 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CMRK Group 00(D), Engine (Diesel)

3. SEALANT APPLICATION DATA

[4DQ71

Where to apply Mating face or parts Sealant Remarks

Cylinder head water Cylinder head Three Bond 1386D Apply to hole and install plug.
hole plug

Crankcase water hole
plug
Crankcase oil gallery
plug
Crankcase camshaft
hole rear expansion
plug
Starter mounting studs
I
Crankcase Three Bond 1386D Apply to hole and install plug.
Three Bond 1386D Apply to hole and install plug.
Crankcase
Apply to hole and install
Crankcase Three Bond 1386D
expansion plug.
Rear plate Three Bond 1344 Apply to studs and tighten.

L34Sl

Where to apply Mating face or parts Sealant Remarks

Crankcase
No. 5 bearing cap Three Bond 1207C Apply to oil pan seal face.
Oil pan Front plate
Timing gear case

Crankcase rear bearing Apply to seats before installing

No. 5 bearing cap Three Bond 1212
can seats cap.

Crankcase Apply to side seal and install.

Side seal Three Bond 12 12
No. 5 bearing cap

Cylinder head water Cylinder head Three Bond 1386D Apply to hole and install plug.
hole plug

Crankcase water hole Crankcase Three Bond 1386D Apply to hole and install plug.
plug
Crankcase oil gallery Crankcase Three Bond 1386D Apply to hole and install plug.
PlW

Crankcase oil return Apply to blind plug or pipe

hole blind plug or Crankcase Three Bond 1344
and tighten.
pipe
Crankcase camshaft Apply to hole and install
hole rear expansion Crankcase Three Bond 1386D expansion plug.
Plug
Starter mounting studs Rear plate Three Bond 1344 Apply to studs and tighten.

Injection pump Flange plate Three Bond 1344 Apply to studs and tighten.
mounting studs I

SM 598,Oct ‘94 S4S Diesel Engine Service Manual l W(D)+29

 Main Table of Contents

ClMK Group 00(D), Engine (Diesel)

SPECIAL TOOLS

SPECIAL TOOL LIST ............................................................................................................... 32

SM 598, Apr ‘96 S4S Diesel Engine Service Manual l 00(D)-6-31

 Main Table of Contents

Group 00(D), Engine (Diesel) ElfIRK

SPECIAL TOOL LIST

- _-

00(D)-6-32 l S4S Diesel Engine Service Manual SM 596, bet ‘94

 Main Table of Contents

CMRK Group 00(D), Engine (Diesel)

SPECIAL TOOLS

~~ ~-
Piston guide 4DQ7 : i Piston installation
(installer) 30$91-58100
S4s:
3449 l-00200

670234

Adaptor 30691-21100 1 Compression pressure

/ measurement

670233 /
/ 1
Turning handle 1 30691-21800 w40s73s i For engine turn%
(4DQT

I
Turnir.g socket 58309-73 100 1 For engine turning
(S4S)
1
I

.400903 i

Socket 3449 l-00300 / Camshaft, thrust plate

and rocker bracket
installation

670235

Stem seal installer 32A9 I-00200 Stem seal installation

WSJ

406736

SM 598,Oct
‘94 S4S Diesel Engine Service Manual l OO(D)-6-33
 Main Table of Contents

ClRRK Group 00(D), Engine (Diesel)

ENGINE PROPER

1. CYLINDER HJZADAND VALVE MECHANISM ............................................................... 36

1.1 Disassembly .............................................................................................................. 36
1.2 Inspection and repair ................................................................................................. 40
1.3 Reassembly ............................................................................................................... 47
1.4 Valve clearance inspection and adjustment .............................................................. 49

2. TIMING GEARS, CAMSHAFT AND OIL PAN .................................................................. 51

2.1 Disassembly .............................................................................................................. 51
2.2 Inspection and repair ................................................................................................. 55
2.3 Reassembly ......................................................... ...................................................... 60

3. FLYWHEEL ........................................................................................................................... 64
3.1 Disassembly ..................................................... ......................................................... 64
3.2 Inspection and repair ................................................................................................. 67
3.3 Reassembly ............................................................................................................... 68

4. PISTONS, CONNIXTING RODS, CRANKSHAFT AND ClUNKCASE ....................... .70

4.1 Disassembly .............................................................................................................. 70
4.2 Inspection and repair ................................................................................................. 74
4.3 Reassembly ............................................................................................................... 87

SM 598, Apr ‘96 S4S Diesel Engine Service Manual l 00(D)-6-35

 Main Table of Contents

Group 00(D), Engine (Diesel) ElmK

1. CYLINDER HEAD AND VALVE MECHANISM

1.1 Disassembly

CQDQ71

Check for worn valve cap

contact surface and
clogged oil hole.

-16

jacks. damage
1fld carbon or scale
build-up.

damage and galling:

405737

1 Rocker cover 8 Oil pip& O-ring 15 Cylinder head

2 Adjusting screw 9 Snap ring 16 Cylinder head gasket
3 Bolt (short) 10 Washer 17 Valve cotter
4 Bolt (long) 11 Rocker arm 18 Upper retainer
5 Rocker shaft bracket 12 Rocker shaft 19 Valve spring

6 Valve
7 Pushrod cap 14
13 Cylinder head spring
Rocker shaft bolt 20 Valve stem seal
21

00(0)-S-36 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

Group 00(D), Engine (Diesel)

Check for cracks

and oil leaks.

Check’for stripped threat

and worn pushrod contact
surface.

Check for worn valve cap contact

surface and clogged oil hoie.

and carbon or scale

Check for cracks.

405738

1 Rocker cover 7 Snap ring 13 Cylinder head gasket

2 Adjusting screw 8 Rocker arm 14 Valve cotter
3 Bolt (short) 9 Rocker shaft spring 15 Valve retainer
4 Bolt (long) 10 Valve cap 16 Valve stem seal
5 Rocker shaft bracket 11 Cylinder head bolt 17 Valve spring
6 Pushrod 12 Cylinder head 18 Valve

SM 598,Oct‘94 S4S Diesel Engine Service Manual 9 00(D)-6-37

 Main Table of Contents

Group 00(D), Engine (Diesel) ClllRK

(1) Removing rocker shaft assemblies

(a) Remove the union nut for oil pipe A

from the connector (4DQ7).

W Loosen the adjusting screw for each

rocker about one turn.

(cl Loosen the short bolt and long bolt

for the rocker bracket in that
order, and remove the rocker shaft
assembly from the cylinder head.

@CAUTION 1
. If the long bolt is loosened in the
first ‘place, the bracket might suffer
damage.

(d) Remove the pushrod.

(2) Disassembling rocker shaft assemblies

Lay the disassembled rocker shaft(s) and

rocker arms in groups, each marked or
tagged for its location, so that the same
clearance as before can be reproduced
at the time of assembling.

00(D)-6-38 9 S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ClRRK Group 00(D), Engine (Diesel)

(3) Removing cylinder head

Unscrew the cylinder head bolts, and lift

the head off with a hoist.

(NOTE]

1) When removing the gasket from

the cylinder head. and crankcase,
be careful not to damage the
gasket contact surfaces of the
head and crankcase. I 405742

2) If any cylinder head parts are out

of order, check the head bolts for
tightening torque with a torque
wrench before removing them.

(4) Removing valves and valve springs

With a valve spring pusher A

(30691-04500), compress the valve spring
squarely, and remove the valve cotter.
Then, remove each valve and spring.

[NOTE) .

If the valves are to be reused, mark

each valve for its location so that it
can be restored to its original
position at the time of reassembling.

SM 598,Oct ‘94 S4S Diesel Engine Service Manual l 00(D)-6-39

 Main Table of Contents

Group 00(D), Engine (Diesel) ElfIRK

1.2 Inspection and repair

Rocker arms, rocker bushings and rocker

shafts (4DQ7) or shaft 64s)

(1) Measuring inside diameter of rocker

bushing and diameter of rocker shaft

Compute the clearance of the bushing on

the shaft on the basis of the
measurements. If the repair limit is
reached, replace the bushing. If it is
exceeded, replace both bushing and
shaft.
Unit: mm (in.)
Nominal Assembly Repair
Item standard limit
VdlX
Measuring rocker bushing and rocker shaft
18.000

hide
hrneter to 0.7 1106)
of rocker 19.010
bushing
S4S
to 0.7492 1)
17.966
to 17.984
4DQ7.(O!h) (0.70732
Diameter to 0.70803)
of rocker
18.980

0.016

(2) Replacing rocker bushings

When installing a replacement bushing,’

align the oil holes in the bushing and
rocker arm.

Replacing rocker bushing

00(D)-6-40 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 00(D), Engine (Diesel)

Valves, valve guides and valve seats

(1) Measuring diameter of valve stem

If the service limit is exceeded, or if

the stem is abnormally worn excessively,
replace the valve.
Unit: mm (in.)
Assembly Service
Item limit
standard
7.940
to 7.955 7.900
Inlet
(0.31260 (0.3 1102)
Diameter to 0.31319)
of valve Measuring valve stem
stems 7 -920
to 7.940 7.850
Exhaust
(0.31181 (0.30905)
to 0.3 1260)

(2) Measuring valve stem clearance in

guicle

The valve guide wears more rapidly at

its both ends than at any other parts.
Measure the guide ends in two
directions, at right angles to each.other.
If the service limit is reached, replace
the guide.
Unit: mm (in.)

Measuringvalveguide
0.055
4DQ7 to 0.085
(0.002 I7
5 4 to 0.00335) 0.15
=I (0.0059)
M E 0.065
.f S4S to 0.095
0)
2 (0.00256
C to 0.00374)
4 CO:l)
u5 4DQ7 0070
t; 0.105
G (0.00276
z
9 to 0.00413) 0.20
‘;j
> 3z ‘0.080 (0.0079)
S4S to 0.115

Height
to top
of valve
guide

SM 598,Oct ‘94 S4S Diesel Engine Service Manual . OO(D)-6-41

 Main Table of Contents

Group UO(D),Engine (Diesel)

(3) Replacing valve guides

(a) Using valve guide remover A

(32A91-00300), remove the guide
(worn) for replacement.

Removing valve guide

(b) To install a replacement guide, use

Unit: mm (in.)
valve guide installer B (30691-10200
4DQ7:
for 4DQ7 or 32A91-00100 for S4S). 18 (0.71)

Height to top of the valve guide is

specified; be sure to use the valve
guide installer to insure this height.

InstaRing valve guide

(4) Inspecting valve face

Coat the. valve face lightly with red

lead and, using a valve lapper, check
the valve contact with its seat. If the
contact is not uniform, or if the valve
is defective or the repair limit is
reached, repair or replace the valve and
valve seat.

[NO=\ 405746

1) Check the valve face after Checking valve face

checking or replacing the valve
guide.

2) Press the valve coated with red

lead into the seat without
rotating it.

Good Bad

4ooo59

Valve contact with its seat

00(D)-6-42 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CIRRK Group 00(D), Engine (Diesel)

Unit: mm (in.)
Nominal Assembly Repair
Item limit
value standard
Angle 30” .
1.0 to 1.4

Valve sinkage

403636

1.20
(0.0472)
4DQ7 (O!i~~O, [service
Valve limit]
margin 1.83
2.13 (0.0720)
S4S
(0.0839) [service
limit]
* Intake ** Exhaust

(5) Refacing valve face

If the valve face is badly worn, reface

it with a valve refacer.

1) Set a valve refacer at an angle

equal to that of valve seat.

2) If the valve margin seems to be

less than the repair limit when
ground, replace the valve. Refacing valve face

SM 595, act ‘94 S4S Diesel Engine Service Manual 9 M)(D)&43

 Main Table of Contents

Group 00(D), Engine (Diesel) EMRK

(6) Refacing valve seat

(a) Using a valve seat cutter or valve

seat grinder, cut the valve seat.
After cutting, grind the seat lightly
by using a sandpaper of #400 grade
or so, inserted between the cutter
and seat.

(b) Lap the valve in the seat.

AOsi7A7

0NOTE Refacing valve seat

1) Cut or grind the valve seat only
as necessary for refacing.

2) If the seat width is in excess of

the repair limit as a result of
wear or cutting, replace the valve
seat.

3) If the valve sinkage exceeds the

repair limit after refacing, replace
the valve seat.

(7) Replacing valve seats

(a) Weld a stud or bar to the valve

seat. Insert- a shaft into the valve
guide hole from the upper side of
cylinder head, and drive the seat
off the head as shown. .

[ii+

When welding the stud or bar, be

careful not to permit spatters to Stud or bar 4-02709

come in contact with the machined Removing valve seat

surfaces of cylinder head.

(b) Measure the dimensions of valve seat

holes in the cylinder head before
installing the valve seats and make
sure that they are as specified.

Inlet. Exhaust

Valve seat dimensions

00(D)-6-44 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ElfIRK Group 00(D), Engine (Diesel)

Unit: mm (in.)
Item, .A B C 1 D
33 +0.02 41 +0.02
+: +~.oooa) 7.8 r 0.1 2.8 f 0.1
4DQ7 (0.307 +-0.004) (0.110 f 0.004)
(1.30 o-0008) (I.61

(cl Chill the valve set in liquid nitrogen

[about -170°C (-274°F)] for more
than 4 minutes with the cylinder
head kept at normal temperature, or
heat the cylinder head to 80°C to
100°C (176OF to 212OF) with the
valve seat chilled in ether or
alcohol containing dry ice.

(d) Using valve inser’t caulking tool A,

install the valve seat by caulking it
there.

Valve insert caulking tool

Item Part No.
4DQ7 3069 l-02700
lnlet
S4s- 3679 l-00200
4DQ7 3069 l-02800
Exhaust
S4S 34491-01300

Installing valve seat

(8) Lapping valves in valve seats

Be sure to lap the valve in the valve

seat after the seat has been refaced or
replaced.

(a) Coat the valve face lightly with a

lapping compound.
&+c2 compound
8
/
1) Do not permit the compound to L
400065
come in contact with the valve Coating valve with lapping compound
stem.
2) Use the compound of 120 to 150
mesh for initial lapping and the
compound of finer than 200 mesh
for finis.h lapping.
3) Mixing the compound with a small
amount of engine oil will
facilitate coating.
SM 598,Oct ‘94 S4S Diesel Engine Service Manual l 00(D)-6-45
 Main Table of Contents

Group 00(D), Engine (Diesel) ElfIRK

Using a valve lapper, lap the valve
in the seat. To lap, rotate the valve
only a part of turn, then raise the
valve off the seat, rotating to a
new position.

Wash off the compound with diesel

fuel.

Coat the valve face with engine oil,

and again lap in the valve.

Check the valve face for contact. Lapping valve in valve seat

Valve springs

Measuring squareness end free length

Squareness
If the squareness or free length exceeds
the service limit, replace the spring. T !l

Unit: mm (in.)

Measuring vaive spring

Test force,
kgf (lbf) WI 18to20
[Length under
test force:
(40 to 44)
[177 to 1961
(:z,
]I471
43 (1.69)1

Cylinder head

Measuring warpage of gasket contact

surface

Measure the warpage of the gasket

contact surface of the head with
straight edge and feeler gauge. If the
warpage is in excess of the repair limit,
reface the surface with a surface
grinder.
Unit: mm (in.)
Measuring war-page of gasket contact
surface of head

00(D)-6-46 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CmK Group 00(D), Engine (Diesel)

Valve pushrods

Measuring runout of valve pushrods

If the runout exceeds’ the assembly

standard, replace the pushrods.
Unit: mm(in.)
Item Assembly standard
1
maximum
1 o-4(O-016),
I Runout (bend)
valve pushrods
of 4m7
S4S I 0.3 (0.012), maximum 400069

Measuringpushrodrunout

1.3 Reassembly

Follow the -reverse of disassembly

sequence.

(1) Installing valve stem seal

I-

I
Steam seal
[4DQ71
After installing the stem seal to the
valve guide, make sure that the seal is
properly fitted in the groove of the
guide.

CS4Sl
Use stem seal installer (32A91-00200) to
install the seal.

[&A~I~N )
Do not apply any oil er sealant to
the mating face of stem seal that
comes in contact with the valve
guide. When installing the stem seal,
coat the seal rubbing surface of the
stem with engine oil to insure initial
lubrication of the stem seal lip.

(2) Installing valves and valve springs

(a) Install the valve spring and retainer

to the valve guide. Using valve
spring pusher A (30691-04500),
install the valve totters.

‘SM 59&t ‘94 545 Diesel Engine Service iManual l 00(D)-6-47

 ’
Main Table of Contents

Group 00(D), Engine (Diesel) ElfIRK

(b) Using a soft hammer, give light blows
to the valve stem top several times
to make sure that the spring and
valve cotter are properly installed.

405752

(3) Installing cylinder head

C4DQ71
(a) Screw two guide bolts into the
crankcase to hold the gasket in
place.

(b) Put the cylinder head on the

crankcase as guided by the two
guide bolts, and tighten the head
bolts.

(7-j’ .
1) Replace the gasket with a new
one. 4DQ7

2) Do not apply any sealant

cylinder head bolts.

CS4Sl
(a) Put the gasket on-the crankcase
to the

as
qgrgrr
guided by the two dowel pins.
6 2 3 7
(b) Put the cylinder head on the
crankcase as guided by the two 402507
dowel pins, and tighten the head
bolts.

(c) Tighten the head bolts to 12 f 0.5 S4S

kgfim (8’7 f 4 lbf-ft) Cl18 f 5
N-ml

00(D)-6-48 l S4SDiesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ClflRK Group 00(D), Engine (Diesel)

- (4) Reassembling rocker shafts

In 4DQ7 engine, the rocker arms for

inlet valves are different in dimension
from those for exhaust valves. After I Unit: mm (in.)
installing the arms, make sure that they
move freely.

21.5 21.5
(0.846), (1%) (0.846) (1 %$,,,,,E

(5) Installing rocker shaft assemblies

Tighten the long bolt 1 and short bolt 2

in that order ,(by following reverse of
loosening order).

1.4 Valve clearance inspection and

adjustment

Check and adjust the valve clearance

when the engine is cold or when it is
warm in whole.
Unit: mm (in.)
I Item 1 Assemblv standard

Valve clearance 0.25 (0.0098)

(cold) I

(1) Inspecting valve clearance

(a) Check the valve clearance by the

firing order, by turning the .
crankshaft by the specified crank
angle in normal direction at a time
to bring the piston to its top dead
center on compression stroke.

Firing order Crank angle

I-3-4-2 180’

SM 598,Oct‘94 545 Diesel Engine Service Manual 9 00(D)-6-49

 Main Table of Contents

Group 00(D), Engine (Diesel) CIRRK

(b) The top dead center on compression

stroke of the piston is identified by
the timing mark rrO1* (on the
crankshaft pulley) being aligned with
the pointer on the gear case. With
the piston so located, the inlet and
exhaust valve rocker arms are not
being pushed up by their pushrods.

(4 Insert a feeler gauge into between

the rocker -arm and valve cap, and
check the valve clearance.

(2) Adjusting valve clearance

(a) Loosen the lock nut for adjusting

screw on the rocker arm, and adjust
the clearance by turning the screw
in either direction to the extent
that the gauge is slightly gripped
between the rocker arm and valve
cap.

(b) After adjusting the clearance, tighten

the lock nut, and again check the
clearance, making sure that it is
correct. _

00(O)-S-SO . S4S Diesel Engine Service Manual SM 698,Oct ‘94

 Main Table of Contents

ClRRK Group 00(D), Engine (Diesel)

2. TIMING ‘GEARS, CAMSHAFT AND OIL PAN

2.1 Disassembly

C4DQ71

Check for cracks and wear.

I Check for wear. 1

Check for clogged

Check cracks and defective dowel Din holes.

goove
~Ie;c.dt
4 I

Check lip for wear, tear and deterioration.

405757

1 Oil pan 5 Baffle plate 9 Camshaft

2 Crankshaft pulley 6 Plate 10 Camshaft gear
3 Cover 7 Idle gear 11 Front plate
4 Timing gear case 8 ,Thrust plate

SM 598, act‘94 S4S Diesel Engine Service Manual l 00(D)-6-51

 Main Table of Contents

Group 00(D), Engine (Diesel) ClRRK

CS4Sl

Check lip for wear, tezx and deterioration.

1 Oil pan 5 Oil pump gear 9 Camshaft

2 Crankshaft pulley 6 Plate 10 Camshaft gear
3 Cover 7 Idle gear 11 Front plate
4 Timing gear case 8 Thrust plate

00( D)-6-52 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CMRK Group 00(D), Engine (Diesel)

(1) Removing timing gear case assembly

Remove’ the crankshaft pulley and timing

gear case assembly. .

[&AunoN J
Take care not to damage the oil
seal.

(2) Measuring backlash and end play

Measure the backlash and end play on

each- gear to obtain the data for parts
replacement. (See page 53.)

Removing oil pump gear

(a) Remove the jam nut.

(b) Remove the oil pump gear by turning

it in the direction of helix of gear
teeth.

(3) Removing idle gear

Remove the idle gear by turning it in

the direction of helix of gear teeth.

I 405762

SM 598,Oct ‘94 S4S Diesel Engine Service Manual 9 00( D)-6-53

 Main Table of Contents

Group 00(D), Engine (Diesel) ClmK

(4) Removing camshaft

(a) Turn the crankcase upside down.

(b) Position the camshaft gear so that

its two holes come to top and
bottom. Unscrew the thrust plate
bolts, and remove the camshaft from
the crankcase.
After removing the camshaft,
remove the tappets.

Take care not to damage the cam

faces of camshaft and the bushings.
It is impossible to remove the
camshaft unless the crankcase is
turned upside down. The camshaft
will suffer damage if you attempt to
remove it without turning the
crankcase.

(5) Removing camshaft gear

Using a puller, remove the gear from the

camshaft. Now, the thrust plate can be
removed.

[NOTE]
It is not necessary to remove
camshaft gear unless camshaft gear
or thrust plate is defective.
I 670066

(6) Removing front plate

Unscrew two front plate mounting bolts,

and remove the plate from the
crankcase.

406763

00(D)-6-64 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 00(D), Engine (Diesel)

2.2 Inspection and repair

Camshaft

(1) Measuring end play of camshaft

If the end play exceeds the service

limit, replace the thrust plate.
Unit: mm (in.)

(2) Measuring cams

Using a micrometer, measure each cam

in two directions and at two positions as
shown. If the measurement exceeds the
Service limit, replace the camshaft.
Unit: mm (in :.)
Nominal Assembly .Service
Item
Glue siandard limit
A-B= A-B=
Inlet cams 4A6.916 6.684 6.184
(I -84708) (0.263 15) (0.24346)
Measuring height of cam lobe
A= A-B= A-B=
g 4DQ7 45.944 7.344 6.844
C (1.80882) (0.28913) (0.26945)
5 A= Y A-B=
s4s 46.880 64;2Bo 6.220
(1.84567) (0.26457) (0.24488)

(3) Measuring runout of camshaft

If the runout exceeds ‘the repair limit,

straighten the camshaft by means of a
press, or replace it with a new one.

[NOTE]
Put a dial indicator as ghown, and
turn the camshaft. Take one half
(l/2) of the gaye indication as the
runout.
Unit: mm (in.) I 401752

Measuring camshaft runout

I Item
I
Assembly
standard

Runout of camshaft 0.02 (0.0008), 0.05

maximum (0.0020)

SM 598,Oct ‘94 S4S Diesel Engine Service Manual l 00(D)-6-55

 Main Table of Contents

Group 00(D), Engine (Diesel)

(4) Measuring diameters of camshaft

journals

If the journals exceed the service limit,

replace the camshaft bushings.

Unit: mm (in.)
Assembly Service
Item standard limit
No. 1 53.94 to 53.96 53.90
Diameter No. 2 (2.1236 to 2.1244) (2.1220)
of camshaft -p-
journals 52.94 to 52.96
No- 3 (2.0842 to 2.0850) (%?7) Measuring camshaft journal diameter

I 1No. 1 1 54.02 to 54.05 1 I

Measuring camshaft bushing inside diameter

Valve tappets

(1) Inspection

Check the cam contact face of each

tappet for abnormal wear,
- and replace it
if necessary.

Good Bad Bad

4ooo68

Cam contact face of tappet

(2) Measuring tappet clearance in tappet

bore

If the clearance exceeds the assembly

standard, replace the tappet.

401200 401532

Measuring tappet clearance

00(D)-6-56 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

Group 00(D), Engine (Diesel)

Unit: mm (in.) .

‘22.tio
22.100
Inside (0.87008)
diameter

4DQ7 to 0.098
Tappet (0.00138
clearance I I to 0.00386)
in tappet
bore

Timing gears

Measuring backlash

Put a dial indicator at the pitch circle

of the gear, and move one gear back
and forth to measure the backlash
between the gears. If the backlash
exceeds the service limit, replace the
gears.

WQ7 I Unit: mm (in.)

Assembly Service
Item
standard limit I 405760

0.05 to 0.15 0.25 Measuring timing gear backlash

1 Backlash
(0.0020 to 0.0059) (0.0098) I

WSI Unit: mm (ir

Assembly Service
Item limit
standard
Idle gear and 0.06 to 0.24 0.30
oil pump gear I (0.0024 to 0.0094) (0.0 118)

Crankshaft Install the injection pump gear to the

0.05 .to 0.18
gea’rand front plate in the state of being
(0.0020 to 0.007 1)
idle gear
installed on the injection pump.

SM 598,Oct‘94 S4S Diesel Engine Service Manual l 00(D)-6-57

 Main Table of Contents

Group 00(D), Engine (Diesel) CMRK

Idle gear, bushing and shaft

(1) Measuring end play of idle gear

Measure the end play with a feeler

gauge or dial indicator. If the end play
exceeds the service limit, replace the
thrust plate.
Unit: mm (in.)

Measuring idle gear end play

(2) Measuring inside diameter of

bushing and diameter of shaft

If the idle gear shaft clearance in

bushing exceeds the service limit,
replace the bushing.
Unit: mm (in.)
Nominal Assembly Service
Item
value standard limit
0.025
401756
Idle gear 4DQ7 $2) ;0”.:6”079”8
shaft to 0.00295) 0,100 Measuring idle gear shaft and bushing
clearance
0.009 (0.00394)
K*ing S4S
$7) ~z%zj
to 0.00197)

(3) Replacing idle gear bushings

(a) To replace the bushing, use idle gear

bushing puller A (30691-51900 for
4DQ7 or 30091-07300 for S4S).

(b) When installing replacement bushing,

press it in until its end face is
flush with that of gear boss.

I Removal Installation ~o,75i

Replacing idle gear bushing

00(D)-S-58 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ClflRK Group 00(D), Engine (Diesel)

(4) Replacing idle gear shaft

To remove the idle gear shaft for

replacement, use idle gear puller A
(MH061077).

[NOTE)

Install the idle gear shaft to the

crankcase with its oil holes
positioned upward.
\\ 670089

Removing idle gear shaft

(Inspecting valve timing) T.D.C.

It is not necessary to inspect the valve \

timing, provided that all matching marks Direction of A
on the timing gears are aligned. Inspect rotation 1

f!ifl%
the timing for verification as follows: A Inlet

Using a 3 mm (0.12 in.) thick smooth

T-
Exhaust \
steel plate, add 3 mm (0.12 in.)
clearance to the inlet and exhaust
valves of No. 1 cylinder. Then, insert a 5_74O
0.05 mm (0.0020 in.) feeler gauge into B.D.C. 401762
between the top of valve cap and Valve timing diagram _
rocker, and slowly_ turn the crankshaft,
trying to find a position where the T.D.C.
feeler gauge is firmly gripped (the valve
starts opening) and a position where the
gauge is just ungripped (the valve starts
closing). Check to make sure that these
positions coincide with the angular Inlet
positions shown in the valve timing Exhaus;
diagram with 3’ mm (0.12 in.) clearance
added to valves.

I B.D.C. 405767
Valve timing diagram with 3 mm (0.12 in.)
clearance added to valves
T.D.C.
S4S
YGW

Inlet

2” 20”
Jr
B.D.C. 401763
Valve timing diagram with 3 mm (0.12 .in.)
clearance added to valves

SM 598,Oct ‘94 S4S Diesel Engine Service Manual . 00(D)-6-59

 Main Table of Contents

Group 00(D), Engine (Diesel) ClflRK

2.3 ‘Reassembly

Follow the reverse of disassembly

sequence.

(1) Installing front plate

(a) Temporarily install the injection pump

ix
to the front plate.

(b) Install the front plate to the

crankcase together with packing. I 405763

(2) Installing camshaft gear and thrust

plate

Put the thrust plate in position before

installing the gear.

Camshaft gear

401761

( 3) Installing camshaft

(a) Carefully put the camshaft in the

crankcase.

(b] Tighten the thrust plate bolts to 1.8

-+ 0.5 kgf*m (13 f 4 lbf-ft) Cl8 f 5
N-m] (4DQ7) or 1.0 to 1.3 kgf*m (7
to 9 lbf-ft) Cl0 to 13 N*m3(S4S).

(4) Installing idle gear

-(a) Install the idle gear by aligning its

mark with those on the mating
gears.

(b) Tighten the thrust plate bolts to 3.5

f 0.5 kgf*m (25 f 4 lbf-ft) [34 ,+ 5
N-ml

iNOTE
On the S4S engine, be sure to install
the oil pump before installing the 405762

idle gear.

00(D)-s-so ’ S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 00(D), Engine (Diesel)

(5) Installing oil seal

Install the oil seal to the timing gear

case with an installer. .

(6) Installing timing gear case

(a) Put the timing gear case on the

crankcase together with gasket.
Make sure the dowel pins enter
their holes.

Apply engine oil to the lip of oil

seal.

(b) Tighten the timing gear case bolts to

1.0 f 0.5 kgf-m (7 * 4 lbf*ft) Cl0 -+
5 N-m] (4DQ7) or 1.0 to 1.3 kgf-m (7
to 9 Ibf-ft) [lo to 13 N-ml (S4S).

(c) Put the crankshaft pulley in position,

and tighten the nut to 40 * 1 kgf-m
(289 f 7 lbf-ft) [392 f 10 N-ml
(4DQ7) or 50 f 1 kgf-m (362 2 7
lbf-ft) [490 2 10 N-m] (S4S).

SM 598,Oct‘94 S4S Diesel Engine Service Manual 9 00(D)-6-61

 Main Table of Contents

Group 00(D), Engine (Diesel)

CIRRK
Timing gear train

The timing marks of the gears should be

aligned as shown when the No. 1 piston
is at top dead center on compression
stroke.

405769

4DQ7 engine timing gear train

S4S engine timing gear train

Installing oil pump gear

(a) Install the oil pump gear to the shaft

while turning it in the direction of
helix.

(b) Tighten the jam nut to 3.4 f 0.5

kgf-m (25 f 4 lbf-ft) 133 * 5 N*ml.
405761

00(D)-6-62 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

EIRRK Group 00(D), Engine (Diesel)

Installing oil pan

(a) Clean the mounting surfaces of

crankcase, timing gear ease and oil
pan.

(b) Put Three Bond 1207C (sealant) to a

thickness of 4 mm (0.16 in.) on the
oil pan flange all the way around.

(c) In 5 minutes after putting the

sealant, install the oil pan to the
crankcase. ..

(d) Tighten the oil pan bolts to 1.0 to

1.3 kgf-m (7 to 9 lbf-ft) 110 to 13
N*m3.

‘1) Replacement gasket (32A13-03200)

available at request may be used
instead of the sealant.

2) To squeeze out of a 4 mm (0.16

in.) thickness of the sealant, cut 405772

the nozzle of the tube at the

position shown.

Inspecting and adjusting timing gears

after installation

After installing the timing gears, be sure

to check and adjust them-as follows:

(Inspecting backlash and end play)

After installing the timing gears, check

the backlash and end play of the gears.
(See page 53.1
v- 405760

SM 598,Oct ‘94 545 Diesel Engine Service Manual l 00(D)-5-63

 Main Table of Contents

Group 00(D), Engine (Diesel) ElIIRK

3. FLYWHEEL

3.1 Disassembly

[4DQ71

40577:

1 Flywheel 4 Gasket
2 Oil seal case 5 Rear plate
3 Oil seal

OO(D)=6-64 l S4S Diesel Engine Service Manual SM 596,Oct ‘94

 Main Table of Contents

ElfIRK Group 00(D), Engine (Diesel)

CS4Sl

Check for cracks. detective 1

405774

1 Flywheel 4 O-ring
2 Oil seal case 5 Rear plate
3 Oil seal

SM 598,Oct ‘94 S4S Diesel Engine Service Manual l 00(D)-6-65

.
 Main Table of Contents

Group 00(D), Engine (Diesel) EUIRK

(1) Removing flywheel

Unscrew the flywheel mounting bolts,

and remove the flywheel.

(2) Removing oil seal ease

Unscrew the oil seal case mounting

bolts, and remove the case.

0NOTE

In case of the 4DQ7 engine, screw

jacking bolts (M6 x 1, 2 pes) into the
holes in the case equally to remove
the case.

Be careful not to damage the oil seal

when removing the oil seal case.

(3) Removing rear plate

Unscrew the rear plate mounting bolts,

and remove the plate.

OO(II)-6-66 l S4S Diesel Engine Service Manual SM 596,Oct ‘94

 Main Table of Contents

CMRK Group 00(D), Engine (Diesel)

3.2 Inspection and repair

Flywheel and ring gear

(1) Measuring flatness of flywheel

Set the flywheel on the surface plate

and, measure the flatness of the friction
surface by moving a dial gauge on and
along that surface. If the flatness
exceeds the repair limit, refinish the
friction surface.
. .
unit: mm (in.)

I Item
I
Assembly
standard

I Flatness of flywheel
0.15 (0.0059)
I maximum
Measuring flywheel flatness

(2) Measuring face runout of flywheel

With the flywheel installed on the

engine, measure its face runout. If the
runout exceeds the assembly standard,
check for improper installation or
foreign matter lodged in the mounting
face.
Unit: mm (in.)

405070

Measuring flywheel face runout

(3) Replacing ring gear

Check the ring gear teeth for wear or

other defects, and replace the gear if
defective. To remove, proceed as
follows:

(Removal)

(a) Heat the ring gear uniformly with an

acetylene torch.

W Using a bar, give light hammer blows Replacing ring gear

to the periphery of ring gear.

SM 598,Oct ‘94 S4S Diesel Engine Service Manual . 00(D)-6-67

 Main Table of Contents

Group 00(D), Engine (Diesel) ClRRK

(Installation1

Heat a replacement ring gear up to

about 150°C (300OF) in a piston heater,
and press the gear onto the flywheel
with its unchamfered teeth foremost.

Crankshaft pulley

Inspecting V-belt groove

Check the groove for wear. Wrap a new 1

belt around the pulley, pressing it in the
groove as far as it goes, and see if the T
top surface of the belt is above the top 1.6mm (0.06in.),
minimum
of the pulley.

If the top surface of the belt is

uniformly above the top of the pulley all
the way around, it is not necessary to
replace the pulley. 40015c

InspectingV-belt groove in crankshaftpulley

If the top surface of the belt sinks into
the groove more than 1.6 mm (0.06 in.),
replace the pulley.

3.3 Reassembly _

(1) Installing rear plate

(a) Apply Three Bond 1104 to the

beveled surfaces of the crankcase
and rear plate.

(b) Install the rear plate, together with

the gasket, to the crankcase. Make
sure the dowel pins enter their
holes.

(cl Tighten the rear plate mounting bolts

to 3.5 f 0.5 kgf*m (25 f 4 lbf*ft)
C34 f 5 N-ml.

00(D)-6-68 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ElfIRK Group 00(D), Engine (Diesel)

(2) Installing oil seal case

(a) Install the oil seal to the oil seal

case.

(b) Apply engine oil to the lip of the oil

seal.

(c) Install the oil seal case, together

with gasket (4DQ7) or O-ring (S4S),
to the rear plate.

(d) l’;g;;en the oil seal case mounting

.

(3) Installing flywheel

(a) Install the flywheel to the

crankshaft. Make sure the dowel
pins enter their holes.

(b) Tighten flywheel mounting bolts with

washers to 8.5 f 0.5 kgf=m (61 f 4
lbfaft) 183 f 5 N-ml.

(cl Cheek the runout and face runout of

the flywheel to make sure they are 405780

within the assembly standard. If

the runout and/or face runout
exceeds the standard, retighten the
bolts. (See page 63.)

SM 598,Oct ‘94 545 Diesel Engine Service Manual l 00(D)-6-69

 Main Table of Contents

Group 00(D), Engine (Diesel) CUIRK

4. PISTONS, CONNECTING RODS, CRANKSHAFT AND CRANKCASE

4.1 Disassembly

C4DQ71
Check cylinder bore

Check for cracks.

Check for cracks, scoring, scratching,

dogged oil hole and wear.

lQleckfor wear, scoring, pitting. flaking, Y R

[ Check for cracks. 1

1
405781

1 Connecting rod cap 7 Connecting rod 13 Second ring

2 Connecting rod bearing 8 Connecting rod bearing 14 Oil ring
3 Main bearing cap 9 Snap ring 15 Tappet
4 Main bearing 10 Piston pin 16 Crankcase
5 Crankshaft 11 Piston
6 Main bearing 12 Top ring

L I

When replacing the crankcase,

carefully remove reusable parts (such
as a relief valve) from a crankcase
to be discarded.
9 S4S Diesel Engine Service Manual
00(D)-6-70 SM 598,Oct’94
 Main Table of Contents

Group 00(D), Engine (Diesel)

I Check for wear, 1 $y-

scoring, pitting,
fbking, chipping J.D- ’
anasign of t=C

Iand
Check for wear, nicks, chips
uneven tooth contact.

flaking, chipping and loss of overlay.

1 Connecting rod cap 7 Connecting rod bearing’ 13 Crankshaft

2 Connecting rod bearing 8. Top ring 14 Main bearing
3 Piston 9 Second ring 15 Tappet
4 Snap ring 10 Oil ring 16 Crankcase
5 Piston pin 11 Main bearing
6 Connecting rod 12 Main bearing

[ZZE]
When replacing the crankcase,
carefully remove reusable ,parts (such
as a relief valve) from a crankcase
to be discarded.,
SM 598,Oct ‘94 S4S Diesel Engine Service Manual 9 00(O)-S-11
 Main Table of Contents

Group 00(D), Engine (Diesel) Emu

(1) Removing connecting rod caps

(a) Unscrew the nuts holding each cap,

and remove the cap together with
the bearing.

(b) Mark the connecting rod bearings

(removed) for their cylinders and
location, upper or lower, to aid in
restoring them to the original
position.

(2) Preparation for piston removal

(a) Lay. the crankcase on its side.

(b) Remove all carbon from the

combustion area with a cloth or oil
paper. Carbon, if any, will make it
difficult to pull the pistons upward.

(3) Removing pistons

Bring the piston assembly (from which

the connecting rod cap has been
removed) to top dead center position.
Push the piston assembly up through the
top of the cylinder wifh the handle of a
hammer as shown.

Push the piston assembly little by I 405789

little to prevent it from falling.

(4) Removing main bearing caps

Unscrew the bolts holding the cap, and

remove the cap together with the
bearing.

lNoTEl
When removing the caps, be careful
not to damage the bearings. Upon
removing the caps and bearings, mark
each combination for its journal to
aid in restoring them to the original
journal at the time of reassembly.

00(D)-6-72 0 S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CUlRU Group 00(D), Engine (Diesel)

(5) Removing crankshaft

(a) Carefully lift the crankshaft.

(b) Remove the upper . shells of the

bearings from the crankcase.

[NOTE]

When removing _,the crankshaft, be

careful not to damage the bearings.
Mark the bearings for their journals
to aid in restoring them to the
original journals at the time of
reassembly .

(6) Removing piston rings

To remove the piston rings, use a piston

ring pliers A (31391-12900).

670101
- -.

(7) Removing piston pin

(a) Remove the snap rings with a snap

ring pliers.

(b) Remove the piston pin, and separate

the piston from the connecting rod.

(c) If it is difficult to pull out the

piston pin,. heat the piston in a
piston heater or in hot water to
expand the pin bore. I 401771

SM 598,Oct ‘94 S4S Diesel Engine Service Manual l 00(D)-6-73

 Main Table of Contents

Group 00(D), Engine (Diesel) ClRRK

4.2 Inspection and repair

Crankcase and cylinder sleeves

(1) Measuring warpage of gasket contact

surface of crankcase

Measure the warpage with a straightedge

and feeler gauge. If the warpage
exceeds the assembly standard, grind the
surface with a surface grinder. Grind
the crankcase only enough to remove the
warpage.
Unit: mm GIL)

Measuring warpage of gasket contact

surface of crankcase
I I I
I

(2) Measuring cylinder bore

(al Measure the bore in two directions,

parallel and transverse to the
crankshaft, at three positions, top
Critgcnd area), middle and bottom, as
.
unit: mm hl.

Item
I Assembly
standard I
Repair
limit
Service
limit
88.000 405794
e 88.200 88.700
.4DQ7 ;3”.tL;y
x (3.47243) (3.49212) Measuring cylinder bore diameter
to 3.46594)
94.000
to 94.035 94.200 94.700
(3 -70078 (3.70865) (3.72834)
to 3.70216)

(b) If the bore diameter has reached the

repair limit within the service limit,
bore the cylinder to the specified
oversize.

(c) Hone the cylinder to +0.25 mm

(+0.0098 in.) or +0.5 mm (+0.0197 (dl If any cylinder is unevenly worn,
in.) oversize accurate within 0 to determine the oversize on the basis
0.035 mm (0.00138 in.). Use the of the maximum wear noted to
piston and piston rings of the same ensure perfect roundness in the
oversize. oversized bore.

00(D)-6-74 . S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ElfIRK Group 00(D), Engine (Diesel)

1) Refinish all cylinders to the same

oversize.

2) If the cylinder is found in good

condition, with the wear far less
than the repair limit, replace the
piston rings, and ream off “ridge”
at the top of the cylinder. Hone
the cylinder if necessary.

Ridge-reaming cylinder

Pistons and piston rings

(1) Measuring diameter of piston

(a) Using a micrometer, measure each

piston at its skirt in the direction
transverse to the piston pin. If the
diameter exceeds the service limit,
replace the piston. If any piston is
to be replaced, select a new piston
so that the maximum permissible
difference between average weight
of all pistons in one engine is
within 5 grams (0.18 ounce).
Measuring piston skirt
Piston diameter (at skirt) unit: mm (in. 1
Nominal Assembly Service Engine front
Item value standard hit
-
87.955 Front mark , t
87 -770
(3%?8)g2789 S4S

0
4DQ7 (3.45550)

an
-0
;;i to 3.46398)
3m 93.955
Gi 93.970 to 93.985 93.770
S4S (3.69960) (3.69901 (3.69172)
to 3.70019)
88.205 Piston weight
88.020
4DQ7 (&%2) ;;.:;;;z (3.46535)
405795

to 3.47381) Piston weight marking

88.455
88.270
4DQ7 (38.:::;) ;;.::,“4; (3.47519)
to 3.48365)
94.455
94.470 to 94.485
S4S
(3.71928) (3.71869 (b) Piston weight is stamped on the top
to 3.71987) of each piston.

SM 598,Oct ‘94 S4S Diesel Engine Service Manual l M)(D)+75

 Main Table of Contents

Group 00(D), Engine (Diesel) CWW

(2) Measuring piston ring end gap

Put the ring in a new or master

cylinder, and measure the gap. If the
gap exceeds the service limit, replace
all rings as a set.
Unit: mm (in.)

$z;s;emeter 4DQ7 88 +f)03’ (3 ~6 +;-Ool38 )

cylinder sleeve ~4s 94 +;035 (3.70 +;00138 )

Measuring piston ring end gap

[NOTE]

Place the piston ring in the master

cylinder by pushing it squarely with
the use of piston.
unit: mm (ii.)
Assembly Service
Item standard limit
0.3 to 0.5
Piston ring end gap (0.012 to 0.020) (OE9)
I I I 1

(3) Measuring: side clearance of piston

ring

Insert new piston rings into the ring

grooves in the piston, and measure the
clearance of each ring with a feeler
gauge and straightedge as shown.

Side clearance unit: mm (in.)

F
Item

4DQ7 0.059
Assembly
standard
to 0.099
Repair
limit 1
-t (0.00232 to 0.00390) 0.20 Measuring piston ring side clearance
0” 0.07 to 0.11 (0.0079)
f- s4s
(0.0028 to 0.0043) .
I

5 4DQ7 0.025 to 0.060

-a (0.00098 to 0.00236)
$ 0.045 to 0.085
S4S (0.00177 to 0.00335)
G 0.15
0.025 to 0.060 (0.0059)
E”
-= 4DQ7 (0.00098 to 0.00236)
=
0 S4S 0.025 to 0.065
(0.00098 to 0.00256)

00(D)-6-76 . S4S Diesel Engine Se/vice Manual SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 00(D), Engine (Diesel)

(4) Measuring diameter of piston

inside diameter of pin hole
pin and
1
If the repair limit has reached, replace
the piston pin. If it has exceeded,
replace the piston.
Unit: mm (in.)
I I !
Nominal Assembly Repair

rl +P-
Item standard limit
value 1

24.994

Diameter
4DQ7 (0%) ~S.~~iz? 1
Measuring piston pin and hole
404153

to 0.98425)
of piston
pin 29.994
S4S $8) ;%?:
to 1.18110)

Piston
pin 4DQ7 $8) $%;; 0.03
clearance 0 to 0.0 16 (o-oo2o)
in piston S4S $8) (0.00063)

(5) Measuring projection of piston

Measure the projection of each piston

and, if it is not within the assembly
standard, inspect the various parts for
clearance.

(a) Determine the top dead center of

piston with a dial indicator.

(b) Set up the dial indicator at the top

of crankcase, and set its pointer to
zero (0).
::L5n
. Measuring piston projection
;
(c) Measure the projection at three
places on the piston head, and
average the three measurements to
determine the projection. Subtract Unit: mm (in.
the projection from the as-installed r item 1 Assembly standard
thickness of cylinder head gasket to
determine the clearance between the 1:; 1 ud).izi;;;;;;
Projection of
piston top and cylinder head. piston

Keeping the piston projection within

the assembly standard is important
not only for engine performance but
also for prevention of interference of
the valve with the piston.

SM 598,Oot ‘94 S4S Diesel Engine Service Manual l DO(D)+77

 Main Table of Contents

Group 00(D), Engine (Diesel) ClMK

Connecting, rods, connecting rod bearings
and small-end bushings

(1) Measuring connecting rod bearing 5.5 kef.m (40 Ibf.ftl

clearance on crankpin

Measure the crankpin diameter and

bearing inside diameter to determine the
clearance between the two. If the
clearance exceeds the repair limit,
replace the bearing. If the crankpin is
worn excessively or unevenly, grind the
crankpin, and use undersize bearing.
The three bearing undersizes are -0.25
mm (-0.0098 in.), -0.50 mm (-0.0197 in.)
and -0.75 mm (-0.0295 in.).
Measuring connecting rod bearing
inside diameter
[i&E)
To measure the bearing inside
diameter, install upper and lower
shells to the connecting rod properly,
and tighten the cap bolts to 5.5 *
0.5 kgf=m (40 -+ 4 lbf*ft) [54 f 5
N*mJ.
Unit: mm (in)

Item
Nominal
Glue
Assembly
standard
Repair
limit 1

00(D)-6-78 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CMRK Group 00(D), Engine (Diesel)

(2) Measuring connecting rod bushing

clearnce on piston pin

Measure the piston pin diameter and

bushing inside diameter to determine the
clearance between the two. If the
clearance exceeds the repair limit,
replace the pin or bushing whichever is
badly worn.
Unit: mm (in.)

Item Nominal Assembly Repair 401779

value standard limit
Measuring connecting rod bushing
25.020
inside diameter
Inside 4DQ7 (os, g.;Ei
diameter to 0.98602)
of 30.020
bushing
S4S $8) [:.::;g
to 1.18287)

1 I

(3) Replacing connecting rod bushing

- Weightmark side
(a) To remove - the bushing for _ _:
replacement, use a connecting rod
bushing puller. Oilhole

(b) Align the oil holes in the bushing

and connecting rod. Position the
ends of bushing as shown.
’ Ends
(c) After installing the bushing, insert
the piston pin to make sure that the I 405798

pin rotates freely. Installing connecting rod bushing

SM 598,Oct ‘94 S4S Diesel Engine Service Manual . O(D)+79

 Main Table of Contents

Group 00(D), Engine (Diesel) EUlRK

(4) Inspecting connecting rods for bend Unit: mni (in.) C 0.05 (0.0020)
and twist -.F
e - 100 (3.9)

(a) Measure ?lC” and ftI.7f If the P

measurement at YY is larger than
0.05 mm (0.0020 in.) (4DQ7) or
mm (0.0039 in.) (S4S) per 100
(3.9 in.) of “1, It straighten
with a press.
the
0.10
mm
rod
< 0.05 (0.0020)
100 (3.9)
c

+-4!h
Twist
:

Unit: mm (in.) Bend

Assembly Repair 400110
item standard limit
Inspecting connecting rod

03 For inspecting connecting rod for

bend and twist, the connecting rod
aligner is generally used.

To check for bend, install the

bearing cap to the connecting rod,
and tighten the can bolts to 5.5 f
0.5 kif-m (40 f 4- lbfeft) [54 f 5
N-ml

Checking connecting rod on aligner

(c) To check the rod- installed to the

piston, place the piston on a surface
plate, insert a round bar equal to
the crankpin in diameter into the
big end bore, and measure the
heights A and B of the bar.

401781

Inspecting connecting rod installed to piston

00(D)-6-80 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

EmI6 Group 00(D), Engine (Diesel)

(5) Inspecting connecting rod bearings .

Check each bearing shell for loss of

overlay, scratching; pitting and failure
due to poor installation. If any of these
defects is present, replace the shell.

Failure due to
poor installation
_ 4OOlli
L

(6) Measuring connecting rod end play

Install the connecting rod to the mating

crankpin, and tighten its cap bolts to
5.5 f 0.5 kgf=m (40 f 4 ibf-ft) 154 f 5
N-ml Then, using a feeler gauge,
measure the end play. If the end play
exceeds the service limit, replace the
connecting rod.
Unit: mm (in.)

I Item
I St
Measuring connecting rod end play
‘91

(7) Max. permissible difference between

average weight of all connecting rods
in one engine

When replacing connecting rods, make

sure that maximum permissible difference
between average weight of all
connecting rods in one engine is within
the assembly standard shown below. tamped weight rank letter

I 404022

SM 598,Oct ‘94 S4S Diesel Engine Service Manual 9 W(D)-&81

 Main Table of Contents

Group 00(D), Engine (Diesel) ElfIRK

Crankshaft

(1) Measuring diameter of journal

Using a micrometer, measure the journal

in two positions and in two directions to
determine the wear, out of round and
taper. If the repair limit is exceeded,
regrind the journal to the undersize, or
replace the crankshaft.
Unit: mm (in.)
Nominal Assembly Repair
Item standard limit
value 670112

64.850 Measuring journals

64.965
to 64.985 g.;zc4)

(2.55767 limit:
to 2.55846) 64.100
(2.523620
77.850 i
77.955 g;-c;5)
to 77.970
(3.06909 limit:
to 3.06968) 77.100
(3.0354311

Out of round

Taper

(2) Measuring diameter of crankpin

Using a micrometer, measure the

crankpin in two positions and in two
directions to determine the wear, out of
round and taper. If the repair limit is
exceeded, regrind the crankpin to the
undersize or replace the crankshaft.
Unit: mm (in.)
Nominal
Item 670113
value
Measuring crankpin diameter

Out of round 0.01

(0.0004),
maximum

06(D)-6-62 l 545 Diesel Engine Service Manual SM 596,Oct ‘94

 Main Table of Contents

ClRRK Group 00(D), Engine (Diesel)

(3) Grinding crankshaft Crankshaft grinding dimensions unit: mm (in.)

Refinkhing dimension
If the crankshaft is ground to any of Undersize
4DQ7 I S4S
the undersizes and refinished to a
dimension which is 0.100 to 0.120 mm
(0.00394 to 0.00472 in.) smaller than the
undersize, it is not necessary. to check
the bearing contact pattern.
When grinding the journals and
crankpins, be sure to produce the same
fillet radius as the original one. They
should have a hardness of 620 or more
in terms of Vickers Hardness Number. If
necessary, reharden the journals and 0.70 57.195 to 57.215 57205 to 57120
crankpins, and inspect them for cracks (0.0276) (225177 to 2.25255) (2.25216 to 2.25275)
by conducting a magnalux (magnetic
particle) test.

(4) Measuring end play of crankshaft

(a) Install the thrust plates in position,

and secure the main bearing caps.
Under this condition, measure the
end play (the end clearance of
thrust plates in the journal). If the
end play exceeds the assembly
standard, replace the thrust plates
(S4S) or No. 1 -main bearing (4DQ7).

(b) If the end play still exceeds the

repair limit (S4S) even after new
thrust plates have been installed,
replace the plates with the next
oversize ones. There are three
oversizes for the thrust plates;
namely, +0.15 mm (+0.0059 in.),
+0.30 mm (+0.0118 in.) and +0.45 mm
(+0.0177 in.). Generally, the rear
journal is likely to be worn more
rapidly than the front journal. This
means that replacement of the rear
thrust plates will, in most cases,
gain the purpose.

Measuring crankshaft end play

Unit: mm (in.)
Assembly Service
Item
I standard limit I

SM 598,Oct ‘94 S4S Diesel Engine Service Manual . 00(D)-6-83

 Main Table of Contents

Group 00(D), Engine (Diesel) ElIIRK

Crankshaft journal grinding dimensions

for oversize thrust plates Unit: mm (in.)
Oversizes for Oversizes for
item journal or journal and Tolerance
thrust plates thrust plates

31.60
(lSl41)

(5) Measuring runout of crankshaft

Support the crankshaft on its front and

rear journals in V-blocks, and measure
the runout at the center journal, using a
dial gauge. Depending on the amount of
runout, repair the crankshaft by grinding
or straightening with a press. If the
runout exceeds the repair limit, replace
the crankshaft. .
unit: mm (in.) .
670111

Measuring crankshaft runout

(61 Replacing crankshaft gear

(a) Using gear puller, remove the gear

from the crankshaft.

[NOTE]
Do not remove the gear by driving
with a hammer.

Replacing crankshaft gear

00(D)-6-84 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ElfIRK Group 00(D), Engine (Diesel)

(b) To install, heat the gear up to about

100°C (212OF) with a gear ‘heater.
Place the new gear on the
crankshaft by aligning the key with
the notch of the gear and give light
blows of a copper hammer to the
end face of the gear.

(7) Replacing rear oil seal

If the seal shows a sign of oil leaks,

replace it with a replacement oil seal
with sleeve.

(Removing sleeve)

Cut the sleeve at three places with a

chisel and hammer. To do this, hold the
chisel at right angles to the sleeve
surface. Remove the sleeve when it
loses tension. If this method is
ineffective, beat out the sleeve just
enough to permit removal by putting the
chisel to the sleeve in the axial
direction.
t 402812

Removingsleeve
Be careful not to damage the
crankshaft when cutting the sleeve.

(Installing sleeve)

To install the . sleeve, apply oil to the

inside surface of the sleeve, and drive it
onto the crankshaft, using crankshaft
sleeve installer set A (30691-13010), as
shown.

AMnCld

Instalhngsleeve

SM 598,Oct ‘94 545 Diesel Engine Service Manual . 00(D)+85

 Main Table of Contents

Group 00(D), Engine (Diesel) EUMK

Main bearings

(1) Inspection
1
Inspect each bearing shell for abnormal
contact, scratching, corrosion, wiped Scoring, corrosion,
overlay and other defects. Also check loss of overlay
for a sign of poor seating in the bore of
the crankcase or bearing cap.

(2) Measuring main bearing clearance on

journal

Fit the bearing shells to the crankcase

and bearing cap, and tighten the cap
bolts to 8.5 f 0.5 kgf=m (61 f 4 lbfeft)
[83 f 5 Nom] (4DQ7) or 10.5 f 0.5 kgf=m
(76’ f 4 lbfeft) Cl03 + 5 Nom] (S4S).
Measure the inside diameter of the
bearing in two positions, front and back
along the longitudinal axis of crankshaft,
in the c&s-cross directions to take an m=.mfl
average. Obtairi the difference between Measuringmain bearing inside diameter
the journal diameter and this inside
diameter to determine the clearance.
Main bearing clearance on journal Unit: mm (in.)
[-ii+ Item Nominal, Assembly Repair Service
value standard limit limit,
1) If the repair limit has reached,
replace the bearings. If this limit
to 0.100
has been exceeded, refinish the 4DQ7 (2%)(0.00138 (0%8)
journals and use undersize
bearings, -0.25 mm (-0.0098. in.),
to 0.00394) Abnormal
wear:
(0%)
at
0.050
-0.50 mm (-0.0197 in.) or -0.75 to 0.110 0.03 journal
mm (-0.0295 in.). S4S
(%) (0.00197 (0.001)

2) If the journals are refinished in

compliance with any of the
undersizes, it is not necessary to
check the bearing contact pattern.

3) The nominal values shown above

are of the journal diameters.

oo(D)=6-66 8 S4S Diesel Engine Servtce Manual SM 598,Oct ‘94

 Main Table of Contents

elmif Group 00(D), Engine (Diesel)

4.3 Reassembly

(1) Assembling piston and connecting rod

(a) Assemble the piston ‘and connecting

rod with their weight and matching
marks on the same side. Matching
marks
(b) Apply engine oil to the piston, and
connect it to the connecting rod.

406601

(c) Using a snap ring pliers, fit the snap

rings to the grooves in the piston,
making sure that they are not
weakened.

[NOTE)

Position the ends of the snap rings

on the lower side of the piston.

(2) Installing piston rings I Up mark

(a) Using piston ring pliers (31391-129001,
install the piston rings on the
piston.

Each piston ring is marked “R” or

“RN” on the side to be up when
installed on the piston.
670131
Piston rings

(b) Install the oil ring with its end gap

positioned at 180° to that of spring
expander. ( Coil spring ends

I
’ Ring gap
AMRCF

SM 598,Oot ‘94 S4S Diesel Engine Service Manual . 00( D)-6-87

 Main Table of Contents

Group 00(D), Engine (Diesel) CMRK

C4DQ71

(3) Installing main bearings

(a) Install each upper shell in the

crankcase by fitting its locking lip
in the groove. Install the shell with
thrust plate to the front side. The
oil holes in the shell and crankcase
will be aligned when the shell is so
installed.

(b) Apply a thin coat of engine oil to

the inside surface of each shell.

(4) Preparation for installing pistons

Clean the cylinder bore surface with a

clean cloth, and apply engine oil to that
surface.

(5) Installing connecting rod bolts and

bearings Lockinglip groove ,

‘@I Insert the bolts into the cap by

settling the flat of each bolt head
in place on the cap.
-
(b) Install the upper shell of the bearing
in the rod by fitting its locking lip
in the groove, and apply engine oil
to the inside surface of the shell.
40179E

(6) Installing pistons

Cam&aft side t Direction Of thrust
(a) Apply engine oil to the piston rings,
and reposition the rings by keeping
their end gaps away from the
direction of piston pin and thrust Direction of
side. piston pin
Second
ring gap
Anti-thrust ’ Combustion
direction + chamber side 4058w

00(D)-6-88 l S4S Diesel Engine Service Manual SM 598,Oot ‘94

 Main Table of Contents

CUIRK Group 00(D), Engine (Diesel)

(b) Using a piston guide A (30691~58100),

but the piston and connecting rod
assembly -:i the crankcase, making
sure the matching marks of the rod
are on the camshaft side of the
crankcase:

slrn~ 405805

(7) Installing crankshaft

(a) Wash the crankshaft with cleaning

_s&vent, and blow dry with
compressed air.

(b) Apply a thin coat of engine oil to

the journals of the crankshaft.

(c) Hold the crankshaft in horizontal

position, and carefully put it on the
crankcase. 405785

(8) Installing main bearing caps

(a) Put the main bearings on the caps.

(b) APPLY engine oil to the inside

surfaces of the main bearings.

(c) Apply Three Bond 1211 to the

mounting surfaces of the front and
rear main bearing caps.

(d) Put the main bearings on the

crankcase, making sure the dowel
pin enters its hole.

(9) Installing main bearing cap bolts

apply engine oil to the bolts, and

tighten the bolts to 8.5 f 0.5 kgf*m (61
f 4 lbfeft) [83 f 5 N-ml.

. _ --.
405784

SM 598,Oct ‘94 S4S Diesel Engine Service Manual l 00(D)-6-89

 Main Table of Contents

Group 00(D), Engine (Diesel) ElmK

(10) Measuring end play of crankshaft

Measure the end play of the crankshaft.

If the end play is out of the assembly
standard, replace the main bearings with
thrust plates.

(111 Installing connecting rod caps

(a) Put the lower shell of the connecting

rod bearings in the cap by fitting
its locking lip in the groove of the
cap, and apply engine oil to the
inside surface the shell.

(b) Put the cap in place, and tighten the

cap nuts to 5.5 f 0.5 kgf*m (40 i 4
lbfeft) C54 f 5 N*mJ.

Make sure the matching marks of the -- _..

cap and rod are on the same side.

CS4Sl

(3) Installiig main bearings

(a) Install each upper shell in the

crankcase by fitting
_ its
_~ locking lip
in the groove. The oil holes in the
shell and crankcase will be aligned
when the shell is so installed.

(b) Apply a thin coat of engine oil to

the inside surface of each shell.

(cl Install the thrust plate to the rear

face of crankcase with its oil
groove facing outside.

OO(D)=6-90 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 00(D), Engine (Diesel)

(4) Installing crankshaft

(a) Wash the crankshaft with cleaning

solvent, and blow drY with
compressed air.,

(b) Hold the crankshaft in horizontal

position, and carefully put it on the
crankcase.

(c) Apply a thin coat of engine

_ _ _.
oil to
the journals of crankshaft.

(5) Installing main bearing caps ADD~VThree Bond

(a) Apply engine oil to each lower shell,

and fit it to the bearing cap.

(b) Apply Three Bond 1212 to the mating

faces of front cap, rear caps and
crankcase before installing the caps.
Apply Three Bond
(NOTE] 1212.

Do not apply Three- Bond 1212 to any

surface other than those mating faces
of the caps and crankcase.

(c) Install the bearing caps to the

crankcase, making sure they are
flush with the crankcase walls on
the front and rear sides.

(d) Apply Three Bond 1212 to the side

seals, and insert them into the
grooves in each bearing cap. Using
the face of a screwdriver, push in
the seals, bringing their rounded Rounded corner
corners on the outer side and taking
care not to twist the seals. I 670136

[NofE]
The bearing caps have bearing
numbers stamped on them. Install the
caps in that order from the front
side of the engine.

SM 598,Oct ‘94 S4S Diesel Engine Service Manual . 00(D)-8-91

 Main Table of Contents

Group 00(D), Engine (Diesel) ElfIRK

(6) Installing bearing cap bolts

apply engine oil to the bolts, and

tighten them to 10.5 f 0.5 kgf-m (76 f 4
lbf-ft) Cl03 f 5 ,N-ml.

(7) Measuring end play of crankshaft

If the end play is out of the assembly

standard, replace the thrust plates.

(8) Preparation for installing pistons

(a) Lay the crankcase on its side.

(b) Clean the cylinder bore surface with

a clean cloth, and apply engine oil
to that surface.

(9) Installing connecting rod bolts and

bearings Locking lip groove

(a) Insert the bolts into the cap by

settling the flat of bolt head in
place on the cap.

(b) Install the upper shell of the bearing

in the rod by fitting its locking lip
in the groove, and apply engine oil
to the inside surface of the sheIl.

OO(D)=6-92l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CIRRK Group 00(D), Engine (Diesel)

(10) Installing pistons

I l
Camshaft side t Direction of thrust

(a) Apply engine oil to the piston rings,

and reposition the rings by keeping
their end gaps away from the
direction of piston pin and thrust
side.

compression ring
Anti-thrust i Combustion
direction chamber side
405804

.(b) Bring the crankpin to which the

piston is to be installed to top dead
center position. Using piston
installer A (34491-OOZOO), insert the
piston assembly into the crankcase.

(c) After resting the big end of

connecting rod on the crankpin, turn
crankshaft by 180° while pressing
down on the piston head to bring
the big end to a position where the
cap can be installed easily. 40581 i

(11) Installing connecting rod caps

(a) Install the lower shell of the bearing

in the cap by fitting its locking lip
in the groove of the cap, apply
engine oil to the inside surface of
the shell.

(b) Install the cap by tightening the nuts

to 5.5 -+ 0.5 kgf=m (40 -+ 4 Ibf*ft)
E54 f 5 Nom).

[ACAUTION ]

Make sure that the matching marks.

of the cap and rod are on the same
side.

SM 598,Oct‘94 S4S Diesel Engine Service Manual l 00(D)-6-93

 Main Table of Contents

ElaRK Group 00(D), Engine (Diesel)

INLET AND EXHAUST SYSTEMS

96
1. DEsCRIPTiON.. .....................................................................................................................

2. EXHAUST MANIFOLD ........................................................................................................

96

SM 598, Apr ‘96 S4S Diesel Engine Service Manual l 00(D)-6-95

 Main Table of Contents

Group 00(D), Engine (Diesel) elmf

INLET AND EXHAUST SYSTEMS

1. DESCRIPTION

Muffler

406038

2. EXHAUST MANIFOLD

Inspection and ripair

(a) Check each flange for cracks.

(b) Check each flange for warpage. If

the warpage exceeds the assembly
standard, repair the flanges.

unit: mm (in.)
Item Assembly standard
Warpage of exhaust 0.2 (O_OOS),
manifold flanges maximum
Checking exhaust manifold flanges for
warpage

00(D)-6-96 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CUlRK Group 00(D), Engine (Diesel)

LUBRICATION SYSTEM

1. DESCRIFTION.. ..................................................................................................................... 98

2. OIL PUMP .............................................................................................................................. 99

2.1 Disassembly .............................................................................................................. 99
2.2 Inspection and repair ............................................................................................... 100
2.3 Reassembly ............................................................................................................. 101

3. OIL FILTER ......................................................................................................................... 104

Disassembly and inspection ............................................................................................... 104

4. REUEF VALVE .................................................................................................................. 105

Inspection ........................................................................................................................... 105

SM 598, Apr ‘96 S4S Diesel Engine Service Manual l 00(D)-6-97

 Main Table of Contents

Group 00(D), Engine (Diesel) ClRRK

1. DESCRIPTION

C4DQ71

Water pump

Oil filter

Relief valve
Oil pressure
alarm switch

Oil pump
Crankshaft

- - ----_ --- --__/

I ---------mm
..----------
:--_---_---_--_-_-_

_-- ___-__--
f
--__
e-m_

-a -_. ( Oil strainer

Oilpan- -_ __ __I
406044

IS4Sl

Rocker arm

- Rocker shaft
Piston
Tappet
Camshaft

Crankshaft

_-- Main gallery

1 Relief valve’

Oil pump -/
1 Bypass valve

\ Oil, filter

Oil pan
406616

00(D)-6-96l 545 Diesel Engine Service Manual SM 596,Oct ‘94

Main Table of Contents
 Main Table of Contents

Group 00(D), Engine (Diesel) ElfIRK

2.2 Inspection and repair

C4DQ71

(1) Measuring clearance between outer

rotor and inner rotor

If the clearance is in excess of the

service limit, replace the pump as an
assembly.
Unit: mm (in.)

~1
670146

Measuring clearance between outer rotor

and inner rotor

(2) Measuring end play of rotors

I I :I I
If the end play is in excess of the
service limit, replace the pump as an
assem bly .

670147

Measuring end play of rotors

(3) Measuring clearance between outer

rotor and pump case

If the clearance is in excess of the

service limit, replace the pump as an
assembly.
unit: mm (in.)

~1 /

Measuring clearance between outer rotor

670146

and case

00(D)-6-100 l S4S Diesel Engine Service Manual SM 598,Oot ‘94

 Main Table of Contents

ClfIRU Group 00(D), Engine (Diesel)

2.3 Reassembly

C4DQ71

401805
L

Reassembly sequence

3-Z-l

Put the outer rotor in the pump case

and, after making sure the matching
marks on the case and cover are
aligned, tighten the bolts. If the
matching marks are not aligned, the
oil will not be pumped.

I 4012191

Matching marks on pump case and cover

SM 598,Oct ‘94 545 Diesel Engine Service Manual l 00( D)-6-101

 Main Table of Contents

Group 00(D), Engine (Diesel) CMRK

rs4s1

405819

Reassembly sequence

4--3+-l

[S4Sl

(1) Measuring clearance between outer

rotor and inner rotor

If the clearance is in excess of the

service limit, replace the outer rotor
and shaft as an assembly.
Unit: mm (in.)
Item
Clearance between 0.13 to 0.15 0.20
outer rotor and (0.005 1 (0.0079)
inner rotor to 0.0059) I I Measuring clearance between outer rotor
and inner rot&

00(D)-6-102 l 545 Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CUllRK Group 00(D), Engine (Diesel)

(2) Measuring end play of rotors

If the end play is in excess of the

service limit, replace the _rotors.

unit: mm (in.)

I Item
I
Assembly
standard I
Service
limit I
0.04 to 0.09
End play of rotors 0.15
(0.0016
(0.0059)
to 0.0035)
405821

Measuring end play of rotors

(3) Measuring clearance between outer

rotor and pump case

If the clearance is in excess of the

service limit, replace the outer rotor.

unit: mm (in

Measuring clearancebetween outer rotor

and pump case
(4) Measuring clearance between shaft
and pump case

Measure the diameter of the shaft .and

0
the inside diameter of the pump case to
determine the clearance -between the
two. If the clearance is in excess of the
service limit, replace the shaft or pump
assembly.
Unit: mm (in.)

Item Assembly Service 405823

standard limit
Measuring clearance between shaft
15 -985 to 16.000
Diameter of
(0.62933
and pump case
rotor shaft
to 0.62992)
Clearance between 0.032 to 0.074
0.150
shaft and pump (0.00126
case (0.00591)
to 0.0029 1)

SM 598,Oct ‘94 545 Diesel Engine Service Manual . 00(b)-6-103

 Main Table of Contents

Group 00(D), Engine (Diesel) EMIRK

3. OIL FILTER

Disassembly and inspection

C4DQ71

405824

1 Oil filter 2 Relief valve 3 dil filter bracket

Check for clogging ad cracks.

Replace every 200 hours or
1 month. Apply engine oil to
packing when installing fdter.

1 Oil filter 2 Relief valve

00(D)-6-104 l 545 Diesel Engine Service Manual SM 598,Oct ‘94
 Main Table of Contents

ClRRK Group 00(D), Engine (Diesel)

4. RELIEF VALVE

Inspection
:,‘-
(1) Check the valve seat for abnormal
contact. Also, check the spring for ;.‘I
’ ‘..j
fatigue and breakage. ‘. 1
‘:

(2) ‘Test the relief valve setting. If it is

in excess of the assembly standard,
make an adjustment as follows:

4DQ7: Loosen the lock nut and turn the j

adjusting screw.
Relief valve for 4DQ7 engine
s4s: Remove the cap bolt and add or
subtract the shims.

Engine oil pressure tap

4DQ7: Rp i/8 thread (PS l/8)
(located on the side of the oil
filter)

s4s: Rp l/8 thread (PS l/8)

(located on the backside of the
starter)

Unit: kgf/cm2(psi) [kPa] 405827

Item 1 Assembly standard 1 Relief valve for S4S engine

SM 598,Oct ‘94 S4S Diesel Engine Service Manual 9 00( D)-6-105

 Main Table of Contents

ElClRU Group 00(D), Engine (Diesel)

COOLING SYSTEM

1. DESCRIPTION ..................................................................................................................... 108

2. WATER PUME’ .................................................................................................................... 109

Disassembly and inspection ............................................................................................... 109

3. THERMOSTAT ................................................................................................................... 110

Inspection ........................................................................................................................... 110

SM 598, Apr ‘96 S4S Diesel Engine Service Manual l 00(D)-6-107

 Main Table of Contents

Group 00(D), Engine (Diesel) ElmK

COOLING SYSTEM

1. DESCRIPTION

Thermostat

Radiator
i=? \

Water pump ’

.
40582

00(D)-6-108 l S4.S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CIIFIRK Group 00(D), Engine (Diesel)

2. WATER PUMP

Disassembly and inspection

The disassembled views of the water What to be checked for on the pump are
pumps given below are for reference only. water leakage, abnormal rotation, cracks,
Generally, the water pump is not to be etc. A faulty pump is to be replaced as
disassembled; when to replace the pump is an assembly.
to be determined by visual inspection.

Check V-belt goove

for wear and damage.

1 Water pump pulley 5 Unit seal 9 Spacer

2 Spacer 6 Snap ring 10 Ball bearing
3 Cover 7 Shaft 11 Washer, ring
4 Impeller 8 Ball bearing 12 Water pump case

SM 598,Oct ‘94 S4S Diesel Engine Service Manual l 00( D)-6-109

 Main Table of Contents

Group 00(D), Engine (Diesel) ClflRK

1
Check V-belt groove
for wear and damage.

1 Water pump pulley 4 Impeller 7 Bearing unit

2 Flange 5 Unit seal 8_ Case
3 Cover 61 Wire clip

3. THERMOSTAT

Inspection

Place the thermostat

test it for thermostatic
in a water tub, and
action by heating
the tub to raise the water temperature.
Measure the temperature at which the
ci
=
Lz
5
>
if
tz5
0 76.5f2 90 (C)

valve lifts more than 10 mm (0.4 in.). If Temperature

the valve fails to operate properly,
replace the thermostat.

r 1 Assembly standard
404058
76.5 f 2°C
4DQ7

I
Temperature (170 k 3.6’F)
at which valve
starts opening

1) Stir the water in the bath with a

Valve lift at stick to maintain its temperature
90°C (194’F) 8 mm (0.31 in.), uniform during test.
S4S
minimum
2) Install the thermostat with its air
vent hole up.

00(D)-6-110 l 545 Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CWRK Group 00(D), Engine (Diesel)

FUEL SYSTEM

1. DEXRlFTION ..................................................................................................................... 112

1.1 Draining (distributor type injection pump) ............................................................. 112
1.2 Priming .................................................................................................................... 114

2.FuELFILTER ...................................................................................................................... 116

Disassembly and inspection ............................................................................................... 116

3. INJECTION NOZZLES ....................................................................................................... 117

3.1 Disassembly ............................................................................................................ 117
3.2 Inspection and adjustment ....................................................................................... 117
3.3 Reassembly ............................................................................................................. 120

4. INJE~ON PTJMP .............................................................................................................. 121

4.1 Removal .................................................................................................................. 121
4.2 Installation ......................................................... ...................................................... 121
4.3 Adjusting injection timing ...................................................................................... 122

SM 598,Apr ‘96 S4S Diesel Engine Service Manual l 00(D)-6-111

 Main Table of Contents

Group 00(D), Engine (Diesel) CUlRK

1. DESCRIPTION

injection nozzle

405831

1.1 Draining (distributor type injection

pump)

The fuel filter collects water and

sediment that may be in the fuel. To
remove the collected water and sediment,
proceed as follows:

(1) Loosen the drain plug at the bottom

of the fuel filter.

100823

00(D)-6-112 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CmK Group 00(D), Engine (Diesel)

(2) Operate (push down on) the priming

pump of the filter seven times to
facilitate draining. Primingpump

(3) After draining, tighten the drain plug.

(4) After draining, prime the fuel system.

(See page 110.)

pzE-J~~

Some fuel may flow’ out together 100824

with water and sediment during

draining. After draining, clean up
spillage of fuel.

(5) Testing water level sensor

(a) Change the element every 6 months

or 1200 hours.

The element is made of paper. Do

not attempt to reuse the element by
washing.

W Replace the packings each time the

sensor is disassembled.
Water level sensor testing
(cl Check the sensor body for cracks,
distortion or stripped threads, and
replace it if defective.

(d) Replace the plug if its threads are

stripped.

(e) Check to make sure the indicator

lamp glows when the float is moved
up, with the sensor connected.

SM 598,Oct
‘94 S4S Diesel Engine Service Manual l 00(D)-S-113
 Main Table of Contents

Group 00(D), Engine (Diesel) ClFllW

1.2 Priming

[Fuel filter side1

(1) Loosen the air vent plug of the fuel

filter with a wrench.

r vent plug

100826

(2) Muffle the air vent plug in a thick

cloth and operate the priming pump
repeatedly to allow the fuel to run
until free of bubbles.

(3) Tighten the air vent plug.

Fviming pum

100825

Unjection pump side1

(1) Turn the starter switch to ON

position.

(2) Loosen the air vent bolt on the side

of the injection pump body.

(3) Feed fuel by operating the priming

pump until the fuel flows free of
bubbles frdm the air vent. *
Air vent bolt ’ .404088
(4) Tighten the air vent bolt. (Tightening
torque for air vent bolt: 46 kgf-m
(333 lbf*ft) [451 N*ml)

(5) Tighten the air vent cap nut by hand

until it will go (about 6.5 turns).

(6) Connect the injection pipe ‘to the

injection pump (after the pump has
been reinstalled).

00(D)-6-114 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ClRRK Group 00(D), Engine (Diesel)

(7) Depress the accelerator pedal all the

way and crank the engine.

(8) Start the engine. Tighten the cap nut

when the fuel. flows free of air
bubbles. (Tightening torque for air
vent cap nut: 80 kgf*m (579 lbf=ft)
1785 N*ml)

Cover the surfaces around the

injection pump with a vinyl sheet to
brevent fuel from splashing on them.

If the priming pump valve is jammed

with dirt, the pump does not create
pressure, resulting in a failure of
priming. In such a case, remove the
air vent bolt and suction-side hose of
the fuel filter, and blow air into the
,pump to remove dirt.

SM 598,Oct
‘94 S4S Diesel Engine Service Manual 8 00( D)-6-115
 Main Table of Contents

Group 00(D), Engine (Diesel) ClfMK

2. FUEL FILTER

Disassembly and inspection

40583:

1 Air vent plug 4 Cartridge kit

2 Drain plug set 5 Body assembly
3 Water level sensor

oop)=s-116 ’ S4S Diesel Englne Servlce Manual SM 598,Oct ‘94

 Main Table of Contents

ElfIRK Group 00(D), Engine (Diesel)

3. INJECTION NOZZLES

3.1 Disassembly

405834

1 Retaining nut 4 Pin 6 Washer

2 Nozzle tip assembly 5 Spring 7 Body
3 Piece

3.2 Inspection and adjustment

(1) Injection pressure

(a) Set up the nozzle on the tester.

Operate the tester handle several
times to prime the pipe and nozzle.

(b) Slowly operate the handle all the

way up and down, completing each
cycle in about a second, while
observing the pressure gauge
indication.

(c) The gauge needle will slowly deflect Testing injection nozzle
and, when the nozzle begins to
spray fuel, it returns quickly. Read
the pressure right then as the
injection pressure.

SM 598,Oct ‘94 545 Diesel Engine Service Manual 9 00(D)-6-l 17

 Main Table of Contents

Group 00(D), Engine (Diesel) ClmK

Injection pressure
(valve opening pressure) Unit: kgf/cm’ (psi) [kPa]
Item Assembly standard

1 4DQ7 1 120 +I; (1706 +14;) [l 1768+g8;] 1

Never expose the hand or other part

of the body to fuel spray nor touch
the spray hole during the test.

(d) If the pressure is out of

specification, make an adjustment by
increasing or decreasing the
adjusting washer thickness.

..
[NOTE ]
Increase or decrease of adjusting
washer thickness by 0.1 mm (0.004
in.) wiI.I than e the injection pressure
by 10 kgf/cm 5 (142 psi) 1981 kPa1
400221
Adjusting washer thicknesses

4DQ7 engine:
0.9 mm (0.035 in.) to 1.95 mm (0.0768
in.) C43 kinds, 0.025 mm (0.00098 in.)
increment}
S4S engine:
1.25 mm (0.0492 in.) to 1.7 mm (0.067
in.) [lo kinds, 0.05 mm (0.0020 in.)
increment]

(2) Spray pattern

(a) At the time of testing the injection

pressure, inspect each nozzle for
clogged spray hole and fuel leaks
from the hole. Also examine spray
pattern. vg-7~~
Good Large Dribble Not Fissured
(b) The nozzle should spray fuel from its angle straight
orifice in a good straight cone,
consisting of finely atomized fuel
particles. 401818

Spray patterns

00(D)-6-118 l S4S DieselEnglneServlce Manual SM 598,Oct ‘94

 Main Table of Contents

CUlRlC Group 00(D), Engine (Diesel)

(3) Washing or replacing nozzle tip

(a) Loosen the retaining nut, and remove

the nozzle tip. Wash the needle
valve and body.

When pulling out the nozzle tip, be

careful not to damage it.

402912
(b) Wash the nozzle tip in clean
. kerosine. After washing, assemble
the needle valve and body in clean
diesel fuel.

The needle valve and body are finely

finished. Do not change the
combination or set of the valve and
body.

(c) Tighten the retaining nut to the

specified torque.

(d) If the spray pattern is still bad after

the nozzle has been adjusted and
cleaned, replace the nozzle tip.

1) Never attempt to touch the sliding

surface of needle valve.

2) When installing a new nozzle tip,

remove synthetic resin inhibitor
from the tip, and slide the needle
valve in the nozzle in clean
gasoline to wash off preservative
which has been sprayed over the
surfaces of the parts.

SM 598,Oct ‘94 545 Diesel Engine Service Manual l 00(D)-6-l 19

 Main Table of Contents

Group 00(D), Engine (Diesel) CMRK

3.3 Reassembly

Tightening torque for

retaining nut :
3.75 ?r 0.25 kgf-m
(27 + 1.8 lbfeft)
[37 f 2.5 Nem]
Tightening torque for
injection nozzle:
6 f 1 kgfmm
(43 2 7 lbfeft)
[59 2 10 N-m]

405835

1Reassembly sequence 1

7-6-5-4-3-2-l

00(D)-6-120 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ElfIRlC Group 00(D), Engine (Diesel)

4. INJECTION PUMP

.4.1 Removal

(1) Remove the fuel pipe, injection pipes Mark

front
and control linkage from the ‘injection plate
pump.

(2) Check the indexing of the matching

mark on the injection pump in
relation to the mark on the front
plate (engine).

(3) Remove the front cover from the

engine.

(4) Put a mark across the injection pump

gear and idle gear.

(5) Unscrew the injection pump mounting

bolts at the pump flange, and remove
the pump complete with the flange
from the front plate (engine).

Do not attempt to turn over the

engine after the injection pump has
been removed.

4.2 Inst,allation
_..
(1) Install the injection pump to the front
plate by aligning the matching marks
on the pump and front plate.

(2) Install the front cover in place.

(3) Install the fuel pipe, injection pipes

and control linkage.

If the fiange happens to have been

removed from the injection pump and
the indexing of the matching mark
has not been checked or recorded
before pump removal, be sure to
adjust the injection timing (for the
beginning of injection) as outlined in
4.3.

SM 598,Oct ‘94 S4S DieselEngineServiceManual l 00(D)-6-121

 Main Table of Contents

Group 00(D), Engine (Diesel) ClClRK

4.3 Adjusting injection timing

The injection timing varies according to

the model of the engine. Be sure to
verify the timing of your engine before
attempting to make an adjustment.

“B.T.D.C.” signifies “before top dead

center on compression stroke.”

(1) Bringing No. 1 cylinder piston to top

dead qsnter on compression stroke

(a) Put turning handle (30691-21800 for

4DQ7) turning socket
(58309-7310: for S4S) on the
crankshaft pulley nut, and turn the
crankshaft in normal direction
(clockwise as seen from the front
side of the engine).

(b) Stop turning the crankshaft when the

timing mark on the crankshaft pulley
is aligned -with the pointer of the
timing gear case.

(c) Attempt to move the inlet and

exhaust valve rocker arms for the
No. 1 cylinder up and down to make
sure they are not being pushed up
by their pushrods. With the piston
at top dead center on compression
stroke, the inlet and exhaust rocker
arms are not being pushed up. If
these rocker arms are being pushed
up, turn the crankshaft once again.

00(D)-6-122S4S Diesel Engine Service Manual

l SM596,Oct'94
 Main Table of Contents

CMRK Group 00(D), Engine (Diesel)

(2) Adjusting injection timing

(a) Loosen the injection pump mounting

nuts.

(b) Turn the crankshaft about 30° in

reverse direction (counterclockwise
as seen from the front side of the
engine). Then, turn the crankshaft
little by little in normal direction
until the correct injection timing
mark is aligned with the pointer.

(c) Remove the inspection cover from

the side of the injection pump.

Cd) Make sure the flat A of the insert

c&lip is aligned with the mark “E”
on the drive plate.

(e) If the flat A is not aligned with the

mark ‘TE,n move the injection pump
to align them.
circlip

(0 Finally, tighten the injection pump 203352

mounting nuts.

SM 598,Oct ‘94 S4S Diesel Engine Service Manual l 00( D)-6423

 Main Table of Contents

CMRK Group 00(D), Engine (Diesel)

ELECTRICAL SYSTEM

Refer to chassis service manual for schematics.

1. STARTER ............................................................................................................................. 126

1.1 Disassembly ............................................................................................................ 126
1.2 Inspection and repair ............................................................................................... 127
1.3 Reassembly ............................................................................................................. 131

2. ALTERNATOR .................................................................................................................... 134

2.1 Disassembly ............................................................................................................ 134
2.2 Inspection ................................................................................................................ 135
2.3 Reassembly ............................................................................................................. 137

3. HEATER PLUGS ................................................................................................................. 139

Inspection ........................................................................................................................... 139

SM 598, Apr ‘98 S4S Diesel Engine Service Manual l 00(D)+125

 Main Table of Contents

Group 00(D), Engine (Diesel) clfllw

1. STARTER

1.1 Disassembly
(M002T62271)

Check cmnmutator surface for roughness,

I
burning and grooved wear. Check gear
for worn and damaged teeth.

1 Switch assembly 7 Bearing 13 Pinion set

2 Rear bracket 8 Cover set 14 Pinion shaft assembly
3 Brush holder assembly 9 Center bracket assembly 15 Sleeve’ bearing set
4 Yoke assembly 10 Gear 16 Front bracket assembly
5 Armature 11 Lever assembly
6 Bearing 12 Spring set

00(D)-6-l 26 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ClRRK Group 00(D), Engine (Diesel)

1.2 Inspection and repair

(1) Armature

(a) Testing for short circuits

Place the armature on a growler,

and slowly revolve it with a
hacksaw blade held above the
armature core. The hacksaw blade
vibrates against the core when it is
above a slot containing a shorted
winding. Replace the armature if
shorted. I 670203

(b) Testing for grounded circuits

If there is continuity between the

commutator and shaft (or core), the
armature is grounded and should be
replaced.

670202

(c) Inspecting commutator

1) Support the armature in V-blocks, and

measure the runout of commutator
with a dial indicator.-If the runout
exceeds the repair limit, repair the
commutator by turning it in a lathe.
If the commutator surface is rough,
smoothen it with a sandpaper of #300
to #500.
When repairing the commutator, make
sure its outside diameter is not
smaller than the service limit.
unit: mm (in.)
Repair
I Item
Assembly
standard I limit
Runout of 0.05 0.10
commutator (0.0020) (0.0039)

SM 598,Oct ‘94 545 Diesel Engine Service Manual 9 00( D)-6427

 Main Table of Contents

Group 00(D), Engine (Diesel) CLRRK

2) Measure the outside diameter of
commutator. If it is smaller than the
service limit, replace the armature.
Unit: mm Cn.~
Nomid
I Item
value
Service
limit I
Diameter of 31.4
commutator $6) (1.236)

I 401827

3) Measure the depth of each mold

between segments with a depth
gauge. If the depth exceeds the
repair limit, recondition the mold.
Unit: mm (ii.)

Mold depth
Good Bad

401828

(2) Field coil

(a) Testing for open circuits

If there is no continuity between

the lead wire and positive (+I brush,
the field coil is open and the yoke
assembly should be replaced.

(b) Testing for grounded circuits

If there is continuity between the

yoke and positive (+I brush, check
the insulation, and repair or replace
the yoke assembly.

00(D)-6-l 28 . S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CIIRRIC Group 00(D), Engine (Diesel)

(3) Brushes and holders

(a) Wear of brushes

Measure the brush length and, if it

is less than the service limit,
replace the brushes. If the brushes
are unevenly worn or rough,
recondition them with a sandpaper
of #300 to #500.’
unit: mm (in.)

I Item
Assembly
I standard
Service
limit I
1 Length of brush 1 18 (0.71) 1 11 (0.43) 1

(b) Brush spring tension

Test the spring tension (test force)

using a new brush. In this test, read
the load at the moment that the
spring moves off the brush. If the
tension is below the service limit,
replace the spring.
Unit: kgf (lbf) [N]

item Assembly Service

standard limit
401832

(c) Testing brush holders for insulation

If there is continuity between the

positive (+I brush holder and
negative (-1 holder plate, replace
the brush holder assembly.

SM 599, Ott ‘94 S4S Diesel Engine Service Manual l 00( D)-6-129
 Main Table of Contents

Group 00(D), Engine (Diesel) CUIRK

(4) Overrunning clutch

Make sure that the pinion shaft turns

smoothly when turned in the direction of
driving (clockwise) and that it locks
when turned in the opposite direction. If
not, replace the overrunning clutch.
._

401834

(5) Pinion shaft thrust gap

The pinion shaft thrust gap is the play Center bracket

.

-a
eihibited by the pinion shaft when it is
moved in the thrust direction. I
Thrust gap
Measure the thrust gap in the following
Stop ring 7 f
manner. If it is out of specification,
select the adjusting washer and adjust Washer
I “y&J
the gap. Pinion shaft
Adjusting washer
(a) When the pinion is removed: 401835

Install the .gear on the pinion shaft,

insert the shaft into the center
bracket, and lock the shaft with the
washer and ring. Under this
condition, move the shaft in the
axial direction, and measure the
thrust gap.

(b) When the pinion is installed:

Install the pinion shaft and gear

between the front and center
brackets, and temporarily tighten
the bolt. Under this condition, move
the shaft in the axial direction, and
adjust the thrust gap.

Unit: mm (in.)
Item I Assembly standard 1
Thrust gap of pinion 0.5 (O-020), maximum
shaft [Below 0 not permissible]

00(D)-6-130 l S4S Diesel Engine Service Manual SM 596,Oct ‘94

 Main Table of Contents

elfiRK Group 00(D), Engine (Diesel)

1.3 Reassembly
CM002T62271)

----_---_

1Reassembly sequence )

16-l5-l4-l3-l1-l2-lO-9-8

S-7-6 1 -4-3-2-l

SM 598, Ott ‘94 S4S Diesel Engine Service Manual l 00(D)-6-131

 Main Table of Contents

Group 00(D), Engine (Diesel) ElfIRK

Inspection and testing after reassembly

(1) Pinion gap adjustment

(a) If the assembled starter is wired as

shown, the pinion will shift and turn
slowly. Remove the connector from
the M terminal to stop the pinion.

(b) Under this condition, lightly push in

the pinion toward the armature, and
measure the movement (gap) of the
pinion.
1836

(4 To adjust the gap, increase or

decrease the packings fitted to the
magnetic switch. Increasing the
packings decreases the pinion gap.
unit: mm (in.)
I Item 1 Assembly standard 1
0.5 to 2.0
I
1
Pinion gap
I
(0.020 to 0.079) II

-(NOTE\
Do not test the starter continuously
for more than 20 seconds to prevent
the switch coil from overheating.

(2) No-load test

After adjusting the pinion gap, hook up

the starter as shown, and test it for no-
load. characteristics.

Use wires as thick as possible and

tighten each terminal securely.

406842

00(D)-6-132 l 545 Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CMRK Group 00(D), Engine (Diesel)

(3) Magnetic switch

(a) Testing coil for open circuits

If there is no continuity between S M terminal

B terminal
and M terminals and between S
terminal and body (ground), replace
the switch.

(b) Checking contactors for fusion

If there is continuity between B and

M terminals, replace the switch.

(c) Checking contactors for poor contact

action

Check for- voltage drop. If voltage

drop is excessive, the contactors are
defective.

SM 598,Oct ‘94 S4S Diesel Engine Service Manual 8 00( D)-6-133

 Main Table of Contents

Group 00(D), Engine (Diesel) EMRK

2. ALTERNATOR

2.1 DisassembIy

For dry-clutch models

(AOOlA25070) ’ ..

Check slip ring for dirt buildup,

burning and other defects.
check oil seal contact surface
of shaft for wear.

405844

1 Pulley assembly 6 Stator

2 Front bracket assembly 7 Terminal set
3 Bearing - 8 Regulator assembly
4 Rotor assembly 9 Rectifier assembly
5 Bearing 10 Rear bracket assembly

00(D)-6-l 34 l S4S Diesel Engine Service Manual SM 596,Oct ‘94

 Main Table of Contents

CUIRK Group 00(D), Engine (Diesel)

For wet-clutch models

(A005T22570)

Check slip ring for dirt buildup,

L**mi-A md otlm defects.
1 seal contact surface
1 01 SnaIr for wear.

I
I 12 1
10
13 1 Check vanes for cracks.

1 Pulley assembly 6 Stator 11 Vane

2 Front bracket assembly 7 Terminal set 12 Bra’cket
3 Bearing 8 Regulator assembly 13 Rear bracket assembly
4 Rotor assembly 9 Rectifier assembly
5 Bearing 10 Housing assembly

2.2 Inspection

(1) Brushes
Unit: mm (in.)
Replace the brushes if they are worn
down to the wear limit line.
Unit: mm (in.)
Assembly Service
Item standard limit
I I

Brush length 1 18.5 (0.73) 1 7 (0.28)

670216

SM 598,Oct ‘94 S4S Diesel Engine Service Manual . 00( D)-6-135

 Main Table of Contents

Group 00(D), Engine (Diesel) CUlRK

(2) Field coil

Measure the resistance between the slip

rings. If the resistance is out of
assembly standard, replace the rotor.

Assembly
Item Models
,
standard
I

Resistance between 1 AOOlA25070 1 3.62

I
slip rings ‘_
(20% (68°F)) : AOOST22570 2.4Q

(3) Stator coil

Check for continuity between the lead

wires. If no continuity is noted, the coil
is open-circuited. Also check for
continuity between the lead wire and
coil. If any continuity is noted, the coil
is grounded.

(4) Rectifier
Heat sink (+)
Test the resistance between the diode
lead wire and heat sink. To test,
connect the positive (+) lead wire of the
tester to the diode and then the
negative (-) lead wire of the tester to
the diode. If the resistance is infinite in
both cases, the diode is open-circuited.
If it is nearly zero in both cases, the Trio diode lead
diode is short-circuited. If the diode is
’ pen- or short-circuited, replace the
rectifier.

00(D)-6-136. S4S Diesel Engine Service Manual SM 596,Oct ‘94

 Main Table of Contents

ElfIRK Group 00(D), Engine (Diesel)

2.3 Reassembly

(AOOlA25070)

6
\ /*

1Reassembly sequence 1

4 -5
10 -9 -8 -7 1
-6 -1
2-3 J

SM 598,Oct ‘94 545 Diesel Engine Service Manual l 00(D)-5-137

 Main Table of Contents

Group 00(D), Engine (Diesel) ElfIRK

(A005T22570)

11

403889

1 Reassembly sequence 1

12 -11 -10
13 5 -4
9 1
-8-7-6-l
2 -3 J

00(D)-6-138 . S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 00(D), Engine (Diesel)

(1) Replacing bearings

Position the bearing (to be fitted to the

rear side of the rotor) with its spring on
the rotor side when installing it.

When fitting the spring in the groove in

the bearing, position its projection in
the deepest portion of the groove.

(2) Holding brush

Push the brush into the holder, and hold

it there by inserting a 2 mm (0.08 in.)
diameter wire into the hole in the brush.
Then, install the rotor, Remove the wire
after installing the rotor.

Rotor

3. HEATER PLUGS

Inspection

If the heater plug glows red with the

portion A of the plug connected with
positive wire (+> and the portion B
grounded, the plug is in sound condition;

SM 598,Oct ‘94 S4S Diesel Engine Service Manual l 00(D)-$139

 Main Table of Contents

EIRRK Group 00(D), Engine (Diesel)

WORKSHOP THEORY

1. SUGGESTIONS ON DISASSEMBLY AND REASSEMBLY.. ......................................... 142

1.1 Oilseals ................................................................................................................... 142
1.2 o-rings .................................................................................................................... 143
1.3 Bearings .................................................................................................................. 143
1.4 Lock plates .............................................................................................................. 144
1.5 Split pins and spring pins ......................................................................................... 144

2. TESTING THB COMPRESSION PRESSURE ................................................................... 145

SM 598, Apr ‘96 S4S Diesel Engine Service Manual l 00(D)+141

 Main Table of Contents

Group 00(D), Engine (Diesel) ElIIRK

WORKSHOP THEORY

1. SUGGESTIONS ON DISASSEMBLY AND

REASSEMBLY

1.1 Oil seals

When installing oil SedS, carefully

observe the following points:

(1) Driving oil seals into housings

(a) Make sure that seal lip is not

damaged, and position it correctly
with respect to oil compartment.

(b) Apply a small amount of grease to

the surface of oil seal to be fitted
into housing bore.

(c) Using a tool of the type shown to

guide seal lip, drive oil seal
squarely. Never give any hammer
blows directly to oil seal since this
will damage the seal, resulting in oil
leakage.

400247A

Oil seal driver

(2) Driving oil seals onto shafts

(a) Apply a thin coat of grease to oil

seal lip.

(b) Use an oil seal guide of the type

shown when driving oil seal over
stepped portion, splines, threads or
keyway to prevent damage to seal
lip.

Oil seal guide

00(b)-6-142 l 545 Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ClRRK Group 00(D), Engine (Diesel)

WORKSHOP THEORY

1.2 O-rings

Use an O-ring guide of the type shown

when installing O-ring . over stepped
portion, splines, threads or keyway to
prevent damage to the ring. Apply a thin
coat of grease to O-ring.

400249A

O-ring guide

1.3 Bearings

(1) When installing a rolling bearing, be

sure to give a push to the race,
inner or outer, by which the bearing
is fitted. Be sure to use a bearing
driver of the type shown.

40025oA

Bearing driver
(2) Use a press whenever possible to
minimize shock to bearing and to
assure proper installation.

I,
I - 400251 A

Bearing installation by a press

SM 598,Oct ‘94 545 Diesel Engine Service Manual l 00(D)-6443

 Main Table of Contents

Group 00(D), Engine (Diesel) ClRRK

WORKSHOP THEORY

1.4 Lock plates

Bend lock plate against one of the flats

of nut or bolt head as shown.

._

0 Right
x wrong
400252A

Bendinglock plates

1.5 Split pins and spring pins

Generally, split pins are to be replaced

and bent properly at the time of
disassembly. Drive each spring pin into
position so that it may not get out of
place after subsequent installation of
parts has been completed.

00(D)-6-144 . S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ClaRK Group 00(D), Engine (Diesel)

2. TESTING THE COMPRESSION

PRESSURE

(1) Remove the heater. plug from a

cylinder on which the compression
pressure is to be measured.

(2) Attach the gauge adaptor

(30691-21100) to the heater plug
hole, and connect the compression
gauge to the adaptor.

(3) Crank the engine by means of the

starter, and read the compression
gauge indication when the engine
begins to run at the specified speed.

(4) If the compression pressure is lower

than the repair limit, overhaul the
engine.

1) Be sure to measure the

compression pressure on all
cylinders. It is not a _ good
practice to measure the
compression pressure on two or
three cylinders and judge the
compression pressure of the
remaining cylinders therefrom.

2) The compression pressure varies

with change of engine rpm. This
makes it necessary to check
engine rpm at thZ time of
measuring the compression
pressure.
Unit: kgf/cm’ (psi) [kPa]
Item Assembly Repair
limit
~CA~JTI~N J
standard
1) It is important to measure the
compression pressure at periodical
Compression intervals to obtain the data on
pressure ;- the gradual change of the
pressure.

2) The compression pressure would be

slightly higher than the assembly
standard in a new or overhauled
engine owing to breaking-in of the
Measure the compression pressure piston rings, valve seats, etc. It
with the engine running at 150 to drops as the engine parts wear
200 rpm. down.

SM 598,Oct ‘94 S4S Diesel Engine Service Manual l OO(D)-5-145

 Main Table of Contents

CWRK Group 00(D), Engine (Diesel)

TROUBLESHOOTING

TROUEKESHOOTING CHART (1) ....................................................................................... 148

TROUBLESHOOTINGCHART (2) ....................................................................................... 152

SM 598, Apr ‘98 S4S Diesel Engine Service Manual l W(D)+1 47

 Main Table of Contents

Group 00(D), Engine (Diesel) ElfIRK

TROUBLESHOOTING CHART (1)
Engine will not start Engine lacks
power
- -
T Abnormal cs-
haust smoke

T TI’ T
Enpine turns
IEngine does When
but does z
-
not start
- Ii tot turn
- - 2
C --
operating
-
l- s
::
y” 5
s =” f x 3
5
ij z
z =U ki f e 2
,_
i 2 2 ::z f4 t
Possible cause 5 z
Jz
ai cz
z=
E
ZE
5
58
a
E
2
=
2
::
2
C
z
2
2
;;
;;
2
z or.2
=*
f 3
$5
2.2
2s
-0

iis
E”d
‘c) zl-
EE zy E
:
!5.,
5% 5” I
._
8
E
5.5 g_;
-iz uvr E
-
:z
-
=:!
x20
-
r: ;
-
_;
-
SE
-VI
-
f
-
se
-
E
inn E
-
y2 f
Insufficient fuel supply to -
0 0 -
injection pump

Greater variance of injec- - -

0 0 0 0 0 0
tion quantity

Defective injection pump

SdS
- - - - - - - -

insufficient
quantity
injection
0 0 - - - - -
Excessive injection
quantity
- - _- - - 0

Improper fuel spray from - -

- 0 - 0 0 0 0 0 0
injection nozzles
Excessive fuel return frorr - 0 - - - - - - - 0
injection nozzles
Injection timing too - - -
- 0 0 0 0
advanced
Injection timing too - -
retarded
- 0 -
O_ 0 0

Defective auto-tirnei
Defective governor
control spring
Maladjusted governor
damper spring
Engine speed too low
0 0 0 -
- - - - - - - -
- - - - - - 0
- - - - - - -

Failure of engine to stop - - - - - - 7

properly
Poor grade of fuel oil - 0 0 0 0 0 0
- -
0 - -
Fuel viscosity too high 0 -

- - - - - - - - -
Poor grade of oil - - - - -

Oil viscosity too high - - 0 - -

- - - 0 -
Oil viscosity too low
Low oil pressure - -

Escessive oil leakage - - - - -

Pumping up of oil - - 0 0 -

Clogged oil filter - - -

Defective oil pressure - - - - -

switch or lamp
- - - - - - -
Insufficient air 0 0 - 0
Poor compression - 0 - - 0 '0 0 0 0 0 0 0
Low pressure at high
atomospheric temperature - - 0 - 0
[or altitude) - - - - - - -

00(D)-6-148S4S Diesel Engine Service Manual

l SM598,Oct‘94
 Main Table of Contents

Group 00(D), Engine (Diesel)

(0 For detaikd information refer to the scparate chart

Defective lubri- Abnormal Defective
cation system water tem- alternator
- peraturerise~

Replace nozzle tips.

Check and replace spring if

neceswy. Then adjust governor
setting on bench.

Adjust idling setbolt. Hold km

in STOP position.

____ _ _----- - - - - - - - use good quality oil.

_--_ - -- ---- - - O-_ - _ Use proper viscosity oil.
__-- - _-_o--_o - c--._ - - Use proper viscosity oil.
___- - ------ - rJ-_- - -.
_--- ---_o--- - - - - - - Retighten and replacepacking
- if necessary.
____ _-_-__o--- _ - - - - - -.
---- - ------ - - o-- - - change ekmellt and oil.
___- - ------ 0 o_-- - - Chaqe element and oil.

__o__o --_o---_-_ - - - - - - -.
_o_ _-_o--_-- - - - - - - -.

__-- - -0-e -- - - - 0 - - - (Adjust full-load setting

of governor.)

SM 598,Oct‘94 S4S Diesel Engine Service Manual . 00( D)-6-149

 Main Table of Contents

Group 00(D), Engine (Diesel) ClflRK

Possible cause

Engine is too cold.

Radiator dissipates heat

Water leak through

cylinder head gasket

Defective starter switch

Defective alternator

Wompistonriugs

Broken valve springs

ii(D)-64 50 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ElfIRK Group 00(D), Engine (Diesel)

- - ( 0 For detailed information refer to the separate chart.)

z= T Defective lubri-
cation system T
P
B g :I-
= EC
2
8 ‘zi BO
f e EZ
E c B et P Remedy
E 0”
z zs z =:
8
2 t;

i -U2
Y 9
8 s
a
z E t;
a a
g
P
3.
3
z .z EO
x” = S ::
5 Y
- -0 -3 w
Gi
-

Heat oil pan from bottom side at

- - - - - starting. After starting, warm up
engine thoroughly.
- - - 0

- 0 - 0 0

0 - 0 0

- - - Ret&ten and replace gasket

0
if necessary.
- 0 - - Replace crankcase.
- - - - - - -
- - - - - - - - - Check for connections and repair.
Replace if necessary.
- 0 - - - - - - Repair or replace if necessary.
- - - - - - - - - - Repair or replace.

- - - - - - - - - Repair or replace starter

if necessary.

- - - - - - - - - Repair or replace ring gear.

Replace pinion.
- 0 0 - - - 0 - Recharge or replace battery.
If necessary heat it.
- - - - - - - - - - - - - Replace.

- - - - - - - - Replace copper packings and .,

if necessary glow plugs.
- - - - - - - - - 0 Replace alternator if necessary.

- 0 - - - - - - 0 0 Adjust or replace. if necessary.

- - - - - 0 - - - 0 - Connect wires properly.

- - - - - -
- - 0 - - 0 - - - 0 - - - 8

- - 0 0 - 0 - - - - - - - Repair or replace.

- 0 0 0 - 0 0 - - - - Repair or replace.

- - - - - - - - - - Check and replace bearing(s) with

- 0
undersize one(s) if necessary.

- - - - - - - - - - - Retighten.

- - -
Re-time timing gear train or
adjust valve sinkage properly. .
0 - - Replace.

0 - - - - Adjust valve clearance to 0.2s mm

(0.0098 in.).
- - - - - - - - - - - Repair.

- - - - - - - Replace gears or idler bushing.

- - - -

SM 598,Oct
‘94 S4S Diesel Engine Service Manual l 00( D)-6-151
 Main Table of Contents

Group 00(D), Engine (Diesel) CIRRK

TROUBLESHOOTING CHART (2)

Possible cause Remedy

Closed fuel tank supply cock Open the cock.

No fuel in tank pill fuel tank.
Clogged fuel lines Repair or clean fuel pipes with air.
Air in fuel system Retighten connections or replace
fuel pipes.
Poor fuel supply to fuel
Clogged fuel feed pump inlet Remove and clean strainer.
injection pump
strainer
Defective fuel feed pump Repair.
Leaky fuel lines or connections Ret&ten connections.
Clogged fuel filter Disassemble and clean filter.
Air in fuel system Bleed air out of fuel system.

Jammed plungers Replace plungers.

Jammed tappets Replace tappets.
Worn plungers Replace plungers.
Worn tappet cams Replace tappet cams.
Worn bearings Replace bearings.
Greater variance of injection
quantity Worn or broken plunger springs Replace plunger springs.
Loose plunger pinions Reinstall properly by matching
mark:.
Defective delivery valves Replace valves.
Worn or broken delivery valve Replace valve spring.
springs

Governor stop lever link is Straighten link, placing

binding. lever in neutral position.
Control rack is sticky. Relubricate or repair.
Jammed plungers Replace plungers.
Jammed tappets Replace tappets.
Worn plungers Replace plungers.
Insufficient injection quantity
Worn tappet cams. Replace tappet cams.
Worn bearings Replace bearings.
Loose plunger pinions Reinstall properly by matching
marks.
Improper full-load setting of Adjust governor setting on
governor bench.

Stop lever jammed in “increase” Repair lever link, placing lever

position. in neutral position.
Improper full-load setting of. Adjust governor setting on bench.
Excessive injection quantity
governor
Loose plunger pinions . Reinstall properly by matching
. marks. .

00( D)-6-152 l S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

ClRRlC Group 00(D), Engine (Diesel)

.
Possible cause Remedy

Sticking needle valve in one Repair and replace nozzles if

Improper fuel spray from
injection nozzles
or more nozzles necessary.
Damaged norzle tip seats Repair and replace seats if necessary.
Worn or broken nozzle springs Replace nozzle springs.
Too low an injection pressure Adjust pressure to no nozzle tester
by inserting shim(s).

Carbon deposited on packings Remove carbon.

at nozzle tips

improper installation of fuel Re-time properly by tilting injection

injection pump pump away from engine.
Injection timing too advanced
Incorrect installation of timing Re-time timing gear train.
gears

Improper installation of fuel Re-time properly by tilting injection

Injection timing too retarded
injection pump pump toward engine.
Incorrect meshing of timing Re-time timing gear train.
gears
Worn cams, tappets or bearings Replace.
in fuel injection pump

Inferior fuel Use goodquality fuel.

Poor grade of fuel
Water in fuel Use goodquality fuel.

Lack of oil in oil pan Add oil to prescribed level.

Air in oil strainer Replace damaged pipes or packings.
Retighten loose connections if any.
Defective oil pump Repair.
Low oil pressure
Clogged oil lines Clean.
- Defective oil pressure relief valve Repair and replace if necessary
Clogged oil ftiter Change element and oil.
Leak in lubricating system Repair.

Excessive oil in oil pan Drain oil to lower oil level.

Worn cylinders, pistons or Repair and replace parts if
piston rings necessary
Sticking piston rings Repair and replace damaged rings
Pumping up of oil
if necessary.
Worn valve guides Replace valve guides.
Prolonged operation under no Overhaul engine if oil-laden gases
load are exhausted.

Clogged air cleaner Clean and replace element if necessar]

Insufficient air
Clogged intake manifold Check and clean.

SM 598,Oct ‘94 S4S Diesel Engine Service Manual . 00(D)-5-153

 Main Table of Contents

Group 00(D), Engine (Diesel) EMRK

Possible cause Remedy

Defective valve seats Repair.

Sticking valve stems Repair and replace valve stems
if necessary.
Failure of rocker arms to Adjust valve clearance to 0.25 mm
lift valves (0.00!38 in.).
Worn cylinders, pistons or Repair and replace parts if
Poor compression piston rings necessary.
Sticking piston rings Replace damaged rings.
Exhaust gases leak through Retighten and replace gasket if
cylinder head gasket necessary.
Worn or broken valve springs Replace springs.
Insufficient torque of starting Replace parts.
motor (at starting)

Insufficient coolant Add water to prescribed level.

.. Overheating
Water leaks from unit seal of water Replace seal.
Insufficient coolant
pump
Crack in crankcase water jacket Replace crankcase.
Water leaks from other parts Check and repair.

_Air in cooling system Bleed air by loosening air bleed

plug,drain plug, or hose clamp.
Rust and scale deposited in Flush.
radiator
Failure of radiator to
dissipate heat properly Dust and dirt around radiator Flush.
Slippage of fan belt Adjust belt tension.
Inoperative thermostat Replace.
(stuck closed)
-
Extremely low atmospheric
temperature
Radiator dissipates heat Uncovered radiator Cover radiator.
excessively
Inoperative thermostat Replace.
(stuck open)

Sticking cylinders, pistons Repair and replace if necessary.

or piston rings
Sticking main bearings and Repair and replace if necessary.
Jammed moving parts crankpin bearings

Sticking cam bushing and Repair and replace if necessary.

. idle gear bushing

00(D)-6-1 54 . S4S Diesel Engine Service Manual SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 00(D), Engine (Diesel)

Section 7.
Balancer for S4S Diesel Engine

SM 598,Oct ‘94 Diesel Engine Balancer l 00(D)-7-l

 Main Table of Contents

Group 00(D), Engine (Diesel) CMRK

ASSEMBLY

I COMPLETE

96.444
00.320

ENGINE BALANCER ASSEMBLY oos12-1

00.300 Balancer Assembly, Engine

00.301 Fastener, Engine Balancer Frame Rear
00.302 Bearing, Balancer Weight Rear
00.394 Dowel, Balancer Frame
00.308 Weight, Engine Balancer
00.313 Key, Balancer Weight Gear
00.314 Bearing, Balancer Weight (Outboard)
00.315 Gear, Balancer Weight Driven
00.316 Retainer, Balancer Weight Gears
00.320 Fastener, Engine Balancer Drive Gear
00.324 Gear, Balancer Weight Drive
00.330 Frame, Engine Balancer
00.331 Weight, Engine Balancer
00.334 Plug, Balancer Frame
00.393 Locator Screw, Engine Balancer
90.550 Lockwasher, Engine Balancer Assembly Fastener
96.444 Washer, Balancer Driven Gear

OO(D>7-2 l Diesel Engine Balancer SM 898,Oct ‘94

 Main Table of Contents

GROUP 00(G)

GROUP 00(G)

ENGINE

(4G64 GAS/LPG/CNG)

Specifications and Description .....”............................... Section 1

Troubleshooting ............................................................. Section 2

Oil and Filter .................................................................. Section 3

fine-Up ........................................................................... Section 4

RPM, Vacuum, and Stall Checks ................................... Section 5

Compression Checks ...................................................... Section 6

Removal and Replacement ............................................. Section 7

Overhaul ......... ..”............................................................. Section 8

NOTICE

DETAILED FUEL SYSTEM INFORMATIONis given in Group

02, “Fuel System.”

DETAILED IGNITION SYSTEM INFORMATIONis given in

Group 12, “Ignition System.”

SM 598, Apt ‘96 Group 00(G)

 Main Table of Contents

CMRK Group 00(G), Engine (Gas)

Section 1.

Engine Specifications
(4064 Gas/LPG/CNG Engine)

General Specifications Tune-Up Specifications

Engine Type: Mitsubishi 4664 in-line, overhead valve, Tune-up specifications are listed in the engine tune-up
single overhead camshaft Section of this Group.
Number Gf Cylinders: 4
Combustion Chamberz Semi-spherical OverhaulSpecifications
Total Displacement: 2350 cu cm (143.4 cu in) Overhaul specifications are listed in the engine overhaul
Cylinder Bore: 86.5 mm (3.41 in) Section of this Group.
piston Stroke: 100.0 mm (3.94 in)
Compression Ratio: 8.5
Cylinder Compression: 1880 kPa (163.5 psi) at 300 rpm
Valve timing:
Camshaft Identification (D)
Intake valve Open 12’ BTDC
Close 40’ ABDC
Exhaust valve Open 54” BBDC
Close 6’ ATDC
Lubrication System: Pressure feed, full-flow filtration
Gil Rump Type: Involute gear type
Engine Gil: lOW30, API, CC, CD/SG, SF engine oil
Sump Capacity: 4.5 L (4.8 qt)
Cooling System: Water-cooled circulation
Water Rump Type: Centrifugal impeller type

SM 596, Apr ‘96 Engine Specifications l 00(6)-1-l

 Main Table of Contents

ElmK Group 00(G), Engine (Gas)

Section 2.
Engine Troubleshooting
(4G64 GaslLPGICNG Engine)

Also use the rpm, vacuum, and stall tests in Section 5 to

analyze engine performance.
The following troubleshooting guide lists typical complaints
or troubles encountered in routine operation of the 4664
engine, and suggests possible remedies.

Engine hard to start or won’t start Engine runs unevenly at high speed
. Fuel system fault; see fuel system troubleshooting in l Fuel system fault; see fuel system troubleshooting in
Group 02. Group 02.
. Ignition system fault; see ignition system trouble- l Ignition system fauls see ignition system trouble-
shooting in Group 12. shooting in Group 12.
. Starter motor faulty; see electrical system trouble- Engine fires erratically
shooting in Group 14.
Fuel system fault; see fuel system troubleshooting in
. Battery, ground, or wiring is faulty; see electrical
Group 02.
system troubleshooting in Group 14.
Ignition system fault; see ignition system trouble-
. Engine oil is too viscous (heavy weight oil); change to
shooting in Group 12.
lighter oil viscosity.
Uneven compression or cylinder head problem:
. Engine timing too advanced; adjust timing.
- Carbon deposits in combustion chamber; clean
. Valves or valve seats worn and leaking; relap or
- Cylinder head water passages clogged; clean.
replace valves.
- Cylinder head gasket leaking; replace.
. Intake manifold gasket leaking: replace gasket if nec-
- Cylinder head bolts not torqued properly; tighten
essary and retighten manifold nuts to correct torque. per specification.
. Cylinder head gasket leaking; replace head gasket and
Leaking intake gasket.
retighten cylinder head nuts to correct torque.
. Internal engine seizure; refer to engine overhaul proce- Valves sticking; repair or replace valves.
dures. Valve springs weak or broken; replace valve springs.
. Instrument pod faulty; see instrument pod trouble- Backfiring
shooting in Group 13.
Fuel system fault; see fuel system troubleshooting in
. Gut of fuel. Group 02.
. LPG tank shut off or improperly coupled. Ignition system fat& see ignition system trouble-
shooting in Group 12.
Irregular idling
Sticking valves; repair.
Fuel system fault; see fuel system troubleshooting in
Group 02. Broken or fatigued valve springs; repair or replace.
Spark plug gap is too wide, adjust.
Cylinder head gasket leaking; replace head gasket.
Valves not seating tight; relap valves.
Excessive clearance between valve and guide; replace
valves and valve guides.

SM 598, Apr ‘96 Engine Troubleshooting l 00(G)-2-l

 Main Table of Contents
Group 00(G), Engine (Gas)
Lack of power or poor acceleration
Ignition system malfunctioning; see ignition system
troubleshooting in Croup 12.
Fuel system malfunctioning; see fuel system trouble-
shooting in Croup 02.
Air intake system restriction:
- Air filter element clogged, replace.
- Throttle control not opening fully; adjust.
- Carburetor choke faulty (gasoline only); adjust or
repair.
- Excessive exhaust back pressure; inspect and re-
pair.
- Sharp bend or kink in hose from air filter to
carburetor, inspect, repair or replace.
- Engine valves sticking or worm repair or replace.
- Engine valves adjusted incorrectly; adjust.
Cylinder head gasket leaking; replace head gasket if
necessary and retighten cylinder head bolts to speci-
fied torque.
Piston rings sticking or worn; replace rings.
Cylinders worm check and replace if necessary. See
also “Faulty Compression.”
Overheating; see “Overheating.”
Valve seats leaking; relap valves.
Valve stems sticking; repair or replace valves.
Valve springs weak or broken; replace springs.
Overheating
. Cooling system malfunctioning; see cooling system
troubleshooting in Croup 01.
. Cylinder head gasket leaks coolant; tighten bolts or
replace.
. Cylinder block or head cracka repair or replace.
. Radiator fins plugged (dirty) or core clogged; clean or
replace.
. Fan installed backwards, remove and reinstall cor-
rectly.
. Thermostat faulty; replace.
. Rust buildup in engine block; clean cooling system or
overhaul.
. Fan belt slipping, worn or damaged; clean, adjust, or
replace.
. Ignition timing incorrect; see ignition system trouble-
shooting in Group 12.
. Engine oil level is low; add oil, inspect for cause.
00(G)-2-2 l Engine Troubleshooting
CMRK
Fuel system malfunctioning; see fuel system trouble-
shooting in Croup 02.
Faulty compression pressure; see “Faulty Compres-
sion.”
Overloading of engine; review operation.
Blown head gasket; replace.
Exhaust system leak or blockage; repair or replace.
Faulty compression
Valve holding open; repair.
Incorrect valve timing; retime engine assembly.
Burned or sticking valves; repair or replace.
Broken or fatigued (weak) valve springs; replace.
Cylinder head gasket faulty (leaking); tighten bolts or
replace.
Piston rings worn, broken or stuck; repair or replace.
Low oil pressure
Oil level is low; check and add oil.
Oil viscosity too light; check and replace oil. Oil may
be diluted by fuel or water, check for cause of contami-
nation.
Pump suction screen clogged, clean.
Dirt in relief valve or broken spring; clean or repair/
replace.
Worn or damaged oil pump; replace.
Worn engine bearings; replace.
Worn cam bushings; replace.
Oil pressure indicator, sensor, or wiring faulty; repair
or replace.
High oil pressure
Oil pressure should not exceed recommended pressures
except when engine is starting up cold Abnormally high
oil pressure is not desirable because it increases oil con-
sumption. Possible causes of high oil pressure are:
Engine oil too viscous (heavy weight); change to
correct oil grade.
Stuck relief valve; repair or replace.
Obstruction in distributing line.
Faulty oil pressure gauge; replace.
Dirty or plugged oil filter replace.
SM 598, Apr ‘98
 Main Table of Contents
CWRIF
High oil consumption
. Loose oil filter, tighten oil filter with gasket.
. Oil leaks in system; inspect and repair.
. Oil pan plug or pan attaching bolts loose; retighten
plug or bolts.
. Damaged oil pan gasket; replace gasket.
. Oil level too high; check cause and maintain correct oil
level.
. Oil pressure too high, stuck relief valve; repair or
replace.
. Incorrect grade of oil used, change to heavier viscosity
grade.
. Clogged crankcase breather, clean.
. Worn, broken or stuck piston rings and clogged oil
control rings; replace.
. Worn pistons and sleeves; replace.
. Worn bearings; replace.
. Worn valve guides and seals; replace.
. Defective front or rear crankshaft oil seals; replace oil
seal.
. Damaged head cover gasket-
. Excessive oil reaching combustion chambers:
- Improperly positioned ring gaps; reposition ring
gaps.
- Worn piston rings or ring grooves; replace rings or
pistons.
- Excessive accumulation of carbon in oil return
hole in oil ring; replace rings.
- Worn pistons and cylinders; rebore cylinders and
replace pistons.
- Too much oil in oil pan; drain oil to specified
level.
Excessive downward oil flow along valve stems:
- Worn valve stems or guides; replace valves or
guides.
- Damaged valve stem oil seals; replace oil seals.
Piston rings not run-in (seated), due to too smooth
cylinder bore finish or glazed condition; repair or
replace rings and deglaze cylinder walls.
SM 598, Apr ‘96
Group 00(G), Engine (Gas)
Engine knocks and other noises
Operating knocks
Fuel, when detonation knock is caused by low octane
gasoline; check fuel specification.
Preignition, when most common cause is due to incor-
rect type plugs which are too hot; replace plugs with
correct heat range.
Carbon buildup, noticeable when engine is accelerated
when hot; clean cylinder head and pistons.
Incorrect timing, when early (advanced excessively)
timing causes knocks similar to carbon buildup, but
may tend to kick back when starting; adjust timing.
Overloads, particularly at lower operating speeds,
review operating methods.
Mechanical knocks
l Crankshaft and main bearings:
Worn, burned-out, or melted main bearings, indi-
cated by a heavy, dull knock when accelerating
under load; locate by shorting out spark plugs on
both sides of the bad bearing; replace bearings and
if melted, check lubrication system.
Crankshaft end play is indicated by an intermittent
knock which will come and go when the load is
released and engaged.
Crankshaft thrust beating worn; replace thrust
bearing.
l Connecting rod and bearings:
- Worn or burned-out bearings indicated by a light
pounding or metallic knock, is noted at idling
speed and to about 2/3 maximum speed; bad
bearings can be located by shorting out spark
plugs; replace rod or bearings.
l Pistons and piston pins:
- Excessive piston clearance in cylinder rebore
cylinders and replace pistons.
- Piston sticking; replace pistons.
- Loose or worn piston pins, which may be located
by shorting out spark plugs; noise incmases when
the correct plug is shorted out, most noticeable at
idling speed; replace pistons or pins.
- piston loose in cylinder or damaged piston rings,
indicated when “piston slap” is noted by metallic
knocking at low speed under load but disappears
at high speed; also most noticeable when starting
cold; test by shorting out spark plugs and replace
piston rings.
Engine Troubleshooting l 00(G)-2-3
 Main Table of Contents

Group 00(G), Engine (Gas) ClRRl6

- Broken piston ring or pin is indicated by a sharp
clicking noise that doesn’t change when spark
plugs are shorted out; repair engine.
Cmnkpin bearings worn, damaged, or melted, replace
bearings and check lubrication system.
valves
- Oil drained from lifters. Lifters should fill within
20 minutes, as engine runs.
- Defective lifters; replace.
- Burned valves and seats indicated when engine
misses, especially at low speeds, or accelerating
under load; repair engine.
- Weak or broken valve springs indicated when the
engine is missing at low or high speeds when
under load; replace springs.
- Sticking valves indicated by a loss of power and
popping sound; overhaul head.
Camshaft makes noise due to loose bearings or end
play, usually occurs at half engine speed; replace
camshaft thrust plate.

Vibration originatingat engine

The most common sources of vibration originating in or on
the engine, as distinguished from causes created outside the
engine, are as follows:
Misfiring
Misalignment of engine
Bent or off-center driveline coupling
Engine loose on mountings, or wrong mountings
Out-of-balance condition of flywheel and clutch as-
sembly.

00(G)-2-4 l Engine Troubleshooting SM 598, Apr ‘96

 Main Table of Contents

ClmK Group 00(G), Engine (Gas)

Section 3.
Engine Oil and Filter
(4664 Gas/LPG/CNG Engine)

Engine Oil Requirements To help achieve proper engine performance and durability,
use only engine lubricating oils of the proper quality. These
Engineoil does not “wear out.” However, the lubricating
oils also help promote engine efficiency, which results in
oil in internal combustion engines becomes contaminated
improved fuel economy. A symbol has been developed by
from the by-products of combustion: dirt, water, unburned
the API (American Petroleum Institute), SAE, and ASTM
fuel entering the crankcase, and the detergents holding the
to help you select the proper engine oil. It should be on the
carbon particles in suspension in the crankcase.
oil container you purchase.
Motor oils used for internal combustion engine lubrication
perform many useful functions including:
l Dissipating heat
l Sealing piston rings
l Preventing metal-to-metal contact wear
l Reducing power loss through friction.
Lubricating oil recommendations are based upon engine IMPORTANT
design, type of service, and the ambient temperature in
which the engine is operating. High-quality oils are re- Use lOW30, API CC, CD/SG, SF engine

quired to assure maximum performance, long engine life, OiL

and minimum cost of operation.

The schedule for changing oil is directly dependent upon
the operational environment. An extremely clean operation
could go 150-250 hours while a dirty operation (foundry or
cement factory) could be 50 hours or less.
NOTE
Oil changes should be scheduled every 50-
350 hours, monthly, or more frequently if
necessary. The time interval for changing
engine oil depends upon your application
and operating conditions. To determine the
correct schedule for your truck, it is sug-
gested that you periodically submit engine
oil samples to a commercial laboratory for
analysis of the condition of the oil.
Engine Oil Level Check
The engine oil level should be checked every 8 hours.
Check the oil level with engine stopped. Allow 5
minutes for the oil level to stabilize. Pull the dipstick
out, wipe it with a clean wiper, and reinsert it fully into
the dipstick tube. Remove the dipstick and check the
oil level.
Oil level should be at the PULL level marking on the
dipstick. Add recommended oil as needed. Wait 5
minutes after adding oil and check the oil level again.
Do not overfill.

NOTE
It is normal to add some oil between oil
changes. Keep the oil level above the ADD
mark on the dipstick. Do not overfill. Use
the correct oil as specified above.
4. check the periodic service schedule (operating hours),
or the condition of the oil to determine if it needs to be
changed.

SM 598, Apr ‘96 Engine Oil and Filter l 00(G)-3-1

 Main Table of Contents
Group 00(G), Engine (Gas)
IMPORTANT
Use lOW30, API, CC, CD/SG, SF engine
0iL Sump capacity is 4.5 L (4.8 qt).
Engine Oil and Filter Change
Recommended service intervals and procedures:
Drain and replace the engine crankcase oil every 50 to
250 operating hours, or sooner, as explained on the
previous page.
Replace engine oil filter at every other oil change.
Drain and replace engine oil in a new or rebuilt engine
after the first 50 hours of operation.
Dram oil after engine is at operating temperature.
To change the engine oil and oil filter:
1. Safely park the truck and place an oil drain pan under
it.
2. Remove drain plug at bottom of engine oil pan and
drain the oil completely.
NOTE
Raise and block up the truck under the
frame to give easier access to the engine
drain plug. Refer to “Lifting, Jacking, and
Blocking” in Group SA.
Dipstick
Drain Plug
\\,,
Engine Side View
00(G)+2 l Engine Oil and Filter
EmK
3. Remove the engine oil filter.
4. Make sure sealing surface on engine is clean.
5. Install new oil filter. Follow installation instructions
printed on the outside surface of the filter. Check that
the oil seal is lubricated and correctly in place.
IMPORTANT
Always use genuine CLARK parts.
6. Clean and inspect the oil drain plug and seal. Replace
the drain plug and/or seal if damaged.
7. Install drain plug. Remove oil drain pan
8. Remove and inspect the condition of the engine oil
filler cap located on top of the engine valve cover.
Replace cap if it is damaged or the seal is broken.
9. Refill the crankcase with fresh engine oil through the
rocker cover oil filler opening. Sump capacity is 4.5 L
(4.8 qt).
10. Wait several minutes after adding oil to check the oil
level. Add oil if necessary.
11. Start the engine and allow it to run at idle for several
minutes. Check the oil filter and drain plug for leakage.
12. Check the engine oil level with the engine stopped for
5 minutes. Add oil as necessary.
IMPORTANT
Discard oil in an environmentally respon-
sible manner.
I_‘\ Oil Filter
SM 596, Apr ‘96
 Main Table of Contents

C:IRRU Group 00(G), Engine (Gas)

Section 4.
Engine Tune-Up
(4664 Gas/LPG/CNG Engine)

Tune-UpSpecifications

Spark Plug Type: Vacuum Advance: Beginning: 00 at 80 mmHg (3.14 inHg)

Gas Engine: NGK BP4ES, Champion NY16 End: 11.5°at280mmHg(11.0inHg)
LPG Engine: NGK BPSES, Champion NY12
Engine Speed (rpm):
Spark Plug Gap: 0.7-0.8 mm (0.028-0.03 1 in) Idle: 650-700
Spark Plug Tightening Torque: 25 Nom (18.4 ft-lb) Maximum No-Load Governed: 2500-2650
Converter Stall-LPG: 1790-1890
Ignitor Air Gap: 0.8 mm (.031 in)
Converter Stall-Gas: 1850-l 950
Ignition Tuning: Gasoline 4” BTDC @ 500 rpm; LPG
9” BTDC @ 500 rpm (vacuum line disconnected and Engine Vacuum kPa (psi):
Idle: 406-457 mmHg (16-18 inHg)
plugged)
MaximumNo-LoadGovemedz 330-381 mmHg(13-15inHg)
Centrifugal Advance: Beginning: 0” at 600 engine rpm. Converter Stall: 38-64 mmHg (1.5-2.5 inHg)
End: 6.5” @ 2600 engine rpm (vacuum line disconnected
and plugged)

Procedures
It is recommended that you perform the entire set of basic 5. Make sure all instrument panel lights indicate normal
planned maintenance procedures described in Section 2 of conditions. Perform service indicated by lights as
Group PS when tuning up the engine. As a minimum, you explained in Group 13, “Instrument Pod”
should perform the following procedures. 6. Listen to the engine idle, then accelerate the truck with
1. Check oil level. Fill as necessary. the tilt lever fully forward or back. If idle or accelera-
tion is erratic, consult fuel system troubleshooting in
2. Check coolant level using safe procedure given in
Group 02, “Fuel System.”
Group 01.
7. Perform the engine rpm, vacuum, and stall tests in
3. Inspect engine for loose or damaged hoses, belts,
Section 5 of this Group (00 G). If these tests indicate
electrical connections, and choke and throttle link-
poor engine performance, perform the fuel system
ages.
checks and adjustments given in Group 02 and the
4. Start the engine and let it warm up. While doing this, ignition systemchecksandadjustmentsgiven inGroup
look for excessive exhaust smoke and listen for un- 12. (Transaxle repair may also be indicated)
usual engine noise that indicates a need for engine
8. Verify engine performance after making adjustments
repair.
by repeating the stab tests in Section 5 of this Group
NOTE (00 G). If adjustments cannot correct engine perfor-
Black exhaust smoke indicates excessive fuel mance, consult engine, fuel system and ignition sys-
consumption caused by carburetor or choke tem troubleshooting charts in Groups 00,02, and 12,
m&adjustment or malfunction (gasoline respectively.
engines only). Blue exhaust smoke indicates
excessive oil consumption caused by faulty
seating of piston rings, dii, or worn engine
components such as rings, cylinders, pis-
tons, or valve guides.

SM 598, Apr ‘96 Engine Tune-Up l OO(G)-4-1

 Main Table of Contents

ElmK Group 00(G), Engine (Gas)

Section 5.
RPM, Vacuum, and Stall Tests
(4G64 Gas/LPG/CNG Engine)

Introduction .. .......................................................“......................................................................... 1

Test Procedures ...................................-..-.............................................................................*...... 2

Preliminary Procedures ................................................................................................................. 2

Engine RPM and Vacuum at Idle .................................................................................................... 2
Engine RPM at Maximum No-Load Governed Speed .................................................................... 3
Engine Vacuum at Maximum No-Load Governed Speed ............................................................... 3
Engine RPM and Vacuum at Stall ................................................................................................... 3

Analysis of Stall Test ..................................................................................................................... 4

Introduction
The tests in this Section should be part of all engine tune- Intake manifold vacuum is determined by how far the
ups and planned maintenance inspections. throttle plate is opened and how much rpm the engine can
produce at a given throttle position. The wider the throttle
These tests check :
plate is opened. the less vacuum (pressure drop) can de-
l Engine speed settings.
velop across the throttle bore. The extent to which the
l Overall engine performance
throttle has to be opened in order to achieve a certain rpm
l Whether major components or systems other than the
or power level. is affected by how well the engine is
engine have problems or are causing problems.
running and how much the fluid coupling (the torque con-
Tests include: verter) in the uansaxle resists engine rotation. Therefore, a
Engine idle speed and vacuum. lower than normal vacuum reading indicates a wider throttle
Engine maximum no-load governed speed and opening and lower performance.
vacuum.
Similarly, when the throttle is held wide open. the vacuum
Engine speed and vacuum at hydraulic tilt bypass
and rpm levels can vary from normal according to how
(relief pressure).
well the engine and torque converter are performing. Other
Engine stall speed and vacuum.
loads, such as the hydraulic pump. can also affect perfor-
NOTE mance.
HYDROSTATIC TRANSMISSION trucks Whenever the engine is running, its drive shaft drives the
are not covered by the stall check proce- torque converter. which is in the transaxle. The torque
dure. converter is a fluid coupling that slips to a varying extent,
Minimum tools required are: depending on the condition of the torque converter compo-
lTachometer nents and the clutches that the torque converter drives. The
lVacuum gauge. resistance offered by the torque converter is reflected in the
engine rpm and vacuum readings when a stall test is per-
formed.

SM 598,Oct ‘94 Engine RPM, Vacuum, and Stall Checks l 00(G)-5-l

 Main Table of Contents

Group 00(G), Engine (Gas) CUlRK

Test Procedures Engine RPM and Vacuum at idle
Perform the tests in the order given here. 1. Check the engine idle speed. If idle speed is not 650-
700 rpm, adjust the carburetor idle screw setting as
Preliminary Procedures explained in Group 02, “Fuel System.”
2. Check the engine intake manifold vacuum with the
Safely park the truck on a level surface. Apply parking
engine idling at the 650-700 rpm, then increase engine
brake and place controls in neutral.
speed.
Connect a tachometer, or a combination test instru-
ment such as the Clark Dynamic Engine Analyzer (part The typical intake manifold vacuum reading at idle should
number 1802047). be 406457 mmHg (16-18 inHg) at 650-700 t-pm. Refer to
the chart below to analyze the reading you obtain.
Install a vacuum gauge between the breather hose
(PCV line) leading from the rocker cover to the intake Vacuum
manifold. Use a tee, short hose, and adapter to connect Gauge Readings Etine Condition
the gauge. High and Steady: Good
Low and Steady: Loss of power in all cylinders
caused by:
-Late ignition or valve timing.
Tee vacuum gauge into
-Loss of compression due to
breather hose (PCV Line).
leakage around piston rings.
Very Low: Manifold, carburetor or cylinder
head gasket leak.
Needle Pulses Steadily as Speed Increases:
A partial or complete loss of
power in one or more cylinders
caused by:
-Leaking intake valve
-Cylinder head or intake manifold
gasket leak
-Fault in the ignition system
-Weak valve spring.
Gradual Drop at Engine Idle; Intermittent Fluctuation:
Excessive back pressure in the
exhaust system.
An occasional loss of power
possibly caused by a defect in the
ignition system or a sticking valve.
Engine Top View
Slow Fluctuation or Drift of the Needle:
4. Checkall throttle control linkage for complete andfree Improper idle mixture adjustment,
movement. or carburetor, spacer or intake
manifold gasket leak.
5. Start the engine and let it warm up until it runs evenly
and accelerates smoothly when you push on the accel-
erator pedal. If vacuum is OK, check the no-load governed speed.
Allow the engine to warm up to operating temperature
before putting it under any load conditions.

W(G)+2 l Engine RPM, Vacuum,and Stall Tests SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 00(G), Engine (Gas)

Engine RPM at Maximum No-Load Governed Engine RPM and Vacuum at Stall
Speed
NOTE
Check the speed to which the governor limits the engine:
HYDROSTATIC TRANSMISSION trucks
1. Push the accelerator pedal slowly to the floor. When are &covered by this procedure.
the governor begins taking control of the throttk
slight variation (hunting) in engine speed may occur. Be sure that uansaxle fluid level has been checked and is
This is normal. correct (see Group 06) and that braking and inching pedals
are adjusted correctly (see Group 23) before you run a stall
2. When the engine speed stabilizes, read the maximum test.
no-load governed speed on the tachometer.
If the no-load governed speed is not 2500-2650 rpm. refer
to Group 02, “Fuel System,” for governor adjustment pro-
n ! CAUTION
Stall tests must be performed with the park-
cedures. ing brake off and with the truck placed
against a solid barrier (such as a wall or
If rpm is OK and if overheating is observed at long mns at another lift truck) to prevent movement.
high speed, check the vacuum at maximum no-load gov- Make sure that the truck cannot move and
erned speed. that the solid barrier is capable of with-
standing the force before you begin.
Engine Vacuum at Maximum No-Load 1. Add load on forks to increase weight and prevent
Governed Speed inadvertent drive wheel spin.
Check the engine intake manifold vacuum with the engine 2. Place truck against an immovable barrier (such as a
running at the maximum speed allowed by the governor wall or another lift truck).
(only if overheating is observed at long runs at high speed):
3. Put the directional control lever in forward (or reverse,
1. Run the engine to the maximum no-load governed depending upon truck position to barrier).
speed. as above. NOTE
2. When the engine speed stabilizes, read the vacuum Use of the POWER SERVICE BRAKES or
gauge. STEERING HANDWHEEL can affect en-
gine rpm. Do not touch either during the
The vacuum at no-load governed speed should be 330-381
test.
mmHg (13-15 inHg).
4. Release the parking brake.
If vacuum is low, such as 229-279 mmHg (9-l 1 inHg). this
is an indication that the transaxle has a fault, such as a 5. Slowly push the accelerator pedal fully down and hold
locked stator. in the torque converter. it there while you read the tachometer and vacuum
gauge.
Perform stall test. IMPORTANT
Do not run engine and converter at stall
longer than necessary to take the ‘pm and
vacuum readings, or longer than 30 sec-
onds at one time. Then, shift transmission
into neutral for 15 seconds and run the en-
gine at one-half speed for one to two min-
utes to cool torque converter oil. Excessive
temperature, 120”C (250°F) maximum, will
overheat the converter and cause damage
to converter, seals, and fluid.
Engine vacuum at stall should be 38-64 mmHg (1.5-2.5
inHg). Engine rpm at stall should be 1790- 1890 rpm for the
LPG engine and 1850-1950 for the gasoline engine. See
analysis chart on next page.
To test both clutch packs in the transmission, check stall
speed and vacuum with transaxle in forward and reverse.

SM 598,Oct ‘94 Engine RPM, Vacuum, and Stall Checks l 00(G)-5-3

 Main Table of Contents

Group 00(G), Engine (Gas) CUIRK

Analysis of Stall Test

NOTE
HYDROSTATIC TRANSMISSION trucks
are not covered by the stall check proce-
dure.

Normal Stall Speed

LPG: 1790-1890 rpm
Gas: 1850-1950 rpm
- Engine performance is good.
- Torque converter is operating correctly.
- Transmission clutch packs are operating correctly (not
slipping).

Below Normal Stall Speed

LPG: 1600-1700 rpm
Gas: 1650-1750 rpm
- Engine performance is poor (needs tune-up or repair).
- Transmission and torque converter are OK.

Very Low Stall Speed

LPG: 1100-1200 r-pm
Gas: 1150-1250 r-pm
Torque converter stator is slipping. Repair of torque
converter is required. See Group 06, “Transaxle,”
troubleshooting.

High Stall Speed

LPG: Above 1890 rpm
Gas: Above 1950 rpm
- Transaxle clutch or converter problems. See Group 06,
“Transaxle,” troubleshooting.

Use the engine compression checks Section of this Group

to further check engine condition.

00(G)-5-4 l Engine RPM, Vacuum, and Stall Tests SM 598,Oct ‘94

 Main Table of Contents

ClmK Group 00(G), Engine (Gas)

Section 6.
Compression Checks
(4G64 Gas/LPG/CNG Engine)

Test Preparation
NOTE
Engine compression test procedures consist of removing
the spark plugs, installing a compression test pressure gauge Check to be sure battery is fully charged.
to the cylinder being tested, and cranking the engine while 6. Rush the accelerator pedal fully down (to open the
the pressure is being measured. throttle and admit a full charge of air).
1. Be sure the oil in the crankcase is the correct viscosity 7. Turn the key switch to the Start position and crank the
and f&d to the proper level. Disconnect or remove all engine until it turns through at least 5 compression
auxiliary engine loads. strokes.
2. If truck has not been operating, start the engine and
warm it up to normal operating temperature. Coolant
temperature should be 80-90’ C (176194’ F). Turn
ignition key switch OFF.

Compression Test Procedure

1. Disconnect the spark plug wires.
IMPORTANT
Do not allow dirt and contaminants to enter 8. Make a record of the highest pressure reading. Also
spark plug open@ when the plugs are re- note the approximate number of compression strokes
moved.Use an air nozzle or equivalentto blow needed to obtain the highest pressure reading. Remove
any dirt and contamination out of the spark gauge and replace spark plug. Tighten spark plug to 25
plug well before and after loosening the plug. Nom (18.4 Mb).
2. Loosenthesparkplugofthe#lcylinder.Repeatblowing
the dirt out of the well. Remove the spark plug.
3. Install a screw-in adapter in the spark plug opening, if
required by the compression pressure gauge.
4. Install a compression gauge to the spark plug opening.
5. Ground the ignition system. Disconnect the high tension
coilwirefromthedistributorcapandconnectittoajumper
wire that is co~ected to ground on the engine. This will
preventtheenginefiomaccidentallybemgstartedandaLso
9. Repeat the above procedure and compression test on
prevent damage to electrical components. each of the other cylinders, using the same number of
compression strokes needed to obtain the highest read-

Q?
Jumper ing on the #l cylinder.

D!StRlBlJlOR ______
IMPORTANT
Lubricate threads on spark plugs with
ANTI-SEIZE grease, Clark part #1802307.

I------ I c

GROUND

SM 598, Apr ‘98 Engine Compression Checks l 00(G)-6-l

 Main Table of Contents

Group 00(G), Engine (Gas) CUlRK

Analysis of PressureReadings
Cylinder compression should be about 1880 kPa (163.5
psi) at 300 tpm (cranking speed).
1. Evaluate the cylinder compression pressure readings
that you have recorded:
a If the pressure readings are all within 10% of the
nominal pressure, the engine is in serviceable
condition.
b. If the pressure readings are all at or below the
minimum specified pressure (Service Limit), the
engine piston rings and/or valves are worn exces-
sively and require service or replacement.
2. Compare the pressure difference between cylinders:
a. A pressure difference between cylinders less than
188 kPa (16 psi), or approximately lo%, is nor-
mal.
b. If the pressure difference is greater than 188 kPa
(16 psi), this is an indication of faulty or worn
valves or piston rings, or leaking head gasket.
3. Retest the cylinder with the lowest pressure. Put ap
proximately 14.8 cc (0.50 oz) of engine oil into the
spark plug opening and on top of the piston in the
cylinder. (Use a squirt oil can, or equal.) This will form
a seal around the rings on the piston.
4. Repeat the compression test in this cylinder.
If compression pressure does not improve, this is
an indication that:
The valves are not operating correctly
The valve seats are worn
The piston may be burned, have a hole, or have a
broken ring.
A valve is burned or sticking open:
- A valve that is stuck open causes low cylinder
compression and is indicated by an irregular
clattering noise and power loss.
- A valve that is bumed causes very low compres-
sion pressure in one cylinder and is indicated by
a constant miss of one cylinder.
5. If two adjacent cylinders have low compression read-
ing and putting oil in the cylinder does not improve
compression, the cause can be the cylinder headgasket
leaking between the cylinders. Further diagnosis and
repair of the engine is required.
6
If the compression test indicates a valve problem, a
lifter may be locked up or a valve seat damaged. Refer
to the overhaul Section of this Croup for repair infor-
mation.

a. If the compression pressure increases, this is an

indication that the piston rings are worn.

00(G)+2 . Engine CompressionChecks SM 598, Apr ‘96

 Main Table of Contents

Group 00(G), Engine (Gas)

Section 7.

Engine Removal and Replacement

(4664 GasILPGICNG Engine)

Engine Removal ................................................................................................ ..”......................... 2

Engine Replacement .............................. ..-..........................................................- ........................ 4

SM 590,Oct ‘94 Engine Removal and Replacement l 00(G)-7-1

 Main Table of Contents

Group 00(G), Engine (Gas) ElmK

Engine Removal 5. Disconnect the battery and remove it from the engine
compartment. Disconnect negative cable fist.
D! CAUTION
SAFE PARKING. Before working on truck: Positive Cable -,
1. Park truck on a hard, level, and solid to Starter
surface, such as a concrete floor with no Solenoid
gaps or breaks.
2. Put upright in vertical position and fully
lower the forks or attachment.
3. Put all controls in neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the
wheels.
To remove the engine:
Tilt the steering column fully forward.
Raise the seat deck
Lift out the operator’s compartment floor plate and
remove the seat deck as explained in Group 38.
Remove the overhead guard from the operator’s cell.

6. Disconnect and remove the air cleaner and hoses as

described in Group 3, “Air Induction System.”
7. Disconnect and remove the exhaust pipe between the
Overhead
engine exhaust manifold and the muffler pipe. See
Guard
Group 3, Section 4.

Muffler Pipe

Exhaust
Pipe

Operator’s
cell

7 Exhaust
>Y Manifold
NOTE >

Remove the overhead guard only ifan over-
head hoist is used to lift the engine out. If
an engine hoist or another fork lift truck
will be used to lift out the engine, removal
of the overhead guard is not necessary.
8. Label and disconnect all wiring from the engine to
components that will remain in the truck frame. See
Group 14 for wiring configurations.

00(G)-7-2 . Engine Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents
ClmK
9. On the standardtransaxletruck,disconnectthe accelera-
torcableatthethrottlelever.Onthehydrostatictransm&
sion truck, disconnect the electrical connection and re-
move the linkageactuatorand linkage with the engine.
Accelerator
Cable Bracket
Throttle Lever
10. Disconnect and cap the fuel line at the fuel tank.
\Fuel Line
11. Drain the coolant from the engine and radiator, and
disconnect the radiator hoses from the engine thennO-
statand water pump, as explained in Group 01.
12. Disconnect and remove the radiator upper shroud, fan
ring, and venturi (as explained in Group 01) to allow
for engine front-to-back movement.
13. Unbolt the engine mounting bolts.
‘Mounting Bolt
SM 598, Apr ‘96
Group 00(G), Engine (Gas)
14. Disconnect the engine from the transaxle (or hydro-
static transmission pump) as explained in Group 06.
15. Using a hoist and chains or engine stand of adequate
capacity, hook the chains to the engine lifting eyes
Remove slack from the chains.
n ! CAUTION
Do not attempt to move the engine with
your bands as it is being discormected from
the transmission or hoisted from the truck.
Always use a prybar to gently clear the
engine from the transmission or the truck
frame.
16. Slowly hoist the engine out of the frame.
IMPORTANT
Do not allow the engine and fan to swing
forward to bump the radiator during re-
moval. Damage to the fan and/or radiator
will result. Slip a sturdy piece of cardboard
iu front of the radiator core to protect the
fius.
Engine Removal and Replacement l 00(G)-7-3
 Main Table of Contents
Group 00(G), Engine (Gas)
Engine Replacement
Before beginning engine replacement, make sure the truck
is parked with the parking brake applied and wheels
chocked. To replace the engine:
1. Make sure the hoist and chains or engine stand you are
using are of adequate capacity to safely lift the engine.
2. Hook the hoist chains to the engine lifting eyes.
3. Slowly 1ifIthe engine and move it into place over the
truck frame.
4. Make sure there are no wires, cables, hoses, or other
equipment in the way of lowering the engine into the
frame.
5. Slowly begin lowering the engine into the frame.
A WARNING
Never use your hands to move the engine
in the frame. Always use a pry bar to gen-
tly shit3 or hold the engine in place. After
the engine is in place, keep the hoist chains
attached and keep slack out of the chains.
Remove the chains only when the engine is
securely mounted in the truck frame and
remounted with the transmission.
00(G)-7-4 . Engine Removal and Replacement
CIRRK
6. Set the engine onto the mounting isolators. Set mount-
ing bolts in place but do not tighten. The engine may
have to be shifted to line up with the transmission.
Connect the engine to the transaxle (or hydrostatic
transmission pump) as explained in Group 06.
Torque engine mounting bolts to 170-190 Nom (125-
140 e-lb).
Align and connect the exhaust pipe to the engine
exhaust manifold using a new gasket for reassembly.
Torque bolts to 40-45 N*m (30-33 ft-lb). Replace the
V-band coupling and torque the bolt to 9- 10 N*m (8 l-
91 in-lb; 6.75-7.5 f&lb).
V-Band
Exhaust
Coupling
Pipe
Muffler
Pipe
SM 598, Apr ‘96
 Main Table of Contents

ClRRK Group 00(G), Engine (Gas)

10. Replace the upper radiator shroud and venturi as de-
scribed in Group 0 1.
11. Reconnect the radiator hoses between the radiator and
the water pump and the thermostat of the engine, as
described in Group 01. Before reinstallation, check
that hoses are in good condition with no drying, crack-
ing, or splitting.
12. Uncap and reconnect the fuel line at the fuel tank.
Make sure the hose is in good condition with no drying,
cracking, or splitting evident. Torque band clamp to
0.8- 1.ON*m (0.6-0.73 ft-lb).
15. Replace the engine air cleaner and hoses. See Group 3
for complete details. Set the canister and hoses in place
and align before tightening clamps and mounting nuts.
Torque the base-mounting nuts to 20-25 Nom (14.8-
18.5 f&lb); torque hose-to-engine clamp to 1.9-2.9
N*m (1.4-2.1 ft-lb).
16. Replace the battery and reconnect the cables to the
battery posts and to the starter and ground.

1 Fuel Line

13. Reconnect the wiring. See Group 14 for drawings that

show the wiring harness and component connection Grounded to
points on the engine.

14. On the standard transaxle truck, reconnect the accel-

a Torque the terminal nuts at the battery posts to 14
erator linkage and adjust length using the adjustment
20 N*m (10.3-14.8 f&lb).
nuts. See Group 02 for throttle linkage adjustments.
b. Torque the nut on the starter terminal to lo-12
Gn the hydrostatic transmission truck, rec0~ec-tthe Nom (90-I 10 in-lb; 7.5-9.1 f&lb).
electricalconnection to the linkage actuator. (Acuator
and linkage not removed from engine.) c. Install covers over cable ends after assembly.
17. Replace the seat deck according to the procedures in
Group 38.

Accelerator
Cable Bracket

:y
l.f&- Throttle Lever

SM 598,Oct ‘94 Engine Removal and Replacement l 00(G)-7-5

 Main Table of Contents

Group 00(G), Engine (Gas) elfllw

18. Install the driver overhead guard. Torque the bolts to

70-75 N-m (52-55 f&lb).

Operator’s
cell

19. Close engine drain valve and fill radiator according to

the procedures presented in “Engine Cooling System
Testing and Maintenance” in Group 01. Check inlet
and outlet hoses for leaks.

20. Restart the engine and check all truck electrical, hy-
draulic, and mechanical components for proper opera-
tion before returning the truck to service.

00(G)-7-6 l Engine Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents

CIRRK Group 00(G), Engine (Gas)

Section 8.

Engine Overhaul
(4G64 Gas/LPG/CNG)

GENERAL INFORMATION ....““...“...........“............................~....“..“.............” ...................... 2

Overhaul Specifications “_U_“...“..“.“.““.._.......“...~.....~................................“..............“..._ .... 2

Service Precautions ..............“..U..._..““.~............“.....”..........~.........................~.......~..........” .... 6

Sealant Specifications ....“U......“.._._...“........““........_......._._....~.................._” .......................... 6

Tightening Method for Permanently Yielding Bolts ....“.“.......___...................”....~...._......_ .. 7

Form-In-Place Gasket (FIPG) ..“~.....W..“...“.“..“.....“........~........~.....~~.~“.......”.~~..........~ ..” 7

Special Tools ..U.......“.............~...............””...”...“.......~~...”...................~...“.....””...........~ ......... 8

OVERHAUL PROCEDURES ,.....~..............,“......................................””...“...............““......” 10

Key to Notations in Overhaul Procedures “I........................“...“.......”.~.......“....““.......”....._. 10

Timing Belt .........“.....UU”........“..“.~“.“.....”...~............~............~..........................~.”..........~~ 11

Intake Manifold and Thermostat .._...UU._“.._U.U.....“.........”........_....................~”.“..~.~.......18

Exhaust Manifold and Water Pump .._...“.........._..“......““.....”......”.....................~._........_ .... 19

Rocker Arms and Camshaft ..“.......“......U...“..~...“.....”......................~..._.~....~.~.~..~_.._..~ . 20

Cylinder Head and Valves ....U....._...._._.......~....“..“~...”....~...~..~.~...~.......”...~..............“... 23

Front Case, Silent Shaft and Oil Pan “..“.....“...U...“.“..“~....“..~.~..~...~~...~................~......... 28

Pistonand Connecting Rod ....“m_...“u.“...“.......“...“.......”...........~..........~.........~......~.......“... 35

Crankshaft, Flywheel, and Drive Plate “.......“.“.........“......“............”.”..............”.........._......~ 42

NOTE
Fuel system and ignition system overhaul
information is given in Groups 02 and 12,
respectively.

SM 598,Oct ‘94 Engine Overhaul-General Information l 00(G)-8-1

 Main Table of Contents

Group 00(G), Engine (Gas) CWRK

GENERALINFORMATION

Overhaul Specifications
Cylinder Head
Standard-mm (in) Limit-mm (in)
Flatness of Gasket Surface 0.05 (0.0020) 0.2 (0.008)
Grinding limit *0.2 (0.008)
* Total resurfacing depth of both cylinder head and cylinder block
Flatness of Manifold Mounting Surface
0.15 (0.0059) 0.3 (0.012)
Overall Height 89.9 - 90.1(3.539 - 3.547)

Oversize Rework Dimensions of Valve Guide Hole (Both Intake And Exhaust):
0 .05 13.05 - 13.07 (0.51 38 - 0.5146)
0.25 13.25- 13.27 (0.5217-0.5224)
0.50 13.50 - 13.52 (0.531 5 - 0.5323)

Oversize Rework Dimensions of Intake Valve Seat Ring Hole:

0.30 47.30-47.33 (1.8622-1.8634)
0.60 47.60-47.63 (1.8740-1.8752)

Oversize Rework Dimensions of Exhaust Valve Seat Ring Hole:

0.30 40.30 - 40.33 ( 1.5866 - 1.5878)
0.60 40.60 - 40.63 (1.5984 - 1.5996)

Camshafts
Standard-mm (in) Limit-mm (in)
Identification Mark: 1
Cam Height
Intake 41.62 (1.6602) 41.12 (1.6405)
Exhaust 42.62 (1 6626) 41.12 (1.6429)
Identification Mark: A
Cam Height
Intake 42.08 (1.6567) 41.58 (1.6370)
Exhaust 42.08 (1.6567) 41.58 (1.6370)
Identification Mark: 3
Cam Height
Intake 42.40( 16693) 41.90 (1.6496)
Exhaust 42.40 (1.6693) 41.90 (1.6436)
NOTE: The camshaft identification mark is stamped on the rear end of the camshaft.
Journal Diameter 33.94 - 33.95 (1.3362 -1.3366)
Oil Clearance 0.05 - 0.09 (0.0020 - 0.0035)

W(G)-&2 l Engine Overhaul-General Information SM 598,Oct ‘94

 Main Table of Contents

ClRRK Group 00(G), Engine (Gas)

Valves
Standard-mm fin) Limit-mm (in)
Overall Length
Intake 106.6 (4.197)
Exhaust 105.2 (4.142)
Stem Diameter
Intake 7.96 - 7.98 (0.3134-0.3142)
Exhaust 7.93 - 7.95 (0.3122-0.3130)
Face Angle 45 - 45” 30
Thickness of Valve Head (Margin)
Intake 1.2 (0.047) 0.7 (0.028)
Exhaust 2.0 (0.079) 1.5 (0.059)
Stem-To-Guide Clearance
Intake 0.02-0.06 (0.0008-0.0024) 0.10(0.004)
Exhaust 0.05-0.09 (0.0020-0.0035) 0.15 (0.006)

Valve Springs
Limit-mm (in)
Free Height-mm (in) 47.5 (1.869) 46.5 (1.829)
Load/Installed
Height-kg (lbs.) / mm (in.) 18.00 (40) / 40.4 (1.59)
Out-of-Squareness 2’ or less Max.4

Valve Guides
mm (in)
Overall Length
Intake 47 (1.85)
Exhaust 52 (2.05)
I.D. 8.00 - 8.02 (0.3150 - 0.3157)
O.D. 13.06 - 13.07 (0.5142 - 0.5146)
Service Size 0.05 (0.002), 0.25 (O.OlO),0.50 (0.020) over size
Press-In-Temperature Room temperature

Valve Seats
mm (in)
Seat Angle 43”30’ - 44O
Valve Contact Width 0.9 -1.3 (0.035 - 0.051)
Sinkage 0.2 (0.008)
Service Size 0.3 (O-012), 0.6 (0.024) Over Size

SM 598,Oct ‘94 Engine Overhaul-General Information l 00(G)-8-3

 Main Table of Contents

Group 00(G), Engine (Gas) CUIRK

Silent Shafts
mm (inI
Journal Diameter
Right (front) 41.96 - 41.98 (1.6520 -1.6528)
(rear) 40.95 - 40.97 (1.6122 -1.6130)
Left (front) 18.47 -18.48 (0.7272 - 0.7276)
(rear) 40.95 - 40.97 (1.6122 -1.6130)
Oil Clearance
Right (front) 0.03 - 0.06 (0.0012 - 0.0024)
(rear) 0.05 - 0.09 (0.0020 - 0.0036)
Left (front) 0.02 - 0.05 (0.0008 - 0.0020)
(rear) 0.05 - 0.09 (0.0020 - 0.0036)

Pistons
mm (in)
O.D. 86.47 - 86.50 (3.404 - 3.4055)
Piston-To-Cylinder Clearance .0.02 - 0.04 (0.0008 - 0.0016)

Piston Rings
Standard-mm (in) Limit-mm (in)
End Gap
No. 1 Ring 0.25 - 0.40 (0.0098 - 0.0157) 0.8 (0.03 1)
No. 2 Ring 0.45 - 0.60 (0.0177 - 0.0236) 0.8 (0.03 1 )
Oil ring 0.1 - 0.4 (0.0039 - 0.0157) 1.0 (0.039)
Ring-To-Ring Groove Clearance
No. 1 Ring 0.03-0.07 (0.0012-0.0028) 0.1 (0.004)
No. 2 ring 0.03-0.07 (0.0012-0.0028) 0.1 (0.004)
Service Size 0 25 (0.010) 0.50 (0.020) 0.75 (0.030) 1.00 (0.039) Over Size

Piston Pins
mm (in)
O.D. 22 00 - 22.01(0.8661 - 0.8665)
Press-In Load N (kg, lbs.) 7.500 - 17.500 (750 -1.750, 1.653 - 3.858)
Press-In Temperature Room temperature

Connecting Rods
Standard-mm (in> Limit-mm (in)
Big End Center-To-Small
End Center Length 149.9 -1 50.0 (5.902 - 5.906)
Bend 0.05 (0.0020)
Twist 0.1 (0.004)
Bin End Side Clearance 0.10 - 0.25 (0.0039 - 0.0098) 0.4 (0.016)

00(G)-8-4 l Engine Overhaul-General Information SM 598,Oct ‘94

 Main Table of Contents

elmu Group 00(G), Engine (Gas)

Crankshafts
Standard-mm (inI Limit-mm (in)
End Play 0.05 - 0.18 (0.0020 - 0.0071) 0.25 (0.0098)
Journal O.D. 56.98 - 57.00 (2.2433 - 2.2441)
Pin O.D. 44.98 - 45.00 (1.7709 -1.7717)
Out-of-Roundness and
Taper of Journal and Pin 0.003 (0.0001)
Concentricity of Journal 0.003 (0.0001)
Oil Clearance of Journal 0.02-0.04 (0.0008 - 0.0016) 0.1 (0.004)
Oil Clearance of Pin 0.02 - 0.05 (0.0008 - 0.0020) 0.1 (0.004)

Cylinder Blocks
Standard-mm (inI Limit-mm (in)
Cylinder I.D. 86.50 - 86.53 (3.4055 - 3.4067)
Flatness of Gasket Surface .0.05 (0.0020) 0.1 (0.004)
Grinding Limit 0.2 (0.008)*
*Total resurfacing depth of both cylinder head and cylinder block

Overall Height 289.9 - 290.1 (11.413 -11.421)

Oil Pump
mm (in)
Side Clearance
Drive Gear 0.08 - 0.14 (0.0031 - 0.0055)
Driven Gear 0.06 - 0.12 (0.0024 - 0.0047)

NOTE
O.D.: Outer Diameter
I.D.: Inner Diameter
U.S.: Undersize Diameter

SM 598,Oct ‘94 EngineOverhaul-General Information l W(G)-8-5

 Main Table of Contents

Group 00(G), Engine (Gas) ClClRK

Service Precautions Sealant Specifications
Use specified brand of sealant.
Match Marks
Use of sealant other than specified sealant may cause water
Mark parts with match marks before disassembly to guide or oil leaks.
reassembly. However, be careful not to place match marks
where they could harm the function of a part.

Specified sealant
Special Tools
Rocker cover 3M ATD Part No. 8660 or equivalent
Be sure to use special tools when their use is specified.
Semicircular 3M ATD Part No. 8660 or equivalent
Using substitute tools will result in malfunction of or dam- packing
age to the part.
Engine support 3M ATD Part No. 8660 or equivalent
bracket bolt
Tightening Torque Oil pan gasket Mitsubishi Genuine Part MD970389 or
Tighten the part properly to specified torque. equivalent
Water outlet Mitsubishi Genuine Part MD970389 or
Replacement Parts fitting equivalent

When oil seal, O-ring, packing, or gasket have been re- Engine coolant 3M ATD Part No. 8660 or equivalent
moved, be sure to replace them with new parts. temperature
gauge unit
However, rocker cover gasket may be reused if it is not
damaged. Engine coolant 3M Nut Locking Part No. 4171
temperature or equivalent
sensor
Rubber Parts
Oil pressure 3M ATD Part No. 8660 or equivalent
Do not stain timing belt and V-belt with oil or water. switch
Do not clean the pulley or sprocket with detergent. Oil pressure 3M ATD Part No. 8660 or equivalent
gauge unit
Oil and Grease
Before reassembly, apply specified oil to the rotating and
sliding parts.

00(G)-8-6 l Engine Overhaul-General information SM 598,Oct ‘94

 Main Table of Contents
ElmK
Tightening Method for Permanently
Yielding Bolts
A new type of bolt is currently used in some parts of the
engine. The tightening method for these bolts differs from
the conventional one. Be sure to observe the method de-
scribed in the text when tightening the bolts.
Service limits are provided for the bolts. Make sure that the
service limits described in the text are strictly observed.
Areas where these bolts are in use:
l Cylinder head bolts
l Main bearing cap bolts
l Connecting rod cap bolts
After tightening the bolts to the specified torque, tighten
them another 90” or 180”. The tightening method varies on
different areas. Observe the tightening method described in
the text.
Form-In-Place Gasket (FIPG)
The engine has several areas where the form-in-place gas-
ket (FIPG) is in use.
The PIPG used in the engine is a room temperature vulcani-
zation (RTV) type and is supplied in a 100~gramtube (Part
No. MD970389 or MD9971 10). Since the RTV hardens as
it reacts with the moisture in the atmospheric air, it is
normally used in the metallic flange areas. The FIPG, Part
No. MD970389, can be used for sealing both engine oil and
coolant, while Part No. MD997110 can be used for only
engine oil sealing.
Disassembly
The parts assembled with the FIPG can be disassembled
without use of a special method In some cases, however,
the sealant between the joined surfaces may have to be
broken by lightly striking with a mallet or similar tool. A
flat, thin gasket scraper may be lightly hammered between
the joined surfaces. In this case, however, care must be
SM 598, Apr ‘98
Group 00(G), Engine (Gas)
taken to prevent damage to the joined surfaces. For re-
moval of the oil pan, the special tool “Oil Pan Remover”
(MD998727) is available. Be sure to use the special tool to
remove the oil pan.
Surface Preparation
Thoroughly remove all substances deposited on the gasket
application surfaces, using a gasket scraper or wire brush
Check to ensure that the surfaces to which the FIPG is to be
applied are flat Make sure that there are no oils, greases
and foreign substances deposited on the application sur-
faces. Do not forget to remove the old sealant remaining in
the bolt holes.
Form-In-Place Gasket Application
When assembling parts with the FIPG, you must observe
some precautions, but the procedure is very simple, as in
the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and
without breaks. Also be sure to encircle the bolt hole cir-
cumference with a completely continuous bead. Too thin a
bead could cause leaks. Too thick a bead could be squeezed
out of location, causing blocking or narrowing of the fluid
feed line. To eliminate the possibility of leaks from a joint,
it is absolutely necessary to apply the gasket evenly and
without a break, while observing the correct bead size.
The FIPG can be wiped away unless it is hardened. While
the PIPG is still moist (in less than 15 minutes), mount the
parts in position. When the parts are mounted, make sure
that the PPIG is applied to the required area only.
The FIPG application procedure may vary on different
areas. GbSeNe the procedure described in the text when
applying the FlPG.
Engine Overhaul-General Information l 00(G)-8-7
 Main Table of Contents

Group 00(G), Engine (Gas) CWRK

SpecialTools

Tool Number Name Use

MB990767 End yoke holder Holding camshaft sprocket when loosening

or torquing bolt. Use with MD998719.

MB990938 Handle Installation of crankshaft rear oil seal. Use

with MD998776.

MD990938 Handle Installation of crankshaft rear oil seal. Use

with MD998776.

MD998285 Crankshaft front Guide for installation of crankshaft front oil

oil seal guide seal.

MD998375 Crankshaft front Installation of crankshaft front oil seal.

oil seal installer

MD998440 Leakdown Leak-down test of lash adjuster

tester

~ 8 MD998441 I././ Air bleeding of lash adjuster

00(G)-8-S l Engine Overhaul--General Information SM 598,Oct ‘94

 Main Table of Contents

URIC Group 00(G), Engine (Gas)

Tool Number Name Use

MD998442 Air bleed wire Air bleeding of lash adjuster

MD998443 Lash adjuster Retainer for holding lash adjuster in rocker

holder arm at time of removal and installation of
rocker arm and rocker shaft assembly

MD998713 Camshaft front Installation of camshaft front oil seal

oil seal installer

MD998719 FWey holding Holding camshaft sprocket when loosening

pins (2) or torquing bolt. Use with MB990767.

MD998719 Oil pan remover Removal of the oil pan

MD998772 Valve spring Compression of valve spring

compressor

MD998776 Crankshaft rear Installation of crankshaft rear oil seal. Use

oil seal installer with MB9900938.

SM 598,Oct ‘94 Engine Overhaul-General Information l 00(G)-8-9

 Main Table of Contents

Group 00(G), Engine (Gas) cu1Rlc

Tool Number Name Use

MD998778 Crankshaft sprocket Removal of crankshaft sprocket

puller

MD998780 Piston pin setting Removal and installation of piston pin

too1

MD998781 Flywheel stopper Holding flywheel and drive plate

OVERHAUL PROCEDURES

Key to Notations In Overhaul Procedures

GXU Denotes removal or disassembly procedure. Let- Denotes non-reusable parts..

ter on main drawing corresponds to service point
in text that follows main drawing.

+X+ Denotes installation or assembly procedure. Let- Denotes torque value for fastener.
ter on main drawing corresponds to service point
in text that follows main drawing.

00(G)-8-10 . Engine Overhaul-General Information SM 598,Oct ‘94

 Main Table of Contents

Group 00(G), Engine (Gas)

Timing Belt

t
10

Removal and installation steps

1. Timing belt front upper cover 11. Tensioner ” B”
2. Tiding belt front lower cover OGO +H+ 12. Timing belt “B”
aA0 +N+ 3. Timing belt aId0 +G+ 13. Silent shaft sprocket
M+ 4. Tensioner spring +F+ 14. Spacer
+K+ 5. Tensioner pulley 010 15. Crankshaft sprocket “B”
GD3 +J* 6. Oil pump sprocket &I0 +A+ 16. Camshaft sprocket bolt
GE+ +I+ 7. Crankshaft bolt 17. Camshaft sprocket
GF0 8. Crankshaft sprocket 18. Tiig belt rear cover
9. Flange
10. Spacer

SM 598,Apr ‘96 Engine Overhaul-Timing Belt l OO(G)-&ll

 Main Table of Contents

Engine (Gas)
Group00(G), CmK

Oil Pump Sprocket Removal

Removal Service Points aD0

GA0 Timing Belt Removal

1. Mark belt running direction for reinstallation.
Notes:
1. Water or oil on the belt shortens its life drastically,
so theremovedtiming belt, sprocket, and tensioner
must be free from oil and water. These parts
should not be washed. Replace parts if seriously
contaminated.
2. If there is oil or water on each part, check front
case oil seals, camshaft oil seal and water pump
for leaks. CEO Crankshaft Bolt Loosening

2. Back off the tensioner spring mounting bolt three

turns.
3. Pinchingtheendofthetensionerspringonthetensioner GF0 Crankshaft Sprocket Removal
side with pliers,unhook it from the bracket hook on the
tensioner to free the tensioner spring.
4. Loosen the tensioner mounting bolt and remove the
timing belt

Engine Overhaul-Timing Belt SM 598, Apr ‘98

OO(G)-8-12 l
 Main Table of Contents

CMRK Group 00(G), Engine (Gas)

a66 Timing Belt “B” Removal a10 Crankshaft Sprocket “B” Removal
h4ake a mark on the back of the timing belt indicating the
direction of rotation so it may be reassembled in the same
direction if it is to be reused.
Notes:
1. Water or oil on the belt shortens its life drasti-
cally, so the removed timing belt, sprocket, and
tensioner must be free from oil and water. These
parts should not be washed Replace parts if seri-
ously contaminated
2. If there is oil or water on each part, check front
case oil seals, camshaft oil seal and water pump
for leaks.

Camshaft Sprocket Bolt Loosening

aHo Silent Shaft Sprocket Removal

SM 598, Apr ‘98 Engine Overhaul-Timing Belt l 00(G)-&13

 Main Table of Contents

Group 00(G), Engine (Gas) CWRK

Inspection
+A+ CamshaftSprocketTightening
Timing Belt
Replace belt if any of the following conditions exist.
. Hardening of back rubber.

Back side is glossy without resilience and leaves no

indent when pressed with fingernail.

. Cracks on rubber back. +F+ Spacer Installation

. Cracks or peeling of canvas. Install the spacer with the chamfered end toward the oil
Seal.
. Cracks on tooth bottom.

. Cracks on belt sides. Spacer

62
Oil seal

Silent
Chamfer %shaft

6. Abnormal wear on belt sides. The sides are normal if

they are sharp as if cut by a knife. Silent Shaft Sprocket Installation
Rounded edge
/

Abnormal wear
FWfy strand)

7. Abnormal wear on teeth or missing tooth.

Rubber exposed

Tooth missing
and canvas fiber
exuosed

OO(G)-S-14 . Engine Overhaul-Timing Belt SM 598, Apr ‘98

 Main Table of Contents

ClRRK Group 00(G), Engine (Gas)

+H+ Timing Belt “B” Installation 4. Turn the tensioner pulley in the direction of the arrow
while lifting with a finger. When there is sufficient
1. Align the timing marks on the crankshaft sprocket “B”
tension on the tension side of the timing belt, tighten
and silent shaft sprocket with their corresponding
the bolt to secure the pulley. Do not allow the pulley to
marks on the front case.
move when tightening the bolt, or the belt will be
2. Install the timing belt “B” on the crankshaft sprocket overtensioned.
“B” and silent shaft sprocket. There should be no slack
on the tension side.

5. Check to ensure that the timing marks on the sprockets

3. Make sure that the relationship between the tensioner
pulley center and the bolt center is as shown in the
illustration.
and the front case are in alignment.
6. Press with index finger on the center of the span on the
tension side of timing belt “B”. The belt must deflect
5-7 mm (0.20-0.28 in.).

+I+ Crankshaft Bolt Tightening

98781

SM 596, Apr ‘96 Engine Overhaul-liming Belt l 00(G)-&15

 Main Table of Contents

Group 00(G), Engine (Gas) ClRRK

&I+ Oil PumpSprocket Installation
1. Inserta Phillips screwdriver [shank diameter 8 mm
(0.31 in.)] through the plug hole on the left side of the
cylinder block to lock the left silent shaft
2. Install the oil pump sprocket.
3. Apply an appropriate amount of engine oil to the
bearing surface of the nut,
4. Tighten the nuts to the specified torque.

3. Align the timing mark on the crankshaft sprocket with

that on the front case.

Scre6driver

+K+ Tensioner Installation

1. Hook the tensioner spring ends to the water pump body
projection and tensioner bracket.
2. Move the tensioner fully toward the water pump and
tighten the bolt and tensioner spacer.
4. Align the timing mark on the oil pump with its mating
mark.

Wate

+N+ Timing Belt Installation

1. Check that the timing belt tensioner and spring have
been installed in position. (See IIK+)
2. Align the timing mark on the camshaft sprocket with
that on the cylinder head.

OO(G)-6-16 l Engine Overhaul-Timing Belt SM 596, Apr ‘96

 Main Table of Contents

ElmK Group 00(G), Engine (Gas)

5. With the plug on the cylinder block removed, insert a 9. Apply force to the tensioner in the direction shown by
Phillips screwdriver [shank diameter 8 mm (0.3 1 in.)] arrow [B] to make the belt engage completely with
through the hole. each sprocket.
Ifit can be inserted as deep as 60 mm (2.4 in.) or more,
the timing marks are correctly aligned. Ifthe inserted
depthisonly20-25mm(0.8-l.Oin.),tumtheoilpump
sprocket one turn and realign the timing marks. Then
check to ensure that the screwdriver can be inserted 60
mm (24 in.) or more. Keep the screwdriver inserted
until installation of the timing belt is finished.

10. Tighten the tensioner attaching bolt then tighten the

tensioner spacer.
n ! CAUTION
If the tensioner spacer is tightened fti,
the tensioner turns as the tensioner spacer
6. Install the timing belt on the crankshaft sprocket, oil is tightened, resulting in an excessive belt
pump sprocket and camshaft sprocket in that order. tension.
There should be no slack on the tension side.
7. Loosen the tensioner mounting bolt and tensioner
spacer. pacer

11. Hold the center of the tension side span of the timing
belt (between the camshaft and oil pump sprockets) as
shown. Then, make sure that the clearance between the
belt back surface and cover meets the standard value.
8. Turn the crankshaft clockwise by two teeth of the
camshaft sprocket (or crankshaft sprocket). Standard value: 14 mm (0.55 in.)

Tlmrng mark _ __

Two teeth / 71

Tlmlng mark ”
Timing belt

SM 598, Apr ‘96 Engine Overhaul--Timing Belt l W(G)-&17

 Main Table of Contents

Group 00(G), Engine (Gas) emK

Intake Manifold and Thermostat

im
18 1.0 13

Removal steps
1. Water outlet fitting 5. Engine hanger
2. Gasket 6. Intake manifold
3. Thermostat 7. Gasket
4. Water temperature gauge unit
btallation: Use Threebond 1104
or equivalent on threads.

OO(G)-8-18 l Engine Overhaul-Intake Manifold SM 598, Apt ‘96

 Main Table of Contents

Group 00(G), Engine (Gas)

ExhaustManifoldand Water Pump

O-ring. Installation: Wet the O-ring (with water) to

facilitate assembly. Keep the O-ring free of oil or
Removal Steps grease.
o-cing
1. Oil dipstick
2. Oil dipstick tube
3. o-ring
4. Heat protector A
5. Heat protector B
6. Engine hanger
7. Exhaust manifold 11. Water hose
8. Gasket 12. Water pump
9. Water inlet pipe
13. Gasket

SM 598, Apr ‘96 EngineOverhaul-Exhaust Manifoldand Water Pump l (JO(G)-&1

9
 Main Table of Contents

Group 00(G), Engine (Gas) CUIRK

RockerArms and Camshaft

1. Breather hose (gas engine)

2. P.C.V. hose
+I+ 20. oilseal
3. Oil filler cap
4. Rocker cover 21. Camshaft

5. Gasket
-6 +J+ 6. Semicircular packing
aA0 +G4 7. Rocker ams and rocker shafts
8. Rear bearing cap
9. Rocker arm D
10. spring
+IH 11. Bearing cap No. 4
12. Rocker am C
+D+ 13. Bearing cap No. 3
+D+ 14. Bearing cap No. 2
+c+ 15. Wave washer
+B+ 16. Right rocker shaft
+B+ 17. Left rocker shaft
18. Front bearing cap
+F+ 19. Lash Adjuster

OO(G)+20 . Engine Overhaul--Rocker Arms and Camshaft SM 698, Apr ‘96

 Main Table of Contents

ClRRK Group 00(G), Engine (Gas)

Removal Service Point

aA0 RockerArm and Rocker Shaft Removal Lash Adjuster Leak DownTest
Before removing rocker arms and shafts assembly, install
the special tool as illustrated to prevent the lash adjusters
from dropping.
n ! CAUTION
The lash adjuster is a precision part. Keep
it free from dust and other foreign matter.
Do not disassemble lash adjusters.
When cleaning lash adjusters, use clean
diesel fuel only.
Immersethe lash adjuster in clean diesel fuel.
While lightly pushing down the inner steel ball using
the special tool, Air Bleed Wire, move the plunger up
and down four or five times to bleed air. Use of the
retainer (special tool) helps facilitate the air bleeding
Inspection
of the rocker arm mounted type lash adjuster.
Camshaft Remove the wire and press the plunger. If the plunger
is hard to be pushed in, the lash adjuster is normal. If
Measure the cam height, using the following values:
the plunger can be pushed in all the way readily, bleed
Identification Standard Limit the lash adjuster again and test again If the plunger is
mark value mm (in) mm (in) still loose, replace the lash adjuster.
Intake 41.62 (1.64) 41.12 (1.62)
Exhaust 41.62 (1.64) 41.12 (1.62)

Rocker Arm
A! CAUTION
Upon completion of air bleeding, hold the
lash adjuster upright to prevent inside die-
sel fuel from spilling and keep it free from
dust and other foreign matter.
4. After air bleeding, set the lash adjuster on the special
tool (Leak down tester MD998440).
Slipper
Check the slipper surface. If any dents, damage, or seizure 5. After the plunger has gone down somewhat (0.2 - 0.5
is evident, replace the rocker arm. mm), measure the time taken for it to go down 1 mm.
Replace if the measured time is not 5-20 seconds/mm.
Diesel fuel at 1520°C (59&T)].

SM 598, Apr ‘96 Engine Overhaul-Rocker Arms and Camshaft . 00(G)+21

 Main Table of Contents

Group 00(G), Engine (Gas) CIRRK

Installation Service Points +G+ RockerShaft Spring, Rocker Arm and Rocker
Shaft Installation
+B+ RockerShaft Installation
1. Temporarily tighten the rocker shaft on the inlet valve
Insertthe rocker shafts into the front bearing cap so that the side with the bolt so that all rocker arms do not push the
notches on the shafts face up, and insert the installation valves.
bolts without tightening them. 2. Fit the rocker shaft spring from the above and position
it so that it is right angles to the spark plug guide.

NOTE
Install the rocker shaft springs before in-
stallation of the exhaust side rocker arms
and shaft.
3. Remove the special tool used to hold the lash adjuster.
4. Make sure that the notch in the rocker shaft is directed
as shown in the illustration.
+c+ Wave Washer installation
Install the wave washer in correct direction as shown.

I W&M
\-
Front No. 1 intake
beating side rockeran
=P

a +I+ CamshaftOil Seal Installation

+M Lash Adjuster Installation

1. Immerse the lash adjuster in clean diesel fuel.
2. Using the special tool (air bleed wire), move the
plunger up and down 4 or 5 times while pushing down
lightly on the check ball in order to bleed out the air.

Semi-CircularPacking Installation
specifiedsealant:
Threebond l2l2D or equivalent

3. Insert the lash adjuster to the rocker arm, being careful

not to spill the diesel fuel. Then use the special tool to
prevent the adjuster from falling while installiig it.

OO(G)-8-22 . Engine Overhaul-Rocker Arms and Camshaft SM 598, Apr ‘98

 Main Table of Contents

elmK Group 00(G), Engine (Gas)

Cylinder Head and Valves

I20 20 4 +1/4tum+l/4tum-1
4

Removal steps
+A0 +D+ 1. Cylinder head bolt
2. Cylinder head assembly
3. Gasket
060 ti+ 4. Retainer lock
5. Valve spring retainer
+B+ 6. Valve spring
7. Intake valve
aB0 +C+ 8. Retainer lock
9. Valve spring retainer
+B+ 10. Valve spring
11. Exhaust valve
a03 +A+ 12. Valve stem seal
13. Valve spring seat
N0 +A+ 14. Valvestem seal
15. Valve spring seat
16. Intake valve guide
17. Exhaust valve guide
18. Intake valve seat
19. Exhaust valve seat
20. Cylinder head

SM 598, Apr ‘96 Engine Overhaul-Cylinder Head and Valves l 00(G)-&23

 Main Table of Contents

Group 00(G), Engine (Gas) ClRRK

Removal Service Points
Inspection
Precaution for Removed Parts
Cylinder Head
Keep removed parts in order according to the cylinder
1. Check the cylinder head for water leaks, gas leaks,
number and intake/exhaust.
damage or cracks before cleaning.
aA9 Cylinder Head Bolt Removal 2. Thoroughly remove oil, water scale, sealant, carbon
deposits, etc. After the oil passages have been cleaned,
Using a 12 mm - 12 point socket wrench, loosen the cylin-
blow air to make sure they are clear.
der head bolts. Loosen evenly, little by little.
3. Check the cylinder head gasket surface for flatness by
using a straightedge and feeler gauge.
Standard value: 0.03 mm (0.0020 in.)
Limit: 0.2 mm (0.008 in.)
Grinding limit: 0.2 mm (0.008 in.)
Cylinder head height (when new):
89.9 - 90.1 mm (3.539 ill. - 3.547 in.)

GBO Retainer Lock Removal

Store removed valves, springs and other parts, tagged to
indicate their cylinder No. and location for reassembly.

4. If the flatness limit is exceeded, correct to meet the

specifications.

CC0 Valve Stem Beal Removal

Do not reuse removed valve stem seal.

OO(G)+24 l Engine Overhaul-Cylinder Head and Valves SM 598, Apt ‘96

 Main Table of Contents

ClClRlC Group 00(G), Engine (Gas)

Valve Valve Guide

Check the valve face for correct contact. If incorrect,
reface.
Valve seat contact should be maintained uniform at the
center of the valve face.
If the margin is less than the limit, replace the valve.
Measure the clearance between the valve guide and valve
stem. If the limit is exceeded, replace the valve guide,
valve, or both.
Standard Value:

Standard Value: Intake 0.02 - 0.06 mm (0.000s - 0.0024 in.)

Intake 1.2 mm (0.047 in.) Exhaust 0.05 - 0.09 mm (0.0020 - 0.0035 in.)

Exhaust 2.0 mm (0.079 in.) Limit:

Liit: Intake 0.10 mm (0.004 ill.)

Intake 0.7 mm (0.028 in.) Exhaust 0.15 mm (0.006 in.)

Exhaust 1.5 mm (0.059 in.)

8
Guide I.D. Stem O.D.

Valve Spring Valve Seat Reconditioning Procedure

Measure the free height of spring and, if it is smaller Before correcting the valve seat, check for clearance
than the limit, replace it. between the valve guide and valve and, if necessary,
replace the valve guide.
Standard value: 49.8 mm (1.961 in.)
Limit: 48.6 mm (1.921 in.) Correct to obtain the specified seat width and angle.

Measure the squareness of the spring and, if the limit After correction, valve and valve seat should be lapped
is exceeded, replace it. with a lapping compound.

Standard value: 2’ or less

Limit: Max.4O

It
out of
squareness

I FfW
height

SM 598, Apr ‘96 Engine Overhaul-Cylinder Head and Valves l 00(G)-&25

 Main Table of Contents

Group 00(G), Engine (Gas) ElmK

Valve Seat ReplacementProcedure Removal lnstal&tion

1. Machineawaythevalveseattothedimenstionsshown. Press Press

0.5- 1 mm (0.020 - 0.039 in.)

0.5-l mm
(0.020 -
0.039 in.1 Note
Do not install a valve guide of the same size again.

2. Rebore the valve seat hole in the cylinder head to a 3. Press in the valve guide so that top of guide is above
selected oversize valve seat diameter. cylinder head top surface by specified value:

3. Before fitting the valve seat, either heat the cylinder mm (0.45 in.)
Standard value: 11.5
head up to approximately 25O“C(482OF)or cool the Press-fit the valve guide, working from the cylin-
valve seat in liquid nitrogen, to prevent the cylinder der head top surface.
head bore from galling. Note that the intake and exhaust side valve guides
4. Using a valve seat cutter, machine the valve seat to the are different in length.
specified width and angle. See “Valve Seat Recondi- Aftex installing valve guides, insert new valves in
tioning Procedure” on previous page. them to check for sliding condition.

Valve Guide ReplacementProcedure

1. Using the special tool and a press, remove the valve
guide toward the cylinder head gasket surface.
2. Rebore the valve guide hole to the new oversize valve
guide outside diameter.
0.05 13.05 - 13.07 mm (0.5138 - 0.5146 in.)
0.25 13.25 - 13.27 mm (0.5217 - 0.5224 in.)
0.50 13.50 - 13.52 mm (0.5315 - 0.5323 in.)

00(G)+26 l Engine Overhaul-Cylinder Head and Valves SM 596, Apr ‘96

 Main Table of Contents

EmK Group 00(G), Engine (Gas)

installation Service Points +D+ Cylinder Head Bolt Installation

1. When installing the cylinder head bolts, check that the
+A* Valve Stem Seal Installation shank length of each bolt meets the limit Ifthe limit is
1. Jnstallthe valve spring seat. exceeded, replace the bolt.

2. The special tool must be used to install the valve stem

seal. Improper installation could result in oil leaking \
Shank Length ’
past the valve guide .

Limit: Max. 120.4 mm (4.74 NIL)

2. Apply engine oil to the bolt threads and washers.
3. According to the tightening sequence shown below,
tighten the bolts to 75 Nm (7.5 kgm, 54 ft. lbs.) using
a 12mrn - 12 point socket wrench.
4. Loosen the bolts completely.
5. Torque the bolts to 20 Nm (20 kgm, 14.5 ft.lbs.)
n! CAUTION
Do not reuse removed valve stem seal.
6. Tighten the bolts l/4 turns (90”) more.
7. Tighten the bolts 114turns (90’) additionally.

+B+ Valve Spring Installation

Direct the valve spring end with identification color toward s 6 1 9
the spring retainer.

khtifiition
akx

io 4 2 5 7

+C+ Retainer Lock Installation

The valve spring, if excessively compressed, causes the
bottom end of the retainer to be in contact with, and dam-
age, the stem seal.

SM 598, Apr ‘96 Engine Overhaul-Cylinder Heed and Valves l 00(G)-&27

 Main Table of Contents

Group 00(G), Engine (Gas)

Front Case, Silent Shaft and Oil Pan

Removal steps
Oil filter 21. Oil pump cover
Drain plug 22. oil pump shaft
Drain plug gasket +G+ 23. Oil pump driven gear
Oil pan +G+ 24. Oil pump chive gear
6. Oil screen +F+ 25. Crankshaft front oil seal
7. Oil screen gasket +E+ 26. oil pump oil seal
+ilM 9. Oil pressure switch +D+ 27. Silent shaft oil seal
11. Relief plug +I+ 28. Front case
12. Gasket 29. Front case gasket
13. Relief spring 30. Silent shaft, left
14. Relief plunger 31. Silent shaft, right
15. Oil filter bracket GE0 +C+ 32. Silent shaft, front bearing
16: Oil filter bracket gasket +FQ +B+ 33. Silent shaft, rear bearing, left
QB0 +K+ 17. Plug aF0 +A+ 34. Silent shaft, rear bearing, right
18. o-ring 35. Check valve
+W N+ 19. Flange bolt 36. Oil jet
4W +H+ 20. Oil pump sprocket 37. Gasket

00(G)&28 l Engine Overhaul-Front Case, Silent Shaft,Oil Pan SM 598, Apr ‘88
 Main Table of Contents

EmK Group 00(G), Engine (Gas)

Removal Service Points 3. Loosen the flange bolt,

4A9 Oil Pan Removal

1. Remove the oil pan bolts.

2. Drive in the special tool between the cylinder block

and oil pan.
NOTE
Never use a screwdriver or chisel, instead
of the special tool, as a deformed oil pan
flange will result, resulting in oil leakage.

MD998727
4EO Silent Shaft Front Bearing Removal
1. Using the special tool, remove the right silent shaft
bearing from the cylinder block.

NOTE
Be sure to remove the front bearing first,
If it has not been removed, the Rear Bear-
ing Puller cannot be used.

aB0 Plug Removal

1. Iftheplugistootight,hittheplugheadwithahammer
two to three times, and the plug will be easily loosened.

4F9 Rear Bearing Removal

1. Using the special tool, remove the rear bearings from
Flange Bolt Removal the cylinder block.

1. Remove the plug on the side of the cylinder block. 2. Toremovetheleftrearbearing,installthespecialtool,

Silent Shaft Bearing Jnstaller Stopper, to the front of
2. Insert a Phillips screwdriver [shank diameter 8 mm the cylinder block, then remove the bearing using the
(0.32 in.)] into the plug hole to lock the silent shaft. special tool, Silent Shaft Bearing Puller.

SM 596, Apr ‘96 Engine Overhaul-Front Case, Silent Shaft, Oil Pan l 00(G)+29
 Main Table of Contents

Group 00(G), Engine (Gas) ClRRK

Inspection 3. Check the side clearance
Standard value:
FrontCase 0.08 - 0.14 mm (0.0031- 0.0055 in.) .... Drive gear
1. Check the oil holes for clogging and clean if necessary. 0.06 - 0.12 mm (0.0024- 0.0047 in.) .... Driven gear
2. Check the left silent shaft front bearing section for
wear, damage and seizure. If there is anything wrong
with the section, replace the front case.
3. Check the front case for cracks and other damage.
Replace cracked or damaged front case.

Oil Seal
1. Checktheoilseallipforwearanddamage.Replacethe
oil seal if necessary.
2. Check the oil seal lip for deterioration. Replace the oil
seal if necessary.

Installation Service Points

Silent Shaft
Check the oil holes for clogging. +A4 RightSilentShaftRearBearinginstallation
Check thejournal for seizure, damage and contact with 1. Install the guide pin of the special tool in the threaded
bearing. If there is anything wrong with the journal, hole of the cylinder block as shown.
replace the silent shaft, bearing or front case assembly.
Check the silent shaft oil clearance. If the clearance is
excessive due to wear, replace the silent shaft bearing,
silent shaft or front case assembly.
Standard value:
Front
0.03 - 0.06 mm (0.0012 - 0.0024 in.)...Right
0.02 - 0.05 mm (0.0008 - 0.0020 in.)...Left
Rear 2. Align the ratchet ball of the special tool with the oil
0.05 - 0.09 mm (0.0020 - 0.0036 in.)...Right hole in the rear bearing to install the bearing on the
0.05 - 0.09 mm (0.0020 - 0.0036 in&Left special tool.
3. Apply engine oil to the outside circumference of the
bearing and the bearing hole in the cylinder block.

Oil Pump
1. Assembletheoilpumpgeartothefrontcaseandrotate
it to ensure smooth rotation with no looseness.
2. Ensure that there is no ridge wear on the contact
surface between the front case and the gear surface of
the oil pump cover.
4. Insert the installer so that it is in alignment with the

00(G)+30 l Engine Overhaul-Front Case, Silent Shaft, Oil Pan SM 598, Apr ‘98
 Main Table of Contents

ClClRK Group 00(G), Engine (Gas)

guide pin, and install the bearing in position.

Silent Shaft Front Bearing Installation
1. Remove the rear bearing installing portion from the
special tool.

Rear bearing
installing portion

2. Install the guide pin of the special tool in the threaded

hole of the cylinder block.

+B+ Left Silent Shaft Rear Bearing Installation

1. Install the special tool (MD998374) to the cylinder
block.
2. Apply engine oil to the rear bearing outer circumfer-
ence and bearing hole in the cylinder block.
3. Align the ratchet ball of the special tool with the oil
hole in the front bearing to install the bearing on the
special tool.
4. Apply engine oil to the outside circumference of the
bearing and the bearing hole in the cylinder block.

Front beartng

3. Using the special tool install the rear bearing.

NOTE
The left rear bearing has no oil hole.

SM 598, Apr ‘98 Engine Overhaul-Front Case, Silent Shaft, Oil Pan l 00(G)-&31
 Main Table of Contents

Group 00(G), Engine (Gas) EIRRK

5. Insert the installer so that it is in alignment with the +F+ CrankshaftFront Oil Seal Installation
guide pin, and install the bearing in position.
Using the special tool, install the crankshaft front oil seal
into the front case.

Oil s

+G+ Oil PumpDrivenGear / Oil Pump Drive Gear

Installation
Apply engine oil to the gears and line up the alignment
rnallcs.

+D+ Silent shaft Oil Seal

0
Socket wrench

Oil Pump Oil Seal Installation

Ic Socket

: case

OO(G)+32 . Engine Overhaul-Front Case, Silent Shaft, Oil Pan SM 598, Apr ‘96
 Main Table of Contents

Group 00(G), Engine (Gas)

ClmK
+I+ Front Case installation 2. Secure the oil pump driven gear onto the left silent
1. Set the special tool on the front end of the crankshaft shaft by tightening the flange bolt to the specified
and apply a thin coat of engine oil to the outer circum- torque.
ference of the special tool to install the front case.

+K+ Plug Installation

2. Install the front case assembly with a new front case 1. Install a new O-ring to the groove of the front case.
gasket and temporarily tighten the flange bolts (other
2. Usingthespecialtool,installtheplugandtightentothe
than those for tightening the filter bracket).
specified torque.
3. Mount the oil filter bracket with the oil Nter bracket
gasket in between, and partially tighten the 4 bolts,
each with a washer.
4. Tighten the bolts to the specified torque.

al* Sealant Application To Oil Pressureswitch

Coat the threads of the oil pressure switch with sealant and
install the switch using the special tool. Tighten to speci-
fied torque.
+J+ Flange Bolt Installation
specsed sealant:
1. Insert a Phillips screwdriver into the hole in the left
Threebond I.211 or equivalent
side of the cylinder block to lock the silent shaft
Important
Keep the end of threaded portion clear of
sealant. Avoid overtightening.

SM 598, Apr ‘96 Engine Overhaul-Front Case, Silent Shaft, Oil Pan l W(G)-643
 Main Table of Contents

Group 00(G), Engine (Gas) CIRRK

+I+& Oil PanInstallation
1. Clean both mating surface of the oil pan and cylinder
Crank pulley side
block.
2. Apply a4 mm (0.16 in.) wide bead of FIPG to the entire
circumference of the oil pan flange.
Specified FIPG:
Threebond 1207F or equivalent.
3. The oil pan should be installed within 15 minutes after
the application of FIPG.
4. Note the difference in bolt lengths at the location
shown. Oil pan viewed from lower side

NOTE
F’IPG APPLICATION is explained in the
GENERAL INFORMATION subsection of
this Section.

OO(G)-844 l Engine Overhaul-Front Case, Silent Shaft, Oil Pan SM 598, Apr ‘96
 Main Table of Contents

EMRK Group 00(G), Engine (Gas)

Pistonand ConnectingRod

Removal steps
+G+ 1. Nut
GAO +F+ 2. Connecting rod cap
+E+ 3. ~Mehlgrodbearing
+D+ 4. Piston and coMecting rod assembly
+E+ 5. connecting rod bearing
+C+ 6. Piston ring No. 1
+C4 7. Piston ring No. 2
+B+ 8. Oil ring
GB0 +A+ 9. piston pin
10. Piston
11. Connecting rod
12. Bolt *1+-q + 1/4turn

SM 598, Apr ‘96 Engine Overhaul-Piston and Connecting Rod l 00(G)-&%

 Main Table of Contents

Group 00(G), Engine (Gas) ElmK

Removal Service Points

QAQ Connecting Rod Cap Removal

1. Mark the cylinder number on the side of the connecting ush rod
rod big end for correct reassembly.
2. Keep the removed connecting rods, caps, and bearings
in order according to the cylinder number.
/
Front
mark

. number

QBO Piston Pin Removal

1. Insertthe special tool, Push Rod, into the piston from 7ENO330
thesideonwhichthefrontmarkisstampedinthepiston
head, and attach the guide C to the push rod end
Piston pin setting toot MD998780 3. Using a press, remove the piston pin.

Push rod Guide A:

17.9 mm NOTE
(0.70 in.)
Keep the disassembled pistons, piston pins
and connecting rods in order according to
1 8
Guide B
the cylinder number.

Y
u

6 Guide A:
18.9 mm
(0.74 in.)
Inspection

Piston

Guide C Replace the piston if it is cracked or damaged.

u

6 Guide A:
20.9 mm
(0.82 in.)
Piston Pin
Insert the piston pin into the piston pin hole, without
the connecting rod, with your thumb. You should feel
a slight resistance. Replace the piston pin if it can be
easily inserted or there is excessive play.
The piston and piston pin must be replaced as an
assembly.
7ENW31

2. Place the piston and connecting rod assembly on the

special tool, Piston Pin Setting Base, with the front
mark facing upward.

OO(G)g-36 l Engine Overhaul-Piston and Connecting Rod SM 598, Apr ‘96

 Main Table of Contents

CmK Group 00(G), Engine (Gas)

Piston Ring Crankshaft Pin Oil Clearance (Plastic Gauge Method)

1. Check the piston ring for damage, excessive wear, and 1. Remove oilfromthecrankshaftpinandtheconnecting
breakage and replace if defects are evident. If the rod bearing.
piston has been replaced with a new one, the piston
2. Cut the plastic gauge to the same length as the width of
rings must also be replaced with new ones. (Or, replace
thebearingandplaceitonthecrankshaftpinmparallel
piston and rings as an assembly.)
with its axis
2. Check for the clearance between the piston ring and
ring groove. Ifthe limit is exceeded, replace the ring or
piston, or replace piston and rings as an assembly.

3. hptall the connecting rod cap carefully and tighten the

bolts to the specified torque
4. Carefully remove the connecting rod cap.
Standard value: 0.03 - 0.07 mm (0.0012- 0.0028 in.)
5. Measurethewidthoftheplasticgaugeatitswidestpart
Limit: 0.1 mm (0.004 ilL) by using the scale printed on theplastic gaugepackage.
3. Install the piston ring into the cylinder bore. Force it
down with a piston, its crown being in contact with the
ring, to correctly position it at right angles to the
cylinder wall. Then, measure the end gap with a feeler
gauge. If the ring gap is excessive, replace the piston
ring.

Standard value: 0.02 - 0.05 mm (0.0008 - 0.0020 in.)

Limit: 0.1 mm (0.004 in.)

1 4bEndgap
Piston ring
Standard value:
No. 1: 0.25 - 0.40 mm (0.0098 - 0.0157 in.)
No. 2: 0.45 - 0.60 mm (0.0177 - 0.0236 in.)
oil Ring: 0.10 - 0.40 mm (0.0039 - 0.0157 in.)
Limit:
No. 1, No. 2: 0.8 mm (0.031 in.)
oil Ring: 1.0 mm (0.039 in.)

SM 598, Apr ‘96 Engine OverhauMiston and Connecting Rod l 00(G)-&37

 Main Table of Contents

Group 00(G), Engine (Gas) CWRK

InstallationService Points 6. Insert the piston pin, push rod and guide A (assembled
in step 3) from the guide A side into the piston pm hole
+A+ Piston Pin Installation on the front marked side.

1. Measure the following dimensions of the piston, piston 7. Screw the guide B into the guide A until the gap
pin and connecting rod. between both guides amounts to the value L obtained
in step 2 plus 3 mm (0.12 in).
A: Piston pin insertion hole length
B: Distance between piston bosses
3 mm (0.12 in.) + L
C: Piston pin length
D: Comxcting rod small end width

Piston

/y
:j
A I Guide A
I hiI/
I

t 8. Place the piston and connecting rod assembly onto the

piston setting base with the front marks directed up-
Ward.

Push rod

Fir
Piston pin
icDG
2. Obtain dimension L (to be used later) from the above
measurements by using by following formulaz ‘-Base

4ulde B
L=(A-C)-(B-D)

3. Insertthespecialtool,PushRod,iutothepistonpinand
attach the guide A to the push rod end
4. Assemble the connecting rod in the piston with their
front marks facing the same direction.
5. Apply engine oil to the entire periphery of the piston
Pin
9. Press-fitthepistonpinusingapress.Ifthepress-fitting
force required is less than the standard value, replace
the piston and piston pm set or/and the connecting rod.
Standard value:
7,350 -17,150 N (750 -1,750 kg, 1,653 - 3,858 lbs.)

OO(G)-6-36 l Engine Overhaul-Piston and Connecting Rod SM 596, Apr ‘96

 Main Table of Contents

EmK Group 00(G), Engine (Gas)

10. Check that the piston moves smoothly. Do not use any piston ring expander when
installing side rails.

Side rail gap

+B+ Oil Ring Installation

3. Install the lower side rail in the same procedure as
1. Fit the oil ring spacer into the piston ring groove. described in step 2.
4. Make sure that the side rails move smoothly in either
direction.

Piston Ring No. 2 / Piston Ring No. 1

Installation
Using a piston ring expander, fit No. 2 and then No. 1
piston ring into position.

NOTE
The side rails and spacer may be installed
in either direction.
The new spacers and side rails are painted in the
following colors to identify their sizes:
Size Identification Color
STD None
0.25 mm O.S. white
0.50 mm O.S. Blue
NOTE
0.75 mm O.S. Black
Note the difference in shape between No. 1 and No. 2
1.00 mm O.S. Yellow piston rings.
2. Install the upper side rail. To install the side rail, first
fit one end of the rail into the piston groove, then press
0 ONo-l
the remaining portion into position by finger. See
illUStRlliOll.

n ! CAUTION

Install piston rings No. 1 and No. 2 with their side

having marks facing up (on the piston crown side).

SM 596, Apr ‘96 Engine Overhaul-Piston and Connecting Rod l 00(G)-&39

 Main Table of Contents

Group 00(G), Engine (Gas) CICIRK

m+ Pistonand Connecting Rod Installation
+E+ Connecting Rod Bearing installation
1. Liberally coat engine oil on the circumference of the
piston, piston ring, and oil ring. When the bearings are replaced, select and install them
according to the identification colors on the crankshaft and
2. Arrange the piston ring and oil ring gaps (side rail and identification marks stamped on the connecting rod bear-
spacer) as shown in the illustration. ing.
Crankshaft Identification Color Journal OD-mm
Yellow 44.995-45.000
None 44.98544995
white 44.980-44.985
Connecting Rod Bearing
Identification Mark Thickness--mm
side
1 1.487-1.491
2 1.491-1.495
3 1.495-1.499

3. Rotate the crankshaft so that the crank journal is on the

Connecting rod inside diameter: 48.000-48.015 nun
center of the cylinder bore.
4. Use suitable thread protectors on the connecting rod
bolts before inserting the piston and connecting rod
assembly into the cylinder block. Care must be taken
not to nick the crankshaft journal..
5. Insert the piston and connecting rod assembly from
above the cylinder in such a way that the front mark
(arrow) on the top of the piston will be directed toward
the camshaft sprocket.
6. Using a suitable piston ring compressor tool, install the
piston and coMecting rod assembly into the cylinder
block.
+F+ Connecting Rod Cap Installation
Timing belt
side, 1. Verifying the mark made during disassembly, install
thebearingcaptotheconnectingrod.Lftheconnecting
rod is new with no index ma& make sure that the
bearing locking notches come on the same side as
shown.

Cylinder No.

Notches

OO(G)-8-40 l Engine Overhaul-Piston and Connecting Rod SM 598, Apr ‘96

 Main Table of Contents

ClmK Group 00(G), Engine (Gas)

2. Make sure that connecting rod big end side clearance

meets the specification.
Standard value: 0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Limit: 0.4 mm (0.016 in.)

+G+ Connecting Rod Cap Nut installation

1. Since the connecting rod bolts and nuts are torqued
using a new procedure, they should be examined
BEFORE reuse. If the bolt threads are “necked down,”
the bolts shouldbereplaced. “Necking” can be checked
bymnninganut thefulllengthofthebolt’sthreadwith
your fingers. Ifthe nut does not run down smoothly, the
bolt should be replaced.
2. Before installing the nuts, the threads should be oiled
with engine oil.
3. Install both nuts on the bolts finger tight, then aher-
nately torque each nut to assemble the cap properly.
4. Tighten the nuts to 20 Nm (2 kgm, 14.5 ft.lbs.) plus l/4
W) turn

SM 598, Apt’ ‘98 Engine Overhaul-FWon and Connecting Rod l 00(G)-8-41

 Main Table of Contents

Group 00(G), Engine (Gas) ClRRK

. Crankshaft, Flywheel, and Drive Plate

&I
25 2.5 18 + 1/4turn

Removal steps

1. Flywheel bolt and washer +B+ 8. Bearing cap

2. Flywheel and ring gear +A+ 9. Crankshaft bearing (lower)
3. Rear plate 10. Crankshaft
4. Bell housing cover +A+ 11. Crankshaft bearing (upper)
+D+ 5. Oil seal case 12. Cylinder block
+c* 6. Oilseal
+B* 7. Bearing cap bolt

00(G)-8-42 . Engine Overhaul--Crank, Flywheel, Drive Plate SM 598,Oct ‘94

 Main Table of Contents

CUiRK Group 00(G), Engine (Gas)

Inspection Cylinder Block

Crankshaft Oil Clearance (Plastic Gauge Method)
1. Remove oil from the crankshaft journal and crankshaft
bearing.
2. Install the crankshaft.
3. Cut the plastic gauge to the same length as the width of
the bearing and place it on the journal in parallel with
its axis.
1. Visually check for scratches, rust, and corrosion.
Use also a flaw detecting agent for the check. If defects
am evident, correct or replace.
2. Using a straightedge and feeler gauge, check the block
top surface for warpage. Make sure that the surface is
free from gasket chips and other foreign matter.
Standard value: 0.05 mm (0.0020 in.)
Limit: 0.1 mm (0.004 in.)

3. If the distortion is excessive, correct within the allow-

4. Install the crankshaft bearing cap carefully and tighten
the bolts to specified torque.
5. Remove the bolt and carefully remove the crankshaft
bearing cap.
6. Measurethewidthoftheplasticgaugeatitswidestpart
by using a scale printed on the plastic gauge package.
Standard value: 0.02-0.04 mm (0.0008- 0.0016 in.)
Limit: 0.1 mm (0.004 in.)
4. Check the cylinder walls for scratches and seizure. If
5. Using a cylinder gauge, measure the cylinder bore and
able limit or replace.
Grinding limit: 0.2 mm (0.008 in.)
The total thickness of the stock allowed to be removed
from the cylinder block and the mating cylinder head
is 0.2 mm (0.008 in.) at maximum.
Cylinder block height (when new):
289.9-290.1 mm (11.413-11.421 in.)
defects are evident, correct (bore to oversize) or re-
place.
cylmdricity. If worn badly, rebore all cylinders to an
oversize and replace pistons and piston rings. Measure
at the points shown in the illustration.
Standard value:
Cylinder I.D.: 86.50-86.53 mm (3.4055-3.4067 in.)
Cylindricity: 0.01 mm (0.0004 in.)

SM 598,Oct ‘94 Engine Overhaul-Crank, Flywheel, Drive Plate l 00(G)-B-43

 Main Table of Contents

Group 00(G), Engine (Gas) CMRK

Cylinder Boring Installation Service Points
1. Oversize pistons to be used should be determined on
the basis of the largest bore cylinder +A+ Crankshaft Bearing Installation
Piston size identification 1. When the bearings are replaced, select and install
them according to the identification colors on the
Size Identification mark crankshaft and the identification marks stamped on the
0.25 mm (0.01 in.) O.S. 0.25 cylinder block.
0.50 mm (0.02 in.) O.S. 0.50
0.75 mm (0.03 in.) OS. 0.75 O.D. Idt#S. LD Id&S. liliw
<mm1 mark (mm) mazk (mm1
1.00 mm (0.04 in.) O.S. 1.00

NOTE
Size mark is stamped on the piston top.
2. Measure the outside diameter of a piston to be used. None 56.988 - 0 61.000 - 2 1.991-
56.994 61.006 1.994
Measure it in the thrust direction as shown.
1 61.006 - 3 1.994 -
61.012 1.997

2 61.012~ 4 1.997-
61.018 2.000

wllir 56.982 - 0 61.OM - 3 1.9?4-

56.988 61.006 1.997

1 61.006 - 4 1.997.
61.012 2.000
Thrust
2 61.012 _ 5 2.000 -
direction 61.018 2.003

3. Based on the measured piston O.D. calculate the bor-

ing finish dimension.
Boring finish dimension = Piston O.D. + (clearance
between piston O.D. and cylinder) - 0.02 mm (0.0008
in.) (honing margin)
4. Bore all cylinders to the calculated boring finish di-
mension.

A CAUTION
To prevent distortion that may result from
temperature rise during boring, bore cyl-
inders, working from No. 2 to No. 4 to No. 1
to No. 3.
5. Hone to the final finish dimension (piston 0-D. +
clearance between piston O.D. and cylinder).
6. Check the clearance between the piston and cylinder.
Clearance between piston and cylinder: 0.02 - 0.04 mm
(0.0008 - 0.0016 in.)

NOTE
When boring cylinders, finish all of four
cylinders to the same oversize. Do not bore
only one cylinder to an oversize.

W(G)-844 l Engine Overhaul-Crank, Flywheel, Drive Plate SM 598,Oct ‘94

 Main Table of Contents

CIRRK Group 00(G), Engine (Gas)

2. Install the bearings having an oil groove to the cylinder 4. After installing the bearing caps, make sure that the
block. crankshaft end play is correct. If the end play exceeds
3. Install the bearings having no oil groove to the bearing the limit replace the crankshaft bearings.
caps. Standard value: 0.05 - 0.25 mm (0.0020 - 0.0098 in.)
Limit: 0.4 mm (0.016 in.)

Upper bearing
(for No. 1.2.4.5)
Lower bearing
(for No. 1.2.4.5)

+B4 Bearing Cap/Bearing Cap Bolt installation +C+ Oil Seal installation
1. Install the bearing caps so that their arrows are posi-
tioned on the timing belt side.

Arrow

2. When installing the bearing cap bolts, check that the +Dt Sealant Application To Oil Seal Case
shank length of each bolt meets the limit. If the limit is Install the oil seal case with the bolts coated with sealant.
exceeded, replace the bolt.
Specified sealant: Threebond 1207F.
Limit: Max. 71.1 mm (2.79 in.)
3. Torque the bearing cap bolts to 25 Nm (2.5 kgm, 18
ftlbs.) and, from that position,retighten them l/4 (90’)
turns more.

SM 598,Oct ‘94 Engine Overhaul-Crank, Flywheel, Drive Plate l W(G)-845

 Main Table of Contents

GROUP 00(G)

GROUP OO(GM)

ENGINE

(General Motors 3.OL LPG)

Specifications and Description ...................................... Section 1

Troubleshooting ............................................................. Section 2

Engien Oil and Filter ..................................................... Section 3

Tune-Up ........................................................................... Section 4

RPM, Stall, and Vacuum Checks .................................. Section 5

Compression Test ............................................................ Section 6

Engine Removal and Replacement ................................ Section 7

Engine Overhaul ............................................................. Section 8

SM 598, Feb’98 Group OO(GM)

 Main Table of Contents

CICIRU Group OO(GM), Engine (Gas)

Section I.

Engine Specifications
(General Motors 3.OL LPG Engine)

General Specifications Tune-Up Specifications

Engine Type: General Motors Powertrain 3.OL in-line, Tune-up specifications are listed in the engine tune-up
overhead valve. Section of this Group.
Number Of Cylinders: 4 Idle RPM: 750-800 RPM
Combustion Chamber: Semi-spherical 2550-2650 RPM
Gov RPM:
Total Displacement: 3 .OL
Advance: 17’ @800 &Total of 24’ 2600 RPM
Cylinder Bore: 101.6 mm (4.00 in)
Conv. Stall: 2400 RPM
Piston Stroke: 91.44 mm (3.60 in)
Hyd By-Bass: 1950 RPM
Compression Ratio: 9.25: 1
Emissions .6 - .9 CO @ Converter Stall
Cam Shaft: Gear Driven
Lubrication System: Pressure feed, full-flow filtration .4 - .6 CO @ Idle

Oil Pump Type: Involute gear type

Overhaul Specifications
Engine Oil: 15W40, API, CC, CD/SG, SF engine oil
Overhaul specifications are listed in the engine overhaul
Sump Capacity: 4.7 L (5.0 qt)
Section of this Group.
Cooling System: Water-cooled circulation
Water Pump Type: Centrifugal impeller type
Valves: Self Adjusting
Firing Order: 1 - 3 - 4 - 2
Materials:
Block: Cast iron
Cylinder Head: Cast iron
Intake Manifold: Cast iron

SM 598, Feb’98 Engine Specifications l OO(GM)-l-l

 Main Table of Contents

ClmK Group OO(GM), Engine (Gas)

Section 2.
Engine Troubleshooting
(General Motors 3.OL)

Also use the rpm, vacuum, and stall tests in Section 5 to

analyze engine performance
The following troubleshooting guide lists typical complaints
or troubles encountered in routine operation of the 3.OL
engine, and suggests possible remedies.

Engine hard to start or won’t start Engine runs unevenly at high speed
. Fuel system fault; see fuel system troubleshooting in l Fuel system fault; see fuel system troubleshooting in
Group 02. Group 02.
. Ignition system fault; see ignition system trouble- l Ignition system fault; see ignition system trouble-
shooting in Group 12. shooting in Group 12.
. Starter motor faulty; see electrical system trouble- Engine fires erratically
shooting in Group 14.
Fuel system fault; see fuel system troubleshooting in
. Battery, ground, or wiring is faulty; see electrical
Group 02.
system troubleshooting in Group 14.
Ignition system fault; see ignition system trouble-
. Engine oil is too viscous (heavy weight oil); change to
shooting in Group 12.
lighter oil viscosity.
Uneven compression or cylinder head problem:
. Engine timing too advanced; adjust timing.
- Carbon deposits in combustion chamber; clean.
. Valves or valve seats worn and leaking; relap or - Cylinder head water passages clogged; clean.
replace valves.
- Cylinder head gasket leaking; replace.
. Intake manifold gasket leaking: replace gasket if nec-
- Cylinder head bolts not torqued properly; tighten
essary and retighten manifold nuts to correct torque.
per specification.
. Cylinder head gasket leaking; replace head gasket and
Leaking intake gasket.
retighten cylinder head nuts to correct torque.
. Internal engine seizure; refer to engine overhaul pro- Valves sticking; repair or replace valves.
cedures. Valve springs weak or broken; replace valve springs.
. Instrument pod faulty; see instrument pod trouble- Backfiring
shooting in Group 13.
Fuel system fault; see fuel system troubleshooting in
. Out of fuel.
Group 02.
. LPG tank shut off or improperly coupled. Ignition system fault; see ignition system trouble-
Irregular idling shooting in Group 12.
Sticking valves; repair.
Fuel system fault; see fuel system troubleshooting in
Group 02. Broken or fatigued valve springs; repair or replace.
Spark plug gap is too wide; adjust.
Cylinder head gasket leaking; replace head gasket.
Valves not seating tight; relap valves.
Excessive valve-to-valve guide clearance; replace
valves and valve guides.

SM 598, Feb’98 Engine Troubleshooting l OO(GM)-2-1

 Main Table of Contents

Group OO(GM), Engine (Gas) ClmK

Lack of power or poor acceleration

. Ignition system malfunctioning; see ignition system l Faulty compression pressure; see “Faulty Compres-
troubleshooting in Group 12. sion.”
. Fuel system malfunctioning; see fuel system trouble- . Overloading of engine; review operation.
shooting in Group 02.
l Blown head gasket; replace.
. Air intake system restriction:
l Exhaust system leak or blockage; repair or replace.
- Air filter element clogged; replace.
- Throttle control not opening fully; adjust.
Faulty compression
- Carburetor choke faulty (gasoline only); adjust or . Valve holding open; repair.
repair. . Incorrect valve timing; retime engine assembly.
- Excessive exhaust back pressure; inspect and re- . Burned or sticking valves; repair or replace.
pair.
. Broken or fatigued (weak) valve springs; replace.
- Sharp bend or kink in hose from air filter to
. Cylinder head gasket faulty (leaking); tighten bolts or
carburetor; inspect, repair or replace.
replace.
- Engine valves sticking or worn; repair or replace.
. Piston rings worn, broken or stuck; repair or replace.
. Cylinder head gasket leaking; replace head gasket if
necessary and retighten cylinder head bolts to speci- Low oil pressure
fied torque. . Oil level is low; check and add oil.
. Piston rings sticking or worn; replace rings.
. Oil viscosity too light or diluted; check and replace oil.
. Cylinders worn; check and replace if necessary. See
. Pump suction screen clogged; clean.
also “Faulty Compression.”
. Dirt in relief valve or broken spring; clean or repair/
. Overheating; see “Overheating.”
replace.
. Valve seats leaking; relap valves.
. Worn or damaged oil pump; replace.
. Valve stems sticking; repair or replace valves.
. Worn engine bearings; replace.
. Valve springs weak or broken; replace springs.
. Worn cam bushings; replace.
Overheating . Oil pressure indicator, sensor, or wiring faulty; repair
. Cooling system malfunctioning; see cooling system or replace.
troubleshooting in Group 01. High oil pressure
. Cylinder head gasket leaks coolant; tighten bolts or
Oil pressure should not exceed recommended pressures
replace.
except when engine is starting up cold. Abnormally high
. Cylinder block or head cracked; repair or replace. oil pressure is not desirable because it increases oil con-
. Radiator fins plugged (dirty) or core clogged; clean or sumption. Possible causes of high oil pressures are:
replace. Engine oil too viscous (heavy weight); change to
. Fan installed backwards; remove and reinstall cor- correct oil grade.
rectly. Stuck relief valve; repair or replace.
. Thermostat faulty; replace. Obstruction in distributing line.
. Rust buildup in engine block; clean cooling system or
Faulty oil pressure gauge; replace.
overhaul.
Dirty or plugged oil filter; replace.
. Fan belt slipping, worn or damaged; clean, adjust, or
replace. High oil consumption
. Ignition timing incorrect; see ignition system trouble- l Loose oil filter; tighten oil filter with gasket.
shooting in Group 12.
. Engine oil level is low; add oil, inspect for cause.
. Fuel system malfunctioning; see fuel system trouble-
shooting in Group 02.

OO(GM)-2-2 l Engine Troubleshooting SM 598, Feb’98

 Main Table of Contents
ClmK
. Oil leaks in system; inspect and repair.
. Oil pan plug or pan attaching bolts loose; retighten
plug or bolts.
. Damaged oil pan gasket; replace gasket.
. Oil level too high; check cause andmaintain correct oil
level.
. Oil pressure too high, stuck relief valve; repair or
replace.
. Incorrect grade of oil used; change to heavier viscosity
grade.
. Clogged crankcase breather; clean.
. Worn, broken or stuck piston rings and clogged oil
control rings; replace.
. Worn pistons and sleeves; replace.
. Worn bearings; replace.
. Worn valve guides and seals; replace.
. Defective front or rear crankshaft oil seals; replace oil
seal.
. Damaged head cover gasket.
. Excessive oil reaching combustion chambers:
- Improperly positioned ring gaps; reposition ring
gaps.
- Worn piston rings or ring grooves; replace rings or
pistons.
- Excessive accumulation of carbon in oil return
hole in oil ring; replace rings.
- Worn pistons and cylinders; rebore cylinders and
replace pistons.
- Too much oil in oil pan; drain oil to specified
level.
Excessive downward oil flow along valve stems:
- Worn valve stems or guides; replace valves or
guides.
- Damaged valve stem oil seals; replace oil seals.
Piston rings not run-in (seated), due to too smooth
cylinder bore finish or glazed condition; repair or
replace rings and deglaze cylinder walls.
SM 598, Feb’98
Group OO(GM), Engine (Gas)
Engine knocks and other noises
Operating knocks
Fuel, when detonation knock is caused by low octane
gasoline; check fuel specification.
Preignition, when most common cause is due to incor-
rect type plugs which are too hot; replace plugs with
correct heat range.
Carbon buildup, noticeable when engine is accelerated
when hot; clean cylinder head and pistons.
Incorrect timing, when early (advanced excessively)
timing causes knocks similar to carbon buildup, but
may tend to kick back when starting; adjust timing.
Overloads, particularly at lower operating speeds;
review operating methods.
Mechanical knocks
l Crankshaft and main bearings:
- Worn, burned-out, or melted main bearings indi-
cated by a heavy, dull knock when accelerating
under load; locate by shorting out spark plugs on
both sides of the bad bearing; replace bearings and
if melted, check lubrication system.
- Crankshaft end play is indicated by an intermittent
knock which will come and go when the load is
released and engaged.
- Crankshaft thrust bearing worn; replace thrust
bearing.
l Connecting rod and bearings
- Worn or burned-out bearings indicated by a light
pounding or metallic knock, is noted at idling
speed and to about 213 maximum speed; bad
bearings can be located by shorting out spark
plugs; replace rod or bearings.
l Pistons and piston pins
- Excessive piston clearance in cylinder; rebore
cylinders and replace pistons.
- Piston sticking; replace pistons.
- Loose or worn piston pins, which may be located
by shorting out spark plugs; noise increases when
the correct plug is shorted out, most noticeable at
idling speed; replace pistons or pins.
- Piston loose in cylinder or damaged piston rings,
indicated when “piston slap” is noted by metallic
knocking at low speed under load but disappears
at high speed; also most noticeable when starting
cold; test by shorting out spark plugs and replace
piston rings.
Engine Troubleshooting l OO(GM)-2-3
 Main Table of Contents

Group OO(GM), Engine (Gas) ClMK

- Broken piston ring or pin is indicated by a sharp
clicking noise that doesn’t change when spark
plugs are shorted out; repair engine.

l Crankpin bearings worn, damaged, or melted; replace

bearings and check lubrication system.
l Valves
- Oil drained from lifters. Lifters should fill within
20 minutes, as engine runs.
- Defective lifters; replace.
- Burned valves and seats indicated when engine
misses, especially at low speeds, or acceleration
under load; repair engine.
- Weak or broken valve springs indicated when the
engine is missing at low or high speeds when
under load; replace springs.
- Sticking valves indicated by a loss of power and
popping sound; overhaul head.

l Camshaft makes noise due to loose bearings or end

play, usually occurs at half engine speed; replace
camshaft thrust plate.
Vibration originating at engine
The most common sources of vibration originating in or on
the engine, as distinguished from causes created outside the
engine, are as follows:
Misfiring
Misalignment of engine
Bent or off-center driveline coupling.
Engine loose on mountings, or wrong mountings.
Out-of-balance condition of flywheel and clutch as-
sembly .

OO(GM)-2-4 l Engine Troubleshooting SM 598, Feb’98

 Main Table of Contents

EmI6 Group OO(GM), Engine (Gas)

Section 3.
Engine Oil and Filter
(General Motors 3.OL)

Engine Oil Requirements To help achieve proper engine performance and durability,
use only engine lubricating oils of the proper quality. These
Engine oil does not “wear out.” However, the lubricating
oils also help promote engine efficiency, which results in
oil in internal combustion engines becomes contaminated
improved fuel economy. A symbol has been developed by
from the by-products of combustion: dirt, water, unburned
the API (American Petroleum Institute), SAE, and ASTM
fuel entering the crankcase, and the detergents holding the
to help you select the proper engine oil. It should be in-
carbon particles in suspension in the crankcase.
cluded on the oil container you purchase.
Motor oils used for internal combustion engine lubrication
perform many useful functions including:
l Dissipating heat
l Sealing piston rings
l Preventing metal-to-metal contact wear
l Reducing power loss through friction.
Lubricating oil recommendations are based upon engine
IMPORTANT
design, type of service, and the ambient temperature in
which the engine is operating. High-quality oils are re- Use 15W40, API CC, CD/SG, SF engine
quired to assure maximum performance, long engine life, oil.
and minimum cost of operation.
The schedule for changing oil is directly dependent upon Engine Oil Level Check
the operational environment. An extremely clean operation
The engine oil level should be checked every 8 hours.
could go X0-250 hours while a dirty operation (foundry or
cement factory) could be 50 hours or less. Check the oil level with engine stopped. Allow 5
minutes for the oil level to stabilize. Pull the dipstick
NOTE
out, wipe it with a clean wiper, and reinsert it fully into
Oil changes should be scheduled every 50- the dipstick tube. Remove the dipstick and check the
250 hours, monthly, or more frequently if oil level.
necessary. The time interval for changing
engine oil depends upon your application Oil level should be at the PULL level marking on the
dipstick. Add recommended oil as needed. Wait 5
and operating conditions. To determine the
minutes after adding oil and check the oil level again.
correct schedule for your truck, it is sug-
gested that you periodically submit engine Do not overfill.
oil samples to a commercial laboratory for NOTE
analysis of the condition of the oil. It is normal to add some oil between oil
changes. Keep the oil level above the ADD
mark on the dipstick . Do not overfill. Use
the correct oil as specified above.
Check the periodic service schedule (operating hours),
or the condition of the oil to determine if it needs to be
changed.

SM 598, Feb’98 Engine Oil and Filter l OO(GM)-3-1

 Main Table of Contents
Group OO(GM), Engine (Gas)
IMPORTANT
Use 15W40, API, CC, CD/SG, SF engine
oil. Sump capacity is 4.7 L (5.0 qt.).
Engine Oil and Filter Change
Recommended service intervals and procedures:
Drain and replace the engine crankcase oil every 50 to
250 operating hours, or sooner as explained on the
previous page.
Replace engine oil filter at every other oil change.
Drain and replace engine oil in a new or rebuilt engine
after the first 50 hours of operation.
Drain oil after engine is at operating temperature.
To change the engine oil and oil filter:
1. Safely park the truck and place an oil drain pan under
it
2. Remove drain plug at bottom of engine oil pan and
drain the oil completely.
NOTE
Raise and block up the truck under the
frame to give easier access to the engine
drain plug. Refer to “Lifting, Jacking, and
Blocking” in Group SA.
OO(GM)-3-2 l Engine Oil and Filter
CmK
3. Remove the engine oil filter.
4. Make sure sealing surface on engine is clean.
5. Install new oil filter. Follow installation instructions
printed on the outside surface of the filter. Check that
the oil seal is lubricated and correctly in place.
IMPORTANT
Always use genuine CLARK parts.
6. Clean and inspect the oil drain plug and seal. Replace
the drain plug and/or seal if damaged.
7. Install drain plug. Remove oil drain pan.
8. Remove and inspect the condition of the engine oil
filler cap located on top of the engine valve cover.
Replace cap if it is damaged or the seal is broken.
9. Refill the crankcase with fresh engine oil through the
rocker cover oil filler opening. Sump capacity is 4.7 L
(5.0 qt.).
10. Wait several minutes after adding oil to check the oil
level. Add oil if necessary.
11. Start the engine and allow it to run at idle for several
minutes. Check the oil filter and drain plug for leakage.
12. Check the engine oil level with the engine stopped for
5 minutes. Add oil as necessary.
SM 598, Feb’98
 Main Table of Contents

CIRRK Group OO(GM), Engine (Gas)

Section 4.
Engine Tune-Up
(General Motors 3.OL)

Tune-Up Specifications

Spark Plug Type: Engine Speed (rpm):

LPG Engine: AC44TS or ACR44TS Idle: 780 to 800
Spark Plug Gap: 0.7-0.8 mm (0.028-0.031 in) Maximum No-Load Governed: 2600 +/- 50
Converter Stall-LPG: Approx. 2400 RPM
Spark Plug Tightening Torque: 25 Nom (18.4 in-lb)
Engine Vacuum kPa (psi):
Ignitor Air Gap: 0.8 mm (.03 1 in)
Idle: 406-457 mmHg ( 16- 18 inHg)
Ignition Timing: LPG 13” to 14’ BTDC @ 780 rpm MaximumNo-LoadGoverned:330-381mmHg(13-15inHg)
GM HE1 Ignition and Coil Converter Stall: 38-64 mmHg (1.5-2.5 inHg)

Procedures
It is recommended that you perform the entire set of basic 5. Make sure all instrument panel lights indicate normal
planned maintenance procedures described in Section 2 of conditions. Perform service indicated by lights as
Group PS when tuning up the engine. As a minimum, you explained in Group 13, “Instrument Pod.”
should perform the following procedures. 6. Listen to the engine idle, then accelerate the truck with
1. Check oil level. Fill as necessary. the tilt lever fully forward or back. If idle or accelera-
tion is erratic, consult fuel system troubleshooting in
2. Check coolant level using safe procedure given in
Group 02, “Fuel System.”
Group 01.
Perform the engine rpm, vacuum, and stall tests in
3. Inspect engine for loose or damaged hoses, belts,
Section 5 of this Group (00 G). If these tests indicate
electrical connections, and choke and throttle link-
poor engine performance, perform the fuel system
ages.
checks and adjustments given in Group 02 and the
4. Start the engine, and let it warm up. While doing this, ignition system checks and adjustments given in Group
look for excessive exhaust smoke and listen for un- 12. (Transaxle repair may also be indicated.)
usual engine noise that indicates a need for engine
Verify engine performance after making adjustments
repair.
by repeating the stall tests in Section 5 of this Group
NOTE (00 G). If adjustments cannot connect engine perfor-
Black exhaust smoke indicates excessive fuel mance, consult engine, fuel system and ignition sys-
consumption caused by carburetor or choke tem troubleshooting charts in Groups 00,02, and 12,
mis-adjustment or malfunction (gasoline respectively.
engines only). Blue exhaust smoke indicates
excessive oil consumption caused by faulty
seating of piston rings, dirt, or worn engine
components such as rings, cylinders, pis-
tons, or valve guides.

SM 598, Feb’98 Engine Tune-Up l OO(GM)-4-1

 Main Table of Contents

CmK Group OO(GM), Engine (Gas)

Section 5.
RPM, Vacuum, and Stall Tests
(General Motors 3.OL)

Introduction ....................................................................................................................................1

Test Procedures .............................................................................................................................. 2

Preliminary Procedures .................................................................................................................2

Engine RPM and Vacuum at Idle ................................................................................................... .2
Engine RPM at Maximum No-Load Governed Speed ................................................................... .3
Engine Vacuum at Maximum No-Load Governed Speed .............................................................. .3
Engine RPM and Vacuum at Stall .................................................................................................. .3

Analysis of Stall Test ...................................................................................................................... 4

Introduction
The tests in this Section should be part of all engine tune- Intake manifold vacuum is determined by how far the
ups and planned maintenance inspections. throttle plate is opened and how much rpm the engine can
produce at a given throttle position. The wider the throttle
These tests check :
plate is opened, the less vacuum (pressure drop) can de-
l Engine speed settings.
velop across the throttle bore. The extent to which the
l Overall engine performance
throttle has to be opened in order to achieve a certain rpm
l Whether major components or systems other than the
or power level, is affected by how well the engine is
engine have problems or are causing problems.
running and how much the fluid coupling (the torque con-
Tests include: verter) in the transaxle resists engine rotation. Therefore, a
Engine idle speed and vacuum. lower than normal vacuum reading indicates a wider throttle
Engine maximum no-load governed speed and opening and lower performance.
vacuum.
Similarly, when the throttle is held wide open, the vacuum
Engine speed and vacuum at hydraulic tilt bypass
and rpm levels can vary from normal according to how
(relief pressure).
well the engine and torque converter are performing. Other
Engine stall speed and vacuum.
loads, such as the hydraulic pump, can also affect perfor-
NOTE mance.
HYDROSTATIC TRANSMISSION trucks Whenever the engine is running, its drive shaft drives the
are not covered by the stall check proce- torque converter, which is in the transaxle. The torque
dure. converter is a fluid coupling that slips to a varying extent,
depending on the condition of the torque converter compo-
Minimum tools required are:
nents and the clutches that the torque converter drives. The
l Tachometer
resistance offered by the torque converter is reflected in the
9 Vacuum gauge.
engine rpm and vacuum readings when a stall test is per-
formed.

SM 598, Feb’98 Engine RPM, Vacuum, and Stall Checks l OO(GM)-5-l

 Main Table of Contents

Group OO(GM), Engine (Gas) CIRRK

Test Procedures Engine RPM and Vacuum at Idle
Perform the tests in the order given here. 1. Check the engine idle speed. If idle speed is not 780-
800 rpm, adjust the carburetor idle screw setting as
explained in Group 02, “Fuel System.”
Preliminary Procedures
2. Check the engine intake manifold vacuum with the
1. Safely park the truck on a level surface. Apply parking
engine idling at the 780-800 rpm, then increase engine
brake and place controls in neutral.
speed.
2. Connect a tachometer, or a combination test instru-
ment such as theClarkDynamic Engine Analyzer (part The typical intake manifold vacuum reading at idle should
number 1802047). be 4.06-4.57 mmHg (16-18 inHg) at 780-800 rpm. Refer to
the chart below to analyze the reading you obtain.
3. Install a vacuum gauge between the breather hose
(PCV line) leading from the rocker cover to the intake Vacuum
manifold. Use a tee, short hose, and adapter to connect Gawe Readiws Ewine Condition
the gauge. High and Steady: Good
4. Check all throttle control linkage for complete and free
Low and Steady: Loss of power in all cylinders
movement.
caused by:
5. Start the engine and let it warm up until it runs evenly -Late ignition or valve timing.
and accelerates smoothly when you push on the accel- -Loss of compression due to
erator pedal. leakage around piston rings.
Allow the engine to warm up to operating temperature Very Low: Manifold, carburetor or cylinder
before putting it under any load conditions. head gasket leak.
Needle Pulses Steadily as Speed Increases:
A partial or complete loss of
power in one or more cylinders
caused by:
-Leaking intake valve
-Cylinder head or intake manifold
gasket leak
-Fault in the ignition system
-Weak valve spring.

Gradual Drop at Engine Idle; Intermittent Fluctuation:

Excessive back pressure in the
exhaust system.
An occasional loss of power
possibly caused by a defect in the
ignition system or a sticking valve.
Slow Fluctuation or Drift of the Needle:
Improper idle mixture adjustment,
or carburetor, spacer or intake
manifold gasket leak.

If vacuum is OK, check the no-load governed speed.

OO(GM)-5-2 l Engine RPM, Vacuum, and Stall Tests SM 598, Feb’98

 Main Table of Contents
CIIFIRK
Engine RPM at Maximum No-Load Governed
Speed
Check the speed to which the governor limits the engine:
1. Push the accelerator pedal slowly to the floor. When
the governor begins taking control of the throttle,
slight variation (hunting) in engine speed may occur.
This is normal.
2. When the engine speed stabilizes, read the maximum
no-load governed speed on the tachometer.
If the no-load governed speed is not 2600rpm +/- 50rpm,
refer to Group 02, “Fuel System,” for governor adjustment
procedures.
If rpm is OK and if overheating is observed at long runs at
high speed, check the vacuum at maximum no-load gov-
erned speed.
Engine Vacuum at Maximum No-Load
Governed Speed
Check the engine intake manifold vacuum with the engine
running at the maximum speed allowed by the governor
(only if overheating is observed at long runs at high speed):
1. Run the engine to the maximum no-load governed
speed, as above.
2. When the engine speed stabilizes, read the vacuum
gauge.
The vacuum at no-load governed speed 2600 RPM should
be 3.30-3.81 mmHg (13-15 inHg).
If vacuum is low, such as 2.29-2.79 mmHg (9-11 inHg),
this is an indication that the transaxle has a fault, such as a
locked stator, in the torque converter.
Perform stall test.
SM 598, Feb’98
Group OO(GM), Engine (Gas)
Engine RPM and Vacuum at Stall
NOTE
HYDROSTATIC TRANSMISSION trucks
are not covered by this procedure.
Be sure that transaxle fluid level has been checked and is
correct (see Group 06) and that braking and inching pedals
are adjusted correctly (see Group 23) before you run a stall
test.
n ! CAUTION
Stall tests must be performed with the park-
ing brake off and with the truck placed
against a solid barrier (such as a wall or
another lift truck) to prevent movement.
Make sure that the truck cannot move and
that the solid barrier is capable of with-
standing the force before you begin.
1. Add load on forks to increase weight and prevent
inadvertent drive wheel spin. Warm the transmission
to normal operating temperatures.
2. Place truck against an immovable barrier (such as a
wall or another lift truck).
3. Put the directional control lever in forward (or reverse,
depending upon truck position to barrier).
NOTE
Use of the STEERING HANDWHEEL can
affect engine rpm. Do not touch during the
test.
4. Release the parking brake.
5. Slowly push the accelerator pedal fully down and hold
it there while you read the tachometer and vacuum
gauge.
IMPORTANT
Do not run engine and converter at stall
longer than necessary to take the rpm and
vacuum readings, or longer than 30 sec-
onds at one time. Then, shift transmission
into neutral for 15 seconds and run the en-
gine at one-half speed for one to two min-
utes to cool torque converter oil. Excessive
temperature, 120” C (250°F) maximum, will
overheat the converter and cause damage
to converter, seals, and fluid.
Engine vacuum at stall should be .38-.64 mmHg (1.5-2.5
inHg). Engine rpm at stall should be approx. 2400 rpm for
the LPG engine. See analysis chart on next page.
To test both clutch packs in the transmission, check stall
speed and vacuum with transaxle in forward and reverse.
Engine RPM, Vacuum, and Stall Checks l OO(GM)-5-3
 Main Table of Contents

Group OO(GM), Engine (Gas) ClmK

Analysis of Stall Test

NOTE
HYDROSTATIC TRANSMISSION trucks
are not covered by the stall check proce-
dure.

Normal Stall Speed

LPG: Approximately 2400 RPM

- Engine performance is good.

- Torque converter is operating correctly.
- Transmission clutch packs are operating correctly (not
slipping).

Below Normal Stall Speed

LPG: 2000 rpm

- Engine performance is poor (needs tune-up or repair).

- Transmission and torque converter are OK.

Very Low Stall Speed

LPG: 1500 rpm or less

- Torque converter stator is slipping. Repair of torque

converter is required. See Group 06, “Transaxle,”
troubleshooting.

High Stall Speed

LPG: Above 2600 rpm

- Transaxle clutch or converter problems, See Group 06,

“Transaxle,” troubleshooting.

Use the engine compression checks Section of this Group

to further check engine condition.

OO(GM)-5-4 l Engine RPM, Vacuum, and Stall Tests SM 598, Feb’98

 Main Table of Contents

ClmK Group OO(GM), Engine (Gas)

Section 6.
Compression Checks
(General Motors 3.OL)

Test Preparation
NOTE
Engine compression test procedures consist of removing
the spark plugs, installing a compression test pressure gauge Check to be sure battery is fully charged.
to the cylinder being tested, and cranking the engine while 6. Rush the accelerator pedal fully down (to open the
the pressure is being measured. throttle and admit a full charge of air).
1. Be sure the oil in the crankcase is the correct viscosity 7. Turn the key switch to the Start position and crank the
and filled to the proper level. Disconnect or remove all engine until it turns through at least 5 compression
auxiliary engine loads. strokes.
2. If truck has not been operating, start the engine and
warm it up to normal operating temperature. Coolant
temperature should be 80-90’ C (176-194” F). Turn
ignition key switch OFF.

Compression Test Procedure

1. Disconnect the spark plug wires.
IMPORTANT
Do not allow dirt and contaminants to enter 8. Make a record of the highest pressure reading. Also
spark plug openings when the plugs are re- note the approximate number of compression strokes
moved Use an air nozzle or equivalent to blow needed to obtain the highest pressure reading. Replace
any dirt and contamination out of the spark the spark plug.
plug well before and after loosening the plug.
Loosen tbe sparkplug of the cylinder to be tested. Repeat
blowing the dirt out of the well. Remove the spark plug.
Install a screw-in adapter in the spark plug opening, if
required by the compression pressure gauge.
Install a compression gauge to the spark plug opening.
Ground the ignition system. Disconnect the high tension
coil wirefromthedistributor cap and connectittoajumper
wire that is connected to ground on the engine. This will 9. Repeat the above procedure and compression test on
prevent the engine from accidentally being started and also
each of the other cylinders, using the same number of
prevent damage to electrical components.
compression strokes needed to obtain the highest read-
ing for #l cylinder.
Jumper 10. Remove the pressure gauge, and adapter if used, and
install the spark plugs. Tighten the spark plugs to 25
DISTRIBUTOR Wm (18.4 in-lb).
IMPORTANT
Lubricate threads on spark plugs with
ANTI-SEIZE grease, Clark part #1802307.

GROUND

SM 598, Feb’98 Engine Compression Checks l OO(GM)-6-1

 Main Table of Contents

Group OO(GM), Engine (Gas) CWRK

b. If compression pressure does not improve, this is
Analysis of Pressure Readings
an indication that:
Cylinder compression should be about 1126.5 kPa (163.5 l The valves are not operating correctly
psi) at 300 rpm (cranking speed).
l The valve seats are worn
1. Evaluate the cylinder compression pressure readings l The piston may be burned, have a hole, or have a
that you have recorded: broken ring.
a. If the pressure readings are all within 10% of the
l A valve is burned or sticking open:
nominal pressure, the engine is in serviceable
- A valve that is stuck open causes low cylinder
condition.
compression and is indicated by an irregular
b. If the pressure readings are all at or below the clattering noise and power loss.
minimum specified pressure (Service Limit), the
- A valve that is burned causes very low compres-
engine piston rings and/or valves are worn exces-
sion pressure in one cylinder and is indicated by
sively and require service or replacement.
a constant miss of one cylinder.
2. Compare the pressure difference between cylinders:
If two adjacent cylinders have low compression read-
a. A pressure difference between cylinders less than
ing and putting oil in the cylinder does not improve
103 kPa (15 psi), or approximately lo%, is nor-
compression, the cause can be the cylinder head gasket
mal.
leaking between the cylinders. Further diagnosis and
b. If the pressure difference is greater than 103 kPa repair of the engine is required.
(15 psi), this is an indication of faulty or worn
If the compression test indicates a valve problem, a
valves or piston rings, or leaking head gasket.
lifter may be locked up or a valve seat damaged. Refer
3. Retest the cylinder with the lowest pressure. Put ap- to the overhaul Section of this Group for repair infor-
proximately 14.8 cc (0.50 oz) of engine oil into the mation.
spark plug opening and on top of the piston in the
cylinder. (Use a squirt oil can, or equal.) This will form
a seal around the rings on the piston.
4. Repeat the compression test in this cylinder.

a. If the compression pressure increases, this is an

indication that the piston rings are worn.

OO(GM)-6-2 . Engine Compression Checks SM 598, Feb’98

 Main Table of Contents

ClmK Group OO(GM), Engine (Gas)

Section 7.

Engine Removal and Replacement

(General Motors 3.OL)

2
Engine Removal .............................................................................................................................

4
Engine Replacement ......................................................................................................................

SM 598, Feb’98 Engine Removal and Replacement l OO(GM)-7-l

 Main Table of Contents

Group OO(GM), Engine (Gas) CIRRK;

Engine Removal
A CAUTION Disconnect the battery and remove it from the engine
SAFE PARKING. Before working on truck: compartment. Disconnect negative cable first.
1. Park truck on a hard, level, and solid Disconnect and remove the air cleaner and hoses as
surface, such as a concrete floor with no described in Group 3, “Air Induction System.”
gaps or breaks.
2. Put upright in vertical position and fully Disconnect and remove the exhaust pipe between the
engine exhaust manifold and the muffler pipe. See
lower the forks or attachment.
Group 3, Section 4.
3. Put all controls in neutral. Turn key switch
OF’F and remove key.
4. Apply the parking brake and block the
wheels.
To remove the engine:

1. Tilt the steering column fully forward.

Exhaust
2. Raise the seat deck. Manifold

3. Lift out the operator’s compartment floor plate and

remove the seat deck as explained in Group 38.

4. Remove the overhead guard from the operator’s cell. Muffler Pipe
-77-Y

Overhead
Guard

- Exhaust
Pipe

8. Label and disconnect all wiring from the engine to

Operator’s components that will remain in the truck frame. See
Cell Group 14 for wiring configurations.

NOTE
Remove the overhead guard only ifan over-
head hoist is used to lift the engine out. If
an engine hoist or another fork lift truck
will be used to lift out the engine, removal
of the overhead guard is not necessary.

OO(GM)-7-2 . Engine Removal and Replacement SM 598, Feb’98

 Main Table of Contents
ClRRlC
9. On the standard transaxle truck, disconnect the accelera-
tor cable at the throttle lever. On the hydrostatic transmis-
sion truck, disconnect the electrical connection and re-
move the linkage actuator and linkage with the engine.
Cable Bracket
Throttle Lever
10. Disconnect and cap the fuel line at the fuel tank.
11. Drain the coolant from the engine and radiator, and
disconnect the radiator hoses from the engine thermo-
stat and water pump, as explained in Group 01.
12. Disconnect and remove the radiator upper shroud, fan
ring, and venturi (as explained in Group 01) to allow
for engine front-to-back movement.
13. Unbolt the engine mounting bolts.
SM 598, Feb’98
Group OO(GM), Engine (Gas)
14. Disconnect the engine from the transaxle (or hydro-
static transmission pump) as explained in Group 06.
15. Using a hoist and chains or engine stand of adequate
capacity, hook the chains to the engine lifting eyes
Remove slack from the chains.
L
n ! CAUTION
Do not attempt to move the engine with
your hands as it is being disconnected from
the transmission or hoisted from the truck.
Always use a prybar to gently clear the
engine from the transmission or the truck
frame.
16. Slowly hoist the engine out of the frame.
IMPORTANT
Do not allow the engine and fan to swing
forward to bump the radiator during re-
moval. Damage to the fan and/or radiator
will result. Slip a sturdy piece of cardboard
in front of the radiator core to protect the
fins.
Engine Removal and Replacement l OO(GM)-7-3
 Main Table of Contents

Group OO(GM), Engine (Gas) CIRRU

Engine Replacement
Before beginning engine replacement, make sure the truck 6. Set the engine onto the mounting isolators. Set mount-
parked with the parking brake applied and wheels chocked. ing bolts in place but do not tighten. The engine may
To replace the engine: have to be shifted to line up with the transmission.

1. Make sure the hoist and chains or engine stand you are
using is of adequate capacity to safely lift the engine.

2. Hook the hoist chains to the engine lifting eyes.

Connect the engine to the transaxle (or hydrostatic

Slowly lift the engine and move it into place over the
transmission pump) as explained in Group 06.
truck frame.
Torque engine mounting bolts to 170-190 Nom (125-
Make sure there are no wires, cables, hoses, or other
140 ft-lb).
equipment in the way of lowering the engine into the
frame. Align and connect the exhaust pipe to the engine
exhaust manifold using a new gasket for reassembly.
Slowly begin lowering the engine into the frame.
Torque bolts to 40-45 Nom (30-33 ft-lb). Replace the

A WARNING
V-band coupling and torque the bolt to 9-10 Nom (8 l-
91 in-lb; 6.75-7.5 f&lb).
Never use your hands to move the engine
in the frame. Always use a pry bar to gen-
tly shift or hold the engine in place. After
the engine is in place, keep the hoist chains
attached and keep slack out of the chains.
Remove the chains only when the engine is
securely mounted in the truck frame and
remounted with the transmission. Muffler
Pipe

Pipe
Coupling

OO(GM)-7-4 . Engine Removal and Replacement SM 598, Feb’g8

Main Table of Contents
 Main Table of Contents

Group OO(GM), Engine (Gas) CWRK

18. Install the driver overhead guard. Torque the bolts to
70-75 Wm (52-55 ft-lb).

Overhead
Guard

Operator’s , ,
Cell

19. Close engine drain valve and fill radiator according to

the procedures presented in “Engine Cooling System
Testing and Maintenance” in Group 01. Check inlet
and outlet hoses for leaks.

20. Restart the engine and check all truck electrical, hy-
draulic, and mechanical components for proper opera-
tion before returning the truck to service.

OO(GM)-7-6 . Engine Removal and Replacement SM 598, Feb’98

 Main Table of Contents

CmK Group OO(GM), Engine (Gas)

Section 8.

Engine Overhaul
(General Motors 3.OL Engine)

SM 598, Feb’98 Engine Overhaul l OO(GM)-8-1

 Main Table of Contents
Table of Contents
Specifications.. ........................................................... 4
Fastener Tightening Specifications .............................. 4
Sealers, Adhesives and Lubricants .............................. 4
Engine Mechanical Specifications (1 of 2) ................... 5
Engine Mechanical Specifications (2 of 2) ................... 6
Diagnostic Information and Procedures .................. 7
Base Engine Noise Diagnosis.. .................................... 7
Engine Compression Test ............................................ 8
Engine Noise Diagnosis ............................................... 8
Knocks Cold and Continues for 2 to 3 Minutes ............ 8
Knocks on Start-Up but Only Lasts a Few Seconds .... 8
Knocks at Idle Hot ........................................................ 8
Valve Train Diagnosis ................................................... 8
Oil Consumption Diagnosis.. ........................................ 8
Low or No Oil Pressure Diagnosis and Testing ............ 9
Oil Leak Diagnosis ....................................................... 9
Block Explode #l Disassembled View (1 of 4) ........... 10
Block Explode #2 Disassembled View (2 of 4) ........... 12
Head Explode Disassembled View (3 of 4) ................ 14
Oil Pump Explode Disassembled View (4 of 4). ......... 15
Draining Fluids and Oil Filter Removal ....................... 16
Engine Flywheel Removal .......................................... 17
Distributor Removal .................................................... 18
Ignition Coil Removal ................................................. 18
Lift Bracket Removal .................................................. 19
Spark Plug Removal .................................................. 19
Intake/Exhaust Manifold Removal .............................. 19
Intake/Exhaust Manifold Disassemble and
Assemble .............................................................. 20
Intake/Exhaust Manifold Clean and Inspect.. ............. 20
Water Pump Removal ................................................ 20
Crankshaft Pulley Removal ........................................ 21
Valve Rocker Arm Cover Removal ............................. 21
Pushrod Cover Removal ............................................ 21
Valve Rocker Arm and Pushrod Removal .................. 22
Measuring Camshaft Lobe Lift ................................... 22
Valve Train Components Inspect (Cylinder Head). ..... 23
Valve Lifter Removal .................................................. 23
Cylinder Head Removal ............................................. 24
Oil Pan Removal ........................................................ 24
Oil Pump Removal ..................................................... 24
Oil Level Indicator and Tube Removal ........................ 25
Engine Front Cover Removal ..................................... 25
Measuring Crankshaft and Camshaft Sprocket
Runout.. ................................................................ 26
Measuring Timing Sprocket Teeth Backlash.. ............. 26
Crankshaft Sprocket Removal.. .................................. 26
Camshaft Removal ..................................................... 27
Crankshaft and Camshaft Sprocket Inspect.. ............. 27
Timing Gear Oil Nozzle Removal ............................... 28
Piston, Connecting Rod and Bearing Removal.. ........ 28
Crankshaft and Bearings Clean and Inspect
(Connecting Rod Bearing Clearance) .................. 29
Crankshaft Rear Oil Seal and Housing Removal ....... 31
Group 00 (GM), Engine 3.OL
Crankshaft, Bearings and Bearing Cap Removal .... .32
Crankshaft and Bearings Clean and Inspect.. ............ 33
Crankshaft and Bearings Clean and Inspect
(Main Bearing Clearance) .................................... 35
Camshaft Bearing Removal ....................................... 37
Distributor Lower Bushing and Thrust Washer
Removal ............................................................... 38
Oil Filter Bypass Valve Removal and Installation ....... 38
Cylinder Block Clean and Inspect .............................. 39
Cylinder Bore Measurements ..................................... 39
Cylinder Boring and Honing ....................................... 40
Distributor Lower Bushing and Thrust Washer
Installation ............................................................ 41
Piston and Connecting Rod Disassemble .................. 41
Piston and Connecting Rod Clean and Inspect ......... 42
Piston Selection ......................................................... 44
Piston and Connecting Rod Assemble.. ..................... 45
Camshaft and Bearings Clean and Inspect ............... 46
Camshaft Sprocket and Retainer Removal and
Installation ............................................................ 48
Camshaft Bearing Installation .................................... 49
Oil Pump Disassemble.. ............................................. 50
Oil Pump Clean and Inspect ...................................... 51
Oil Pump Assemble.. .................................................. 52
Cylinder Head Disassemble.. ..................................... 53
Cylinder Head Clean and Inspect .............................. 54
Valve Guide ReamingNaIve and Seat Grinding.. ....... 57
Rocker Arm Stud Removal and Installation.. .............. 58
Cylinder Head Assemble.. .......................................... 59
Service Prior to Assembly.. ........................................ 60
Crankshaft, Bearings and Bearing Cap Installation ... 60
Crankshaft Rear Oil Seal and Housing Installation.. .. 61
Piston, Connecting Rod and Bearing Installation.. ..... 62
Timing Gear Oil Nozzle Installation.. .......................... 64
Crankshaft Sprocket Installation.. ............................... 64
Camshaft installation.. ................................................ 64
Engine Front Cover and Oil Seal Installation ............. 65
Oil Pump Installation .................................................. 66
Oil Pan Installation ..................................................... 66
Crankshaft Pulley Installation ..................................... 67
Cylinder Head Installation .......................................... 67
Valve Lifter Installation ............................................... 68
Valve Rocker Arm and Pushrod Installation ............... 68
Pushrod Cover Installation ......................................... 70
Valve Rocker Arm Cover Installation .......................... 71
Oil Level Indicator and Tube Installation.. ................... 71
Water Pump Installation ............................................. 71
Intake/Exhaust Manifold Installation ........................... 72
Spark Plug Installation ............................................... 72
Lift Bracket Installation ............................................... 72
Ignition Coil Installation .............................................. 73
Distributor Installation.. ............................................... 73
Engine Flywheel Installation.. ..................................... 74
Engine Block Coolant Plug/Oil Filter Installation.. ...... 74
00 (GM)-8-1
 Main Table of Contents

Group 00 (GM), Engine 3.OL CLSRK

Description and Operation ...................................... 76 Lubrication ................................................................. 77
Engine Component Description ................................. 76 Thread Repair ............................................................ 77
Engine Block .............................................................. 76 Cleanliness and Care.. ............................................... 78
Cylinder Head ............................................................ 76 Replacing Engine Gaskets ......................................... 78
Crankshaft.. ................................................................ 76 Use of RTV and Anaerobic Sealer ............................. 78
Camshaft.. .................................................................. 76 Separating Parts ........................................................ 79
Pistons and Connecting Rods.. .................................. 76 Tools and Equipment.. ................................................ 79
Valve Train .................................................................. 76 Special Tools and Equipment ..................................... 80

00 (GM)-8-2
 Main Table of Contents

clfm Group 00 (GM), Engine 3.OL

3.OL
NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part
number of that application.

Clark Materiel Handling Co. will call out those fasteners that require a replacement after removal. Clark Materiel Handling
Co. will also call out the fasteners that require thread lockers or thread sealant.

UNLESS OTHERWISE SPECIFIED, Do Not use supplemental coatings (paints, greases or other corrosion inhibitors) on
threaded fasteners or fastener joint interfaces. Generally, such coating adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.

When you install fasteners, use the correct tightening sequence and specifications.

Following these instructions can help you avoid damage to parts and systems.

00 (GM)-8-3
 Main Table of Contents

Group 00 (GM), Engine 3.OL Cl!‘lRK

Engine Mechanical - 3.OL
Specifications
Fastener Tightening Specifications

Water Pump Bolts

Sealers, Adhesives and Lubricants

GM Part Number I Type of Material I Application
1052080 Sealant Rear camshaft bearing hole plug
1052080 Sealant Cylinder head bolt threads
1052914 Sealant Oil pan sealing surfaces
1052365 Lubricant Valve train component prelube
1052080 Sealant Valve rocker arm stud threads
1052080 Sealant Oil level indicator tube

00 (GM)-8-4
 Main Table of Contents

Cl!mK Group 00 (GM), Engine 3.OL

Engine Mechanical Specifications (1 of 2)

Application Metric I English

Engine Type L4
Displacement 3rI 181 CID
Bore 101.60lml 4.OOOin
Slrcke 91.44nml 36Oin
Compression Ratio 925A
Firing Order l-342
Spark Plug Gap 0.9nnl I OKBin

Oil Pressure (Minimum - Hot) 41A kPaat 6.Opsigat

1,ooO
enginerpm 1,OOOenginerpm
124.1kPaat 18.Opsigat
2,OOOenginerpm 2,COOenginerpm
165.5kPaat 24.opsigat
4,OOOengine
rpm 4,090 enginerpm
Oil Capacity (WithOil FilterChange) 3.8-l 4.ooqls
Oil Pump Type Gear Driven

Bore Diameter 101.5873101.6635n-tn 3.99954.0325m

Bore Out-of-RoundProduction O.O254mrn(~mum) 0.001in (Mtimum)
Bore Out-of-RoundSe&e Limit O.O508mm(MeAmum) 0.002in (MaAmum)
Bore Taper Thrust Side Production 0.0127mm(Madmun) O.OCO5in
(Madmum)
Bore Taper Thrust Side Service Limit 0.0254n-rn(Maximun) 0.001in (lvlaxjmum)
Bore Taper Relief Side Production 0.0127rMl(Madmdn) O.COO5
in (Maxfmum)
Bore Taper Relief Side Service Limit 00254nml(Maxfmum) 0.001in (Mtimum)
Runout- Rear Face of Blockto Crankshaft Center tine 0.05mm (Maximum) O.OMin(Mtimum)
f%tl
Piston-To-Bore Clearance Production O.rX350.0889nY7l I O.rX259.0335i7
Piston-To-Bore Clearance Service Limit 0.0889mll 0.0035in(M&rUnl)
PistulFpncs

* Measured in cylinder bore

00 (GM)-8-5
 Main Table of Contents

Group 00 (GM), Engine 3.OL CUIRIC

Engine Mechanical Specifications (2 of 2)

Rod Bearing Clearance Production 0.04318-0.06858mn 0.0017-O.w7ii

Rod Bearing Clearance Service Limit 0.0782mm (Maxjmun) 0.003in (Meximum)
Rod Side Clearance 0.1524-0.4318mn 0.0384.017h

00 (GM)-8-6
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Diagnostic Information and Procedures

Base Engine Noise Diagnosis

Step Action Value Yes No

1. With the engine running, try to determine if the noise is
timed to the crankshaft speed or the camshaft speed.
1 2. Using a timing light, two knocks per flash is the
crankshaft or one knock per flash is the camshaft.
Is the noise timed to the crankshaft speed? - Go to Step 2 Go to Step 3

1. Remove the rod bearings and inspect the bearings and

the journals for wear.
2. If the parts are OK, remove the crankshaft and inspect
2
the main bearings and journals for wear.
3. Replace the parts as necessary.
Does the engine continue to knock? - Go to Step 3 System OK

Check to see if the noise is timed to the camshaft speed.

3
Is the noise timed to the camshaft speed? - Go to Step 5 Go to Step 4

1. Inspect for loose accessory attachments, the flywheel.

4 2. Tighten or adjust as necessary.
Does the engine continue to knock? - Go to Step 5 System OK

1. Remove the pushrod cover.

Refer to Pushrod Cover Removal.
l

2. Rotate the engine and measure the lifter movement in

5 the bore.
3. Compare the measurement with the specifications in
Engine Mechanical Specifications.
Is the camshaft within specifications? - Go to Step 7 Go to Step 6

Replace the camshaft. Refer to Camshaft Removal and

6 Installation.
Does the engine continue to knock? - Go to Step 7 System OK

1. Remove the rocker arms, the pushrods and the lifters.

2. Inspect the parts for excessive wear or damage.
7
3. Replace the parts as necessary.
Are the repairs complete? - System OK -

00 (GM)-8-7
 Main Table of Contents
Group 00 (GM), Engine 3.OL
Engine Compression Test
Perform the following steps in order to conduct a
compression test:
1. Conduct the following steps in order to check
cylinder compression:
1.l. Engine should be at room temperature.
1.2. Disconnect the two electrical connectors from
the distributor.
1.3. Remove the spark plugs.
1.4. Throttle plates should be wide open.
1.5. Battery should be at or near full charge.
2. For each cylinder, crank engine through four
compression strokes.
3. The lowest cylinder reading should not be less than
70% of the highest.
4. No cylinder reading should be less than 689 kPa
(100 psi).
Important: The results of a compression test will fall into
the following categories:
Normal - Compression builds up quickly and
evenly to specified compression on each cylinder.
Piston Rings - Compression low on first stroke.
Tends to build up on the following strokes but does
not reach normal. Improves considerably with
addition of oil.
Valves - Compression low on first stroke. Does not
tend to build up on the following strokes. Does not
improve much with addition of oil. Use approximately
three squirts from a plunger-type oiler.
Engine Noise Diagnosis
There are four steps to diagnosing engine noise. You must
determine the following conditions:
l Type of noise.
l The exact operating condition under which the
noise exists.
l Determine the rate and location of the noise.
l Compare the sounds in other engines to make sure
you are not trying to correct a normal condition.
Identify the type of noise. For example, a light rattle or low
rumble.
Remember,engine noises are generally synchronized to
either engine speed (caused by the crankshaft, pistons or
connecting rods) or one-half engine speed (valve train noise).
Try to determine the rate at which the noise is occurring.
Knocks Cold and Continues for 2 to 3 Minutes
l Engine flywheel contacting the splash shield.
Reposition the splash shield.
l Loose or broken crankshaft balancer or drive
pulleys. Tighten or replace as necessary.
l Excessive piston to bore clearance. Replace the
piston.
00 (GM)-8-8
Cl!lRK
l Cold engine knock usually disappears when the
specific cylinder secondary ignition circuit is
grounded out. Cold engine piston knock which
disappears in 1.5 minutes should be considered
acceptable.
Knocks on Start-Up but Only Lasts a Few
Seconds
l Improper oil viscosity. Install recommended oil
viscosity for expected temperatures.
l Excessive piston to bore clearance.
l Excessive piston pin to piston clearance.
l Excessive crankshaft end clearance.
l Excessive crankshaft bearing clearance.
Knocks at Idle Hot
Detonation or spark knock. Check operation of
ignition controls or knock sensor circuit.
Loose flywheel bolts.
Exhaust leak at manifold. Tighten the exhaust
manifold bolts and/or replace the gasket.
Excessive connecting rod bearing clearance.
Replace the bearings as necessary.
Excessive piston pin clearance.
Excessive crankshaft thrust bearing clearance.
Bent connecting rod.
Valve Train Diagnosis
A light tapping at one-half engine speed or any varying
frequency, can indicate a valve train problem. These
tapping noises increase with engine speed.
Before attempting to judge the valve train noises,
thoroughly warm up the engine. By doing this you will
bring all engine components to a normal state of
expansion. Also, run the engine at various speeds and
listen for engine noise. The causes of the valve train noise
include the following conditions:
. Incorrectly adjusted valve lash.
. Low oil pressure.
. Loose valve rocker arm attachments.
. Worn valve rocker arm and/or pushrod.
. Broken valve spring.
. Sticking valves.
. Lifters worn, dirty or faulty.
. Camshaft lobes worn.
. Worn valve guides.
. Worn or damaged valve keys.
. Bent pushrods.
Oil Consumption Diagnosis
Excessive oil consumption (not due to leaks) is the use of
1.9L (2 qts.) or more of engine oil within 50 hours of use.
The causes of excessive oil consumption include the
following conditions:
 Main Table of Contents
External oil leaks. Tighten bolts and/or replace
gaskets and oil seals as necessary.
Incorrect oil level or improper reading of oil level
indicator. With the engine at a level surface, allow
adequate drain down time and check for the
correct oil level.
Improper oil viscosity. Use a recommended SAE
viscosity for the prevailing temperatures.
Continuous high speed operation and/or severe
usage.
Crankcase ventilation system restrictions or
malfunctioning components. Possible improper
PCV valve.
Valve guides and/or valve stem oil seals worn, or
the seal omitted. Ream guides and install oversize
service valves and/or new valve stem oil seals.
Piston rings broken, improperly installed, worn or
not seated properly.Allow adequate time for rings to
seat. Replace broken or worn rings as necessary.
Piston improperly installed or mis-fitted.
Low or No Oil Pressure Diagnosis and
Testing
. Low oil level. Fill to full mark on oil level indicator.
. Incorrect or malfunctioning oil pressure switch.
. Incorrect or malfunctioning oil pressure gauge.
. Improper oil viscosity for the expected temperature.
. Oil pump worn or dirty.
. gasket is replaced, but the sealing surface is damaged,
Maffunctioning oil pump pressure regulator valve.
. Plugged oil filter.
. Oil pump screen loose, plugged or damaged.
. Excessive bearing clearance. Replace as
necessary.
. Cracked, porous or restricted oil galleys. Repair
or replace the engine block.
. Oil galley plugs missing or incorrectly installed.
Install the plugs or repair as necessary.
. Oil diluted by moisture or unburned fuel m’&ures.
Oil Leak Diagnosis
Most fluid oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may be
difficult to locate or repair.
Use the following steps in order to find the leak:
1. Identify the fluid, determine whether it is engine oil,
transmission fluid or power steering fluid.
2. At what point is the fluid leaking from? After running
the engine at normal operating temperature, place a
large sheet of paper under the engine. After a few
minutes, you should be able to find the approximate
location of the leak by the drippings on the paper.
Group 00 (GM), Engine 3.OL
Visually check around the suspected component.
Check around the gasket mating surfaces for leaks.
A mirror is useful for finding leaks in areas that are
hard to reach.
If the leak still cannot be found, it may be necessary
to clean the suspected area with a degreaser,
steam or spray solvent. Clean the area well, then
dry the area. Run the engine for several minutes at
normal operating temperature and varying speeds.
After running the engine, visually check the
suspected area. If you still cannot locate the leak,
try using the powder or black light and dye method.
Perform the following steps in order to perform the powder
method:
Clean the suspected area.
Apply an aerosol-type powder (such as foot
powder) to the suspected area.
Run the engine under normal operating conditions.
Visually inspect the suspected area. You should be
able to trace the leak path over the white powder
surface to the source.
Perform the following steps in order to use the black light
and dye method:
Repairing the Leak
Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must be
determined in order for it to be repaired properly. If a
the new gasket will not repair the leak. Before attempting
to repair a leak, be sure that the gasket and sealing
surfaces are correct.
Performthe following steps in order to check for gasket leaks:
1. Inspect the fluid level/pressure for being too high.
2. Check the crankcase ventilation system for
restrictions or malfunctioning components.
3. Inspect for improperly tightened fasteners or dirty/
damaged threads.
4. Look for warped flanges or sealing surfaces.
5. Check for scratches, burrs or other damage to the
sealing surface.
6. Look for a damaged or worn gasket.
7. Check for cracking or porosity of the component.
8. Check for use of an improper sealant used (where
applicable).
00 (GM)-8-9
 Main Table of Contents

Group 00 (GM), Engine 3.OL CMRIC

1 4

< /* _

I
VEOOl -3L
Block Explode #1
00 (GM)-8-1 0
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Disassembled View (1 of 4)

VALVE ROCKERARM COVER BOlT

VALVE ROCKERARM COVER REINFORCEMENT
VALVE ROCKERARM COVER
OIL FILLER CAP
VALVE ROCKERARM COVER GASKET
EFE VALVE THERMOSIT
INTAKE MANIFOLD
INTAKE MANIFOLD NUT
INTAKE/EXHAUST MANIFOLD CLAMP
INTAKE/EXHAUST MANIFOLD WASHER
INTAKE/EXHAUST MANIFOLD BOLT
INTAKE/EXHAUST MANIFOLD GASKET
EFE VALVE SPRING
EFE VALVE BUSHING
EXHAUST MANIFOLD
INTAKE/EXHAUST MANIFOLD BOLT
EXHAUST MANIFOLD STUD
INTAKE/EXHAUST MANIFOLD GASKET
CYLINDER HEAD BOU
CYLINDER HEAD
CYLINDER HEAD GASKET
LIFT BRACKET
LIFT BRACKET BOLT
ENGINE BLOCK
WATER PUMPGASKET
WATER PUMP
WATER PUMPBOLT
WATER PUMPBOLT
PUSHROD COVER GASKET
PUSHROD COVER
PUSHROD COVER BOI
VALVE LIFTER
ENGINE BLOCK COOLANT PLUG
DISTRIBUX)R GASKET
DISTRIBU1DR
DISTRIBUKJR HOLD DOWN
DISTRIBUDR HOLD DOWN BOU
OIL LEVEL INDICATOR TUBE
OIL LEVEL INDICATOR
PRIMAW IGNITION HARNESS
IGNITION COILBOLT
IGNITION COILWASHER
IGNITION COIL
IGNITION COILWIRE
SPARK PLUG WIRE RE;RINER
SPARK PLUG WIRE HARNESS
SPARK PLUG
VALVE PUSHROD
VALVE ROCKERARM
VALVE ROCKERARM BALL
VALVE ROCKERARM NUT

00 (GM)-8-1 1
 Main Table of Contents

Grow 00 (GM). Enaine 3.OL

2
\
A_ 4
-_

I/ 6
48.

18

VE002-3L
Block Explode #2
00 (GM)-8-1 2
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Disassembled View (2 of 4)

1 ENGINE BLOCK
2 PISTON PIN
3 PISmN RING KIT
4 PISTON
5 CONNECTING ROD
6 CONNECTING ROD BOT:
7 CONNECTING ROD BEARING KIT
8 CONNECTING ROD CAP
9 CONNECTING ROD NUT
10 OIL NOZZLE
11 CAMSHAFT BEARINGS
P CAMSHAFT
t3 CAMSHAFT RETAINER
14 CAMSHAFT RETAINER WASHER
15 CAMSHAFT SPROCKET
16 CAMSHAFT RETAINER BOU
I7 CAMSHAFT WOODRUFF KEY
18 CRANKSHAFT PULLEY
19 ENGINE FRONTCOVER SEAL
al ENGINE FRONTCOVER BOU
21 ENGINE FRONTCOVER
22 ENGINE FRONTCOVER GASKET
23 CRANKSHAFT SPROCKET
2t CRANKSHAFT KEYWAY
a OIL PUMP
;6 OIL PUMPBOLT
27 CRANKSHAFT BEARING KIT
23 CRANKSHAFT
29 CRANKSHAFT BEARING CAP
3 CRANKSHAFT BEARING CAPBOLT
31 OIL PAN GASKET
32 OIL PAN
3 OIL PAN WASHER
3x OIL PAN BOLT
35 OIL DRAIN PLUG WASHER
35 OIL DRAIN PLUG
8 CRANKSHAFT REAR OIL SEAL HOUSING PIN
3 CRANKSHAFT REAR OIL SEAL HOUSING
3 CRANKSHAFT REAR OIL SEAL HOUSING STUD
0 CRANKSHAFT REAR OIL SEAL HOUSING BOU
41 CLUTCH PILOT BEARING
42 ENGINE FIYWHEELBOLT
43 ENGINE FIYWHEEL
44 CRANKSHAFT REAR OIL SEAL
45 CRANKSHAFT REAR OIL SEAL HOUSING BOU
% CRANKSHAFT REAR OIL SEAL HOUSING GASKET
47 CAMSHAFT REAR BEARING HOLE PLUG
48 ENGINE BLOCK CORE PLUG

00 (GM)-8-1 3
 Main Table of Contents

Group 00 (GM), Engine 3.OL WIRIC

VE003-3L
Head Explode

Disassembled View (3 of 4)
1 CYLINDER HEAD
2 VALVE ROCKERARM STUD
3 VALVE STEM KEY
4 VALVE SPRING CAANTAKE
5 VALVE STEM OILSHIELD
6 VALVE SPRING
7 VALVE STEM OILSEAL
8 VALVE SPRING CAPEXHAUST
9 EXHAUSTVALVE
10 INTAKE VALVE

00 (GM)-8-1 4
 Main Table of Contents

Cl!‘YRIC Group 00 (GM), Engine 3.OL

Oil Pump Explode VE004-3L

Disassembled View (4 of 4)
1 DRIVE GEAR
2 DRIVEN GEAR
3 OIL PRESSURE RELIEF VE
4 OIL PRESSURE RELIEF VAE SPRING
5 OIL PUMP SCREEN
6 OIL PUMP
7 OIL PUMP COVER GASKET
8 OIL PUMP COVER
9 OIL PUMP COVER WASHER
10 OIL PUMPCOVER BOU

00 (GM)-8-1 5
 Main Table of Contents

Group 00 (GM), Engine 3.OL El!YRIC

Draining Fluids and Oil Filter Removal
1. Remove the oil pan drain plug and allow the oil to drain.

VEOO5-34

2. Remove the oil filter.

VEOS3L

3. Remove right rear engine block coolant plug and allow the
coolant to drain.

vmJ7-34

00 (GM)-8-1 6
 Main Table of Contents

Group 00 (GM), Engine 3.OL

4. Remove the left rear engine block coolant plug and allow
the coolant to drain.

Engine Flywheel Removal

Important: Note the position and direction of the engine flywheel
before removal. The flywheel center alignment hole is a tapered fit
to the crankshaft. The engine flywheel must be reinstalled to the
original position and direction.
1. Remove the engine flywheel bolts.
2. Remove the engine flywheel.

VEOC9-3L

00 (GM)-8-1 7
 Main Table of Contents

Group 00 (GM), Engine 3.OL CMRU

Distributor Removal
Disconnect the secondary ignition wires (1) from the spark
plugs and the ignition coil.
Disconnect the primary ignition harness (4) from the ignition
coil. Do not remove the wires from the distributor unless it is
necessary.
Remove the distributor hold down bolt (6).
Remove the distributor (2) and gasket (3).

VEO1O-t

Ignition Coil Removal

1. Remove the ignition coil bracket attaching bolts.
2. Remove the ignition coil.

VEu11a

00 (GM)-8-1 8
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Lift Bracket Removal
1. Remove the lift bracket bolts.
2. Remove the lift bracket.

VEO12-3L

Spark Plug Removal

1. Remove the spark plugs.

Intake/Exhaust Manifold Removal

1. Remove the intake/exhaust manifold bolts.
2. Remove the intake/exhaust manifold.
3. Remove the intake/exhaust manifold gaskets.

VEO143L

00 (GM)-%1 9
 Main Table of Contents

Group 00 (GM), Engine 3.OL Cl!!RIC

Intake/Exhaust Manifold Disassemble and
Assemble
If necessary to replace either the intake or exhaust manifold,
separate them as follows:
1. Remove the one attaching bolt and the two nuts at the
center of the assembly.
2. Reassemble manifolds using a new gasket.

Tighten
Tighten the bolts to 27-34 N*m (20-25 lb ft).

VEOIM

Intake/Exhaust Manifold Clean and Inspect

Clean and inspect the following areas:
l The manifold bolts and studs.
l All manifold sealing surfaces.
l Any old RTV from the manifold.

VEOlE-3L

Water Pump Removal

Make sure the coolant is drained.
1. Remove the water pump bolts.
2. Remove the water pump and gasket.
3. Discard the water pump gasket.
4. Inspect the water pump for the following:
Gasket sealing surfaces for excessive scratches or
gouges.
Excessive side-to-side play in the pulley shaft.
Leakage at the water inlet housing or rear cover gaskets
areas.
Leakage at the water pump vent hole.
A stain around the vent hole is acceptable. If leakage
occurs at the vent hole with the engine running and the
cooling system pressurized, replace the pump.

00 (GM)-8-20
 Main Table of Contents

CLRRK Group 00 (GM), Engine 3.OL

Crankshaft Pulley Removal

Tools Required
l J 24420-C Universal Crankshaft Pulley Remover
1. Use the J 24420-C in order to remove the crankshaft
pulley.

I
J 24420-C

Valve Rocker Arm Cover Removal

1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover.
3. Remove the gasket.

Pushrod Cover Removal

1. Remove the pushrod cover bolts.
2. Remove the pushrod cover.
3. Remove the gasket.

00 (GM)-8-21
 Main Table of Contents

Group 00 (GM), Engine 3.OL CLSRK

Valve Rocker Arm and Pushrod Removal
1. Remove the following components from the cylinder head:
1.l . The valve rocker arm nuts (1).
1.2. The valve rocker arm balls (2).
1.3. The valve rocker arms (3).

VEO213L

Measuring Camshaft Lobe Lift

Tools Required
l J 8520 Camshaft Lobe Lift Indicator
1. Position the J 8520 with the ball socket adapter on the
valve pushrod. Be sure that the valve pushrod is in the valve
lifter socket.
2. Slowly rotate the crankshaft until the valve lifter roller is on
the heel of the cam lobe. The valve pushrod will be in its
lowest position.
3. Set the J 8520 on zero.
4. Slowly rotate the crankshaft until the valve pushrod is raised
fully.
5. Compare the total lift shown on the J 8520 with the
specifications. Refer to Engine Mechanical Specifications.
6. Remove the J 8520.

VEGZML

r 2. Remove the valve pushrods.

3. Place the following parts in a rack so that they can be
reinstalled in their original locations:
l The valve rocker arms.
l The valve rocker arm bails.
l The valve pushrods.

00 (GM)-8-22
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Valve Train Components Inspect (Cylinder Head)

Inspect the following areas:
l The valve rocker arms and ball at the mating surfaces.
These surfaces should be smooth and free of scoring or
other damage.
l The valve pushrod sockets and valve stem mating
surfaces. These surfaces should be smooth with no
scoring or exceptional wear.
l The valve pushrods for bends or scored ends.

VEO24-3L

Valve Lifter Removal

Tools Required
l J 3049 Valve Lifter Remover (Plier Type)
l J 9290-01 Valve Lifter Remover (Slide HammerType)
1. Use the J 3049 in order to remove the valve lifters.

2. If the valve lifters cannot be removed with the J 3049 use

the J 9290-01 in order to remove the valve lifters.

J 9290-01

00 (GM)-8-23
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Cl!‘lRK
Cylinder Head Removal
1. Remove the cylinder head bolts.
Notice: After removal, place the cylinder head on two wood
blocks to prevent damage.
2. Remove the cylinder head.
3. Remove the gasket.
4. Discard the gasket

Oil Pan Removal

1. Remove the oil pan bolts.
2. Remove the oil pan.
3. Remove the gasket.
4. Discard the gasket.

Oil Pump Removal

Remove the bolts that attach the oil pump to the engine
block.
Remove the oil pump and gasket.
Discard the gasket.

VEO29-3L

00 (GM)-8-24
 Main Table of Contents

CLSRIC Group 00 (GM), Engine 3.OL

Oil Level Indicator and Tube Removal

1. Remove the oil level indicator from the tube.
2. Use a drift punch in order to remove the oil level indicator
tube from the engine block.

Engine Front Cover Removal

1. Remove the engine front cover bolts.
2. Remove the engine front cover.
3. Remove the gasket.
4. Discard the gasket.

I
VECBC-3L

5. Remove the oil seal from the front cover.

6. Clean the engine front cover in solvent.
7. Inspect the engine front cover for damage to the gasket
surface or the oil seal surface.

00 (GM)-8-25
 Main Table of Contents

Group 00 (GM), Engine 3.OL

c
Measuring Crankshaft and Camshaft Sprocket
Runout
Tools Required
l J 8001 Dial Indicator
1. Use the J 8001 in order to measure the crankshaft and
camshaft sprocket runout. Refer to Engine Mechanical
Specifications.
/
2. If the sprocket runout exceeds specifications, clean and
remove any burrs from the shaft or replace the sprocket.

Measuring Timing Sprocket Teeth Backlash

Tools Required
l J 8001 Dial Indicator
1. Use the J 8001 in order to measure the backlash between
the timing sprocket teeth.
2. Refer to Engine Mechanical Specifications.

Crankshaft Sprocket Removal

Tools Required
l J 6978-E Crankshaft Sprocket Puller
1. Use the J 6978-E in order to remove the crankshaft
sprocket.
2. If necessary, remove the crankshaft keys.

VEG?4-24

00 (GM)-8-26
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Camshaft Removal
1. Remove the two camshaft retainer bolts, working through
the holes in the camshaft sprocket.

Important: All camshaft journals are the same diameter, so care

must be used in removing the camshaft to avoid damage to the
bearings.
2. Carefully rotate and pull the camshaft out of the bearings.

Crankshaft and Camshaft Sprocket Inspect

l The camshaft and crankshaft sprockets for wear.
l One edge of worn teeth or that are no longer concentric.
l The valley between worn teeth.
l The keys and crankshaft keyways for wear.

VE126-2

00 (G M)-8-27
 Main Table of Contents

Group 00 (GM), Engine 3.OL CDIRIC

Timing Gear Oil Nozzle Removal

1. Remove the oil nozzle with pliers.

Piston, Connecting Rod and Bearing Removal

Tools Required
l J 5239 Connecting Rod Guide Tool
l J 24270 Ridge Reamer
1. Remove the ring ridge as following:
1.1. Turn the crankshaft until the piston is at the bottom of
the stroke.
1.2. Place a cloth on top of the piston.
1.3. Use the J 24270 to remove the cylinder ring ridge.
1.4. Turn the crankshaft so the piston is at the top of the
stroke.
1.5. Remove the cloth.
1.6. Remove the cutting debris.

VEo363L

Important: Place matchmarks or numbers on the connecting

rods and the connecting rod caps. Upon removal of the piston and
connecting rod assembly, install the connecting rod caps to the
matching connecting rods.
2. Remove the connecting rod nuts.
3. Remove the connecting rod cap.
4. Remove the connecting rod bearings.
Keep bearings with the original connecting rod and
connecting rod cap.
Wipe the oil from the bearings.
Wipe the oil from the crankpins.

00 (GM)-8-28
 Main Table of Contents

Cl!YRK Group 00 (GM), Engine 3.OL

5. Use the J 5239 in order to remove the connecting rod and

the piston out of the engine block.
6. Use a hammer and tap lightly on the end of the connecting
rod guide tool to remove the piston and connecting rod
assembly from the cylinder bore.

VEO3S-34

Crankshaft and Bearings Clean and Inspect

(Connecting Rod Bearing Clearance)
Important: Connecting rod bearings are a precision insert type.
Connecting rods are of a powdered metal design and cannot be
shimmed or filed for bearing fit. If clearances are found to be
excessive, a new bearing and/or connecting rod are required. Do
not rotate the crankshaft while gauging plastic is between the
crankshaft journal and the bearing surface.
1. Remove the connecting rod nuts.
2. Remove the connecting rod cap and bearing.

3. Inspect the crankshaft bearings for craters or pockets.

Flattened sections on the bearing halves also indicate
fatigue.

\r-q
VIZ-

00 (GM)-8-29
 Main Table of Contents

Group 00 (GM), Engine 3.OL EMIRK

4. Inspect the crankshaft bearings for excessive scoring or
discoloration.
5. Inspect the crankshaft bearings for dirt or debris imbedded
into the bearing material.

VEO4C-34

6. Install the gauging plastic (1) onto the connecting rod

bearing journal. Install the gauging plastic the full width of
the journal.

7. Install the connecting rod cap and bearing.

Tighten
Tighten the nuts evenly to 61 N*m (45 lb ft).

VEo373L
00 (GM)-8-30
 Main Table of Contents

Group 00 (GM), Engine 3.OL

8. Remove the connecting rod nuts.
9. Remove the connecting rod cap and bearing.

VEC37-3L

10. Measure the gauging plastic at its widest area using the
scale supplied with the plastic gauging kit.
11. Compare the measurements to Engine Mechanical
Specifications.

Crankshaft Rear Oil Seal and Housing Removal

1. Remove the crankshaft rear oil seal housing bolts.
2. Remove the crankshaft rear oil seal housing, seal and
gasket.

VEO433L

00 (GM)-8-31
 Main Table of Contents

Group 00 (GM), Engine 3.OL

3. Remove the crankshaft rear oil seal from the crankshaft
rear oil seal housing.

VEO44-SL

Crankshaft, Bearings and Bearing Cap Removal

1. Remove the crankshaft bearing cap bolts.
2. Remove the crankshaft bearing caps.

3. Remove the crankshaft.

4. Remove the crankshaft bearings from the bearing caps and
from the engine block.
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Crankshaft and Bearings Clean and Inspect

Tools Required
l J 7872 Magnetic Base indicator Set
Caution: Wear safety g/asses in order to avoid eye damage.
1. Clean the crankshaft in solvent.
2. Inspect the crankshaft oil passages for restrictions.
3. Dry the crankshaft with compressed air.
4. Inspect the crankpins for scoring or wear.

VEO473L

5. Inspect the crankshaft bearings for craters or pockets.

Flattened sections on the bearing halves also indicate
fatigue.

VECBQ-34

6. Inspect the crankshaft bearings for excessive scoring or

discoloration.
7. Inspect the crankshaft bearings for dirt or debris imbedded
into the bearing material.

VEO4Ci

00 (GM)-8-33
 Main Table of Contents

Group 00 (GM), Engine 3.OL CL9RK

8. Inspect the crankshaft bearings for improper seating
indicated by bright, polished sections of the bearing.
l If the lower half of the bearing is worn or damaged, both
the upper and lower halves must be replaced.

9. Measure the crankpins for out-of-round, taper or undersize

with a micrometer. Refer to Engine Mechanical
Specifications.

10. Support the crankshaft front and rear journals on V-blocks.

11. Measure the crankshaft run-out at front and rear
intermediate journals with J 7872. Refer to Engine
Mechanical Specifications,
J 7872
12. Replace or recondition crankshaft if measurements are not
within specifications.

VEC!S3L

00 (GM)-8-34
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Crankshaft and Bearings Clean and Inspect (Main

Bearing Clearance)
Important: Crankshaft main bearings are a precision insert type.
Main bearing caps are machined with the engine block for proper
clearance and cannot be shimmed or filed for bearing fit.
Crankshaft bearing clearances are critical. If the clearances are
found to be excessive, new bearings and/or engine block and cap
repair may be required.
Do not rotate the crankshaft while gauging plastic is between the
crankshaft journal and the bearing surface.
1. Remove the crankshaft bearing cap bolts.
2. Remove the crankshaft bearing caps.

3. Install gauging plastic (1) onto the crankshaft journal. Install

the gauging plastic the full width of the crankshaft bearing
journal.

4. Install the bearing, bearing cap and bolts.

Tighten
Tighten the crankshaft bearing cap bolts to 88 N*m (65 lb ft).
 Main Table of Contents

Group 00 (GM), Engine 3.OL WIRK

5. Remove the crankshaft bearing cap bolts.

6. Remove the crankshaft bearing caps.

7. Measure the gauging plastic at its widest area using the

scale supplied with the plastic gauging kit.
8. Compare the measurements to Engine Mechanical
Specifications.
If the gauging plastic shows irregularity in the journal
exceeding 0.025 mm (0.001 in), remove the crankshaft
and measure the journal with a micrometer.
If the clearance is greater than Engine Mechanical
Specifications, select and install an undersized bearing
set. Measure the clearance with gauging plastic.
If clearance cannot be brought to specifications, grind
the crankshaft for use with the next undersized bearing.

9. Use a dial indicator or feeler gauge in order to measure end

play between the front of the rear of the crankshaft bearing
cap and the crankshaft thrust surface in order to determine
the crankshaft end play.
10. If you use a feeler gauge, measure between the
thrust surface of the crankshaft bearing and the crankshaft.
Refer to Engine Mechanical Specifications.

00 (GM)-8-38
 Main Table of Contents

Cl!lRK Group 00 (GM), Engine 3.OL

Camshaft Bearing Removal

Tools Required
l J 6098-01 Camshaft Bearing Remover/Installer
1. Remove the camshaft rear bearing hole plug.
2. Use the J 6098-01 in order to remove the inner camshaft
J 6096-01 2
bearings. Repeat the following procedure for each of the \
inner camshaft bearings:
2.1. With the nut (4) and the thrust washer (3) installed to
the end of the puller screw threads, index the pilot (2)
in the camshaf front bearing and install the puller
screw through the pilot (2) and the bearing to be
removed.
2.2. Install the bearing tool (1) with the shoulder toward
the bearing.
2.3. Using two wrenches, hold puller screw (5) while you
turn the nut (4) in order to draw the bearing out of the
bore.
2.4. When the bearing has been pulled from the bore,
remove the bearing tool and the bearing from the
puller screw.
2.5. Index the pilot in the rear camshaft bearing in order to
remove the rear inner camshaft bearing.

3. Use the J 6098-01 in order to remove the front and rear

camshaft bearings.
3.1. Assemble the bearing tool to the driver.
3.2. Drive the front and rear camshaft bearings out of the
block bore. Drive inward toward the center of the
engine block.

VEC653L

00 (GM)-8-37
 Main Table of Contents

Group 00 (GM), Engine 3.OL CLSRIC

Distributor Lower Bushing and Thrust Washer
Removal
Tools Required
l J 9534 Distributor Lower Bushing Remover
l J 6585 Slide Hammer
Install the J 9534 into the distributor lower bushing.
Use the J 6585 in order to remove the bushing.

Use a drift punch up through the bushing bore in order to

drive the thrust washer (if installed) out of the bore.
Clean the bushing bore in the cylinder block and inspect for
burrs or damage.

Oil Filter Bypass Valve Removal and Installation

1. Check the spring and fiber valve for operation.
2. Inspect for a cracked or broken valve.
3. Use a screwdriver in order to pry the valve out.
4. Use a 9/l 6 in thin-wall deep socket in order to tap the new
bypass valve in place.

00 (GM)-8-38
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Cylinder Block Clean and Inspect

1. Clean the following areas:
l The engine block in solvent, removing all sludge, dirt or
debris
Caution: Wear safety glasses in order to avoid eye damage.
l Dry the block with compressed air.
l The gasket surfaces.
l The coolant passages.
l The oil passages.
l The main bearing caps.
2. Inspect the following areas:
l The cylinder walls for excessive scratches, gouging or
ring ridge.
l The coolant jackets for cracks.
l The valve lifter bores for excessive scoring or wear.
l The crankshaft bearing webs for cracks.
l The gasket sealing surfaces for excessive scratches or
gouging.
l The oil passages for restrictions.
l All threaded bolt holes for thread damage.

VEO59-3L

Cylinder Bore Measurements

Tools Required
. J 8087 Cylinder Bore Gauge
1. Use the J 8087 in order to check cylinder bore taper and
out-of-round as follows:
1.l. Set the gauge so that the thrust pin must be forced in
about 114in to enter the gauge in the cylinder bore.
1.2. Center the gauge in the cylinder and turn the dial to
‘0.”
1.3. Work the gauge up and down to determine the taper.
1.4. Turn the gauge to different point around the cylinder
to determine the out-of-round condition. Refer to
Engine Mechanical Specifications. 3J=ql”O (

00 (GM)-8-39
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Cylinder Boring and Honing 5. The finish marks should be clean but not sharp. The
finish marks should be free from imbedded particles
Boring Procedure
and torn or folded metal.
Before you start the honing or reboring process,
6. By measuring the piston to be installed at the sizing
measure all new pistons with the micrometer,
point specified and by adding the average of the
contacting at points exactly 90” from the piston pin
clearance specification, you can determine the
centerline. Refer to Piston Selection. Select the
finish hone cylinder measurement. Refer to Engine
smallest piston for the piston fitting. Slightly varied
Mechanical Specifications. Measure the block and
pistons in a set may provide correction, in case the
the piston at normal room temperature.
first piston is too loosely fitted.
7. True up the refinished cylinder bores to have less
Before you use any type of boring bar, file the top of
than the specified out-of-round or taper. You must
the cylinder block in order to remove any dirt or
final hone each bore in order to remove all stone or
burrs. If you do not check the cylinder block, the
cutter marks and in order to provide a smooth
boring bar may be tilted, this could result in the
surface.
rebored cylinder wall being at incorrect right angles
from the crankshaft. 8. For piston-to-bore tolerance specifications, Refer to
Engine Mechanical Specifications.
Carefully follow the instructions furnished by the
manufacturer regarding the use of the equipment. 9. After final honing and before the piston is checked
for fit, clean the bores with hot water and detergent.
When you rebore cylinders, make sure all
Scrub the bores with a stiff bristle brush and rinse
crankshaft bearing caps are in place. Tighten the
the bores thoroughly with hot water. Do not allow
bearing caps to the proper torque in order to avoid
any abrasive material to remain in the cylinder
distortion of the bores in the final assembly. The
bores. This abrasive material will wear the new
crankshaft must be clear of the boring cutter when
rings, the cylinder bores and the bearings lubricated
you bore each cylinder. Cover or tape the
by the contaminated oil. After you wash the bore,
crankshaft bearings and other internal parts to
brush the dry bore clean with a power-driven fiber
protect during the boring or honing process.
brush.
10. Permanently mark the piston for the cylinder to
Honing Procedure which the piston has been fitted.
1. When honing the cylinders, follow the 11. Apply clean engine oil to each bore in order to
manufacturer’s recommendations for use, cleaning prevent rusting.
and lubrication. Use only clean, sharp stones of the
proper grade for the amount of material you remove.
Dull, dirty stones cut unevenly and generate
excessive heat. When using coarse or medium-
grade stones, leave sufficient metal so that all stone
marks may be removed with the fine stones you use
for finishing in order to provide for proper clearance.
2. During the honing process, thoroughly clean the
cylinder bore. Check for a correct fit of the piston
you select for the individual cylinder.
3. When honing to eliminate taper in the cylinder,
make full strokes of the hone in the cylinder.
Repeatedly check the measurement at the top, the
middle and the bottom of the bore.
Notice: Handle the pistons with care. Do not force the
pistons through the cylinder until you hone the cylinder to
the correct size. The piston can be distorted through
careless handling.
4. When finished honing a cylinder bore to fit a piston,
move the hone up and down at a sufficient speed to
obtain very fine, uniform surface finish marks in a
cross hatch pattern at 45-65 degrees.

00 (GM)-8-40
 Main Table of Contents

c19RK Group 00 (GM), Engine 3.OL

Distributor Lower Bushing and Thrust Washer

Installation
Tools Required
l J 9535 Distributor Lower Bushing Installer
1. Use the J 9535 in order to drive the thrust washer (if
removed) into the cylinder block.
2. Use the J 9535 with the driver-bolt in the driver handle.

3. Install the driver into the new bushing from the large inside
diameter.
4. Drive the new bushing into the cylinder block until the
J 9535 bottoms against the cylinder block.

VEO62-3L

Piston and Connecting Rod Disassemble

Tools Required
l J 24086-C Piston Pin Removal Set
1. Remove the piston rings from the pistons.

VtwL

00 (GM)-8-41
 Main Table of Contents

Group 00 (GM), Engine 3.OL Cl!‘lRIC

2. Remove the pin from the piston.
Notice: After the J 24086-C Installer bottoms on the support
assembly, do not exceed 34,475 kPa (5000 psi) or the tool may be
damaged.

Piston and Connecting Rod Clean and Inspect

1. Clean the piston ring grooves with a groove cleaner.

Caution: Wear safety glasses in order to avoid eye damage.

2. Clean the connecting rod in cleaning solvent.
VEC65-34 3. Clean the varnish from the piston skirts and the pins with
cleaning solvent
4. Dry the components with compressed air.
5. Do not use a wire brush in order to clean any part of the
piston.
6. Clean the piston oil ring holes and the slots.
7. Inspect the connecting rod for twisting, nicks and cracks.
Replace any damaged connecting rods.
8. Inspect the pistons for the following conditions:
l Cracked ring lands, skirts or pin bosses.
l Nicks or spurs in the grooves that may cause binding.
l Warped or worn ring lands.
. Scuffed or damaged skirts.
l Eroded areas at the top of the piston.
l Worn piston bores and piston pins.
9. Replace pistons that are damaged or show signs of
VEW-SL
excessive wear.

00 (GM)-8-42
 Main Table of Contents

c19RK Group 00 (GM), Engine 3.OL

10. Measure the pin bore-to-piston clearance.

10.1. The piston pin bores and the piston pins must be free
of varnish or scuffing when being measured.
10.2. Use a micrometer in order to measure the piston pin.

VEO67-3L

10.3. Use an inside micrometer in order to measure the

piston pin bore. Replace the piston and piston pin if
the clearance is in excess of 0.0254 mm (0.001 in).
10.4. Match the piston and piston pin. Do not service
separately.

VECW3L

11. Measure the piston compression ring end gap.

Important: Fit each compression ring to the cylinder in which it
will be used.
11.1. Place the compression ring into the cylinder bore.
11.2. Push the compression ring into the cylinder bore
approximately 6.5 mm (0.25 in) above the ring travel.
The ring must be square to the cylinder wall.
11.3. Use a feeler gauge in order to measure the end gap.
11.4. Select another size ring set if the end gap exceeds
specifications.

00 (GM)-8-43
 Main Table of Contents

Group 00 (GM), Engine 3.OL Cl!YRIC

12. Measure the piston ring side clearance.
12.1. Roll the piston ring entirely around its ring groove on
the piston.
12.2. Dress the groove with a fine cut file if the ring groove
causes binding.
12.3. Replace the piston ring if a distorted piston ring
causes binding.

VEO70-3L

12.4. Use a feeler gauge in order to measure the side

clearance of the piston ring and groove.
12.5. Try another piston ring if the side clearance is too
small.

VEO713L

Piston Selection
Important: Measurements of all components should be taken
with the components at normal room temperature.
For proper piston fit, the engine block cylinder bores must not
have excessive wear or taper.
A used piston and pin set may be reinstalled if, after cleaning and
inspection, they are within specifications.
Inspect the engine block cylinder bore. Refer to Cylinder
Block Clean and Inspect.
Inspect the piston and piston pin. Refer to Piston and
Connecting Rod Clean and Inspect.
Use a boring gauge in order to measure the cylinder bore
diameter at a point of 66 mm (2.5 in) from the top of the
cylinder bore.

00 (GM)-8-44
 Main Table of Contents

Group 00 (GM), Engine 3.OL

4. Measure the bore gauge with a micrometer and record the

reading.

5. With a micrometer or caliper at a right angle to the piston,

measure the piston 11 mm (0.433 in) from the bottom of the
skirt.
6. Subtract the piston diameter from the cylinder bore
diameter in order to determine piston-to-bore clearance.
7. For proper piston-to-bore clearance, Refer to Engine
Mechanical Specifications.
8. If the proper clearance cannot be obtained, select another
piston and measure for the clearances. If the proper fit
cannot be obtained, the cylinder bore may require boring or
honing. Refer to Cylinder Boring and Honing.
9. When the piston-to-cylinder bore clearance is within
specifications, permanently mark the top of the piston for
installation to the proper cylinder.

I
VEO7S-34

Piston and Connecting Rod Assemble

Tools Required
l J 24086-C Piston Pin Removal Set
Important: When assembling the piston and connecting rod, the
flange or the heavy side on the connecting rod must face toward
the front of the piston (stamped arrow in top of the piston head).
1. Install the piston pin and connecting rod assembly.
1.I. Lubricate the piston pin holes in both the piston and
the connecting rod assembly.
1.2. Press the piston pin into the piston and connecting
rod assembly using the J 24086-C.
1.3. Inspect for freedom of movement of the piston on the
piston pin.

00 (GM>8-45
 Main Table of Contents

Group 00 (GM), Engine 3.OL Cl!YRK

2. Install the piston rings onto the piston.
The marked side of the piston rings must face toward the top of
the piston.

VE123-3L

3. Use the folfowing procedure in order to locate the piston

FAN END OF ENGINE
ring gaps:
3.1. Install the oil ring spacer in groove and insert anti-
B rotation tang in oil hole.

c3
3.2. Hold the spacer ends together and install lower oil
ring rail with the gap properly located.
C A D 3.3. Install the upper oil ring rail with the gap properly
located.
3.4. Flex the oil ring assembly to make sure the rings are
B
Free.
A - POSITION OF THE GAP FOR THE 3.5. Install the lower compression ring.
SPACER OF THE OIL RING
B - POSITION OF THE GAP FOR THE 3.6. Install the upper compression ring.
OIL RING
C - POSITION OF THE GAP FOR THE
LOWER COMPRESSION RING
D - POSITION OF THE GAP FOR THE
UPPER COMPRESSION RING

VE074-34

Camshaft and Bearings Clean and Inspect

Tools Required
l J 7872 Magnetic Base Indicator Set
Caution: Wear safety g/asses in order to avoid eye damage.
1. Clean the camshaft in solvent.
2. Dry the camshaft with compressed air.
3. Inspect the camshaft bearing journals for scoring or
excessive wear.
4. Inspect the camshaft valve lifter lobes for scoring or
excessive wear.
5. Inspect the camshaft retainer plate for wear.

VEO75-3L

00 (GM)-8-46
 Main Table of Contents

Cl!‘lRIC Group 00 (GM), Engine 3.OL

6. Inspect the camshaft bearings for proper fit in the engine

block. Camshaft bearings have an interference fit to the
engine block and should not be loose in their engine block
bearing bores.
7. Inspect the camshaft bearings for excessive wear or
scoring. Bearings with excessive wear or scoring must be
replaced.

a. Measure the camshaft for out-of-round, taper or undersize

with a micrometer. Refer to Engine Mechanical
Specifications.

9. Support the camshaft front and rear journals on V-blocks.

10. Measure the camshaft run-out at the intermediate journal
with J 7672. Refer to Engine Mechanical Specifications.
11. Replace camshaft if measurements are not within
specifications.

VEO7&?-3L

00 (GM)-8-47
 Main Table of Contents

Group 00 (GM), Engine 3.OL CLSRCC

Camshaft Sprocket and Retainer Removal and

Installation
Removal
Tools Required
l J 791 Camshaft Sprocket Remover
If the inspection indicated that the camshaft, gear and
retainer were in good condition, the camshaft end play
should be checked. Refer to Engine Mechanical
Specifications.

VEO79-3

If the inspection indicated that the camshaft, gear or

retainer should be replaced, the gear must be removed
from the camshaft as follows:
2.1. Place the camshaft through the J 791.
2.2. Place the end of the remover on the table of a press
and press the camshaft out of the gear.
Important:
The retainer must be positioned so that the woodruff key in the
camshaft does not damage it when the camshaft is pressed out of
the gear. Also, support the hub of the gear or the gear will be
seriously damaged.

Installation
1. Install the camshaft sprocket, retainer and gear spacer ring
to the camshaft as follows:
1.l. Firmly support the camshaft at the back of the front
journal in an arbor press.
1.2. Place the gear spacer ring and retainer over the end
of the camshaft and install the woodruff key in the
camshaft keyway.
1.3. Align the sprocket keyway with the woodruff key in
the camshaft and press it onto the shaft until it
bottoms against the gear spacer ring.

00 (GM)-8-48
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Camshaft Bearing Installation

Tools Required
l J 6098-01 Camshaft Bearing Installer
Important:
l A loose camshaft bearing may be caused by an
enlarged, out of round or damaged engine block bearing
bore.
l The outer front and rear camshaft bearings must be
installed first. These bearings serve as guides for the tool
pilot and help center the inner bearings during the
installation process.
l The camshaft bearing oil holes must align with the oil
galleys in the engine block. An improperly aligned
camshaft bearing oil galley hole will restrict oil flow to the
bearing and camshaft journal.
1. Use the J 6098-01 in order to install the front and rear
camshaft bearings: VEC55-3L

1.l. Assemble the bearing tool to the driver handle.

1.2. Align the oil holes.
1.3. Drive the front and the rear camshaft bearings inward
toward the center of the engine block.

2. Use the J 6098-01 in order to install the inner camshaft

bearings. Repeat the following steps for each of the inner
camshaft bearings:
2.1. With the nut (4) and the thrust washer (3) installed to
the end of the puller screw threads, index the pilot in
the camshaft front bearing and install the puller screw
through the pilot (2). J 6098-01

2.2. Index the camshaft bearing in the bore. Make sure

you align the oil galley holes.
2.3. Install the puller screw through the bearing bore and
bearing to be installed and assemble bearing tool (1)
to the puller screw with the shoulder toward the
bearing. Make sure that enough threads are
engaged.
2.4. Using two wrenches, hold the puller screw (5) while
you turn the nut in order to draw the bearing into the
bore. When the bearing has been pulled into the
bore, remove the bearing tool and the puller screw
and check the alignment of the bearing oil hole to the
bore oil hole.
3. Install a new camshaft rear bearing hole plug. Coat the plug
outside diameter with GM P/N 1052080 sealant, or the
equivalent.
00 (GM)-8-49
 Main Table of Contents

Group 00 (GM), Engine 3.OL Cl!!lRIC

Oil Pump Disassemble

1. If necessary, remove the oil pump screen.
. The oil pump screen has a press fit in to the pump cover.
l Do not remove the screen from the pipe. The pipe and
screen are serviced as a complete assembly.

VE082-34

2. Remove the cover bolts.

3. Remove the pump cover.

4. Remove the drive gear (2) and the driven gear (1).
Matchmark the gear teeth for assembly.

vE@s4-s4
00 (GM)-8-50
 Main Table of Contents

Group 00 (GM), Engine 3.OL

5. Remove the following items:
l The retaining pin (1).
l The pressure relief valve spring (3).
l The pressure relief valve (2).

VEO85-3L

Oil Pump Clean and Inspect

Important: The internal parts of the oil pump are not serviced
separately. If the oil pump components are worn or damaged,
replace the oil pump as an assembly.
The oil pump pipe and screen are to be serviced as an assembly.
Do not attempt to repair the wire mesh portion of the pipe and
screen assembly.
1. Clean all of the parts in cleaning solvent.
Caution: Wear safety glasses in order to avoid eye damage.
2. Dry the parts with compressed air.
3. Inspect the following areas:
The oil pump housing and cover for cracks, scoring,
casting imperfections and damaged threads.
The drive gear shaft (If the shaft is loose in the oil pump
housing, replace the oil pump).
The pressure relief valve for scoring and sticking (Burrs
may be removed with a fine oil stone).
The pressure relief valve spring for loss of tension.
The oil pump screen for broken wire mesh or looseness
(If the pipe is loose or has been removed from the
screen, the oil pump screen must be replaced).
The gears for chipping, galling and wear.
Important: If the drive gear and driveshaft are worn,
replace the entire oil pump.
The drive gear and driveshaft for looseness and wear.

00 (GM)-841
 Main Table of Contents

Group 00 (GM), Engine 3.OL WIRK

Oil Pump Assemble

Tools Required
l J 21882 Oil Suction Pipe Installer
Important: Replace the pressure relief valve spring when you
reuse the oil pump.
1. install the following items:
l The pressure relief valve (2).
l The pressure relief valve spring (3).
l The retaining pin (1).

VEO&-SL

2. Coat the drive gear, the driven gear and the housing gear
surfaces with clean engine oil.
3. Install the drive gear (2) and the driven gear (1) into the
pump body. Align the matchmarks on the gears. Install the
smooth side of the gear toward the pump cover.

VEOS4-3L

4. Install the pump cover.

5. Install the cover bolts.
Tighten
Tighten the bolts to 8 N*m (72 lb in).

VEO533L

00 (GM)-862
 Main Table of Contents

CLSRIC Group 00 (GM), Engine 3.OL

6. Inspect the pump for smoothness of operation by turning

the oil pump driveshaft by hand.
7. Install the oil pump screen.
7.1. If removed, replace the oil pump screen. The oil
pump screen must have a good press fit into the oil
pump body.
7.2. Mount the oil pump in a soft jawed vise.
7.3. Apply sealer to the end of the pipe.
7.4. Use the J 21882 and a soft-faced hammer in order to
tap the oil pump screen into the pump body. The
screen must align parallel with the bottom of the oil
pan when it is installed.

VEO873L

Cylinder Head Disassemble

Tools Required
l J 8062 Valve Spring Compressor
Important: Mark, organize or sort the cylinder head components
for assembly. Return the components to their original location
during assembly.
1. Measure the valve spring installed height using a ruler.
Measure from the machined surface of the cylinder head to
the top of the valve spring cap. Refer to Engine Mechanical
Specifications

I
VEO86-3L

2. Use the J 8062 in order to compress the valve springs.

J 8062

vEo8Q-k

00 (GM)-8-53
 Main Table of Contents

Group 00 (GM), Engine 3.OL cl!!wIC

3. Remove the valve stem keys (1).

4. Remove the cap from the valve spring ( 2&6).
5. Remove the valve stem oil shield (3).
6. Remove the valve spring (4).
7. Remove the valve stem oil seal (5).
8. Remove the valve (7&8).
Important: Place the valves in a rack in the proper sequence so
that you can install them in the same order.

I
vEo9l-34

Cylinder Head Clean and Inspect

Tools Required
l J 8089 Carbon Remover Brush
l J 9666 Valve Spring Tester
l J 8001 Dial Indicator
Caution: Wear safety g/asses in order to avoid eye damage.
Use the J 8089 in order to clean the carbon from the
combustion chambers and the valve ports. Be careful not to
scuff the chamber.
Clean the following areas:
2.1. The carbon and the sludge from the valve pushrods
and the valve rocker arms.
2.2. The valve stems and heads on a buffing wheel.
2.3. The cylinder head and engine block gasket surfaces.
2.4. The bolt holes and threads in the cylinder head and
vEo91-31 the engine block.

Inspect the following areas:

3.1. The cylinder head for cracks in the exhaust ports and
the combustion chambers.
3.2. The cylinder head for external cracks in the water
chamber.
3.3. The valves for burned heads, cracked faces or
damaged stems.

00 (GM)-8-54
 Main Table of Contents

Cl!MRK Group 00 (GM), Engine 3.OL

4. Use the J 9666 and a flex bar torque wrench in order to
measure the valve spring pressure.
l Replace the valve spring if the spring pressure is less
than 444 N (100 lb.) at 40.9 mm (1.61 in). Refer to
Engine Mechanical Specifications.

VEOB3L

5. Excessive valve stem-to-bore clearance will cause

excessive oil consumption and may cause a valve to break.
Insufficient clearance will result in noisy and sticky
functioning of the valve and will disturb the engine assembly
smoothness.
5.1. Install the valve into the guide.
5.2. Install the J 8520 onto the cylinder head.
5.3. Locate the indicator so that the movement of the
valve stem from side to side (crosswise to the
cylinder head) will cause a direct movement of the
indicator stem.
5.4. The indicator stem must contact the side of the valve
stem just above the valve guide.
5.5. Drop the valve head about 1.6 mm (0.0064 in) off the
valve seat.
5.6. Use light pressure and move the valve stem from
side to side in order to obtain a clearance reading. VEO94-3L
5.7. If the valve stem to guide clearance is excessive, the
valve must be replaced and/or the guide must be
repaired to obtain the proper clearances. Refer to
Engine Mechanical Specifications.

00 (GM)-8-55
 Main Table of Contents

Group 00 (GM), Engine 3.OL Cl!!lRK

6. Inspect the valve springs for squareness.

VEo953L

7. Measure the valve seat runout.

l Use the J 8001 in order to check the valve seat runout.
l The valve seats should be concentric to within 0.0508
mm (0.002 in).

VEO%-3L

8. Measure the cylinder head for warpage with a straight edge

and a feeler gauge. A cylinder head with excessive warpage
must be repaired or replaced. Refer to Engine Mechanical
Specifications.

VE097-34

00 (GM)-846
 Main Table of Contents

Cl!YRK Group 00 (GM), Engine 3.OL

Valve Guide ReamingNaIve and Seat Grinding

1. Ream the valve guides for oversize valves if the clearance
exceeds the specifications.
2. Service valves are available in the standard and 0.038 mm J 4822
(0.015 in).
3. Ream the valve guide bores for the service valves as
necessary.

4. Reconditioning the valve seats is very important.

5. Recondition the valve seat after reaming the valve guide
bores or installing the new valve guides.
The valves must seat perfectly for the engine to deliver
optimum power and performance.
Cooling the valve heads is another important factor.
Good contact between each valve and its seat in the
cylinder head is necessary to ensure that the heat in the
valve head is properly carried away.
Regardless of what type of equipment is used, it is
essential that the valve guide bores are free from carbon
or dirt to ensure the proper centering of the pilot in the
guide.
The valve seats should be concentric to within 0.0508
mm (0.002 in) total indicator reading.

6. Reface pitted valves on a valve refacing machine in order to

ensure the correct relationship between the head and the
stem.
l Replace the valves that show excessive wear or are
warped.
l Replace the valve if the edge of the head is less than 0.8
mm (0.031 in) thick after grinding.
l Several different types of equipment are available for
reconditioning valves and valve seats. Use the
manufacturers recommendations of equipment to obtain
the proper results.

00 (GM)-847
 Main Table of Contents

Group 00 (GM), Engine 3.OL cl!!wIC

Rocker Arm Stud Removal and Installation

Tools Required
l J 5802-01 Rocker Arm Stud Remover
l J 6880 Rocker Arm Stud Installer
Rocker arm studs with damaged threads or with loose fit in
cylinder head should be replaced with new, oversize studs.
1. Remove the old stud by placing J 5802-01 over the stud,
installing nut and flat washer and removing the stud by
turning out.

VElOO-FL

2. Ream the hole for the oversize stud.

Important: Do not attempt to install an oversize stud without
reaming the stud hole.

I J5715

00 (GM)-8458
 Main Table of Contents

Group 00 (GM), Engine 3.OL

3. Coat the press-fit area of the stud with Perfect Seal.

4. Install the new stud, using J 6880 as a guide.

Cylinder Head Assemble

Tools Required
l J 8062 Valve Spring Compressor
1. install the valve (7&8) into the proper port.
2. Lubricate oil seal (5) with clean engine oil.
3. Install the oil seal onto the valve stem.
4. Install the valve spring (4).
5. Install the valve stem oil shield (3).
6. Install the cap on the valve spring (2&6).

VEO933L

00 (GM)-8-59
 Main Table of Contents

Group 00 (GM), Engine 3.OL Cl!‘lRIC

Caution: Wear safety glasses in order to avoid eye damage.
7. Use the J 8062 in order to compress the valve spring.
8. Install the valve stem keys.
8.1. Use grease to hold the keys in place while
disconnecting the J 8062.
8.2. Make sure that the keys seat properly in the upper
groove of the valve stem.
8.3. Tap the end of the valve stem with a plastic-faced
hammer in order to seat the keys if necessary.

Service Prior to Assembly

Dirt or debris will cause premature wear of the rebuilt
engine. Clean all components. Refer to Cleanliness and
Care.
Use the proper tools to measure components when
checking for excessive wear. Components that are not
within the manufacturers specifications must be repaired
or replaced.
When components are reinstalled into an engine, return
the components to their original location, position and
direction. Refer to Separating Parts.
During assembly, lubricate all moving parts with clean
engine oil or engine assembly lubricant (unless
otherwise specified). This will provide initial lubrication
when the engine is first started. Refer to Sealers,
Adhesives and Lubricants.

Crankshaft, Bearings and Bearing Cap

Installation
Important
l Crankshaft bearing caps must be installed to the proper
location and direction.
. When installing the crankshaft bearings, align the
locating tabs on the bearings with the locating notches in
the engine block journal bore and the bearing cap.
l Always install crankshaft bearings with their machined
partner. Do not file bearings or mix bearing halves.
1. Install the crankshaft bearings into the engine block and the
crankshaft bearing caps.
2. Coat the crankshaft bearings with clean engine oil.
3. Install the crankshaft.

00 (GM)-8-60
 Main Table of Contents

CL’YRIC Group 00 (GM), Engine 3.OL

4. Install the crankshaft bearing caps with the crankshaft

bearings.
5. Be sure that the cap directional arrows point toward the
front of the engine block and the cap is in its original
position.
6. Install the crankshaft bearing cap bolts.
7. Thrust the crankshaft rearward in order to set and align the
thrust bearings and the bearing caps.
8. Thrust the crankshaft forward in order to align the rear faces
of the rear crankshaft bearings.
Tighten
Tighten all of the bolts to 88 Nom (65 lb ft).

Crankshaft Rear Oil Seal and Housing Installation

Tools Required
l J 35621 Crankshaft Rear Oil Seal Installer
Important: Always use a new crankshaft rear oil seal and new
crankshaft rear oil seal housing gasket when you install the
crankshaft rear oil seal housing.
1. Install the new gasket and the crankshaft rear oil seal
housing on to the studs.
2. Install the rear oil seal housing nuts and bolts.
Tighten
Tighten the crankshaft rear oil seal housing nuts and bolts to 15
N*m (135 lb in).

3. Coat the new oil seal entirely with clean engine oil.
4. Install the seal onto the J 35621.
5. Install the J 35621 onto the rear of the crankshaft. Tighten
the screws snugly in order to ensure that the seal will be
installed squarely over the crankshaft.
6. Install the crankshaft rear oil seal onto the crankshaft and
into the crankshaft rear oil seal housing. Tighten the wing
nut on the J 35621 until the oil seal bottoms.
7. Remove the J 35621 from the crankshaft rear oil seal
housing.

00 (GM)-8-81
 Main Table of Contents

Group 00 (GM), Engine 3.OL CWW

Piston, Connecting Rod and Bearing Installation
Tools Required
FACING FRONT OF l J 5239 Guide Set
ENGINE BLOCK
l J 8037 Piston Ring Compressor
Important
l The piston and cylinder bore have been measured and
the bore has been sized for the proper clearance. Install
the piston and connecting rod assembly into the proper
cylinder bore.
l The piston alignment mark MUST face the front of the
engine block.
1. Lubricate the following components with clean engine oil:
l The piston.
l The piston rings.
l The cylinder bore.
l The bearing surfaces.
Install the connecting rod bearing into the connecting rod
and bearing cap.
Install the J 5239 onto the connecting rod.
Install the J 8037 or equivalent onto the piston and
compress the piston rings.

5. Install the piston assembly into its matched bore with the

J 8037 I
I
6.
stamped arrow facing forward.
Use the J 8037 and the J 5239 and lightly tap the top of
the piston with a wooden hammer handle.
l Hold the J 8037 firmly against the engine block until all
of the piston rings enter the cylinder bore.
l Use the J 5239 in order to guide the connecting rod
onto the crankshaft journal.

00 (GM)-8-62
 Main Table of Contents

Group 00 (GM), Engine 3.OL

7. Remove the J 5239.

8. Install the connecting rod cap and nuts.

Tighten
Tighten the nuts evenly to 61 Nom (45 lb ft).

8. When all of the connecting rod bearings are installed, tap

each connecting rod assembly lightly parallel to the
crankpin in order to make sure that they have clearance.
9. Use a feeler gauge or a dial indicator in order to measure
the side clearance between the connecting rod caps. Refer
to Engine Mechanical Specifications.

00 (GM)-8-63
 Main Table of Contents

Group 00 (GM), Engine 3.OL cl!!wIC

Timing Gear Oil Nozzle Installation

1. Drive the new nozzle in place (oil hole facing up) with a
suitable light plastic or rubber hammer.

VEX

Crankshaft Sprocket Installation

Tools Required
l J 5590 Crankshaft Sprocket Installer
1. Install the keys into the crankshaft keyways.
2. Use the J 5590 in order to install the crankshaft sprocket.
J 5590

Camshaft Installation
Important: If camshaft replacement is required, the valve lifters
must also be replaced.
1. Carefully rotate and install the camshaft into the engine.
2. Install the two camshaft retainer bolts working through the
holes in the camshaft sprocket. Be sure to align the
camshaft and the crankshaft sprocket alignment marks.
Tighten
Tighten the camshaft retainer bolts to 9 Nom (80 lb in).

00 (GM)-8-64
 Main Table of Contents

CMIRIC Group 00 (GM), Engine 3.OL

Engine Front Cover and Oil Seal Installation

Tools Required
l J 35468 Engine Front CoverAligner and Oil Seal
Installer
1. Use the J 35468 in order to install the engine front cover oil
seal.

2. Install the engine front cover gasket.

3. Install the engine front cover and bolts.
Tighten
Tighten engine front cover bolts to 3.4 N*m (30 lb in).

00 (GM)-8-65
 Main Table of Contents

Group 00 (GM), Engine 3.OL CLSRIC

Oil Pump Installation
Important: inspect the oil pump and engine block oil galley
passages. These surfaces must be clear and free of debris or
restrictions.
1. Install the oil pump.
2. Install the bolts that attach the oil pump to the engine block.
Tighten
Tighten the oil pump bolts to 14 N*m (120 lb in).

VE1103L

Oil Pan Installation

Important: Apply the sealer 25 mm (1 .O in) in either direction of
the radius cavity of the junctions.
1. Apply a small amount of sealer, GM P/N 1052914 or
equivalent, 10 mm (0.393 in) wide and 20 mm (0.787 in)
long at the engine front cover to engine block junction.
2. Apply a small amount of sealer, GM P/N 1052914 or
equivalent, 25 mm (1.O in) long at the crankshaft rear oil
seal housing to engine block junction.
3. Install the new oil pan gasket.
4. Install the oil pan.
5. Install the nuts and bolts to the oil pan.
Tighten
Tighten the rear oil pan nuts to 18.6 N*m (165 lb in).
Tighten the oil pan bolts to the crankcase to 9 N*m (80 lb in).
vE111-34 Tighten the oil pan bolts to the front cover to 5 N*m (45 lb in).
Tighten the oil pan studs to the oil seal retainer to 1.7 N-m
(15 lb in).

00 (GM)-8-86
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Crankshaft
Tools Required
l
Pulley Installation

J 8792 Crankshaft Pulley Installer

n
1. Coat the front cover oil seal contact area of the crankshaft
pulley with clean engine oil.
2. Assemble the J 8792 as shown.

VE112i3LJ

3. Install the J 8792 onto the crankshaft pulley.

4. Position the pulley on the crankshaft and drive into position
until it bottoms against the crankshaft sprocket.
\

I\ \ J 8792

Cylinder Head Installation

1. Install the new cylinder head gasket over the locating pins.
2. Install the cylinder head over the locating pins and the
gasket.

00 (GM)-8-67
 Main Table of Contents

Group 00 (GM), Engine 3.OL CLSRIC

3. Install the cylinder head bolts finger tight.
Tighten
Tighten the cylinder head bolts in sequence to 122 Nom (90 lb f-t).

GM 4-181

,
VE115-3L

Valve Lifter Installation

1. Coat the bottom of the valve lifters with prelube, GM P/N
1052365 or equivalent.
2. If reusing the valve lifters, install in their original location.
3. Install the valve lifters.

VE116-3L

Valve Rocker Arm and Pushrod Installation

Important: Be sure to keep parts in order. Parts must be installed
from where they were removed.
1. Install the valve pushrods. Be sure that the valve pushrods
seat in the valve lifter sockets.

VEOZ3-3L

00 (GM)-8-68
 Main Table of Contents

Group 00 (GM), Engine 3.OL

2. Install the following components:
2.1. The valve rocker arms (3).
2.2. The valve rocker arm balls (2).
2.3. The valve rocker arm nuts (1).

VEO213L

3. Adjust the valve rocker arm nuts as follows:

3.1. Turn the crankshaft until the mark on the crankshaft
pulley lines up with “0” on the timing tab and number
1 cylinder is at top dead center.
3.2. Place fingers on the number 1 valves as the mark
approaches “0.” If the valves move as the mark
approaches “0,” the engine is on number 4 top dead
center and should be rotated one more revolution in
order to reach number 1 top dead center.
3.3. With the engine at number 1 top dead center, adjust
the following valves:
- The exhaust valves I,3
- The intake valves 1,2,4
3.4. Adjust the correct valves as follows:
314.1. Back off the valve rocker arm nut until the
lash is felt in the valve pushrod.
3.4.2. Tighten the valve rocker arm nut until all the
lash is removed.
3.4.3. Zero lash can be felt by moving the valve
pushrod up and down between your thumb
and forefinger until there is no more
movement.
3.4.4. When all the free play is gone, tighten the
valve rocker arm nut 1 additional turn (360
degrees).

00 (GM)-8-69
 Main Table of Contents

Group 00 (GM), Engine 3.OL cl!!wIC

3.5. Turn the crankshaft 1 revolution until the mark on the
crankshaft pulley lines up with “0” on the timing tab.
This is number 4 top dead center.
3.6. With the engine at number 4 top dead center, adjust
the following valves:
- The exhaust valves 2,4
- The intake valves 3
3.6.1. Back off the valve rocker arm nut until the
lash is felt in the valve pushrod.
3.6.2. Tighten the valve rocker arm nut until all the
lash is removed.
3.6.3. Zero lash can be felt by moving the valve
pushrod up and down between your thumb
and forefinger until there is no more
movement.
3.6.4. When all the free play is gone, tighten the
valve rocker arm nut 1 additional turn (360
degrees).

Pushrod Cover Installation

1. Install the pushrod cover gasket.
2. Install the pushrod cover.
3. Install the pushrod cover bolts.
Tighten
Tighten the pushrod bolts to 4.5 Nom (40 lb in).

00 (GM)-8-70
 Main Table of Contents

Valve Rocker Arm Cover Installation

1. Install the valve rocker arm cover gasket.
2. Install the valve rocker arm cover.
3. Install the valve rocker arm bolts.
Tighten
Tighten the valve rocker arm cover bolts to 4.5 Nom (40 lb in).

Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube into the engine block.
2. Use a light plastic or rubber hammer in order to tap the tube
until it seats in the engine block.
3. Install the oil level indicator into the tube.

Water Pump Installation

1. Position the water pump and gasket to the engine block.
2. Install the water pump bolts.
Tighten
Tighten the water pump bolts to 20 N*m (15 lb ft).
 Main Table of Contents

Group 00 (GM), Engine 3.OL Cl!!lRK

Intake/Exhaust Manifold Installation
1. Install the intake/exhaust manifold gasket over the locating
pins on the cylinder head.
2. Install the bolts and clamps while holding the manifold in
place.
Tighten
Tighten the two center bolts to 27-34 N*m (20-25 lb ft).
Tighten the end bolts to 20-27 N*m (15-20 lb f-t).

vEOw3L

Spark Plug Installation

1. Install the spark plugs.
Tighten
Tighten the spark plugs to 30 N*m (22 lb ft).

Lift Bracket Installation

1. Install the lift bracket.
2. Install the lift bracket bolts.
Tighten
Tighten the lift bracket bolts to 54 Nom (40 lb ft).

VEOlXL

00 (GM)-&72
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Ignition Coil Installation

1. Install the ignition coil.
2. Install the ignition coil bracket attaching bolts.
Tighten
Tighten the attaching bolts to 22 Nom (16 lb fi).

Distributor Installation
Important: To ensure correct ignition timing, the distributor must
be installed in the correct position. Position the engine at top dead
center on number one cylinder. The distributor cap must be
removed in order to position the rotor when installing the
distributor.
1. Install the distributor (2) and new gasket (3), making sure
the distributor rotor is pointing to number one tower on the
distributor cap.
2. Install the distributor hold down (5) and bolt (6).
Tighten
Tighten the hold down bolt to 27 N*m (20 lb ft).
3. Connect the primary ignition harness (4) to the ignition coil.
4. Connect the secondary ignition wires (1) to the spark plugs
and the ignition coil.

00 (GM)-8-73
 Main Table of Contents

Group 00 (GM), Engine 3.OL CLSRK

Engine Flywheel Installation
Important: Note the position and direction of the engine flywheel
before removal. The flywheel center alignment hole is a tapered fit
to the crankshaft. The engine flywheel must be reinstalled to the
original position and direction. The engine flywheel will not initially
seat against the crankshaft flange, but will be pulled onto the
crankshaft by the engine flywheel bolts.
1. Install the engine flywheel.
2. Install the engine flywheel bolts.
Tighten
Tighten the flywheel bolts to 88 N*m (65 lb ft).

Engine Block Coolant Plug/Oil Filter Installation

1. Install the left rear engine block coolant plug.

VEOO8-3L

2. Install the right rear engine block coolant plug.

VEoo73L

00 (GM)-8-74
 Main Table of Contents

Group 00 (GM), Engine 3.OL

3. Install the oil filter.

4. Install the oil pan drain plug.

--
\ ---\

00 (G M)-8-75
 Main Table of Contents

Group 00 (GM), Engine 3.OL CL’IRIC

Description and Operation
Engine Component Description

Engine Block
The engine block has four cylinders arranged in an “in-line” construction. Starting at the front of the engine, the cylinders
are numbered l-2-3-4. The firing order of the cylinders is l-3-4-2. The cylinders are encircled by coolant jackets.

Cylinder Head
The cylinder head has one intake and one exhaust valve per cylinder. A spark plug is located between the valves in the
side of the cylinder head. The valve guides are integral and the valve rocker arms are retained on individual threaded
studs.

Crankshaft
The crankshaft is cast nodular iron and is supported by five crankshaft bearings. The bearings are retained by crankshaft
bearing caps that are machined with the engine block for proper alignment and clearences.

Camshaft
A billet steel one piece camshaft is supported by four full round, sleeve-type bearings. These bearings are a press fit into
the engine block. The camshaft timing sprocket is mounted to the front of the camshaft and is driven the crankshaft
sprocket.

Pistons and Connecting Rods

The pistons are made of cast-aluminum alloy using two compression rings and one oil control ring assembly. The piston
pins are a press fit in the connecting rods and a floating fit in the pistons.

Valve Train
The valve train is a ball-pivot type. Motion is transmitted from the crankshaft through the valve lifter and valve pushrod to
the valve rocker arm. The valve rocker arm pivots on its ball and transmits the camshaft motion to the valve. The valve
lifters keep all parts of the valve train in constant contact. Each lifter acts as an automatic adjuster and maintains zero
lash in the valve train. This eliminates the need for periodic valve adjustment.

00 (GM)-8-76
 Main Table of Contents

Group 00 (GM), Engine 3.OL

Lubrication Caution: Wear safety glasses in order to avoid eye

damage.
The oil pump is gear driven from the camshaft. Oil is
drawn from the oil pan through a pickup screen and tube. 1. Determine the size, pitch and depth of the damaged
The gear type oil pump has a pressure regulator valve thread. If necessary, adjust the stop collars on the
which controls the lubrication system pressure by cutting tool and tap to the required depth.
bypassing excess oil back to the oil pan sump. 2. Drill out the damaged thread. Clean out any chips.
Pressurized oil from the oil pump flows to the full flow filter. 3. Avoid any buildup of chips. Back out the tap every
A bypass valve allows oil to bypass the filter if it becomes few turns and remove the chips.
clogged or restricted. Oil then flows into an oil passage 4. Tap the hole. Lubricate the tap with light engine oil.
that runs along the right side of the block and intersects Clean the thread.
the lifter bosses. Oil from this passage is routed to the
crankshaft main bearings and camshaft bearings through
smaller drilled passages. Oil is supplied to the connecting
rod bearings by holes drilled in the crankshaft. Oil is
supplied to the rocker arms through holes in the hydraulic
lifters which feed oil up the pushrods to the rocker arms.
The oil is metered by discs under the pushrod seat.
Many internal engine parts have no direct oil feed and are
supplied by either gravity or splash from other direct feed
components. Timing gears are lubricated by oil supplied
through a passage from the front of the camshaft to a
calibrated nozzle above the crankshaft gear.

Thread Repair
Tools Required
General purpose thread repair kits. These kits are
available commercially
L

5.Thread the insert onto the mandrel of the installer.

Engage the tang of the insert onto the end of the
mandrel.
Important: The insert should be flush to one turn below
the surface.
6. Lubricate the insert with light engine oil (except
when installing in aluminum) and install the insert.
7. If the tang of the insert does not break off when
backing out the installer, break the tang off with a
drift.

00 (GM)-8-77
 Main Table of Contents
Group 00 (GM), Engine 3.OL
Cleanliness and Care
l Throughout this section, it should be understood
that proper cleaning and protection of machined
surfaces and friction areas is part of the repair
procedure. This is considered standard shop
practice even if not specifically stated.
l When any internal engine parts are serviced,
care and cleanliness is important.
l When components are removed for service, they
should be marked, organized or retained in a
specific order for reassembly. Refer to
Separating Parts.
l At the time of installation, components should be
installed in the same location and with the same
mating surface as when removed.
l An engine is a combination of many machined,
honed, polished and lapped surfaces with
tolerances that are measured in millimeters or
thousandths of an inch. These surfaces should
be covered or protected to avoid component
damage.
l A liberal coating of clean engine oil should be
applied to friction areas during assembly.
l Proper lubrication will protect and lubricate
friction surfaces during initial operation.
Replacing Engine Gaskets
1. Gasket reuse and applying sealants:
l Do not reuse any gasket unless specified.
l Gaskets that can be reused will be identified in
the service procedure.
l Do not apply sealant to any gasket or sealing
surface unless specified in the service
procedure.
2. Separating components:
l Use a rubber mallet to separate components.
l Bump the part sideways to loosen the
components.
. Bumping should be done at bends or reinforced
areas to prevent distortion of the parts.
3. Cleaning gasket surfaces:
. Remove all gasket and sealing material from the
part using a plastic or wood scraper (if required).
l Care must taken to avoid gouging or scraping
the aluminum sealing surfaces.
l Do not use any other method or technique to
remove sealant or gasket material from a part.
. Do not use abrasive pads, sand paper or power
tools to clean gasket surfaces.
- These methods of cleaning can cause
damage to the component sealing
surfaces.
00 (GM)-8-78
CLSRIC
- Abrasive pads also produce a fine grit
that the oil filter cannot remove from the
oil.
- This grit is abrasive and has been known
to cause internal engine damage.
4. Assembling components:
When assembling components, use only the
sealant specified or equivalent in the service
procedure.
Sealing surfaces should be clean and free of
debris or oil.
Specific components such as crankshaft oil
seals or valve stem oil seals may require
lubrication during assembly.
Components requiring lubrication will be
identified in the service procedure.
When applying sealant to a component, apply
the amount specified in the service procedure.
Do not allow the sealant to enter into any blind
threaded holes, as it may prevent the bolt from
clamping properly or cause component damage
when tightened.
Tighten bolts to specifications. Do not
over-tighten.
Use of RTV and Anaerobic Sealer
Important: Three types of sealer are commonly used in
engines. These are RTV sealer, anaerobic gasket
eliminator sealer and pipe joint compound. The correct
sealer and amount must be used in the proper location to
prevent oil leaks. DO NOT interchange the three types of
sealers. Use only the specific sealer or the equivalent as
recommended in the service procedure.
Pipe Joint Compound
Pipe joint compound is a pliable sealer that does
not completely harden. This type sealer is used
where two nonrigid parts (such as the oil pan
and the engine block) are assembled together.
Do not use pipe joint compound in areas where
extreme temperatures are expected. These
areas include: exhaust manifolds, head gasket or
other surfaces where gasket eliminator is
specified.
Follow all safety recommendations and
directions that are on the container.
To remove the sealant or the gasket material,
Refer to Replacing Engine Gaskets.
Apply a continuous bead of pipe joint compound
to one sealing surface. Sealing surfaces to be
resealed must be clean and dry.
Tighten the bolts to specifications. Do not
overtighten.
 Main Table of Contents
Cl!“lRIC
RTV Sealer
l Room Temperature Vulcanizing (RTV) sealant
hardens when exposed to air. This type sealer is
used where two nonrigid parts (such as the oil
pan and the engine block) are assembled
together.
l Do not use RTV sealant in areas where extreme
temperatures are expected. These areas include:
exhaust manifolds, head gasket or other
surfaces where gasket eliminator is specified.
l Follow all safety recommendations and
directions that are on the container.
l To remove the sealant or the gasket material,
Refer to Rep/acing Engine Gaskets.
l Apply RTV to a clean surface. Use a bead size
as specified in the service procedure. Run the
bead to the inside of any bolt holes. Do not allow
the sealer to enter any blind threaded holes, as it
may prevent the bolt from clamping properly or
cause damage when the bolt is tightened.
l Assemble components while RTV is still wet
(within three minutes). Do not wait for RTV to
skin over.
l Tighten the bolts to specifications. Do not
overtighten.
Anaerobic Sealer
Anaerobic gasket eliminator hardens in the
absence of air. This type sealer is used where
two rigid parts (such as castings) are assembled
and no sealer or gasket is readily noticeable, the
parts were probably assembled using a gasket
eliminator.
Follow all safety recommendations and
directions that are on the container.
To remove the sealant or the gasket material,
Refer to Rep/acing Engine Gaskets.
Apply a continuous bead of gasket eliminator to
one flange. Surfaces to be resealed must be
clean and dry.
Spread the sealer evenly with your finger to get a
uniform coating on the sealing surface. Do not
allow the sealer to enter any blind threaded
holes, as it may prevent the bolt from clamping
properly or cause damage when the bolt is
tightened.
Tighten the bolts to specifications. Do not
over-tighten.
After properly tightening the fasteners, remove
the excess sealer from the outside of the joint.
Group 00 (GM), Engine 3.OL
Separating Parts
Important: Many internal engine components will develop
specific wear patterns on their friction surfaces.
When assembling the engine, internal components MUST
be separated, marked or organized in a way to ensure
reinstallation to original location and position.
Mark or identify the following components:
. Piston and the piston pin.
. Piston assembly to the specific cylinder bore.
. Piston rings to the specific piston assembly and
cylinder bore.
. Connecting rod to the crankshaft journal.
. Connecting rod to bearing cap.
. Crankshaft main and connecting rod bearings.
. Camshaft and valve lifters.
. Valve lifters, guides, pushrods, pivot supports
and rocker arms.
. Valve to the valve guide.
. Valve spring and shim .
. Engine block main bearing cap location and
direction.
. Oil pump drive and driven gears.
Tools and Equipment
Special tools are listed and illustrated throughout this
section with a complete listing at the end of the section.
These tools (or their equivalents) are specially designed to
quickly and safely accomplish the operations for which
they are intended. The use of these special tools will also
minimize possible damage to engine components. Some
precision measuring tools are required for inspection of
certain critical components. Torque wrenches and a torque
angle meter are necessary for the proper tightening of
various fasteners.
To properly service the engine assembly, the following
items should be readily available:
Approved eye protection and safety gloves.
A clean, well-lit work area.
A suitable parts cleaning tank.
A compressed air supply.
Trays or storage containers to keep parts and
fasteners organized.
An adequate set of hand tools.
Approved engine repair stand.
An approved engine lifting device that will
adequately support the weight of the
components.
00 (GM)-8-79
 Main Table of Contents

Group 00 (GM), Engine 3.OL Cl!“lRK

Special Tools and Equipment

J 791
Camshaft Sprocket Remover Crankshaft Sprocket Installer

J 3049-A J 5715 or J 6036

Valve Lifter Remover Rocker Stud Hole Reamer

J 3936-03 J 5802-01
Piston Ring Groove Cleaner Rocker Arm Stud Remover

J 4822 J 6098-01
Valve Guide Reamer Camshaft Bearing
Remover/Installer

J 5239
Slide Hammer
>onnecting Rod Bolt Guide Set

00 (GM)-8-80
 Main Table of Contents

Group 00 (GM), Engine 3.OL

J 6680
Rocker Arm Stud Remover J 8062
Valve Spring Compressor

J 6978-E J 8087
Crankshaft Sprocket Puller Cylinder Bore Gauge

J 8089
J 7872
Carbon Remover Brush
Magnetic Base Dial Indicator

J 8001 J 8520
Dial Indicator Camshaft Lobe Lift Indicator

J 8792
J 8037 Crankshaft Pulley Installer
Piston Ring Compressor

00 (GM)-8-81
 Main Table of Contents

Group 00 (GM), Engine 3.OL Cl!!YRCC

J 9290-01
Valve Litter Remover J 24066-C
(Slide Hammer Type) Piston Pin Remover/Installer Se

J 24270
Distributor Lower Bushing
Ridge Reamer
Remover

J 24420-C
Distributor Lower Bushing Universal Crankshaft Pulley
Installer Remover

J 35466
Valve Spring Tester Engine Front Cover Aligner
and Oil Seal Installer

J 21882 J 35621
Oil Suction Pipe Installer Crankshaft Rear Oil Seal
Installer

00 (GM)-8-82
 Main Table of Contents

GROUP 01

GROUP 01

ENGINE COOLING
SYSTEM

Engine Cooling System Specifications

and Description ...... .. .... ...... .. ..... .... ... ... ... .. ... . .... ... .... Section 1

Engine Cooling System Troubleshooting ... .... ... ... ... ... .. . Section 2

Engine Cooling System Testing and Maintenance ... .... Section 3

Cooling System and Alternator Belt Service ... ... . .... ... .. Section 4

Radiator Removal and Replacement ... ... ... ... .... ... .. ... .... Section 5

Radiator Removal and Replacement (GM 3.OL) . ... ... . Section 5a

NOTE
Removal and replacement procedures for the water pump and thermo-
stat are covered in the Overhaul section of Group 00, “Engines.”

SM 598, Feb’98 Engine Cooling System

 Main Table of Contents

CMRK Group 01, Engine Cooling System

Section 1.

Engine Cooling System

Specifications and Description
Specifications
Radiator Type: Crossflow radiator with coolant recovery Coolant Hoses Inspection/Replacement: As needed and ev-
system. ery 50-250 hours or each PM and every year or 2000 hours
of operation.
System Pressure (Radiator cap): 89- 103 kPa (13- 15 psi).
Coolant Protection Check (hydrometer test): Every six
Thermostat:
months or 1000 hours of operation.
Gas/LPG/CNG
Radiator Core Air Cleaning: Every 50-250 hours or monthly.
. Open (cracking) at 82’C + 1.5” (180°F + 2.7”)
Radiator Cap Inspection and Test: Every year or 2000
. Fully open at 95°C (203°F). hours of operation.
Diesel
Thermostat Test/Replacement: Every 2000 hours or each
. Open (cracking) at 76.5”C f 1.5” (170’F + 2.7’) PM.
. Fully open at 90°C ( 194°F). Fan Belt Tension Wear Inspection: After the first 50 hours
GM3.0LLPG of operation, then every 50-250 hours or each PM.

. Open (cracking) at 77’C f 1.5” (170°F + 4”) Fan Inspection for Loose or Damaged Blades: Every 50-
. 250 hours or each PM.
Fully open at 89°C (192°F).
Coolant Mixture: 50% water and 50% low-silicate, ethyl-
ene glycol, permanent-type antifreeze with rust and corro-
Fastener Torques
sion inhibitors. Cooling System Brace: 20-25 Nom (14.8- 18.5 ft-lb)
Cooling System Coolant Capacity: Shroud Mounting Bolts: 5-6 Nom (3.7-4.4 ft-lb)
Cushion-tire truck with 3-row radiator capacity is 6.3 Oil Cooler to Radiator Brackets: 40-45 I+m (29.5-33.3 ft-
L (6.6 qt )
lb)
Pneumatic-tire truck with 3-row radiator capacity is
Fan to Pulley Assembly Bolts (Diesel): 40-45 I+m (29.5-
7.5 L (7.9 qt)
33.3 ft-lb)
Diesel truck with 4-row radiator capacity is 10 L (10.5
Pulley to Flywheel Bolts (Diesel): 20-25 pm (14.8-18.5
qt).
ft-lb)
Fan Type: Pusher type
Fan to Engine Pulley (Gas/LPG/CNG): 20-25 Nom (14.8-
Fan Drive Belt: V-type belt 18.5 ft-lb)
Water Pump Type: Centrifugal Venturi to Engine Bolts: 20-25 Nom (14.8-18.5 ft-lb)
Hose Clamp Sizes: Venturi to Fan Ring: 8-10 Nom (5.9-7.4 ft-lb)
l Gas/LPG: 47 mm (1.8 in) @ radiator end; 44 mm (1.7 Oil Cooler Hose Clips: 5-6 Nom (3.7-4.4 ft-lb)
in) @ engine (water pump or thermostat) end
Water Bottle Mounting Bracket: 20-25 Nom (14.8- 18.5 ft-
l Diesel: 51mm (2 in).
lb)
Overflow Line Clips: 8-10 Nom (5.9-7.4 ft-lb)
Service Intervals
Coolant Level Check: Every 8- 10 hours or daily.
Coolant Change (drain and refill): Every year or 2000
hours of operation.

SM 598, Feb’98 Engine Cooling System Specifications and Description l 01-1-I

 Main Table of Contents

Group 01, Engine Cooling System ElRRlF

Description
The engine cooling system is a conventional setup and
consists of the radiator, the fan and drive belt, the thermo-
stat, the water pump, and associated hoses. The radiator is
filled through the overflow bottle, a reservoir for extra
coolant that allows for fluid expansion as the fluid gets
warmed in the engine. The transmission oil cooler is sepa-
rate from the engine cooling system, but is mounted di-
rectly below the radiator.
The radiators of the different models of the truck are not the
same, but the procedures for general service are the same.
Radiator repair is not covered in this manual. Radiator
service shops should be consulted if the radiator is clogged,
cracked, or otherwise unserviceable. The components that
can be serviced include the belts (gas and LPG engines
have two belts; diesel engines have only a single belt), the
thermostat, the water pump, and hoses.

Cooling
f System
Brace

Radiator

Cooling System - Cushion-Tire Truck

01-I-2 l Engine Cooling System Specifications and Description SM 598, Feb’98

 Main Table of Contents

ClRRK Group 01, Engine Cooling System

Cooling
System
Brace

Radiator

r To Water Pump

‘\\
‘\
‘\ To Thermostat
‘\. 7

Cooling System - GM 3.0 Liter Engine

SM 598, Feb’98 Engine Cooling System Specifications and Description l 01-l-3

 Main Table of Contents

Group 01, Engine Cooling System

ClmK-
Section 2.

Engine Cooling System Troubleshooting

Temperature gauge in red zone Engine shuts down (automatic engine

l Radiator fins plugged; blow debris from radiator. shutdown sensor)
l Blockage in system; drain, flush, and refill system. l High transmission temperature; check transmission
oil cooler components.
Engine overheating l Low engine oil pressure; check oil level and fill and
. Loose fan belt; tighten to correct tension (see Section check for leaks.
4 for belt tensioning procedure).
l High coolant temperature; check “Engine overheat-
. Low coolant level; refill and check for leaks. ing” for symptoms and remedies.
. Radiator pressure cap is defective.
Water pump leaks
. Inadequate air flow to the radiator; check that fan
l Pump has a worn shaft and/or seal.
blades have the coined imprinting facing the engine
and are not installed backwards. l Bad gasket.
. Missing or damaged fan shroud or shields on radiator. l Broken pump impeller.
. Radiator fins plugged; blow debris from radiator. Replace the seals and gaskets or replace the pump.
. Radiator clogged; drain and flush radiator.
Water pump making noise
. Scale or deposits in cooling system; drain and flush
Worn pump shaft or bearings loose or worn.
entire cooling system.
Pump impeller broken.
. Radiator defective; repair or replace the radiator.
Loose fan belt.
. Thermostat incorrect or defective.
Bent or broken fan blade.
. Collapsed radiator hose(s) on suction side of cooling
system. Fan hitting engine or shroud.

. Water pump defective. Engine runs cold, emits excessive blue/white

. Water passages in engine are clogged. exhaust smoke or idles roughly
. Air in cooling system; drain and flush. Contaminated fuel.
. LP gas leak into cooling system. Autochoke malfunctioning - gas model only.
. Ignition timing misadjusted. Fouled spark plugs.
. Excessive exhaust system back pressure. Coolant temperature below normal due to incorrect or
. Engine oil level is low or needs changing. defective thermostat; replace the thermostat.

. Engine overloaded. . Defective temperature sender or indicator light; check

and replace if necessary.
. Engine internal parts worn.
. Leaking head gasket. Oil in coolant or coolant in crankcase
. Defective . Leaking head gasket.
temperature gauge.
. Cylinder head bolts not tight.
. Cylinder head cracked.
. Engine cylinder block water jackets cracked.

SM 598,Oct ‘94 Engine Cooling System Troubleshooting l 01-2-l

 Main Table of Contents

ClRRK Group 01, Engine Cooling System

Section 3.

Engine Cooling System

Testing and Maintenance

Engine Coolant Level Check ......................................................................................................... 2

Adding Coolant ................................................................................................................................ 3

3
Cooling System Inspection ............................................................................................................

Cooling System Tests ..................................................................................................................... 4

Testing the Radiator Cap ................................................................................................................. 4
Testing Radiator and Cooling System ............................................................................................. 4
Testing the Thermostat ................................................................................................................... .4

Engine Coolant Change ................................................................................................................. 5

Draining Radiator and Cooling System ........................................................................................... 5
Cleaning and Flushing Cooling System ........................................................................................... 6
Filling Cooling System .................................................................................................................... 6

The engine coolant fan, on all internal combustion engines, can cause
extensive injury and bodily harm. Keep hands, arms and clothing away
from a spinning fan. Also, don’t stand in line with a spinning fan.

SM 598,Oct ‘94 Engine Cooling System Testing and Maintenance l 01-3-l

 Main Table of Contents
Group 01, Engine Cooling System
D! CAUTION
SAFE PARKING. Before working on truck:
Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
Put upright in vertical position and fully
lower the forks or attachment.
Put all controls in neutral. Turn key switch
OFF and remove key.
Apply the parking brake and block the
wheels.
Engine Coolant Level Check
A! CAUTION
Use extreme care when removing the cap
from the radiator. Never remove the radia-
tor cap from a hot engine. It is a good
safety practice to use a shop cloth over the
cap as shown if there is any possibility of
pressure being present. Turn cap to the
first stop and note if any steam is released.
When you are sure all pressure has been
released, press down on the cap with the
cloth in place, turn and remove the cap.
Stand clear of the radiator opening; hot
coolant can splash out. Steam or hot cool-
ant can cause severe burns. Failure to fol-
low these instructions could result in seri-
ous personal injury and/or damage to the
cooling system or engine.
Heated coolant expands and is driven from the radiator into
the reservoir. The engine must be cooled for at least 4 hours
before the coolant will flow back to the radiator. To check
the coolant levels in the engine:
1. Park the truck as described in “Safe Parking.”
01-3-2 l Engine Cooling System Testing and Maintenance
ElaRK
2. Open the engine cover and check the coolant level in
the reservoir:
l When at operating temperature, the coolant level
must be within the hot range mark.
l When cold, the coolant level must be within the
cold range mark.
Hot
Range
Mark
Cold Range Mark
3. Remove the radiator cover. See Group 38 for instruc-
tions.
4. Use a rag to cover the radiator cap and turn to the first
stop to release any steam. Let all pressure and steam
run out of the radiator before removing the cap.
5. Check the coolant level in the radiator, coolant level
should be to the bottom of the filler neck opening.
6. Fill the reservoir and radiator to the correct level of
coolant and close tightly.
IMPORTANT
Do not overfill the system. If necessary,
wait 4 hours or until the engine is com-
pletely cool before adding coolant to the
correct levels in the reservoir and radiator.
The cooling system should be filled at all times with a 50%
water and 50% ethylene glycol, permanent-type antifreeze
solution containing rust and corrosion inhibitors. Plain wa-
ter may be used in an emergency, but should be replaced
with specified coolant as soon as possible to avoid damage
to the system or engine. When only water is used in the
system, do not let the engine run hot.
NOTE
Do not use alcohol or methanol antifreeze.
Add coolant as required. If frequent refilling or as much as
a quart is required at one time, inspect cooling system for
leaks.
SM 598,Oct ‘94
 Main Table of Contents
emu
Adding Coolant
1. The coolant level should be at the cold mark on the
coolant reservoir when the engine is cold.
NOTE
Fork lift truck applications require also
checking the coolant level directly in the
radiator. Lift truck radiators will plug up
and overheat which forces coolant into the
overflow bottle and on out at the vent. This
results in a low coolant level which may
cause overheating.
2. Coolant level in the radiator should be checked daily
(or before each shift of operation) to make sure the
radiator is full at all times. Radiatoris full when coolant
level is at the bottom edge of the filler neck opening.
n ! CAUTION
Use extreme care when removing the cap
from the radiator. When checking coolant
level in the radiator, use a rag over the cap.
Turn cap to the first stop and allow all
pressure and steam to be released.
If the cooling system requires the addition of a large
quantity of coolant and the engine has been overheat-
ing, perform the following cooling system inspection.
Cooling System Inspection
Check water pump, thermostat, radiator, andall plumb-
ing for leaks.
n ! CAUTION
Use extreme care when removing the cap
from the radiator. When checking coolant
level in the radiator, use a rag over the cap.
Turn cap to the first stop and allow all
pressure and steam to be released before
removing cap.
Remove the radiator cap. See CAUTION above.
Inspect the condition of the coolant. Look for exces-
sive contamination, rust, oiliness, or gummy deposits
in the coolant solution. The coolant should have aclean
appearance.
Check the planned maintenance time interval (operat-
ing hours), or the condition of the coolant to determine
if it needs to be changed (drained and replaced).
SM 598,Oct ‘94 Engine Cooling System Testing and Maintenance
Group 01, Engine Cooling System
5. Inspect the radiator cap. Check condition of the upper
and lower seals. Check the seal holder and spring for
correct movement and operation. The rubber seal face
should be clean and undamaged. Look for nicks or
cracks in the seals. Replace the cap if the seal is
defective. Cap should have a pressure rating of 96 kPa
(14psi)nominaland89-103kPa(13-15psi)limits. See
“Cooling System Tests” in this Section for procedures
to test the radiator cap.
6. Inspect the radiator cap sealing surfaces located in the
radiator filler neck. Look for nicks, deep scratches, or
damage which may cause radiator cap leakage.
7. Inspect the overflow pipe and tubing for clogging,
damage, or wear. Clean the overflow pipe. Remove
any contaminants that can cause restriction. Replace
the tubing if it is faulty.
8. Inspect and clean the overflow bottle (reservoir) as
needed.
9. Inspect the inlet and outlet hoses for damage, cracks,
wear, or evidence of collapsing. Inspect hose clamps to
determine if they need to be replaced.
10. Use a coolant tester to test the low temperature protec-
tion level (the proportion of ethylene glycol to water)
of the coolant solution. Add coolant solution (anti-
freeze or water) to provide maximum protection (501
50 mixture).
‘. .,
,’
I
:
.,
., ,’
: ,”
I
%.; *.-
NOTE
A coolant solution containing 50% ethyl-
ene glycol provides freezing protection to -
37’ C (-34’ F). Refer to Service Informa-
tion Bulletin, SI-01-207-78 for more infor-
mation on the use of antifreeze.
l 01-3-3
 Main Table of Contents

Group 01, Engine Cooling System CIRRK

11. If the engine has been requiring the addition of large 2. The gauge pressure reading should hold within the
amounts of coolant: specified limits of the cap relief pressure. Cap should
have a pressure rating of 96 kPa (14 psi) nominal and
Inspect the radiator for blockage of airflow through
89- 103 kPa ( 13- 15 psi) limits. If the test relief pressure
the fins. Air clean the radiator.
either exceeds or is below the specified limits, replace
Check the tailpipe. Be sure exhaust flow is not the cap with a new Clark part.
blowing into the radiator. Make sure all baffles
and shrouds are in place.
Check fan belt and cooling fan.
Testing Radiator and Cooling System
Check and make sure the fan is not installed 1. Pressure test the radiator and cooling system to deter-
backward. The coined imprinting on the fan blades mine if it will hold the correct pressure without leaks
should be facing the engine for correct operation. or failure. Wet the rubber sealing surfaces and install
the tester cap tightly on the radiator fill neck. Apply
Check engine oil to see if it contains coolant.
pressure to the cooling system equal to the radiator cap
Check the radiator cap to see that it has the correct specified relief pressure of 96 kPa ( 14 psi) nominal and
rating. 89-103 kPa (13-15 psi) limits.
Pressure test the radiator and cooling system. See
“Cooling System Tests” in this Section for proce-
dures to test the radiator and cooling system.
Repair any leaks or blockage.
Test the engine thermostat. See “Cooling System
Tests” in this Section for procedures to test the
thermostat. Replace the thermostat if faulty.

Cooling System Tests

If the need is indicated for further maintenance and testing
of the cooling system, check for both external and internal
leaks in the cooling system with an accurate pressure pump
and gauge tester.
Testing the Radiator Cap
1. Pressure test the radiator cap to determine if it is
holding the correct pressure. Wash the cap in clean
water to remove any dirt or scale from the valve sealing
surfaces. Wet the rubber sealing surface and install the
cap tightly on the tester. Pressurize the tester and
radiator cap.
- l
2. Observe the gauge reading for approximately two
minutes. The pressure should not drop during this time.
If pressure drops, check for leaks in the radiator, hoses,
connections, and the engine components.
Testing the Thermostat
1. Remove and test the engine thermostat to determine if
it closes correctly and opens at the correct temperature:
Gas/LPG/CNG
Open (cracking) at 82’C + 1.5’ (180’F f 2.7”)
l Fully open at 95°C (203°F).

Diesel
l Open (cracking) at 76.5”C + 1.5” (170°F + 2.7’)
l Fully open at 90°C (194’F).

01-3-4 l Engine Cooling System Testing and Maintenance SM 598,Oct ‘94

 Main Table of Contents

CIRRK Group 01, Engine Cooling System

2. Fully immerse the thermostat in a pan of water. Heat 3. Place a hose on the drain valve nipple and run to the
the pan slowly while stirring the water to produce an drain pan. Open the coolant drain valve on the engine
even temperature. Use a thermometer to measure the block.
temperature at which the thermostat valve cracks (starts
to open) and when it is fully open. If the test results are
not to specification, replace the thermostat.

3. Replace the thermostat even if a slight opening of the

Gas/L.PG Engine Coolant Drain Valve
valve at normal temperature is found or if its appear-
ance shows any breakage. If the sensing part is dam-
aged, the thermostat valve will remain closed. Drain
Valve

Engine Coolant Change

NOTE -Fly-
Drain and replace the engine coolant after wheel
2000 hours of operation or once a year.
System coolant capacities are listed in Sec-
tion 1. Hose

Draining Radiator and Cooling System

To drain the radiator and cooling system:
Remove the radiator cap.
n ! CAUTION
Allow engine to cool first, then use extreme
care when removing the cap from the ra-
diator. Use a rag over the cap, turn cap to
the first stop, and allow all pressure and
steam to be released.
Diesel Engine Coolant Drain Valve
IMPORTANT
Dispose of the fluid in accordance with the
manufacturer’s and state and local regula-
tions.
4. Inspect coolant hoses and clamps to determine if they
need to be replaced.

Place a large, 20-liter @-gallon) drain pan under the

engine.

SM 598, Ott ‘94 Engine Cooling System Testing and Maintenance l 01-3-5
 Main Table of Contents

Group 01, Engine Cooling System ElRRK

Cleaning and Flushing Cooling System

NOTE
If the condition of the used coolant indi-
cates severe contamination, rust deposits,
scale, or oil in the system, determine the
cause’of the contamination and make sure
to clean and flush the cooling system with a Hot
Range
commercial cleaner. Choose a product from
Mark
a reliable manufacturer and follow all in-
structions for its use.

1. Close coolant drain valve in the engine block.

2. Fill cooling system and perform the cleaning and

flushing operation according to the manufacturer’s
instructions.

3. Drain the system completely again using the steps Mark

from “Draining Radiator and Cooling System.”
4. Remove the drain pan.
IMPORTANT
Dispose of the fluid in accordance with the
manufacturer’s and state and local regula-
tions.
Filling Cooling System
With the cooling system drained, the following procedure
should be used to insure complete fill:
Close coolant drain valve in engine block.
Fill the radiator to the bottom of the filler neck with
new coolant (50% water and 50% ethylene glycol,
permanent-type antifreeze solutioncontainingrust
corrosion inhibitors).
Install radiator cap securely.
Fill the coolant recovery bottle (overflow reservoir) to
the cold range mark line with new coolant.
Start and run the engine until the radiator upper hose is
warm, indicating the thermostat is open and coolant is
circulating through the system. Check for leaks at hose
connections and engine drain valve.
Turn engine off and check coolant level in radiator
again. Add coolant as required to fill to bottom of filler
neck.
/!/ CAUTION
Use extreme care when removing the cap
from the radiator. When checking coolant
level in the radiator, use a rag over the cap.
Turn cap to the first stop and allow all
pressure and steam to be released.
and Check coolant level in reservoir again. Add coolant as
required to fill to the Cold Mark on the bottle.
NOTE
To cycle coolant from the recovery bottle
into the radiator, mn the engine until it
reaches operating temperature, then stop
the engine. Check coolant level in the cool-
ant recovery bottle once the engine is again
cold.

Again inspect cooling system hoses, connections and com-

ponents for any leaks that may have developed when sys-
tem was fully pressurized.

01-3-6 l Engine Cooling System Testing and Maintenance SM 598,Oct ‘94

 Main Table of Contents

CIRRK Group 01, Engine Cooling System

Section 4.

Engine Cooling System and Alternator Belt Service

2
Belt Checks .....................................................................................................................................

Gas/LPG/CNG Truck Belt Removal ............................................................................................ 2

Fan Drive Belt Removal .................................................................................................................. 2
Alternator/Water Pump Belt Removal ............................................................................................. 2

Diesel Truck Fan and Alternator/Water Pump Belt Removal ..................................................

3

Gas/LPG/CNG Truck Belt Replacement ..................................................................................... 3

Alternator/Water Pump Belt Replacement ...................................................................................... 2
Fan Drive Belt Replacement.. .......................................................................................................... 2

Diesel Truck Fan and Alternator/Water 4

Pump Belt Replacement ...........................................

4
Belt Tensioning ..............................................................................................................................
Alternator/Water Pump Belt Tension (Gas/LPG/CNG Engines) ................................................... .4
Fan Drive Belt Tension (GasLLPGICNG Engines) .......................................................................... 5
Fan and Alternator/Water Pump Belt Tension (Diesel Engines). ................................................... .5

Fan Bearing

- Fan and Alternator/

Water Pump Belt
Water Pump
Belt
GadLPG Engine Cooling System Belts Diesel Engine Cooling System Belt

SM 598,Oct ‘94 Engine Cooling System and Alternator Belt Service l 01-4-l
 Main Table of Contents

Group 01, Engine Cooling System ClllRK

3. When you create enough slack in the fan bearing
A CAUTION support, slip the belt off the fan and engine pulleys.
SAFE PARKING. Before working on truck:
1. Park truck on a hard, level, and solid 4. Move a blade of the fan into place below the indenta-
surface, such as a concrete floor with no tion molded in the fan ring. Slip the belt over the fan
gaps or breaks. blade.
2. Put upright in vertical position and fully
lower the forks or attachment. Slip belt over
fan blade at
3. Put all controIs in neutral. Turn key switch
indentation in
OFF and remove key.
ring.
4. Apply the parking brake and block the
wheels.

Belt Checks 5. Rotate the fan so the next blade is under the indentation
To check the belts: and slip the fan over the blade. Continue around all the
fan blades. Pull belt out of venturi.
l Check belt tension by pushing and pulling on the span;
belt should move only about 4 mm (0.16 in). IMPORTANT
Use the fan pulley to turn the blades into
l Inspect belt and pulleys for damage.
position. Too much force can bend or break
l Belt must not have any cracks or ride in the bottom of the fan blades.
the pulley grooves.
l Be sure there is no oil on the belt.
Alternator/Water Pump Belt Removal
l A belt which has been slipping will be glazed and
cracked, and should be replaced. 1. Remove fan drive belt.
2. Loosen the locknut and back off the adjustment bolt on
Belt tensioning procedures follow belt removal and re-
the alternator mounting bracket to create slack in the
placement steps.
belt.

Gas/LPG/CNG Truck Belt Removal

Fan Drive Belt Removal

1. Tilt steer column forward, open the operator’s seat
deck, and remove the battery cables.
2. Back off the jam nut and the set screw from the top of
the fan bearing support. Loosen the mounting bolts
holding the fan bearing support and bracket in position
on the engine-mounted brackets.

3. Slip the belt off the alternator and engine pulleys.

4. Remove the belt over the fan as described above and
remove from venturi.

support

01-4-2 l Engine Cooling System and Alternator Belt Service SM 598,Oct ‘94
 Main Table of Contents

Group 01, Engine Cooling System

ElmK
Diesel Truck Fan and Alternator/Water 5. Tighten belt using adjustment bolt. Belt should deflect
only 4 mm (0.16 in) when resetting with the adjustment
Pump Belt Removal bolt. Tighten lock nut when correct belt deflection is
1. Loosen the bolt holding the alternator in place on the measured.
alternator mounting bracket.

Loosen bolt here

Alternator

Push the alternator in toward the engine to create slack

Fan Drive Belt Replacement
in the belt.
To replace the fan drive belt, the alternator/water pump belt
Slip the belt off the alternator/water pump and engine
must be installed first as shown above. Then:
pulleys.
1. Slip the fan drive belt into the venturi.
Move a blade of the fan into place below the indenta-
tion molded in the fan ring, work the belt over the fan 2. With a fan blade positioned at the fan ring indentation,
blades one at a time and pull it out of the venturi. slip the belt over the blade.
3. Continue to position the fan blades at the indentation
and work the belt over blades one at a time.
Gas/LPG/CNG Truck Belt Replacement
4. Seat the belt onto the fan and engine pulley and tighten
the fan bearing support mounting bolts to hold the belt
Alternator/Water Pump Belt Replacement and bearing support in position.

1. Slip the belt into the venturi.

2. With a fan blade positioned at the fan ring indentation,
slip the belt over the blade.

Use fan ring

indentation to
slip belt over fan
blades.

Bearing
support
3. Continue to position the fan blades at the indentation
and work the belt over blades one at a time. 5. Use the set screw to adjust the tension on the fan belt

IMPORTANT
and tighten the jam nut. Belt should deflect 4 mm (0.16
in) when adjusted correctly.
Use the fan pulley to turn the blades into
position. Too much force can bend or break 6. Torque the fan bearing support mounting bolts to 40-
the fan blades. 45 Nom (29.5-33.3 ft-lb).

4. Remount the belt over engine and alternator/water

pump pulleys.

SM 598,Oct ‘94 Engine Cooling System and Alternator Belt Service l 01-4-3
 Main Table of Contents

Group 01, Engine Cooling System EUlRK

NOTE
Diesel Truck Fan and Alternator/Water
New belts will lose a substantial amount of
Pump Belt Replacement the original tension in the first few hours of
1. Slip the belt into the venturi. operation as the belts seat into the pulleys.
Belt tension should be set initially upon
2. With a fan blade positioned at the fan ring indentation, installation, then checked and reset again
slip the belt over the blade. after a short period (8 hours) of engine
3. Continue to position the fan blades at the indentation operation.
and work the belt over blades one at a time.
IMPORTANT Alternator/Water Pump Belt Tension (Gas/
Use the fan pulley to turn the blades into LPGKNG Engines)
position. Too much force can bend or break
the fan blades. With the engine off:
1. Adjust the belt deflection to 4 mm (0.16 in). Turn the
4. Remount the belt over engine and alternator/water
adjusting bolt clockwise the increase the belt tension
pump pulleys.
and the adjusting bolt counterclockwise to decrease
5. Use a pry bar to gently force the alternator away from the belt tension.
the engine and put tension on the belt. Do not pry too
much because you will damage the alternator housing.
When the belt deflects 4 mm (0.16 in), tighten the bolt /> /- Water Pump
Ruler 7 ,
on the alternator mounting bracket.
Carefully pry
between
alternator and
engine.

L Crankshaft
Pulley
Measuring belt deflection with a ruler.

Belt Tensioning

A WARNING
Never attempt belt checks or adjustments
with the engine running.

Particular attention should be paid to V-belt tension, as

slipping belts are the cause of many other problems in
accessory drives as well as in the cooling system. Low belt
tension induces slipping and excessive belt and pulley wear.
A slipping belt does not drive the alternator to full output,
eventually leading to battery discharge problems. Exces- Alternator
sive belt tension creates an overload on the alternator front Pulley
bearing and in the water pump bearings.
Measuring belt deflection with a gage.
2. Tighten the lock nut.
3. Tighten the pivot bolt at the base of the alternator.

01-4-4 ’ Engine Cooling System and Alternator Belt Service SM 588, Ott ‘84
 Main Table of Contents

CMRK Group 01, Engine Cooling System

Fan Drive Belt Tension (Gas/LPG/CNG

Engines)
With the engine off:
1. Loosen set screw and jam nut on fan bearing support.
2. Loosen fan bearing support mounting bolts. Leave
enough torque on the bolts to hold the bearing support
in position.
Use the set screw to set the static belt tension by
deflecting span 4 mm (0.16 in).
Tighten the bearing support mounting bolts to 40-45
Nom (29.5-33.3 ft-lb).
Set the jam nut on the set screw to prevent the screw
from moving.

Fan and Alternator/Water Pump Belt Tension

(Diesel Engines)
With the engine off:
Use a pry bar wedged between the engine and the
alternator to pry out on the alternator and create tension
on the belt.

IMPORTANT
When tensioning the fan belt, apply pres-
sure to the alternator front housing only.

Measure static belt tension by deflecting span 4 mm

(0.16 in).
Tighten the alternator mounting bolt and pivot bolt
when tension on the belt is correct.

SM 598, Ott ‘94 Engine Cooling System and Alternator Belt Service l 01-4-5
 Main Table of Contents

ClmK Group 01, Engine Cooling System

Section 5.

Radiator Removal
and Replacement

Radiator Removal ..........................................................................................................................

2

Radiator Replacement ...................................................................................................................

4

.
p f- Cooling
\ / System
.

Pylons A3.2: Brace

Radiator

\ \

/-To Water Pump

\

Oil !

Seal

Cooling System - Cushion-Tire Truck

SM 598,Oct ‘94 Radiator Removal and Replacement l 01-5-l

 Main Table of Contents

Group 01, Engine Cooling System CUIRU

A CAUTION Brace -7
SAFE PARKING. Before working on truck:
1. Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
2. Put upright in vertical position and fully
lower the forks or attachment,
3. Put all controls in neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the
wheels.

Radiator Removal
The radiators on the cushion, pneumatic, diesel, and gas/
LPGKNG trucks are different from each other. However,
procedures for removing the radiator for service are basi- 6. Remove the two flange capscrews and washers secur-
cally the same. Any differences in the service procedures ing the upper fan shroud to the radiator.
will be noted in the instructions. The radiator and oil cooler
are separate. See Group 6 for transaxle oil-cooler removal.

NOTE
Servicing radiators is not covered in this
manual and radiator repair shops should
be consulted for service and repair of de-
fective radiators.

1. Do not attempt to remove the radiator when the engine

is hot. Wait until the system has entirely cooled down.

n ! CAUTION
Use extreme care when removing the cap
from the radiator. When removing the ra-
diator cap, use a rag over the cap. Turn cap
to the first stop and allow all pressure and
steam to be released.

Park the truck and block the wheels. Tilt the steering
7. Remove the two flange capscrews at the base of the
column forward and raise the operator’s seat deck.
upper fan shroud securing it to the lower fan shroud.
Remove the radiator cover and operator’s seat deck. Lift out the upper shroud and attached fan seal.
See Group 38 for procedures.

Drain the radiator/engine coolant as described in Sec-

tion 3.

Disconnect the overflow bottle hose from the filler

neck of the radiator. Remove the lock nuts holding the
clamps and hose to the cooling system brace. Secure
overflow hose out of the way.

01-S-2 l Radiator Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents

Glmu Group 01, Engine Cooling System

8. Remove the fan ring and venturi.
l For gas/LPG/CNG engines, remove the fan bear-
ing support assembly and lift out entire assembly.
10. Remove the two carriage bolts and nuts securing the
cooling system brace to the frame-mounted pylons.
Retain the rubber grommet used between the brace and
the radiator.

Bolt and Nut

11. Lift the radiator and radiator cushion brackets out from
the pylons.

support
Assembly
Cushion
GasLPG/CNG engine fan, venturi, and fan ring assembly. Bracket
l For diesel engines, unbolt the venturi from its
mounts and lift out venturi and attached fan ring.

Diesel engine venturi and fan ring assembly.

9. Loosen and remove water pump and thermostat clamps

and hoses from the ports of the radiator. Hose connec-
tion locations differ in cushion and pneumatic, gas and
diesel trucks.

SM 598, Ott ‘94 Radiator Removal and Replacement l 01-5-3

 Main Table of Contents
Group 01, Engine Cooling System EWRK

RadiatorReplacement 4. Reposition the upper radiator shroud and fan seal.

Make sure the fan seal is clipped securely to the fan
The radiators for the various truck models have their hose shroud and does not interfere with the shroud, fan, or
ports located at different positions. However, replacement fan ring.
procedures are the same for each of the radiators.
w Shroud
1. Fit the radiator cushion brackets onto the lower comers
of the radiator.

2. Slip the radiator between the mounting pylons. Make

sure the radiator is completely seated.

5. Replace the fan ring and venturi:

. For gas/LPG engines, set the assembly into place
and tighten the fan bearing support bracket bolts
to 40-45 Nom (29.5-33.3 ft-lb). See Section 4 to
set tension on belt.
-- Fan

3. Set the cooling system brace into place with the rubber
grommet positioned between the post of the radiator
and the hole in the brace. Insert carriage bolts between
braces and pylons. Tighten the two carriage bolt nuts
to 20-25 Nom (14.8- 18.5 f&lb).

Cooling

Place grommet
between brace
and top of radia- GasILPGICNG Fan, Venturi, and Fan Ring Assembly
tor.

01-5-4 l Radiator Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents

CIRRK Group 01, Engine Cooling System

l For diesel engines, set the venturi and attached fan 8. Reset the hose from the overflow bottle across the
ring into place on the engine and tighten the bolts cooling system brace. Refit the hose to the overflow
to 15-20 Nom (11.1-14.8 ft-lb). outlet on the radiator. Tighten the lock nuts for the
clamps to 8-10 Nom (6-7.5 f&lb).

9. Close engine drain cock and refill the radiator with a

mixture of 50% ethylene glycol (antifreeze) and 50%
Diesel Venturi and Fan Ring Assembly.
water as described in Section 3.
Replace the flange capscrews mounting the shroud to
10. Remount the radiator cover and operator’s seat deck.
the radiator. Tighten thecapscrews to 5-6 Nom (3.7-4.4
See Group 38 for instructions.
ft-lb).
11. Check the operator’s seat deck for correct .operation
IMPORTANT
once you have completed reassembly. Make sure the
Fan ring-to-shroud clearance should be 14
engine cover latch works correctly and securely.
mm (0.56 in). If belt is wrong size, clear-
ance will not be correct because fan drive 12. Once you have completed all the tests recommended
assembly will be too high or low when belt for radiator refill (see Section 3), check to make sure no
is adjusted tight. leaks are evident in the radiator hoses before returning
the truck to service.
Remount the water pump and thermostat hoses be-
tween theengine and radiator. Tighten the hose clamps
sufficiently to prevent leaks.

IMPORTANT
Use new hoses if cracking or drying is evi-
dent around the positions of the clamps or
if the hoses are deteriorated in any way.

SM 598,Oct ‘94 Radiator Removal and Replacement l 01-5-5

 Main Table of Contents

CmK Group 01, GM 3.0 L Engine Cooling System

Section 5a.

Radiator Removal
and Replacement
Radiator Removal .......................................................................................................................... 3

Radiator Replacement ................................................................................................................... 3

SM 598, Feb’98 Radiator Removal and Replacement l Ol-5a-1

 Main Table of Contents
Group 01, GM 3.OL Engine Cooling System
ElfIRK

Cooling
System
Brace

Pylons

Radiator

To Water Pump

To Thermostat 7

Cooling System - GM 3.0 Liter Engine

Ol-5a-2 l Radiator Removal and Replacement

SM 598, Feb’98
 Main Table of Contents
C1RRK Group 01, GM 3.0 L Engine Cooling System
A CAUTION
SAFE PARKING. Before working on truck:
1. Park truck on a hard, level, and solid surface, such as
a concrete floor with no gaps or breaks.
2. Put upright in vertical position and fully lower the
forks or attachment.
3. Put all controls in neutral. Turn key switch OFF and
remove key.
4. Apply the parking brake and block the wheels.
Radiator Removal
NOTE
Servicing radiators is not covered in this manual
and radiator repair shops should be consulted
for service and repair of defective radiators.
1. Do not attempt to remove the radiator when the engine
is hot. Wait until the system has entirely cooled
down.
A CAUTION
Use extreme care when removing the cap from
the radiator. When removing the radiator cap,
use a rag over the cap. Turn cap to the first stop
and allow all pressure and steam to be released.
Park the truck and block the wheels. Tilt the steering
column forward and raise the operator’s seat deck.
Remove the radiator cover and operator’s seat deck.
See Group 38 for procedures.
Drain the radiator/engine coolant as described in Sec-
tion 3.
Disconnect the ovefflow bottle hose from the filler
neck of the radiator. Remove the lock nuts holding the
clamps and hose to the cooling system brace. Secure
overflow hose out of the way.
6. Remove the two flange capscrews and washers secur-
ing the upper fan shroud to the radiator.
7. Remove the two flange capscrews at the base of the
upper fan shroud securing it to the lower fan shroud.
Lift out the upper shroud.
8. Loosen and remove water pump and thermostat clamps
and hoses from the ports of the radiator.
9. Remove the two carriage bolts and nuts securing the
cooling system brace to the frame-mounted pylons.
Retain the rubber grommet used between the brace and
the radiator.
10. Lift the radiator and radiator cushion brackets out from
the pylons.
SM 598, Feb’98
Radiator Replacement
The radiators for the various truck models have their hose
ports located at different positions. However, replacement
procedures are the same for each of the radiators.
1. Fit the radiator cushion brackets onto the lower comers
of the radiator.
2. Slip the radiator between the mounting pylons. Make
sure the radiator is completely seated.
3. Set the cooling system brace into place with the rubber
grommet positioned between the post of the radiator
and the hole in the brace. Insert carriage bolts between
braces and pylons. Tighten the two carriage bolt nuts
to 20-25 Nom (14.8-18.5 ft-lb).
4. Reposition the upper radiator shroud and fan seal.
Make sure the fan seal is clipped securely to the fan
shroud and does not interfere with the shroud, fan, or
fan ring
5. Replace the flange capscrews mounting the shroud to
theradiator.Tightenthecapscrews to5-6Wm(3.7-4.4
ft-lb).
IMPORTANT
Shroud clearance should be 14 mm (0.56 in). If
belt is wrong size, clearance will not be correct
because fan drive assembly will be too high or
low when belt is adjusted tight.
6. Remount the water pump and thermostat hoses be-
tween the engine and radiator. Tighten the hose clamps
sufficiently to prevent leaks.
IMPORTANT
1Jse new hoses if cracking or drying is evident
around the positions of the clamps or if the
hoses are deteriorated in any way.
7. Reset the hose from the overflow bottle across the
cooling system brace. Refit the hose to the overflow
outlet on the radiator. Tighten the lock nuts for the
clamps to 8-10 Nom (6-7.5 ft-lb).
8. Close engine drain cock and refill the radiator with a
mixture of 50% ethylene glycol (antifreeze) and 50%
water as described in Section 3.
10. Remount the radiator cover and operator’s seat deck.
See Group 38 for instructions.
11. Check the operator’s seat deck for correct operation
once you have completed reassembly. Make sure the
engine cover latch works correctly and securely.
12. Once you have completed all the tests recommended
forradiatorrefill (see Section 3), check to make sure no
leaks are evident in the radiator hoses before returning
the truck to service.
Radiator Removal and Replacement l Ol-5a-3
 Main Table of Contents

GROUP 02(LP)

GROUP 02(LP)

LPG FUEL SYSTEM

(CARBURETED)

LPG Fuel System Specifications

and Description ............................................................... Section 1

LPG Fuel System Troubleshooting ........... .................... Section 2

LPG Fuel System Adjustments and Maintenance ....... Section 3

LPG Carburetor and Throttle Body Removal

and Overhaul .................................................................. Section 4

LPG Vaporizer Removal and Overhaul ............ ........... Section 5 j

LPG Fuel Lock Removal and Overhaul ... .................... Section 6

SM 590,Oct ‘94 LPG Fuel System

 Main Table of Contents

ClmK Group 02(LP), LPG Fuel System

Section 1.

Fuel System Specifications and Description

(Carbureted LPG Fuel System)

LPG Tank ......................................................................................................................................... 2

Carburetor and Throttle Body .......................................................................................................... 4
Vaporizer-Regulator ........................................................................................................................ 5
Lock-Off Valve and Vacuum Switch .............................................................................................. 6
Governor .......................................................................................................................................... 7

Specifications

LPG Tank Vaporizer-Regulator

Capacity: 9.1,15.2, 19.7 kg (20,33-S, or 43.5 lb). PrimaryChamber Pressure: tank pressure to 10.3 kPa (1.5
psi).
Working Pressure: 138-1654 kPa (20-240 psi).
Secondary Chamber Pressure: 10.3 kPa (1.5 psi) to vapor
Safety Relief Valve: Opens when pressure exceeds 1896
outlet pressure.
kPa (275 psi).
Vapor Outlet Pressure: -38.1 mm (-1.5 in) water column.
Shut-off Valve: Manual with maximum withdrawal valve.
Maximum Withdrawal Valve: Closes when flow rate ex-
Lock-Off Valve
ceeds 5.7 Lpm (1.5 gpm).
Type: Solenoid-operated valve actuated by external vacuum
Fuel Gauge: Float level type.
switch.
Low Fuel Light: Instrument pod light comes on at 138 kPa
Filter element: Replace every 2000 hours.
(20 psi).

Fuel
Carburetor
HD-5 Propane
Type: Diaphragm-operated air-gas valve design with self-
contained air-fuel metering device
Idle air-fuel mixture: 0.30-0.70% CO (carbon
monoxide) @ 650 rpm.
Power Mixture: 0.6 to 1.5 % CO at converter stall.
Idle Speed: 650-700 rpm.
Maximum No-Load Governed Speed:
Standard Transaxle Truck: 2550-2650 rpm
Hydrostatic Transmission Truck: 2950-3050 rpm with
electronic governor control disconnected

SM 598, Apr ‘96 LPG Fuel System Specifications and Description . 02(LP)-l-1
 Main Table of Contents
Group 02(LP), LPG Fuel System
Description
The complete LPG (liquefied petroleum gas) system is
illustrated on the next page.
The LPG systems consist of a tank to hold the fuel under
pressure in a liquefied form, a lock-off valve to block flow
of fuel from the tank when the engine is not running, a
vacuum switch to operate the lock-off valve, a vaporizer-
regulator to lower the fuel pressure and allow the fuel to
become vapor, and a carburetor to mix the vapor with air
and feed the mixture to the engine.
The flow of air through the carburetor is controlled by the
throttle body, which is located between the carburetor and
the governor. The governor limits maximum engine rpm.
A water line from the engine cooling system circulates
warm engine coolant through the vaporizer-regulator to
counteract the frosting effect of the vaporizing fuel.
A hydrostatic relief valve relieves pressure in the fuel
lines should it build to a dangerous level. Another safety
valve on the tank relieves excessive tank pressure.
A balance line communicates pressure from the carburetor
air inlet to the vent port on the vaporizer-regulator.
A pressure switch on the fuel lock off valve sends a firel-
low signal to the LPG level light on the instrument pod
when the tank pressure falls below 138 kPa (20 psi).
Further details about the major fuel system components are
given on the following pages of this Section.
02(LP)-l-2 l LPG Fuel SystemSpecificationsand Description
CUlRU
LPG Tank
One end of the LPG fuel tank is equipped with a shut-off
valve, fuel gauge, safety relief valve, and vent valve.
Safety Relief
Vent Valve 7 j- Valve
Shut-Off
Valve
Float Filler Valve
The vent valve should be opened manually only when
filling or cleaning the inside of the tank.
The safety relief valve opens automatically when pressure
in the tank rises above 1922 kPa (275 psi). It closes when
the excess pressure is reduced.
The tank should always be mounted or stored so that the
relief valve is up or at top. The LPG tank mounting
bracket has a positioning pin that engages a mating hole in
the tank flange at the 6-o’clock position to ensure that the
tank is held in the proper position with relief valve up.
The fuel gauge is a float level type that indicates percent-
age of fuel remaining in the tank.
The shut-off valve is operated manually to control the
flow of fuel from the tank. The valve opens counterclock-
wise and closes clockwise. Threaded into its base is a
maximum withdrawal valve that closes automatically when
a large surge of fuel occurs, such as caused by a hose
bursting. At the end of each day’s operation, close the
shut-off valve no tighter than hand snug to avoid crushing
the valve seat.
A screw-type coupling is attached to the shut-off valve. It
requires no tools to operate. When disconnected, it auto-
matically seals off any flow through the valve and the
hose. For maximum safety, however, always close the
shut-off valve, mn the engine until it stops, and turn off
the ignition switch before disconnecting the coupling.
Maximum
Withdrawal Valve
Shut-Off Valve
SM 598,Oct ‘94
 Main Table of Contents

ClmK Group 02(LP), LPG Fuel System

Shut-Off Valve - Hvdrastatic Relief

Carburetor
f

Tank -_I

Balance Line

Vaporizer- -
Regulator

Fuel Line A\ Lock-Off Valve

LPG Fuel System

SM 598,Oct ‘94 LPG FuelSystemSpecificationsand Description l 02(LP)-l-3

 Main Table of Contents

Group 02(LP), LPG Fuel System EIRRK

Carburetor and Throttle Body

The LPG carburetor mounts on the throttle body, which
mounts on the velocity governor, which mounts on the
intake manifold. The carburetor requires no linkage or idle
vacuum line to the intake manifold.
Vacuum supplied from the throttle body operates the dis-
tributor timing advance and a vacuum switch that controls
the lock-off valve.
The proportions of air and gas allowed into the carburetor Diaphragm
are controlled by the air-gas valve that is fastened to the
diaphragm. The up and down positioning of the diaphragm
opens or closes the air-gas valve to a varying extent. The
positioning of the diaphragm is controlled by engine vacuum
@ y Air-Gas Valve
and spring force acting on the top of the diaphragm and
atmospheric pressure acting on the bottom. As engine
vacuum increases or decreases in response to throttle valve
position, the air-gas valve changes the quantity and relative Air Inlet
LPG
proportions (mixture) of air and gas entering the mixer.
inlet
From the mixer, the mixture is drawn into the engine through
the governor and intake manifold.
Balance
The air/gas valve assembly consists of an air valve and a Line
gas metering valve. The air valve meters air into the mixer. (vent)
The gas metering valve moves with the air valve to admit Port
the correct amount of fuel into the mixer. Mixtures between
idle and full-load are controlled by the gas metering valve Mixer
shape: lean mixtures at light loads and increasingly rich Power
mixtures at heavier loads and higher speeds. Mixture
Adjust-
Speed and load can increase to a point at which the gas my;; 2
metering valve fully withdraws from the jet. Then, the
major restriction to gas flow becomes the power mixture
adjustment, which is most effective at full load and de- Mixture
creasingly effective down to approximately one-half load Adjust-
where it no longer has much effect. ment

When the engine is initially cranked, a pressure drop under

the air valve opens it. This vacuum also actuates the fuel Throttle body
lock-off valve and the vaporizer-regulator to draw out fuel
from the LPG tank. With the engine running, the flow of air
through the carburetor is controlled by the throttle body, as
with any other carburetor. With the engine stopped, fuel
flow is sealed off within the carburetor as well as in the
vaporizer-regulator and fuel lock-off valve, giving a triple
sealforsafety.
Vacuum
The carburetor provides two ranges of mixture adjustments:
Connec-
l Idle Mixture Adjustment. The idle adjustment by- tions Throttle J
passes a portion of incoming air around the air valve Return Spring
opening. As the idle adjustment is opened, the air
valve partially closes, thereby closing the gas meter-
ing valve and leaning the idle air-fuel mixture.
l Power Mixture Adjustment. Full-power mixtures are
controlled by this adjustment. This adjustment must
LPG Carburetor and Throttle Body
be made with the engine under full or working load.

02(LP)-1-4 . LPG Fuel System Specifications and Description SM 598, act ‘94
 Main Table of Contents

CMRK Group 02(LP), LPG Fuel System

Vaporizer-Regulator
Balance Line
The vaporizer-regulator is a combined two-stage regulator (Vent) Port Primer Button
and vaporizer. It receives liquid fuel at tank pressure from
the fuel lock-off valve and reduces that pressure to slightly
less than atmospheric in two stages: the first stage is at the Q
primary regulator and the second is at the secondary regula-
tor. When the engine is cranking or running, a partial
vacuum is created in the fuel line to the carburetor, which
opens the regulator and permits fuel to flow to the carbure-
tor.
Each regulator stage has a valve operated by a diaphragm.
The balancing of spring and pressure forces on the dia-
phragm causes the valve to open or close in order to main-
tain specified pressure. Pressure in the primary chamber is
from tank pressure to 10.3 kPa (1.5 psi). Secondary cham-
ber pressure is from 10.3 kPa (1.5 psi) to vapor outlet
pressure, which is -38.1 mm (-1.5 in) water column.
In the process of reducing the pressure from approximately
150-l 80 psi in the tank to atmospheric pressure or slightly -4 I

below, the liquid propane expands to become a vapor, Vapor

causing refrigeration of the fuel. To compensate for this Outlet w f 1
and to assist in vaporization, engine coolant circulates
through a heat exchanger in the vaporizer-regulator body
and raises the temperature of the fuel as it enters the vapor-
izer. The vaporizer-regulator seals off fuel flow when the
engine is stopped.
The vaporizer-regulator uses a mechanical primer for cold
weather starts. The primer mechanically opens the second-
ary regulator valve to dispense gas when operated.
The vent port allows an external balancing pressure into the
secondary regulator. Rather than use atmospheric pressure
for the balancing pressure, a balance line communicates Valve Seat -
pressure from the carburetor air inlet to the vent port. This
pressure, which varies according to the condition of the air
filter and the routing of the air induction system, enables
the vaporizer-regulator to adjust the fuel supply to the Diaphragm
actual air supply.
NOTE
MODEL K vs MODEL J. Do not use Model
J parts in this vaporizer-regulator. Vaporizer-Regulator

SM 598, Apr ‘96 LPG Fuel System Specifications and Description l 02(LP)-1-5
 Main Table of Contents

Group 02&P), LPG Fuel System ClaRK

Lock=Off Valve and Vacuum Switch

The lock-off valve blocks flow from the LPG tank to the
remainder of the fuel system when the engine is not run-
ning.
The fuel path includes an orifice that is normally blocked
by a plunger. The plunger is held closed by spring force and
Solenoid
by pressure from the LPG tank. When the engine is run-
ning, engine vacuum activates a vacuum switch, which
passes current to the lock-off valve. This current energizes
a solenoid in the lock-off valve; this solenoid moves the
plunger off the orifice, allowing fuel to flow. The solenoid
is also energized by a connection to the ignition system,
which allows fuel to flow as the engine is starting.
A filter and magnet in the lock-off valve assembly removes
fuel contaminants from the supply stream. The filter must
be replaced and the magnet cleaned every 2000 hours.

Lock-Off Valve 7
Fuel
Valve Body Outlet
To vaporizer-

Magnet

source on
Filter
Element

-To fuel
Fuel Inlet tank
Vacuum 1
Switch
L To ignition
circuit

Lock-Off Valve Assembly Vacuum Switch and Lock-off Valve Electrical, Vacuum,
and Fuel Connections

02(LP)-l-6 l LPG Fuel System Specifications and Description SM 598, Apr ‘96
 Main Table of Contents

CIRRK Group 02(LP), LPG Fuel System

Governor
The velocity governor, or “governor,” limits maximum
engine rpm and is located between the carburetor throttle Stabilizer

1
Throttle Plate Piston
body and intake manifold. (On hydrostatic transaxle trucks
the governor’s function is normally overridden by the elec-
tronic control system.)
The governor has a throttle plate whose shaft is offset from
the center of the governor bore. The full-open position of
the throttle plate does not coincide with the true full-open
position, but leans to the closing side. This arrangement
enables the velocity pressure of the flowing mixture to
rotate the throttle plate in the direction of closing. The
resulting torque on the throttle plate stretches the return
spring linked to it until the torque balances the tension of
the spring, which maintains the throttle plate at that open- / Bush Nut--\ \
Return J L
ing angle. The spring tension can be adjusted with the Adjustment
Spring Screw
adjustment screw.
This balance between the air velocity pressure applied to
the throttle plate and the spring tension keeps the throttle Velocity Governor
plate at a position between full-open and full-closed to
control the amount of mixture flowing into the engine.
The throttle plate opening angle of this governor is set
under the full-open condition of the carburetor. Therefore,
as the carburetor throttle valve closes, pressure applied to
the governor throttle plate lessens and the governor throttle
plate rotates in the direction of opening, which causes
engine speed to increase. To prevent this, the governor has
a stabilizer piston that tends to close the throttle plate when
a large vacuum acts on the upper side of it.
The bush nut is for adjusting the preload on the return
spring in order to obtain the correct idle speed at maximum
no-load governed rpm. The adjustment screw is for adjust-
ing the number of active return spring coils (which changes
spring rigidity) in order to minimize hunting. “Hunting” is
a momentary surge in engine speed that occurs when en-
gine speed is increased from idle by quickly depressing the
accelerator pedal.
A small amount of hunting is a normal condition and does
not require governor adjustment. If the surge is prolonged,
however, it may be necessary to adjust the governor.

SM 598,Oct ‘94 LPG Fuel System Specifications and Description . 02(LP)-l-7

 Main Table of Contents

Group 02(LP), LPG Fuel System

Section 2.

Fuel System Troubleshooting

(Carbureted LPG Fuel System)

SM 598,Oct ‘94 LPG Fuel System Troubleshooting l 02(LP)-2-l

 Main Table of Contents

Group 02(LP), LPG Fuel System ClRRK

LPG System Check
A WARNING
If the engine does not start:
BEFORE WORKING ON TRUCK:
l Park truck in well-ventilated area. 1. Check that LF’G tank gauge and instrument panel
Park well away from or eliminate all light indicate tank has sufficient fuel in it. Open shut-
open flames, sparks, or other sources off valve on LPG tank.
of ignition. Position truck so LPG
tank is out of path of forced air heat- 2. Turn ignition switch to On.
ers and direct heat radiation. Do not 3. Remove vacuum line at throttle body and apply
smoke. suction on the vacuum hose to actuate the vacuum
l Have a MULTI-PURPOSE ABC type switch, which should operate the solenoid in the
fiie extinguisher (preferably dry pow- lock-off valve. If you hear the solenoid in the lock-
der) available and in good working off valve operate (“click”), electrical components
condition. ale OK; go to step 4.
l Use gloves on high-pressure frosted If you do not hear the solenoid, bypass the vacuum
lines or components. switch with a jumper wire. If solenoid operates,
vacuum switch is bad. If solenoid still does not
PreliminaryChecks operate, check voltage supply to vacuum switch
with voltmeter or test lamp. If voltage is present,
Since the carburetor has the least complicated function to
solenoid is bad and must be replaced
perform and has the fewest moving parts, examine every
other possibility of mechanical or electtical failure be-
fore removing the carburetor or tampering with carbure-
tor adjustments.
Vacuum Line Carburetor
A large percentage of all engine problems will be found
in the ignition system, air cleaner system, or the cooling to Throttle
system. To eliminate these possibilities, check the fol-
lowing:
1. Battery voltage (starter requires 9.6 volts, leaving
not enough for ignition system).
2. Ignition coil, plugs, wires, ignition timing.
3. Radiator coolant level, hoses, and thermostat.
4. Indicator lights on instrument panel.
5. Governed rpm.
6. Throttle travel. With the foot pedal fully down, there
must be a 1.1 mm (0.031 in) clearance between
throttle stop pin and stop screw.
7. Hoses. All LPG system hoses must be free of kinks
and breaks, and fittings are not leaking.

02(LP)-2-2 l LPG Fuel System Troubleshooting SM 598, act ‘94

 Main Table of Contents
In following steps, keep the ignition switch on and apply
suction to the vacuum switch:
4. Push primer button. Listen for a hiss: gas should flow
into the vapor line.
5. If gas does not flow into the vapor line, loosen fitting
between lock-off valve and vaporizer-regulator. If
gas leaks from fitting, the vaporizer-regulator valve
is defective (not allowing gas to flow through). See
overhaul procedure.
Symptoms and Causes
Engine Won’t Start
Tank shut-off valve closed.
Low or no fuel in tank.
Tank not positioned properly with pm at 6-o’clock.
Low battery voltage.
Quick-disconnect fitting failure at tank, plunger
missing, double gasket, or coupling missing.
Vacuum line loose, pinched or plugged.
Withdrawal valve closed.
Electrical or mechanical faihrre of lock-off valve or
vacuum switch.
Hard Starting
l Loss of vacuum in system.
l Secondary valve iu vaporizer sticking.
Erratic Idle
l Loss of vacuum in system.
l Primary valve in vaporizer-regulator defective.
l Air-gas valve diaphragm in carburetor stiff (inflex-
ible) .
Lack of Power
l Tank shut-off valve not fully open.
l Tank low on fuel-pulling vapor only.
l Lock-off valve filter plugged.
SM 598,Oct ‘94
Group 02(LP), LPG Fuel System
6. If gas does not leak Erom loosened fitting, loosen fuel
fitting at fuel line supplying fuel to lock-off valve. If
gas leaks from fitting, the lock-off valve is defective
(not allowing gas to flow through). See overhaul
_
procedure. - -
7. If gas does not leak from fitting the tank is empty or
shut-off.
Low vacuum in system.
Carburetor mounting loose on manifold.
Improper power jet adjustment.
Maximum withdrawal valve closed due to sudden
filling of fuel line after tank change. Close and
reopen tank shut-off valve.
Engine “Hunts” at Governed RPM
Secondary diaphragm in vaporizer-regulator stiff or
leaking.
Secondary valve in vaporizer-regulator dirty and
sticking.
Governor surge adjustment. (See governor adjust-
ment in fuel system adjustments Section).
Frost, Ice or Moisture on Lock-Off Valve
l Lock-off valve filter plugged.
l Maximum withdrawal valve closed.
Frost, Ice or Moisture on Vaporizer-
Regulator
Vaporizer coolant hoses improperly connected, bad
hoses or air lock.
Primary valve seat in vaporizer-regulator not seat-
ing.
Engine coolant level low.
NOTE
Recommended LPG fuel is HD-5 Pro-
pane.
LPG Fuel SystemTroubleshooting l 02(LP)-2-3
 Main Table of Contents

CIRRU Group 02(LP), LPG Fuel System

Section 3.

Fuel System Adjustments and Maintenance

(Carbureted LPG Fuel System)

General LPG Maintenance ......“.“............~..._.......................”.....~.......”.........._......~..~ ............ 2

LPG Tank Maintenance ................................................................................................................... 2
. Changing Tanks ............................................................................................................................... 2
LPG Fuel Lines ................................................................................................................................ 3
Fuel Line Support ............................................................................................................................ 3
Coolant Lines ................................................................................................................................... 3
Vacuum Connections ....................................................................................................................... 3

Carburetor Adjustment .................................................... ..“..._...._......~.................~~...........~ ... 4

Idle Speed Adjustment ..................................................................................................................... 4
Idle Mixture Adjustment .................................................................................................................. 4
Power Mixture Adjustment .............................................................................................................. 4

Governor Inspection and Adjustment .._....._.“.._.U”......._.......~_~..._.....~....._...~.~ ............... 5

Governor Inspection ......................................................................................................................... 5
Governor Adjustment.. ..................................................................................................................... 5
High Idle Speed (No-Load Governed Speed) Adjustment ...................................................... .5
Hunting Adjustment .................................................................................................................. 6

Linkage Check ...................~....................._...~.~......._..~.~”...“.....“.~.._...~.~.....~~.~..........~...... 6

Accelerator Cable Adjustment ..............“..........~..........“........”.....~...........................“............... 6

SM 598,Oct ‘94 LPG Fuel System Adjustments and Maintenance l 02(LP)-3-l

 Main Table of Contents

Group 02(LP), LPG Fuel System CICIRK

General LPG Maintenance

LPG Tank Maintenance

5. To install, place tank in mounting bracket and
guard. Make sure hole in tank valve guard flange
A WARNING lines up with and engages positioning pin on tank
LPG TANK STORAGE, REFILL, AND mounting bracket.
REPAIR. Do not store LPG fuel tanks
near heat or open flame. Do not store LPG To get maximum usage of fuel in tank, mounting
tanks upside down, whether full or empty. hole must be down at 6-o’clock position. Tank
Relief valve should be up (at top). bracket should be repaired to replace pin, if pin is
missing.
Fuel tanks should be filled only by quali-
fied personnel in accordance with local 6. Install and tighten withdrawal hose coupling by hand.
ordinances. Do not overtighten. Keep shut-off valve closed until
coupling is tight.
LPG tanks are explosive even when empty.
Federal and State regulations prohibit 7. Before tightening the clamps holding the tank in
welding or soldering to repair a damaged place, check the fuel gauge by moving the tank
LPG tank. Replace it instead. Do not re- slightly and observe the gauge. The gauge pointer
move any components from tank. should oscillate with the movement of fuel in the tank.
A defective gauge can be suspected if the pointer fails
Clean outside surface of tank with a clean cloth and kero- to move.
sene or equivalent petroleum solvent. Carefully check for
frosted areas and gas odor that would indicate leakage. 8. Close and latch the clamps holding tank in bracket
Open shut-off valve and again check for leakage at shut- 9. Carefully check for system leaks when the tank
off and quick-disconnect valves. shut-off valve is fu-st opened. A leak-detecting
solution may be applied to the connections to
locate a leak. (See next page.)
Changing Tanks
A WARNING
LPG FUEL IS HIGHLY FLAMMABLE
Park truck in a well-ventilated area. Never
change tanks when the engine is running.
Never smoke when changing tanks. Do not
smoke or perform maintenance near open
flame or other sources of ignition. Do not
disconnect any lines when exhaust mani-
fold is excessively hot. LP gas is highly
flammable.
1. Park truck safely.
2. Close shut-off valve on LPG tank, snug tight.
3. Run engine until it stops. Turn ignition switch
OFF.
NOTE
Running engine until it stops after closing
the shut-off valve burns the fuel from lines,
preventing fuel bleed-off to air.
4. Disconnect the outlet (withdrawal) hose coupling.
Pull down on each of the two latches to release the
tank from guard

02(LP)-3-2 l LPG Fuel System Adjustments and Maintenance SM 598,Oct ‘94

 Main Table of Contents
emu
LPG Fuel Lines
Only UL-approved high-pressure type LPG hose is used
between the tank and the vaporizer-regulator. The hose is
pressure and temperature stabilized, and specially for-
mulated to carry liquid petroleum gas. All other hoses in
the system are to Clark specification for vacuum or cool-
ant usage.
AWARNING
Use UL-approved hoses only. Never use
a substitute for UL approved LPG hose.
All lines in the LP Gas system should be inspected
periodically. generally every 30 days or every PM.
A WARNING
LPG FUEL IS HIGHLY FLAMMABLE
Park truck in a well-ventilated area. Do
not smoke or perform thii maintenance
near open flame or other sources of igni-
tion. Do not disconnect any lines when
exhaust manifold is excessively hot.
NOTE
An odorant is added to LP gas to help
detect leaking. If at any time this odor is
detected, shut the engine OFF and have
the leak fixed.
Wipe hoses and fittings with a clean cloth moistened
with kerosene or equivalent petroleum solvent.
Use soap and water or leak detector solution and check
hoses, connections, and assemblies with tank at least half
full. When hose assemblies with reusable fittings are
used, also test between the fitting ferrule and the hose.
SM 598,Oct ‘94 LPG Fuel System Adjustments and Maintenance
Group 02(LP), LPG Fuel System
When necessary to remove and replace fittings and hoses,
or to reseal connections:
1. Close shut-off valve on LPG tank, snug tight.
2. Run engine until it stops and turn ignition switch
OFF. Then open connection. This bums the fuel
from lines, preventing bleed-off to air.
Apply a I-IL-approved thread sealant to all fittings with
pipe threads (male threads only).
IMPORTANT
It is recommended to use only a pipe com-
pound in stick form (solid). Do not use a
liquid or plastic thread sealer; it may enter
the LPG lines during assembly.
Standard torque specifications do not apply to pipe threads.
When installing fittings:
1. Hand tighten fast.
2. Then tighten with a wrench l-1/2 turns to a maxi-
mum of 3 turns.
3. Pressurize the complete system and recheck for
leaks.
Fuel Line Support
Fuel lines must be supported by clamps, straps, or tape to
minimize chafing or wear.
Coolant Lines
Coolant hoses between engine and vaporizer-regulator
may be either clamp type or push-on type with reusable
fittings. Cut off bad portions of hose and strip from
fittings (or replace hoses). Push hoses firmly back into
position.
Vacuum Connections
The proper operation of the LPG system is based on
vacuum originating at the carburetor. To assure full avail-
ability of vacuum at all components, at scheduled PM
intervals:
1. Check vacuum hoses. Tighten clamps, clip off bad
ends, or replace hoses as required.
2. Tighten carburetor mounting flange bolts.
3. Tighten throttle body andcover screws to the carbu-
retor housing.
4. Check for loose intake manifold or leaking gasket.
l 02(LP)-3-3
 Main Table of Contents
Group 02(LP), LPG Fuel System
CarburetorAdjustment
Before you make any carburetor or fuel adjustments:
A clean air cleaner element and end cap should be
installed.
Ignition timing must be checked and set per specifi-
cation for LPG fuel operation.
Governor and idle speed must be set to specified
r-pm.
Engine and transmission should be at operating
temperatures.
The tank should contain HD-5 propane.
A
WARNING
LPG FUEL IS HIGHLY FLAMMABLE
Park truck in a well-ventilated area. Do
not smoke or perform maintenance near
open flame or other sources of ignition.
Do not disconnect any lines when exhaust
manifold is excessively hot.
Idle Speed Adjustment
With engine and tachometer connected, turn idle speed
screw until tachometer reads 675 rpm.
Idle Mixture Adjustment
1. Turning the screw IN makes the fuel mixture richer,
turning it OUT makes it leaner.
n
02(LP)-3-4 . LPG Fuel System Adjustments and Maintenance
ClRRK
IMPORTANT
The idle air-fuel ratio screw is sensitive
and should be changed (adjusted) only with
the use of a CO (carbon monoxide) exhaust
analyzer.
2. Set the idle air-fuel adjustment at 0.30 to 0.70 per cent
CO (carbon monoxide) @ 650 r-pmwith warm engine
and I-ID-5propane fuel.
Alternate Method: With warm engine running @ 650
rpm, turn idle air-fuel mixture screw OUT until engine
runs rough, then turn the idle air-fuel mixture screw IN
approximately l/4 to l/2 turn. Continue turning until
engine begins to run smooth.
Power Mixture Adjustment
Full-power mixtures are controlled by the mixture adjust-
ment at the fuel inlet of the carburetor (mixer). The fuel
mixer casting is marked with an “R&L” indicating the full
rich and lean positions of the valve. This adjustment con-
trols air-fuel mixture when gas metering valve during op-
eration is fully withdrawn from its jet. It is effective only
when the engine approaches full-load condition and can be
set only with the engine loaded and at or close to its rated
rpm limit-converter stall rpm.
If adjustment is necessary:
1. For standard transaxle trucks, operate engine at full
power stall condition, as described in Group 00. For
hydrsotatic transmission trucks disconnect the elec-
tronic control as described in Group 06(H) before
stalling the truck.
A! CAUTION
This procedure must be performed with
the parking brake off and the truck placed
against a solid barrier (such as a wall) to
prevent movement. Be careful that the truck
does not move unexpectedly when operat-
ing the engine and converter at stall.
To avoid excessive heat buildup, do not
operate engine at stall longer than neces-
sary to make carburetor adjustment,.
SM 598,Oct ‘94
 Main Table of Contents
ClRRU
2. For best performance, adjust power valve to 0.6-
1.0% CO at converter stall, using a CO analyzer.
Less than 0.6% CO improves emissions but reduces
power. (On cushion-tire trucks insert analyzer probe
in port near the flexible exhaust pipe coupling.)
An alternate method is to back off adjustment to lean
side of best power at stall until rpm drops about 20-
25 rpm for low CO.
3. Readjust idle air-fuel mixture after power adjust-
ment is made.
Governor Inspection and Adjustment
A velocity (air) governor is used on the truck. The function
of the governor is to limit the maximum speed of the engine
to:
l Protect the main hydraulic pump.
l Limit the maximum travel speed of the truck.
l Prevent runaway or excessive engine rpm.
On hydrostatic transmission trucks, the governor’s func-
tion is normally overridden by the electronic control sys-
tem.
IMPORTANT
GOVERNOR ADJUSTMENT AND
OVERHAUL RESTRICTIONS.
Normally, adjustment of the governor is
not required. The correct no-load governed
speed setting adjustment is made at the
factory and the governor sealed before ship-
ment. All operators should be instructed
not to break the seal to tamper with the
governor.
If troubleshooting proves the governor to
be defective, replace the governor. Do not
attempt to overhaul the governor.
When engine speed is increased from idling speed by push-
ing on the accelerator pedal quickly, slight variation (“hunt-
ing”) in engine speed may occur.
A small amount of hunting is a normal condition and does
not require governor adjustment. However, if the surge is
prolonged, it may be necessary to adjust the governor.
Governor Inspection
1. Clean the entire governor before disassembly.
2. Remove side cover.
3. Do not use gasoline or similar solvent when cleaning
the throttle plate shaft (to prevent deterioration of
greaseenclosedintheneedlebearingsattheendsofthe
shaft).
SM 598,Oct ‘94 LPG Fuel System Adjustments and Maintenance
Group 02(LP), LPG Fuel System
4. Check carefully for smooth action of the coupling
between the stabilizer rod and throttle plate. If any
stiffness is found, replace the governor assembly.
Stabilizer Rod
I- ?
\-Throttle Plate
5. Count the active spring coils. The typical number of
active coils is 14 and should be no less than 11
6. Look for broken or misaligned parts and realign the
parts or replace the governor if necessary.
7. Reinstall cover with a new gasket.
Governor Adjustment
NOTE
Governor adjustment should be made with
a warm engine mnning at normal operating
temperature. Be sure there is no load placed
on the engine (transmission and hydraulic
controls in neutral).
On HYDROSTATIC TRANSMISSION
trucks, the electronic governor control must
be disco~ected as explainedin Group 06(H).
High-idleSpeed (No-LoadGovernedSpeed)
Adjustment
The governor adjusting screw and bush nut are en-
closed with a rubber protective cover. Loosen the
retaining screw and remove the protective cover.
With engine running and all hydraulic and direction
controls in neutral, push accelerator pedal fully down
and hold. The carburetor throttle valve must be in the
wide-open throttle position.
Hold the adjusting screw to prevent it from turning.
Turn the bush nut to adjust the engine speed to:
l 2600 rpm (range: 2550-2650 rpm) for the stan-
dard transaxle truck
l 3000 r-pm(range: 2950-3050 rpm) for the hydro-
static transmission truck, with the electronic gov-
ernor control disconnected.
- ,R
,-Bush Nut
Adjusting
Screw
(Cover Off)
l 02(LP)-3-5
 Main Table of Contents
Group 02(LP), LPG Fuel System
Turn bush nut clockwise to increase speed (spring preload
is increased). Turn bush nut counterclockwise to decrease
speed (spring preload decreased).
Hunting Adjustment
This adjustment should be performed only if indicated by
troubleshooting. Set the high idle speed (see page 5), then:
1. With engine running and all hydraulic and direction
controls in neutral, fully depress the accelerator pedal
and hold The carburetor throttle valve must be in the
wide-open throttle position.
2. Turn the adjusting screw gradually clockwise until
huntingceases(enginerunsatasteady,constantspeed).
3. As a result of step 2, the engine speed may have
increased to an excessively high level. Check and
adjust high idle speed as explained on page 5.
4. Operate the accelerator to check for hunting.
5. Repeat steps 2 through 4 until hunting and high idle
speed are satisfactory.
NOTE
Turning the adjusting screw clockwise in-
creases return spring rigidity (number of
spring active coils decreases).
Turning counterclockwise decreases spring
rigidity (number of active coils increases).
Although, increasing the spring rigidity re-
duces hunting, excessive increase of spring
rigidity changes governor characteristics,
affecting engine output. Therefore, you
should limit movement of the adjusting
screw to less than two turns in either direc-
tion from the standard position.
When the adjustment is correct, the num-
ber of active return spring coils typically
should be about 14, and no less than 11. If
the hunting adjustment is not providing
the expected response, inspect the spring
as described previously.
Largerspringrigidity
F
-;
I
I-
Smallerspringrigidity
_I I NOTE
I
B I
; I
B
d
- Engine speed, fpm
02(LP)-3-6 . LPG Fuel System Adjustments and Maintenance
ElRRK
MPORTANT
HYDROSTATIC TRANSMISSION
TRUCKS. The throttle linkage for the
standard transaxle truck is covered in
this Section. If you are servicing a hy-
drostatic transmission truck, refer to the
control system Section in Group 06(H)
for information about checking and ad-
justing throttle linkage.
LinkageCheck
Refer to illustrations on next page.
1. Turn off the engine and safely park the truck.
2. Depress the accelerator pedal roller and check for free
movement of the entire throttle linkage. Lubricate and
repair as needed.
3. Check accelerator pedal travel: Move the accelerator
pedal to the fully-down position. If the pedal stops
before it hits the floorplate, the accelerator cable is
adjusted too short.
4. Check throttle stop gap at carburetor: Hold the pedal
fully down and check the gap between the throttle stop
pin and stop screw. If the cable has a spring on the
pedal end, there should be no gap and no deflection of
the spring. If the cable does not have a spring on the
pedal end, gap should be 1.6 mm (l/l 6 in).
AcceleratorCable Adjustment
With the floorboard installed:
1. Loosen the jam nut at the accelerator cable bracket.
2. Press the accelerator pedal to the floor. Adjust the set
nut to obtain the proper throttle stop gap:
l If the cable has a spring on the pedal end, there
should be no gap and no deflection of the spring.
l If the cable does not have a spring on the pedal
end, gap should be 1.6 mm (l/16 in).
3. Retighten the jam nut
Perform the check procedure.
4.
Make sure no hoses or other items bind
against the throttle linkage.
SM 596, Apr ‘96
 Main Table of Contents

ElmK Group 02(LP), LPG Fuel System

Accelerator Pedal Mounting. No adjustment.

IMPORTANT Jam Nut

HYDROSTATIC TRANSMISSION
TRUCKS. The bottle linkage for the Bracket
standard trawaxle truck is covered in
this Section. If you are servicing a hy-
drostatic transmission truck, refer to tlie Throttle Lever (at
carburetor)
control system Section in Group 06(H)
for information about checking and ad-
justing throttle linkage. Linkage at Carburetor. Adjust with set nut.

Accelerator Cable
with and without
Spring

Pedal Lever

Linkage at Accelerator Pedal. Pedal rests on roller. No adjustment.

SM 698, Apr ‘96 LPG Fuel System Adjustments and Maintenance l 02(LP)4-7
 Main Table of Contents

EmK Group 02(LP), LPG Fuel System

Section 4.

LPG Carburetor and Throttle

Body Removal and Overhaul

Carburetor and Throttle Body Removal ..“....................................._.........._ .............................. 2

Carburetor and Throttle Body Installation .............. .._............................................................... 2

Carburetor Overhaul ...._.“........._........“.....“................................”.....~ ....................................... 3

Cleaning and Inspection ................................................................................................................... 3
Disassembly and Assembly ............................................................................................................. 3

Throttle Body Overhaul .............. ..“_.._..........~............~............~...“.....~_...............~ ............... 4

Disassembly ..................................................................................................................................... 4
Assembly.. ........................................................................................................................................ 4

Adjustments after Overhaul .........“.I..“.........................”..._.......”.................~.....~.................~ . 4

A
WARNING
LPG FUEL IS HIGHLY FLAMMABLE.
Park truck in a well-ventilated area. Never
change tanks when the engine is running. Never
smoke when changing tanks. Do not smoke or
perform maintenance near open flame or other
sources of ignition. Do not disconnect any lines
when exhaust manifold is excessively hot.

A
WARNING
DO NOT STORE LPG FUEL TANKS NEAR
HEAT OR OPEN FLAME. Fuel tanks should
be filled only by qualified personnel in accor-
dance with local ordinances. Do not remove
any components from tank.

SM 598,Oct ‘94 LPG Carburetor Removal and Overhaul l 02(LP)-4-1

 Main Table of Contents
Group 02(LP), LPG Fuel System
Carburetor and Throttle Body Removal
1. Park truck safely in a well-ventilated area.
2. Close shut-off valve on LPG tank, snug tight.
3. Startandrunengineuntilitstops.Tumignitionswitch
OFF. This burns the fuel from lines, preventing fuel
bleed-off to air.
4. Disconnect battery ground cable from the engine
ground connection to prevent accidental sparking.
5. Disconnect accelerator linkage, return springs, etc.,
from carburetor.
6. Disconnect air, balancer, timing advance, and fuel
lines from carburetor and throttle body.
7. Remove carburetor and throttle body from engine
mounting. Separate throttle body and carburetor and
discard gaskets.
r Carburetor
02(LP)-4-2 l LPG Carburetor Removal and Overhaul
CUlRK
Carburetor and Throttle Body
Installation
1. Mount carburetor to throttle body using anew gasket.
Install mounting washer and nuts and torque to 20-25
Nom (15-18 ft-lb).
2. Mount throttle body to governor using a new gasket.
3. Connect air, balancer, timing advance, and fuel lines
to carburetor and throttle body (observe notice be-
low.)
IMPORTANT
Overtightening hose fittings may crack the cast-
ings.
4. Connect governor and throttle linkage. (Refer to the
adjustments Section of this Group for procedue.)
5. RecOMeCt battery ground cable at engine ground
connection.
6. Open shut-off valve at LPG tank, and start engine.
Push primer button on vaporizer-regulator if neces-
sarY*
7. Test all connections for leaks with soap and water, or
leak detector solution, with the LPG tank at least half
full.
8. When engine is at operating temperature, adjust car-
buretor according to instructions in the adjustments
Section of this Group.
NOTE
HOSE CONNECTIONS: At instal-
lation, be sure to apply UL-approved
thread sealant to all fittings with pipe
threads (male threads only). To avoid
getting sealant in line, do not place
_A sealant on final thread of fitting.
( Lightly snug fittings.
SM 598,Oct ‘94
 Main Table of Contents

ElfIRK Group 02(LP), LPG Fuel System

Carburetor Overhaul Disassembly and Assembly

Remove carburetor parts as follows. Assembly is the re-
verse of disassembly. Perform adjustments on next page
after assembly.
1. Cover.
2. Air valve spring.
Air Valve - 3. Air valve diaphragm assembly. Diaphragm must be
oriented with position mark pointing toward LPG
inlet.

.
-(i7J(
O
0
Diaphragm

43
Position
.A \
Mark

a $,
C \ LPG Fuel
‘8’
Inlet
0 0

4. Idle adjustment screw.

5. Idle adjustment screw spring.
NOTE
Always use a Clark repair kit and new gaskets
when rebuilding the carburetor. Discard old parts
that will be replaced. Repair kit includes com-
plete air valve diaphragm assembly. Use only the
parts specified for this truck model.

Idle Mixture
Cleaning and Inspection
Adjustment Screw 1. Wash ail parts in kerosene or equivalent petroleum
solvent. Dry with compressed air.

A! CAUTION
Do not use carburetor cleaner or lacquer thin-
ner. These products will continue to attack spe-
cial coatings or synthetic rubber seals after reas-
sembly. Do not soak throttle body in cleaning
solution. The oilite bushings may be damaged.

2. Inspectallsmfacesforcracks,nicks,andburrs.Check
springs for damage.
3. Remove any nicks and burrs from sealing surfaces
with a sharpening stone.
if
4. Replace damaged parts. However, threads are dam-
aged, you may retap holes and/or replace screws. Be
sure blind hole threads are clean full depth.

SM 598,Oct ‘94 LPG Carburetor Removal and Overhaul l 02(LP)-4-3

 Main Table of Contents

Group 02(LP), LPG Fuel System ElRRu

Throttle Body Overhaul Adjustments after Overhaul

At time of carburetor overhaul, the throttle body nor- 1. Turn idle mixture adjusting screw in lightly against
mally requires only cleaning. However, if throttle shaft seat, then back off 3 turns for initial setting.
assembly fit is sloppy, you should overhaul it. -

Idle
Mixture
Screw

2. Adjust idle speed screw to open throttle valve 1.6

mm (l/16 in).

Idle

ABCDEFG HI JKLMNOp

A Plug I Seal
B Retainer J Washer
C Washer K Washer
D Washer L Throttle Spring
E Seal M Bushing
F Screw N Bushing
G Throttle Plate 0 Shaft Spring
H Shaft P Actuator
Q Housing Boss
L Turn idle speed
Disassembly screw to obtain 1.6
1. Remove in this order: A, B, F, G. mm (l/l6 in) gap
here.
2 Unhook L from P and Q.
3. Remove shaft assembly (H and P). 3. Perform final adjustments after installing carbure-
4. Remove remaining contents from housing. tor andthrottlebody as describedin the adjustments
Section of this Group.
Assembly
1. Install in this order: I, J, K, 0, M, L, N.
2. Install shaft assembly (H and P) through previously
installed parts, hooking L over P and Q.
3. Install in this order: E, D, C, B, A.
4. Install G into H while keeping shaft assembly (Hand
P) shifted toward side P is on.
5. Install F (two screws) with Loctite 242 (Clark part
#1802300) and torque to 1.1 Nom (10 in-lb).

02(LP)-4-4 . LPG Carburetor Removal and Overhaul SM 598,Oct ‘94

 Main Table of Contents

CmK Group 02(LP), LPG Fuel System

Section 5.

Vaporizer-Regulator
Removal and Overhaul
(LPG Carbureted Fuel System)

Removing the Vaporizer-Regulator ...........N..._..._......~.............._........................~....”......._..... 2

Installing the Vaporizer-Regulator ......I.......................~..........” ................................................. 2

Overhauling the Vaporizer-Regulator “.......U.......U..................~_............................................... 3

Disassembly/Assembly .................................................................................................................... 3
Cleaning and Inspection ................................................................................................................... 4
Tests after Reassembly .................................................................................................................... 4

A
WARNING
LPG FUEL IS HIGHLY FLAMMABLE. Park
truck in a well-ventilated area. Never change
tanks when the engine is running. Never smoke
when changing tanks. Do not smoke or per-
form maintenance near open llame or other
sources of ignition. Do not disconnect any lines
when exhaust manifold is excessively hot.

A
WARNING
LPG STORAGE: Do not store LPG fuel tanks
near heat or open flame. Fuel tanks should be
fdled only by qualified personnel in accordance
with local ordinances. Do not remove any com-
ponents from tank.

SM 598,Oct ‘94 LPG Vaporizer-Regulator Removal and Overhaul l 02(LP)-5-l

 Main Table of Contents
Group 02(LP), LPG Fuel System
Removing the Vaporizer-Regulator
1. Park truck safely, as noted on page 1.
2. Close shut-off valve on LPG tank, snug tight.
3. Start and run engine until it stops. Turn ignition
switch OFF. This burns the fuel from lines, prevent-
ing bleed-off to air.
4. Disconnect battery ground cable from the engine
ground connection to prevent accidental sparking.
5. Drain the radiator as described in Group 01.
6. Disconnect the fuel, water, and balance lines from
the vaporizer-regulator. Put caps on or plugs in the
ends of the lines to prevent entrance of dirt
7. Remove mounting bolts and vaporizer-regulator from
truck mounting.
Balance Line
\
Torque 20-25 Nom (15-18 in-lb)
02(LP)-5-2 l LPG Vaporizer-Regulator Removal and Overhaul
ElfIRK
Installing the Vaporizer-Regulator
1. Place the vaporizer-regulator in its mounting posi-
tion. Install and securely tighten mounting bolts.
2. Connect fuel and water lines.
NOTICE
At installation, be sure to apply UL-ap-
proved thread sealant to all fittings with
pipe threads (male threads only). Lightly
snug fittings/
IMPORTANT
Overtightening hose connections may
crack the castings.
3. Refill the radiator with specified coolant as de-
scribed in Group 0 1.
4. Reconnect battery ground cable at engine ground
connection.
5. Open fuel shut-off valve at LPG tank, and start
engine. Push primer button on vaporizer-regulator if
necessary.
6. Test ah connections for leaks with soap suds, or leak
detector solution, with tank at least half full.
SM 598,Oct ‘94
 Main Table of Contents

Group 02(LP), LPG Fuel System

Overhauling the Vaporizer-Regulator

Overhaul includes disassembly, cleaning and inspection,
and reassembly using the Clark Repair Kit. Procedures
are given below.
Secondary Fulcrum
Regulator Cover Secondary Pin
NOTICE Regulator
7 1
Perform all disassembly and assembly
work in a clean area. Be sure the work
bench and the work area are kept clean.
Thoroughly clean the outside of the va-
porizer-regulator before disassembling.
Use kerosene or equivalent petroleum-
base solvent, as these will not damage the
Secondary
synthetic rubber seals used in these as-
Regulator
semblies. Diaphragm

Disassembly/Assembly -
.’ Spring
Remove in order listed, install in reverse order:
1. Secondary cover assembly.
2. Secondary regulator diaphragm: Link on underside
of diaphragm slides over lever. To remove dia- .Converter
phragm, slide it toward the LPG inlet port. Body
3. Secondary lever assembly: Hold lever down while
removing or replacing screw. LPG Inlet

NOTE
Color of secondary regulator spring de-
termines vapor outlet pressure and must
be replaced with one of same color.
4. Fulcrum pin.
5. Valve seat on secondary regulator lever. Tear out
and discard. Push in new one.
6. primary regulator cover.
Primary
7. Primary diaphragm assembly.
Regulator
8. Primary valve pin, spring, and O-ring. Replace O- Spring
I-- Diaphragm
ring with new one.
9. Converter body cover plate. O-ring @ Primary
Regulator
10. Gasket. Replace with new gasket.
1 Cover

NOTE
Always use a Clark Repair Kit and new Primary i
Regulator
gaskets when rebuilding the vaporizer-
Valve Pin
regulator. Discard old parts that will be
replaced.

SM 598,Oct ‘94 LPG Vaporizer-Regulator Removal and Overhaul l 02(LP)-5-3

 Main Table of Contents

Group 02(LP), LPG Fuel System CICIRU

Cleaning and inspection Tests after Reassembly

1. Wash all parts thoroughly, especially the vaporizing After reassembly is completed, pressure test vaporizer-
chamber and passages,using kerosene or equivalent regulator to detect possible leaks using soap suds or leak
petroleum-base solvent. Dry with compressed air. detector solution.
Do not use carburetor cleaner or lacquer thinner. 1. Temporarily install proper fittings and pressurize
These products will continue to attack special coat- the “LPG In” port with air. Check for leakage at
ings or synthetic rubber seals after reassembly. primary diaphragm, body cover plate gasket and in
outlet port past secondary regulator seat.
2. Inspect primary and secondary valve seats for proper
sealing surface. If damaged, replace valve body. 2. Plug outlet port. While pressurizing the “LPG In”
port with air, push down on hand primer button.
3. Be sure gas inlet and the 4 vaporizing ports in heat
Check for leakage at secondary diaphragm.
exchange labyrinth are clean and open. Check with
penlight-size flashlight or small diameter screw-
driver.
4. Check the body for evenness by drawing a straight-
edge across body and cover sealing surfaces. Dress
burrs or nicks with a sharpening stone where re-
quired Carefully inspect for cracks at body ports
and cover flanges.
5. Check coolant passage to ensure good heat transfer.
If heavily scaled, this indicates need to clean and
flush the engine cooling system.

02(LP)-5-4 l LPG Vaporizer-Regulator Removal and Overhaul SM 598,Oct ‘94

 Main Table of Contents

ClClRU Group 02(LP), LPG Fuel System

Section 6.

Fuel Lock-off Valve

Removal and Overhaul
(Carbureted LPG Fuel.System)

Removal and Installation

Vaporizer-Regulator

Torque 6-10 N-m (6-7 in-lb)

Vacuum Switch

Switch
To ignition/
starting
circuits

SM 598,Oct ‘94 Fuel Lock-Off Valve Removal and Overhaul l 02(LP)-6-l

 Main Table of Contents

Group 02(LP), LPG Fuel System

Overhaul

Solenoid

Fuel
Valve Body Outlet

Gasket

Magnet

Filter
Element

Fuel Inlet

Replace fuel filter element every 2000 hours. Replace

gasket with filter element.
If troubleshooting indicates that solenoid is bad, replace
solenoid.
If valve is sticking or clogged, replace valve body.

02(LP)-6-2 l Fuel Lock-Off Valve Removal and Overhaul SM 598,Oct ‘94

 Main Table of Contents

GROUP 02(G)

GROUP 02(G)

GASOLINE-CARB FUEL SYSTEM

This Group covers the carbureted gasoline fuel system. See

Group 02(LP) for the LPG fuel system.

Gas-Carb Fuel System Specifications and

Description .. ..... ... ....... ... ... ... .. .. .. ............ ........... ... ... .. Section 1

Gas-Carb Fuel System Troubleshooting .......... .... .... .. ... Section 2

Gas-Carb Fuel System Checks and Adjustments . ..... . . Section 3

Gas Carburetor Removal, Replacement,

and Overhaul .. ... ..... .. .... ... . .... . ... .......... ....... .... .... .. .. . Section 4

Gas Fuel Pump and Filter .. .. ... .. .. .. ..... .................... ... ... . . Section 5

SM 598, Ott ‘94 Gas-Carb Fuel System

 Main Table of Contents

ClRRK Group 02(G), Gas-Carb Fuel System

Section 1.

Gas-Carb Fuel System

Specifications and Description

Fuel Supply System .._.._U.........~....“.~.~..........”................~....”....~~..~...~...~....~~~~....~“.~~ 2

Description and Operation ............ .._._._................“..................._”_..~....“...._....~...._.“._....~ .. 4

Air System ....................................................................................................................................... 4
Float System.. ................................................................................................................................... 4
Idle System ....................................................................................................................................... 5
Fuel Cut-Off Solenoid ...................................................................................................................... 6
Idle Compensator ............................................................................................................................. 6
Main Metering System.. ................................................................................................................... 6
Enrichment System .......................................................................................................................... 7
Accelerator Pump System ................................................................................................................ 7
Starting System ................................................................................................................................ 8
Governor .......................................................................................................................................... 8

Specifications
Carburetor Type: Downdraft, 2-barrel (using 1 barrel) Pilot Air Jet Diameter: 1.6 mm
Choke Control: Electrically-heated bi-metallic coil Enrichment Jet Type: #85
Fuel Cut-Off Solenoid Valve Resistance: 9OQ @ 20°C Enrichment Spring: 65mmHg
(66°F) Fast Idle Opening Angle: 18.5”
Throttle Bore Diameter: 32 mm Fuel Pump Type: Electric
Outer Venturi Diameter: 24 mm Octane Recommended: 87-93
Inner Venturi Diameter: 9- 12 mm Speed Settings:
Main Jet: 120 mm l Maximum No Load Governed: 2600 rpm
Main Air Jet Diameter: 0.9 mm l Idle: 650-700 rpm (w/o accessories).
Pilot Jet Diameter: 0.55 mm Throttle Stop Gap: 1.1 mm (0.031 in)

SM 598, Apr ‘96 Gas-Carb Fuel System Specifications and Description l 02(6)-1-l
 Main Table of Contents
Group 02(G), Gas-Carb Fuel System GIRRK

Fuel Supply System

Carburetor Y Fuel
Tank

! ‘! rue1
’ + Line
>J-

Filter

02(G)-1 -2 Gas-Carb Fuel System Specifications SM 598,Oct ‘94

l and Description
 Main Table of Contents

CMRK Group 02(G), Gas-Carb Fuel System

Carburetor

-- Autochoke

Idle
Compensator

Float Chamber
Cover

\ r ,‘-
Float
and Valve

Lever Assembly

Enrichment
Valve
Speed Adjusting
Enrichment Screw (SAS)
Jet

Main P 8
Fuel Cut-Off
Fuel . Solenoid
Jet 1 B,
1 \= \
Main Body
\
c Pilot Jet

Accelerator
Pump

ve Mixture
Throttle Adjusting
Body Screw

SM 598,Oct ‘94 Gas-Carb Fuel SystemSpecificationsand Description l 02(G)-1-3

 Main Table of Contents

Group 02(G), Gas-Carb Fuel System ClRRK

Description and Operation Float System

This carburetor is a two-barrel body carburetor, but its
secondary venturi is not in use. On the secondary-venturi
side, an air passage from the idle compensator leads into
the opening under the throttle body cover.
Air System
Intake air from the air cleaner flows through the carburetor
choke bore and outer venturi into the throttle valve clear-
ance during low speed (idle) operation of the engine. When
engine speed increases, intake air is metered by the inner
venturi and air flow is controlled by the throttle valve.
Fuel is pumped from the fuel tank to the carburetor by the
electric fuel pump. A filter in the line to the fuel pump
protects the carburetor from contaminants in the fuel.
Fuel enters the carburetor through the float chamber. The
inlet to the float chamber contains a needle valve operated
by a hinged float. The float, by moving up or down with
the fuel flow demand from the carburetor, maintains an
almost constant level of fuel in the float chamber during
engine operation.

rr
A B

LP - / /r--/Y

A. Float I. Plug Q. Accelerator Pump Lever

B. Float Chamber Cover J. ThrottleBody R. Fuel Cut-off Solenoid
C. Inner Venturi K. ThrottleValve S. Pump Outlet Check Ball
D. Choke Valve L. Mixture Adjusting Screw (MAS) T. Pilot Jet
E. Accelerator Pump Nozzle M. BypassScrew U. Pump Outlet Valve Weight
F. Idle Compensator N. Body V. Needle Valve
G. Diaphragm (Membrane) Cover 0. Main Fuel Jet W. Fuel Strainer Screen
H. Enrichment Jet P. Pump Inlet Check Ball

CarburetorOverview

02(G)-l-4 . Gas-Carb Fuel System Specificationsand Description SM 590,Oct ‘94

 Main Table of Contents

CUWK Group 02(G), Gas-Carb Fuel System

Fuel from the float chamber flows through the main fuel jet
in the bottom of the float chamber then through the pilot jet,
where it is metered. Air enters the venturi air leak and the
pilot air jet No. 2 and is metered at the pilot air jet No. 1. As
a result of metering, fuel mixes with air and flows to the
Needle pilot outlet.
Valve This initial air-fuel mixture then passes through the sole-
noid valve and enters the manifold through the bypass hole
and the pilot outlet. The flow rate of the air-fuel mixture is
set by the bypass screw. The mixture then mixes with the
small amount of air that gets past the closed or slightly-
opened throttle valve. The fmal mixture then flows to the
engine cylinders.

Float System The mixture-adjusting screw (MAS) is used for adjusting

Idle System
This system provides adequate mixture richness for smooth
low-speed engine operation ranging from idling to light-
load operation.
the richness of air-fuel mixture necessary for good idling.
The bypass screw sets the flow of air-fuel mixture to the
bypass hole when the throttle valve plate is open past the
bypass hole to provide sufficient mixture richness mainly
for engine operation ranging from “off-idle” to a part of
medium-load operation.

Pilot Pilot Air Jet No. 2

Pilot Jet \
Air Jet \
No. 1 \
f
r Venturi
Air

ignition
Switch

Main Fuel - - Bypass

Jet Hole

KEY
Bypass Screw / /&4
Air (not adjustable)

Mixture Adjusting
Fuel
+ Screw (MAS) - Throttle
Suction Valve
Pilot Outlet / Plate

Y Air/Fuel
Idle System

SM 598,Oct ‘94 Gas-CarbFuel System Specificationsand Description l 02(G)-l-5

 Main Table of Contents

Group 02(G), Gas-Carb Fuel System CWIRK

Fuel Cut-Off Solenoid Main Metering System

The fuel cutoff solenoid valve in the idle system functions
as follows: When the ignition key switch is turned ON, the
solenoid pulls the needle valve to open the fuel feed line.
When the key switch is turned OFF, the needle valve
closes, blocking air/fuel mixture flow and preventing “die-
seling” or spontaneous running of a heated engine after
being turned off.
Idle Compensator
The idle compensator is operated by a bimetal element.
When the carburetor temperature increases (rises) during
idling or “off-idle” operation, fuel vaporization tends to
increase, which changes the air-fuel mixture. As the tem-
perature rises, the bimetal spring bends enough to open the
compensator valve. This allows additional air from the
choke bore to flow through the auxiliary air passage di-
rectly to the intake manifold. This leans out the mixture
enough to make up for the added gasoline vapor coming
from the float chamber.
When the throttle plate opens, the main metering system
begins controlling the air-fuel mixture. The wider the
throttle valve is opened, the faster the air flow through the
outer venturi and the greater the vacuum in the inner ven-
turi will be. As the vacuum becomes greater, additional
fuel is discharged from the main nozzle.
Fuel metered by the main fuel jet is bled by air from the
main air jet and enters the bleed pipe through its holes. The
fuel is discharged from the main nozzle.
If fuel percolates in the main well, gasoline vapor can
escape from the main air jet. This prevents liquid fuel from
spurting from the main nozzle, thus assuring stable engine
operation and easy restarting.

_________ - Main \ Main Nozzle

--‘-----:I

Main Inner
Well Venturi
LCompensaitor
Valve Outer
Venturi

L Auxiliary Air / Main Fuel Jet Bleed Pipe

Passage

Idle Compensator Main Metering System

02(G)-1-6 l Gas-Carb Fuel System Specifications and Description SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 02(G), Gas-Carb Fuel System

Enrichment System Accelerator Pump System

The enrichment system provides additional fuel feed to the
main metering system during high-speed high-torque op-
eration. This system uses a diaphragm (membrane) which
is actuated by intake-manifold vacuum and a diaphragm
spring to open or close the enrichment valve. The vacuum
is conducted through a passage to the vacuum chamber.
During part-throttle operation, a high (large) manifold
vacuum is applied to the vacuum chamber through the
vacuum line and acts on the diaphragm to close the valve
against the diaphragm spring force. When the throttle is
opened wide, manifold vacuum decreases. This allows the
diaphragm spring to open the valve. Now, more fuel from
the float chamber is metered by the enrichment jet and can
flow through the valve into the main metering system.
Rapid opening of the throttle for acceleration allows a
sudden inrush of air. Thus there is a sudden demand for
additional fuel. To provide this extra fuel, the accelerator-
pump system can feed fuel immediately under pressure.
Fuel from the inlet check valve is sent to the pump jet
through the outlet check valve by reciprocating movement
of the diaphragm. The fuel is then injected into the main
bore.
When the throttle opens quickly, the pump lever, which is
linked to the throttle valve, flexes the diaphram, which
forces fuel to flow under pressure. When the throttle re-
turns, the diaphragm is pushed back by the spring and the
pump chamber is refilled with fuel.
Pump delivery decreases with engine speed from which
acceleration is started. It does not deliver fuel at all when
the angle of throttle valve from the idling position exceeds
the preset angle.

Jet
AcceleratorPumpSvstem. EnrichmentSvstem

Enrichment and Accelerator Pump System

SM 598,Oct ‘94 Gas-Garb Fuel System Specifications and Description l 02(G)-1-7

 Main Table of Contents

Group 02(G), Gas-Carb Fuel System ElfIRK

Starting System Throttle Plate -,
r Stabilizer Piston
The starting system consists of the choke valve, lever as-
sembly, choke connecting rod, and automatic choke con-
trol. This system feeds a very rich air-fuel mixture to the
engine when the engine starts (until the engine warms up).
When the engine is cold, some throttle opening must be
maintained so that the engine idles faster than it would
when warm. This is done with “fast idle”. With the fast
idle, the choke valve is closed while the throttle valve is
held at a partially-opened position most suitable to warm-
Adjustment L
ing-up running. Return Spring -/ Screw

Choke
0 Governor Construction
j j / Autochoke
Lever -\ The governor has a throttle plate whose shaft is offset from
the center of the governor bore. The full-open position of
the throttle plate does not coincide with the true full-open
position, but leans to the closing side. This arrangement
enables the velocity pressure of the flowing mixture to
rotate the throttle plate in the direction of closing. The
resulting torque on the throttle plate stretches the return
spring linked to it until the torque balances the tension of
the spring, which maintains the throttle plate at that open-
ing angle. The spring tension can be adjusted with the
adjustment screw.
This balance between the air velocity pressure applied to
the throttle plate and the spring tension keeps the throttle
-Fast idle Adjrrstment plate at a position between full-open and full-closed to
Screw control the amount of mixture flowing into the engine.

Starting System The throttle plate opening angle of this governor is set
under the full-open condition of the carburetor. Therefore,
as the carburetor throttle valve closes, pressure applied to
Governor the governor throttle plate lessens and the governor throttle
plate rotates in the direction of opening, which causes
The velocity governor, or “governor,” is located between
engine speed to increase. To prevent this, the governor has
the carburetor throttle body and intake manifold.
a stabiier piston that tends to close the throttle plate when
R a large vacuum acts on the upper side of it.
ii
The bush nut is for adjusting the preload on the return
Carburetor
spring in order to obtain the correct idle speed at maximum
no-load governed rpm. The adjustment screw is for adjust-
ing the number of active return spring coils (which changes
Governor spring rigidity) in order to minmize hunting.“Hunting” is a
momentary surge in engine speed that occurs when engine
speed is increased from idle by quickly depressing the
Manifold accelerator pedal.
Flange A small amount of hunting is a normal condition and does
not require governor adjustment. If the surge is prolonged,
./$ 0 E however, it may be necessary to adjust the governor.
L .-_+.-J-
/

Governor Location

02(G)-1-8 l Gas-Garb Fuel System Specifications and Description SM 598,Oct ‘94

 Main Table of Contents

Group 02(G), Gas-Carb Fuel System

Section 2.

Carbureted Gasoline Fuel System Troubleshooting

NOTE - ignition System Faults
Most of the symptoms listed below can also be caused by ignition system
faults. See Group 12 Troubleshooting for further help.

Poor engine starting Poor acceleration

Choke misadjusted; readjust choke. Defective accelerating pump plunger; disassemble
Choke valve stuck; repair choke valve. and clean or replace.

Autochoke failure; check choke electrical connec-
tions.
Needle valve and valve seat not seating properly;
clean or replace needle valve and valve seat.
Incorrect float level; adjust float level.
Worn float lip; replace float lip.
Worn float level pin and related components;
place level pin and its related parts.
Engine will not start
Engine flooded; hold accelerator pedal completely
down and crank engine for 20 seconds to clear out
excess fuel.
Fuel pump not filling bowl; see checks in fuel pump
section in this Group.
Starting system fault; see Group 14 Troubleshoot-
ing.
Ignition system fault; see Group 12 Troubleshoot-
ing.
Clogged pump jet; clean or replace.
Defective accelerating linkage; replace linkage.
Clogged power main jet; clean or replace.
Float level too low; adjust float.
Throttle valve not opening completely; adjust valve.
Enrichment system defective; repair or replace as
re- necessary.
lnsufficient output
Clogged main jet; clean main jet.
Incorrect float level; adjust float.
Malfunctioning enrichment system; repair or re-
place as necessary.
Worn throttle shaft, replace shaft.
Throttle valve not opening completely; adjust valve.
Choke valve stuck closed; repair or replace choke
valve.
Governor broken; inspect and repair or replace.

Poor idle Excessive fuel consumption (black

Check for gasket leaks and replace as necessary. exhaust)
Idle rpm out of adjustment; adjust idling speed. Float level too high; adjust float.

Damaged idle adjustment screw; replace adjustment Defective enrichment system; inspect and repair or
screw. replace.

Clogged idle passage or idle port; clean. Choke valve not opening completely; check linkage,
replace if necessary.
Clogged bypass screw; clean jet.
Improper idling speed; adjust idling speed
Worn throttle shaft; replace shaft.
Loose vacuum pipe union; retighten union. Engine “hunts” at governed RPM
Idling circuit not airtight; clean circuit. l Governor not stabilizing quickly enough after rapid
Incorrect float level; replace float level. acceleration. See fuel system checks and adjust-
ments Section..
Abnormal combustion
l Mixture too lean; clean carburetor and readjust.
l Dirty inner carburetor; clean carburetor.
l Defective float level; adjust float or replace.

SM 598, Ott ‘94 Gas-Carb Fuel System Troubleshooting l 02(G)-2-1

 Main Table of Contents

ClClRK Group 02(G), Gas-Carb Fuel System

Section 3.

Gas Carburetor Fuel System Checks and Adjustments

Basic Checks .._....__.._m._...._....~..~............~..””~..~..~.....~....”.“.“....~...“.~..~...~.“~..~...” .1

Idle Speed and Mixture Checks and Adjustment ..“....................~......“....~......._.”..._““_._ - 1

Fast Idle Checks and Adjustment .U.......“.....U.U....-...“....“”.-...-...”...-....~..-...~...--” -2

Lie Checks .U...“U..“.....“........~~..~.“.”...~....~...~....~..~~..~...”....~....“.....“....“..-.- .3

Accelerator Cable Adjustment ..U........._...._...-....-..........”.”..”.-...-....-.......”.”....~....-.-- .3

Governor Inspection and Adjustment .-........._....“..........-..-...........-....-...........-...~.......-” .4

n
! CAUTION
SAFE PARKING. Before working on
tl7lCk:
L Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks
2. Put upright in vertical position and fully
lower the forks or attachment.
3. Put all controls iu neutraL Turn key
switch OFF and remove key.
4. Apply the parking brake and block the
wheels.
Basic Checks
To make a basic check of fuel system operation:
1. Startthe truck and let it warm to normal idle tem-
peram=
2. Listen for smooth idle.
3. Check acceleration, which should be smooth, with-
out hesitation, and with a smooth return to idle.
4. Check exhaust, which should be colorless. Black
exhaust indicates excessive fuel consumption and
problems with the carburetor or choke.
See “Troubleshooting” for remedies if you observe any
of these problems.
Idle Speed and Mixture Checks and
Adjustment
.
1. Connect a tachometer to the engine..
2. Start the engine.
3. Check the condition of the accelerator linkage to the
carburetor to be sure it operates freely. Press the
accelerator pedal to accelerate the engine speed and
let it return to idle. Check to be sure that the throttle
arm idle stop screw makes contact with the idle stop
tab on the throttle lever, or idle stop pm on the
carburetor.
4. If the idle stop tab or screw does not contact the idle
stop, check for damage to or binding of the linkage,
or defective throttle return springs.
L
J. The condition of the acceleratorremm springs should
be checked for signs of wear or failure.
6. Adjust or repair linkage before making adjustments
to the idle speed setting. Refer to “Linkage Check”
in this Section for procedures.
7. Check the idle speed setting using a tachometer.
Engine idle speed should be 650-700 rpm.
NOTE
Engine should be warmed up to normal
operating temperature for adjustments.

SM 598, Apr ‘96 Gas Carburetor Fuel System Checks and Adjustments . 02(G)-3-1
 Main Table of Contents

Group 02(G), Gas-Carb Fuel System CUIRK

8. Use an infrared analyzer and set the air-fuel mixture Fast Idle Checks and Adjustment
adjustment screw (MAS) to get a 1% CO reading. If
an infrared analyzer is not available, turn back the 1. Connect a tachometer to the engine (Dynamic En-
MAS 2 or 3 turns from the fully-closed position. gine Analyzer,Clarkpartnumber 1802047, orequal).
Turn on the engine.
2. Close the choke by lifting the lever assembly to close
speed the choke lever.
Adjusting
Screw
(SAS)

Mixture
Adjusting
Screw (MAS)

9. Set the idle speed to 675 rpm with the speed adjust-
ing screw (SAS). Turn the SAS clockwise to in-
crease speed or counterclockwise to decrease speed.
10. Check the mixture adjustment again. Using the
infrared analyzer, adjust the air-fuel mixture to 1%
CO. If an infrared analyzer is not available, adjust
(tighten) the mixture adjusting screw (MAS) gradu-
ally until engine speed just starts decreasing.
3. While holding the choke closed, open the throttle
11. Accelerate engine to full no-load governed speed 2
assembly so that the screw on the fast idle lever is on
or 3 times. Then, readjust the idle speed to 675 rpm
the full open stop (third step).
with idle speed adjusting screw (SAS).
NOTE

m
Repeat steps 10 and 11 to make sure the
proper air-fuel ratio is obtained at idle.

@ bird Step

4. Adjust the screw on the fast idle lever to reach 1200

rpm on the tachometer.
5. Operate the throttle to release the choke lever.

02(G)-3-2 . Gas Carburetor Fuel System Checks and Adjustments SM 598, act ‘94
 Main Table of Contents
GlmK
Linkage Check
1. Turn off the engine and safely park the truck
2. Depresstheacceleratorpedalrollerandcheckforfree
movement of the entire throttle linkage. Lubricate and
repairasneedxk
Accelerator Peak’ Mounting. No ~ju.stment.
Check accelerator pedal travel: Move the accelera-
tor pedal to the fully-down position. If the pedal
stops before it hits the floorplate, the accelerator
cable is adjusted too short
Check throttle stop gap at carburetor: Hold the
pedal fully down and check the gap between the
throttle stop pin and stop screw. If the cable has a
spring on the pedal end, there should be no gap and
no deflection of the spring. If the cable does not
have a spring on the pedal end, gap should be 1.6
mm (l/16 in).
Cablewith
and without
Spring
Linkage at Accelerator Pedal. No adjustment. Pedal rests on roller.
SM 598, Apr ‘96 Gas Carburetor Fuel System Checks and Adjustments
Group 02(G), Gas-Carb Fuel System
Accelerator Cable Adjustment
With the floorplate installed:
1. Loosen the jam nut at the accelerator cable bracket.
Throttle Lever (at
Linkage at Carburetor. Adjust with set nut.
2. Press the accelerator pedal to the floor. Adjust the
set nut to obtain the proper throttle stop gap:
l If the cable has a spring on the pedal end, there
should be no gap and no deflection of the spring.
l Ifthe cable does not have a spring on the pedal
end, gap should be 1.6 mm (l/16 in).
3. Retighten the jam nut.
4. Perform the check procedure.
NOTE
Make sure no hoses or other items bind
against the throttle linkage.
Assembly
l 02(G)+3
 Main Table of Contents
Group 02(G), Gas-Carb Fuel System
Governor Inspection and Adjustment
The function of the velocity (air) governor is to limit the
maximum speed of the engine to:
l Protect the main hydraulic pump.
l Limit the maximum travel speed of the truck
l Prevent runaway or excessive engine rpm.
IMPORTANT
GOVERNOR ADJUSTMENT AND
OVERHAUL RESTRICTIONS.
Normally, adjustment of the governor is
not required. The correct no-load gov-
erned speed setting adjustment is made
at the factory and the governor sealed
before shipment. All operators should be
instructed not to break the seal to tamper
with the governor.
If troubleshooting proves the governor
to be defective, replace the governor. Do
not attempt to overhaul the governor.
When engine speed is increased from idling speed by
pushing on the accelerator pedal quickly, slight variation
(“hunting”) in engine speed may occur.
A small amount of hunting is a normal condition and
does not require governor adjustment. However, if the
surge is prolonged, it may be necessary to adjust the
governor.
Governor Inspection
1. Clean the entire governor before disassembly.
2. Remove side cover.
3. Do not use gasoline or similar solvent when cleaning
the throttle plate shaft (to prevent deterioration of
grease enclosed in the needle bearings at the ends of
the shaft).
4. Check carefully for smooth action of the coupling
between the stabilizer rod and throttle plate. If any
stiffness is found, replace the governor assembly.
Stabilizer Rod
IF 7
Throttle Plate 1
02(G)-3-4 l Gas Carburetor Fuel System Checks and Adjustments
CLCIRK
5. Count the active spring coils . The typical number of
active coils is 14 and should be no less than 11
6. Look for broken or misaligned parts and realign the
parts or replace the governor if necessary.
7. Reinstall cover with a new gasket.
Governor Adjustment
NOTE
Governor adjustment should be made
with a warm engine running at normal
operating temperature. Be sure there is
no load placed on the engine (transmis-
sion and hydraulic controls in neutral).
High Idle Speed (No-Load Governed Speed)
Adjustment
1. The governor adjusting screw and bush nut are
enclosed with a rubber protective cover. Loosen the
retaining screw and remove the protective cover.
2. With engine running and all hydraulic and direction
controls in neutral, push accelerator pedal fully
down and hold. The carburetor throttle valve must
be in the wide-open throttle position.
3. Hold the adjusting screw to prevent it from turning.
4. Turn the bush nut to adjust the engine speed to 2600
r-pm(range: 2550-2650 rpm).
. Turn bush nut clockwise to increase speed
(spring preload is increased).
l Turn bush nut counterclockwise to decrease
speed (spring preload decreased).
-Bush Nut
Adjusting
Screw
(Cover Off)
SM 590,Oct ‘94
 Main Table of Contents

CUIRK Group 02(G), Gas-Carb Fuel System

Hunting Adjustment
This adjustment should be performed only if indicated by
troubleshooting. Set the high idle speed as explained
previously, then:
1. With engine running and all hydraulic and direction
controls in neutral, fully depress the accelerator
pedal and hold. The carburetor throttle valve must be
in the wide-open throttle position.
2. Turn the adjusting screw gradually clockwise until
hunting ceases (engine runs at a steady, constant
speed).
3. As a result of step 2, the engine speed may have
increased to an excessively high level. Check and
adjust high idle speed again.
4. Operate the accelerator to check for hunting.
5. Repeat steps 2 through 4 until hunting and high idle
speed are satisfactory.
Larger spring rigidity
Smaller spring rigidity
% spring as described previously.
;
s
z
NOTE
Turning the adjusting screw clockwise
increases return spring rigidity (number
of spring active coils decreases).
Turning counterclockwise decreases
spring rigidity (number of active coils
increases).
Although increasing the spring rigidity
reduces hunting, excessive increase of
spring rigidity changes governor charac-
teristics, affecting engine output. There-
fore, you should limit movement of the
adjusting screw to less than two turns in
either direction from the standard posi-
tion.
When the adjustment is correct, the num-
ber of active return spring coils typically
should be about 14, and no less than 11.
If the hunting adjustment is not provid-
ing the expected response, inspect the

- Engine speed, rpm

SM 598, act ‘94 Gas Carburetor Fuel System Checks and Adjustments l 02(G)-3-5
 Main Table of Contents

CMRK Group 02(G), Gas-CarbFuel System

Section 4.

Gas Carburetor Removal, Replacement, and Overhaul

Carburetor Removal and Replacement .....“.....“.....“..._....................................~ ....................... 1

Overhaul Preparations ....“......“......._........................................................................................... 2

Carburetor Disassembly/Assembly ............_.................~............~ ............................................... 2

Disassembly Inspection and Checks ............................................................................................. 6

Inspection After Reassembly ..........._.....“....“........................~.....~ ............................................. 5

ACAUTION
SAFE PARKING. Before working on truck:
Park truck on a hard, level, and solid surface,
such as a concrete floor with no gaps or breaks.
Put upright iu vertical position and fully lower
the forks or attachment
Put all controls in neutral. Turn key switch OFF
and remove key.
Apply the parking brake and block the wheels.

Carburetor Removal and Replacement

To remove carburetor, loosen mounting nuts from studs and carburetor. At replace-
ment, use new gaskets and torque mounting nuts to 20-25 N-m (14.8-18.5 ft-lb).

Torque to 20-25 N-m

Carburetor

Gasket

- Governor

SM 598,Oct ‘94 Gas Carburetor Removal, Replacement, and Overhaul l 02(G)-4-1

 Main Table of Contents

Group 02(G), Gas-Carb Fuel System CIRRU

Overhaul Preparations Carburetor Disassembly/Assembly
l Use proper wrenches and screwdrivers matching in Use the illustration on the next page and the steps below to
size with jets, nuts and screws to be removed so as not disassemble the carburetor. Assembly is the reverse of dis-
to cause burrs and scratches. assembly. Refer to the service notes where indicated.
l The carburetor assembly has a large number of parts. NOTE
Keep the disassembled parts neatly and systematically Before beginning disassembly, remove the
arranged to prevent confusion. ground wire attached to the float cham-
l Do not remove the inner venturi unless it is necessary. ber cover (5) and the power wire from
l Do not turn the bypass screw unless it is necessary. the autochoke assembly (11).
Turning the bypass screw breaks the seal on its head. The following parts must not be disas-
l Do not disassemble the throttle shaft and throttle body sembled from the carburetor.
unless it is necessary. l Choke valve and choke shaft
l Do not disassemble the choke lever and shaft unless it l Inner venturi.
l Throttle valve and throttle shaft.
is necessary.
The throttle body should be cleaned during carbu-
l Before attempting any disassembly of parts, carefully
examine the exterior of the carburetor to become retor overhaul. If throttle body, throttle valve, or
throttle shaft are faulty, replace throttle body.
familiar with the location and correct position of all
subassemblies,levers, springs, connecting links, shafts, 1. Throttlereturn spring (See Note A)
etc. 2. Damper spring
3. Choke rod (See Note A)
4. screw
5. Float chamber cover (See Note B)
6. Float chamber cover gasket
7. Cover
8. Packing
9. Bimetal
10. o-ring
IMPORTANT
11. Autochoke (See Note C)
GOVERNOR OVERHAUL. If trouble-
12. Float pin (See Note D)
shooting proves the governor to be defec-
13. Float (See Note D)
tive, replace the governor. Do not attempt
14. Needle valve assembly
to overhaul the governor.
15. Packing
16. Filter/Strainer
17. Weight (See Note E)
18. Ball (See Note E)
19. Main jet (See Note F)
20. Screw
21. Screw
22. Accelerator pump cover
23. Diaphragm
24. Spring
25. Fuel cut solenoid
26. o-ring
27. Enrichment
28. Packing
29. Enrichment jet
30. Speed adjusting screw (SAS)
31. Pilot jet
32. Lever assembly (See Note C)
33. Main body
34. Top gasket/heat insulator/bottom gasket (See Note G)
35. Throttle lever
36. Mixture adjusting screw (MAS) (See Note H)
37. Throttle body.

02(G)-4-2 l Gas CarburetorRemoval,Replacement,and Overhaul SM 598,Oct ‘94

 Main Table of Contents

cmK Group 02(G), Gas-CarbFuel System

lo-
4-Y
W

16

15

14

27

._._-I?
0 6Titk$J

r26

31

02(G)-4-3
SM 598,Oct ‘94 Gas Carburetor Removal, Replacement, and Overhaul l
 Main Table of Contents

Group 02(G), Gas-Carb Fuel System ElfIRK

Note A - Throttle Return Spring and Choke Rod Note C - Autochoke and Lever Assembly
1. When the throttle return springs are removed, avoid To remove autochoke and mounting bracket,
prying with undue force or any other action that can
1. Loosen connecting rod from autochoke to lever
cause damage.
assembly.
2. Press the end of the choke rod to force the rod out.
Avoid applying a strong force to the plastic grommet
of the rod fit-in hole.
- wire
Ground

Choke
Rod

2. Loosen and remove carburetor mounting stud fas-

tening autcchoke mounting bracket. Remove the
ground wire attached to the float chamber cover
(upper body). Remove the power wire from the
autochoke, then remove bracket
After reassembling the carburetor, make sure the throttle
and autochoke linkage operate smoothly. If any there is
any hesitation or sticking, clean or replace the linkage
Note B - Float Chamber Cover and make sure the carburetor operates smoothly.

Since the screws require great force to loosen, use a NOTE

Phillips screwdriver that exactly fits in the cross The rich-lean mixture is set on the
recess in the screw heads. autochoke by loosening the collar around
the electrical coil and turning the coil for
adjustment.

If the strangler spring of the choke valve shaft is out of

position, set it correctly in the positions as shown in the
following illustration.

Hole A Spring

To remove the float chamber cover, slowly lift it

while using care not to damage the float. Don’t tilt
the main body, as the pump discharge weight and the
related parts may come out and could be lost.

02(G)-4-4 l Gas Carburetor Removal, Replacement, and Overhaul SM 598,Oct ‘94

 Main Table of Contents

ClmK Group 02(G), Gas-CarbFuel System

Note D - Float Pin and Float
To reassemble the float and float pin:
1. Turn float chamber cover upside down.
l When replacing a main jet, make sure the old jet and
the new jet are the same size because the jet is
selected after exact flow measurement determined
at the factory. For identification, each jet is stamped
with a size mark on its end face.

Needle
Valve

Description
62 120
Size stamp

Jet Size
Main jet (primary) 120
Pilot jet (primary) 55
2. Install the fuel strainer and fuel inlet (needle) valve Enrichment jet #85
seat with gaskets (packings) into float chamber
cover. Note G - Top Gasket/Heat Insulator Plate/Bottom
Gasket
Fuel strainer
Place new gaskets on both sides of heat insulator plate
Packing 4
when securing main body to throttle body. Heat insulator
plate may be reused if not cracked or damaged.

Needle valve
assembly iop
Gasket
3. Assemble needle valve and float and install in valve
seat. Note that slot in float lever fits neck in needle
valve for positive control. These parts must be
assembled correctly together. Heat
4. Hold float and needle valve in position and install Insulator
the loose-fitting float hinge pin to mount float in Plate Bottom
place in float chamber cover.
5. Check to be sure that float lever controls the move-
ment of the needle valve in both directions.
6. Make sure the float is in a level position by adding or
removing needle valve seat packing. Float and lever Note H - Idle Mixture Adjusting Screw
should be level to packing and sealing edge of the
. Check tapered end of mixture adjusting screw (MAS)
float chamber cover.
for damage from overtightening or other causes.
Replace if damaged.
Note E -Weight and Ball
l To remove, turn the main body upside down to
remove the weight and ball.

Note F - Main Jet

l To remove the main jet, be sure to use a screwdriver
whose tip exactly fits in the slot of the jet. Check the
jets and air bleed for clogging and damage.
L Check for damage
. When reassembling the MAS, turn needle in lightly
against the seat, then back needle out 2-3 tums~asa
preliminary setting.

SM 598,Oct ‘94 Gas Carburetor Removal, Replacement, and Overhaul l 02(G)-4-5

 Main Table of Contents

Group 02(G), Gas-Carb Fuel System CIRRK

Disassembly Inspection and Checks 6. Check operation of the choke lever, throttle lever,
and link. If they do not operate lightly, wash well and
Inspection apply engine oil sparingly to the shafts.

Check the following and repair or replace parts if faulty.

Check fuel passages (jets) and air passages (jets or
orifices) for clogging. If clogged, wash thoroughly
with cleaning solvent or detergent and remove dirt
by compressed air.
NOTE
Do not use wire brushes or other metallic
devices for cleaning jets and passages.

Check diaphragms, O-rings, and springs for damage

and cracks.
Check that needle valve and assembly operates
lightly. If the valve is hard to operate or is binding,
repair or replace. If there is overflow, poor valve-to-
seat contact is suspected. Check thoroughly.

Fuel Inlet Filter/ 7. Check the float chamber cover and main body for
damage and cracks.

Fuel Cut-Off Solenoid Valve Operation Check

1. Connect the battery directly to the body and terminal
of the fuel cut solenoid valve (25) to apply the
voltage_

4. Check the fuel inlet filter/strainer for clogging and

damage.
5. Checkthefloatoperation.Checkfloat,pin,andlever
for deformation and damage and replace if neces-
sary- n
! CAUTION
Use care not to short-circuit the battery.

2. If the valve is operating normally, you should hear a

click at the moment the battery is connected. If there
is no click, the solenoid or associated wiring is
faulty.

02(G)-4-6 l Gas Carburetor Removal, Replacement, and Overhaul SM 598,Oct ‘94

 Main Table of Contents
Emu
Fuel Cut-Off Solenoid Valve Resistance Check
Measure the resistance between the body and the termi-
nal of the fuel cut-off solenoid valve with a tester.
Standard value: Approx. 90 fi at 2OT (66°F)
Reassembly Steps
For reassembly, reverse the order of assembly. Before
beginning reassembly:
l Clean every part with cleaning fluid and ahow to dry
completely. Wipe off any accumulated dirt or dust
before reassembling the part
l Replace all packing and gaskets with the correct
parts from the overhaul kit.
SM 590,Oct ‘94 Gas Carburetor
Group 02(G), Gas-CarbFuel System
Inspection after Reassembly
Choke Valve Operation
1. With the choke valve lever set to its full open
position, move the choke valve with your finger to
make sure that the choke valve shaft does not have
excess play and the valve moves smoothly without
sticking
2. If the choke valve does not move smoothly, clean the
choke valve and the area around it.
3. If the play of the choke valve shaft is loose, replace
the float chamber cover.
Ports
l Connect a hand vacuum pump and check the timing
advance port for clogging. If clogged, clean the port
and blow out with air.
After inspecting the choke valve and ports after reassem-
bly, perform the check and adjustments in Section 3.
Removal, Replacement, and Overhaul l 02(G)-4-7
 Main Table of Contents

EWRK Group 02, Gas-Carb Fuel System

Section 5.
Fuel Pump and Filter

Fuel Filter Replacement 4. Check fuel pump output.

a. Disconnect fuel line at the carburetor.
Replace the fuel filter every 2000 hours of operation.
b. Place end of line in a plastic bottle.
c. Have an assistant turn the key On for a few
Pump Checks seconds then turn key Off.
If troubleshooting indicates that the carburetor is not d. A steady stream of fuel is normal. If fuel stream
receiving fuel, do the following: is broken, dribbles, or bubbles, pump is faulty
and should be replaced.
1. Check fuel level in tank
2. Check condition of fuel filter and fuel lines. 5. If pump output is low or nothing, and electrical
connections are good, replace the pump.
3. Check the pump’s electrical connections.
a. When electrical system is operating normally
and ignition switch is on, the pump should Removal and Replacement
vibrate from operation.
Remove and replace the fuel pump as shown in the
b. Listen for a clicking from pump operation. illustration. Torque fasteners to 8- 10 Nom (5.9-7.4 ft-lb).
c. If you feel no vibration and hear no clicking,
check voltage at the unit.
d. If voltage is not present, wiring or fuse is at
fault. See wiring diagrams in Group 14.
e. If voltage is present, pump is faulty and should
be replaced.

To carburetor
Electrical Supply
Connector

From fuel tank

Fuel Pump and Filter

SM 598,Oct ‘94 Fuel Pump and Filter l 02-5-l

 Main Table of Contents

GROUP 03

GROUP 03

AIR INDUCTION
AND EXHAUST SYSTEMS

Air Induction and Exhaust Systems Specifications

and Description ... .. ... .. .. .... ... .. ........... .. ..... .... .... .... ..... Section 1

Air Induction and Exhaust Systems Troubleshooting. Section 2

Air Induction System Service .. .. ... ........... . .... ...... ..... .. ... . Section 3

Exhaust Systems .. .. .. . .. ....... ... ... .. .... .. ........ ... ... .. .... ..... .. .. .. Section 4

SM 598,Oct ‘94 Air Induction and Exhaust Systems

 Main Table of Contents
Group 03, Air Induction and Exhaust Systems
Section 1.
Air Induction and Exhaust Systems
Specifications and Description
Specifications
Air Cleaner Type: Canister style with replaceable paper
element and air-restriction indicator.
Fastener Torques
Canister Hose Clamp Torques: 1S-2.5 N*m (1.09- 1.8 ft-lb)
Gas/LPG Air Horn Intake Hose Clamp Torques: 1.9-2.9
Wm (1.3-2.1 ft-lb)
Diesel Air Horn Intake Hose Clamp Torques: 1S-2.5 N*m
(1.1-1.8 ft-lb)
Canister Bracket Mounting Nut Torques: 20-25 N*m (14.5-
18.5 ft-lb)
Service intervals
Air Cleaner (Filter) Replacement:
l Gas/LPG/CNG trucks, replace every 2000 hours
l Diesel trucks, replace every 1000 hours.
IMPORTANT
Filter replacement intervals also depend
on operating conditions. The filter canister
and element should be check visually at
regular intervals to check for leaks, holes,
or other conditions that wilI affect the air
restriction indicator. Air cleaner should be
serviced when the air restriction indicator
shows service is required.
An optional safety element is also available
which fits inside the standard element. If
the optional element becomes dirty, the
standard element is also bad and both in-
ner (optional element) and outer (standard
element) should be changed.
Air Hoses and Clamps Inspection: Every 50-250 hours or
each PM.
Exhaust Pipe and Muffler Inspection: Every 50-250 hours
or each PM.
SM 598,Oct ‘94 Air induction and Exhaust Systems Specifications
Description
The reason for providing an air cleaner for the engine is to
protect the engine from abrasive dust and dirt entering the
cylinders and causing excessive wear. Industrial truck op-
erating environments can contain a high concentration of
dust, fibers, or other contaminants. Dirty filter elements or
loose, leaking, or broken hoses or clamps can dramatically
shorten engine life. Clogged air filters cause engine power
loss and poor fuel economy.
The air cleaner used on the truck is a canister style filter
with a large centrifugal air pre-filter and a larger filter
element to increase service intervals. A dirt ejector port of
the bottom of the canister allows particles to be expelled
from, rather than trapped in, the filter. All trucks are equipped
with an “air restriction indicator” that warns the driver of
dirty and restricted air intake. The air cleaner should only
be serviced when the air restriction indicator shows service
is required or every 2000 hours. However, the system
components should be visually checked regularly for leaks,
holes, or other damage that could affect the readings of the
air restriction indicator. The air restriction indicator light is
in the driver’s instrument pod.
The air filter assembly includes intake and outflow hoses,
the filter cannister, the filter element, the air restriction
indicator, the dirt ejector, and a mounting clamp. The air
intake opening is located in a leg of the operator’s cell, high
enough above the ground to prevent excessive dust and dirt
from entering the system. The outflow hose is connected to
the gas or LPG carburetor or the diesel intake manifold.
The mounting bracket for the canister is under the seat deck
to the driver’s left and is easy to reach for service.
and Description l 03-l-l
 Main Table of Contents
CMRK Group 03, Air Induction and Exhaust Systems
Section 2.
Air Induction System Troubleshooting
Dii or restricted air induction components can cause
several problems with your truck’s operation. Regular main-
tenance and service of the filter element and related compo-
nents can prevent problems with your truck. The air
restriction indicator also automatically gauges the air in-
duction system performance and can warn you when prob-
lems arise. The air restriction indicator switch is an
electromechanical control mounted on the air filter canis-
ter. The switch monitors the vacuum present in the system
and determines when the air flow is not adequate; either a
clogged air intake or dirty filter element prevents the full,
required amount of air from reaching the engine. The air
restriction indicator light in the instrument pod (dash panel)
comes on to warn you of the problem.
Clogged air filters may cause the following symptoms:
Engine starts but does not remain running.
Engine lacks power.
Excessive black exhaust smoke.
Fuel or oil leaks from exhaust manifold
Excessive fuel consumption.
Engine overheats.
SM 598, Apr ‘96
If any of these problems occur with the truck, the air filter
may be clogged or the air intake system is restricted. Ser-
vice the entire system to make sure that air flow is clean
and unrestricted. Change the filter element and check all
hoses, tubing, and the filter canister for tight fittings. Look
at all connections for fan-shaped dust deposits that indicate
possible air leaks. Check all hoses for proper seating and
look for cracks or damage. Make sure all hose clamps are
properly torqued.
If you believe the air restriction indicator is faulty, perform
the following checks:
Harness check: Short across the air restriction terminal
switch with wires #34 and #37 and the light will come on.
Function check: Remove the switch from the air filter
canister and test by connecting to a vacuum source. Check
terminal for open and closed condition using the following
measurements:
When vacuum source is set at 0 cm (0 in) inches of water
vacuum, switch should be open.
For gas/LPG/CNG, when vacuum source is set at 3.80 cm
(15 in) of water vacuum, switch should be closed.
For diesel, when vacuum source is set at 6.35 cm (25 in) of
water vacuum, switch should be closed.
Air Induction System Troubleshooting . 03-2-l
 Main Table of Contents
Group 03, Air Induction and Exhaust Systems
CMRK
Section 3.
Air Induction System Service
Use the illustrations on the following pages to service the
air induction system, including changing the air filter ele-
ment. Illustrations for the gas-, diesel-, and LPG-engine
trucks are included.
NOTE
The air restriction indicator gauges vacuum
present in the system. For gas/LPG/CNG
engines, the filter should be replaced every
2000 hours. For diesel engines, the filter
should be replaced every 900-1000 hours,
or sooner if the air restriction indicator
light is on. Generally, the air filter should
not be replaced until the air restriction in-
dicator lights up during truck operation to
show that service is required. This reduces
the amount of service for the air induction
system and prevents unnecessary service
which itself can cause increased contami-
nation within the system. Regularly check
the system components, however, to check
for leaks, holes, or other damage that could
affect the air restriction indicator.
A CAUTION
SAFE PARKING. Before working on truck:
Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
Put upright in vertical position and fully
lower the forks or attachment.
Put all controls in neutral. Turn key switch
OFF and remove key.
Apply the parking brake and block the
wheels.
Air Filter Replacement
1. Tilt the steering column forward and raise the seat
deck. The air filter canister is located to the left of the
driver’s seat.
2. Inspect the components and look for fan-shaped dust
accumulation at all hose connections. Clean compo-
nents of dust, dirt, and other contaminants that might
enter the system on disassembly.
SM 598, Ott ‘94
3. Remove the canister cover clamps and remove the
filter element.
4. Clean the inside of the air filter canister.
5. Install the new filter element. Be sure that the filter
element is fully seated in the canister.
NOTE
Do not try to air clean and blow out the
filter. Filter is further clogged by air clean-
ing. Always replace with a new filter ele-
ment.
6. Reseat the canister cover, making sure that it fits
tightly around the canister.
7. Close and latch the canister cover clamps.
8. Close and latch the seat deck.
Air Cleaner Removal
1. Remove the two bolts that mount the canister to the
frame.
3. Disconnect and label the wiring terminals from the air
restriction indicator switch.
4. Loosen the clamp and remove the hose from the engine
air horn. On LPG engines, hose is connected directly to
the carburetor.
5. Remove the hose from the leg of the overhead guard
cell.
6. Remove the air cleaner canister and hosing from the
truck.
Air Cleaner Replacement
Installation is the reverse order of removal.
l Torque the hose clamp bolts to 1.9-2.9 Nom (1.3-2.1
ft-lb).
l Torque canister bracket mounting bolts to 20-25 Wm
(14.8-18.5 ft-lb).
Air induction System Service l 03-3-l
 Main Table of Contents
Group 03, Air Induction and Exhaust Systems
CiRRlC

Air Filter - Gas Engine

Air Filter
Torque to 1 S-2.5 Element
Canister

Torque to 1.9-2.9 N*m (1.4-2.1 ft-lb).

-Torque to
2.5 N-m (1
1.8 ft-lb).

Torque to 20-25 N=m

(14.8-18.5 ft-lb).

03-3-2 l Air Induction System Service SM 598, Qct ‘94

 Main Table of Contents

ElRRK Group 03, Air Induction and Exhaust Systems

Air Filter - Diesel Engine

Torque to 1S-2.5 Nom,

(1.1-l .8 ft-lb). \ Air Filter
Torque to 1S-
2.5 N*m (1 .l-
1.8 f&lb).

\ Torque to 20-
25 Nom (14.&
18.5 ft-lb).

SM 598, Ott ‘94 Air induction System Service l 03-3-3

 Main Table of Contents

Group 03, Air Induction and Exhaust Systems EIRRK

Air Filter - LPG Engine

Connect to vent hose

from velocity governor
supplied with engine.

Torque to 1 J-2.9
Nom (1.4-2.1 ft-lb).

Operator’s
Cell Leg

-Torque to 20-25 N=m

- (14.8-18.5 ft-lb).

03-3-4 l Air induction System Service SM 598,Oct ‘94

 Main Table of Contents

Group 03, Air Induction and Exhaust Systems

CUlRK

Section 4.

Exhaust Systems

2
Exhaust System . Cushion-Tire Truck ........................................................................................

Exhaust System . Pneumatic-Tire 3

Truck ....................................................................................

4
Exhaust System . Vertical System ................................................................................................

! ACAUTION
SAFE PARKING. Before working on truck:
1. Park truck on a hard, level, and solid surface,
such as a concrete floor with no gaps or breaks.
2. Put upright in vertical position and fuuy lower
the forks or attachment.
3. Put aIi controls in neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the wheels.

SM 598,Oct ‘94 Exhaust Systems l 03-4-l

 Main Table of Contents
Group 03, Air Induction and Exhaust Systems
CMRK

Exhaust System - Cushion-Tire Truck

Torque to 20-25 N*m

(14.8-18.5 ft-lb).
Torque to
/ 9-10 Nom

Torque to 20-25
Nom (14.8-l 8.5
ft-lb).

03-4-2 l Exhaust Systems SM 598,Oct ‘94

 Main Table of Contents
Group 03, Air Induction and Exhaust Systems
EIRRK

Exhaust System - Pneumatic-Tire Truck

Torque to 20-25 N*m -

(14.8-l 8.5 f&lb).

r
Torque to 20-25
Nom (14.8-I 8.5
ft-lb).

__

L
‘-Toraue to 40-
45 N;m (30-33
ft-I b).
Torque to 18-
20 Nom (13.3-
14.8 ft-I b).

SM 598, Ott ‘94 Exhaust Systems l 03-4-3

 Main Table of Contents

Group 03, Air Induction and Exhaust Systems CMRU

Exhaust System - Vertical System

Torque to
40-45 N*m Torque to 18-
(30-33 ft-lb). 20 Nom(13.3-
14.8 f&lb).

Torque to
40-45 Nom
(30-33 ft-lb).

3’

03-4-4 l Exhaust Systems SM 598,Oct ‘94

 Main Table of Contents

GROUP 06(S)

GROUP 06(S)

TRANSAXLE

(TA-30 STANDARD TRANSAXLE)

Transaxle Specifcations and Description ...................... Section 1

Transaxle Troubleshooting ............................................. Section 2

Transaxle Oil and Filter ................................................. Section 3

Transaxle Oil Cooler ...................................................... Section 4

Transaxle Removal and Replacement ........................... Section 5

Transaxle Overhaul ........................................................ Section 6

Drive Axle Ends Overhaul ............................................. Section 7

Transaxle Control Valve Overhaul ................................ Section 8

SM 599,Oct ‘94 Transaxle

 Main Table of Contents

EmK Group 06(S), Transaxle (Standard)

Section 1.
Transaxle Specifications and Description
Specifications ............ ..“.....“.........................”.....................................................~ ......................... 1
General Specifications ..................................................................................................................... 1
Pressure Specifications .................................................................................................................... 1
Service Intervals.. ............................................................................................................................. 1
Locations ......._.........“............................”.....“............”.............“.......” .......................................... 2
Description ................................................................... ..- ............................................................... 3
Operation ......“._...~.....U~.~.......~~“.~.......~-~~..”.””.....~~..........~..~.~...............~.......~.....~ .. 7
Transaxle Hydraulic Schematic ....“........“I...l...~..~...~.~.......”.”_........_........................~ .......... 9
Sectional View Along Turbine Shaft .......~.......~..........................._........................................... 10
Sectional View Along Drive Axle ..“.......” ................................................................................... 11

Specifications
General Specifications Fastener Torques
. Model: Clark TA-30 Transaxle . Axle Shaft-to-AxleAssemblyMounting Bolts: 90-l 10Nom
. No. Ratios: l-speed, forward and reverse (27-33 ft-lb)
. Transaxle Ratio Forward 19.86 Ax&o-Fmme MountingBolts:542-596Nom(X&l40 &lb)
. Transaxle Ratio Reverse: 16.17 Breather:45-50 Nom (33-37 f&lb)
. Ring & Pinion Gear Type: Spiral Bevel Clutch Lube Tube Fittings: 73-90 N-m (54-66 ft-lb).
. Ring Gear Backlash: 0.20-0.28mm (0.008-0.011in). Clutch PressureTube Fittings:Tube end: 3342 Nom (24-30
. Differential Type: 2-pinion ft-lb); Boss end-42-53 Nom (31-39 ft-lb)
. Differential bearing preload: 0.075 mm (0.003 in) deflec- Control Valve Mounting Bolts: 28-35 Nom (21-26) f&lb.
tion of each carrier ear DifferentialPinion Shaft Nut: 270-340Nom (200-250ft-lb)
. Service Brake Size: 300 x 500 mm (11.81-19.68in) Drain Plug: 90-110Nom (66-81 ft-lb)
. Torque Converter Size: 310 mm (12.20in) Drive Plate MountingBolts: 20-25 Nom (15-18 ft-lb)
. Torque Convener Stall Ratio: 3.2 Engine-to-TransaxleHousing Mounting Bolts: 4045 Nom
. Hydraulic Pump Drive Ratio: 1.028x engine rpm (30-33 ft-lb)
. Dry Weight 390 kg (858 lb) Oil DipstickTube Fitting: 171-209Nom (126-154ft-lb).
. Fluid Capacity 18.5L (19.5 qt) Solenoid Valves: Valve body: 30.5-37 Nom (22.5-27.5 ft-
. Transaxle Fluid (Oil): Clark# 2776236 lb); Coil nut 5-5.7 Nom (4-5 ft lb)
Pressure Specifications* Stator SupportCapscrews:54-64 Nom (40-48 ft-lb).
Transaxle Oil Cooling Lines: Tighten fittings hand-tight
Charge Pump Flow: 10 gpm (37.8 L/m@ @ 1800rpm
and turn with a wrench 1.5 to 3 full turns
Regulator Valve Pressure: 190-245psi @ 1800rpm
TransaxleTemperature Sensor: 45-55 Nom (33-40 ft-lb)
Clutch Pressure (Forward/Reverse): 1240 kPa (180 psi)
@idle rpm TransmissionCase-to-Axle& -Convertor HousingsMount-
ing Bolts: 54-65 N-m (4048 ft-lb)
CoolerRetumPressurez5O-125psi(345-862kPa)@ 18OOrpm
*Notes Service Intervals
All rpm’s noted are engine speed. Replace transaxleoil every 2000 operating hours.
All clutch pressures are at engine idle speed with clutch engaged.
Remove and clean the transaxle sump oil strainer screen
Oil at operating temperature (82-93 “C) 180-200 “F
each time the transaxle fluid is changed.
CAUTION
Replacethe transaxleoil filter every 1 year or 2000 operat-
A!
ing hours, whichever comes first.
Before checking clutch pressures,park safely,
chock the steer wheels, raise the front of the IMPORTANT
truck, block the truck by the frame, return all When the transaxle is new or rebuilt, change
controls to neutral, and disengagethe parking the oil filter after the first 50 hours and again
brake. after 100 operating hours.

SM 598,Oct ‘94 Transaxle Specs and Description l 06(S)-l-l

 Main Table of Contents

Group 06(S), Transaxle (Standard) ClRRK

Locations

Control Valve

Oil Filter Hydraulic Pump

Solenoid Valves

,- Inching Rod
r Pressure Tube

To/From Oil -I Tdbe

Cooler
I Temperature Oil Drain Plug
Sensor and Screen

Figure I. Locations

D6(S)-l-2 l Transaxie Specs and Description SM 598,Oct ‘94

 Main Table of Contents

CllmK Group 06(S), Transaxie (Standard)

Transmission Housing

Converter Housing

Figure 2. Transaxle Housings

Torque Converter

Description

Torque Con verfer

The torque converter provides a fluid coupling between the
engine and transaxle. The converter is filled with hydraulic
fluid and encases an impeller, a stator, and a turbine.
The fan-lie impeller-assisted by the stator-drives the
fluid; the turbine is driven by the fluid. The impeller is
connected to the engine flywheel by the drive plate; the
turbine is splined to the clutch shaft. The stator is splined to
the stator support, which bolts to the converter housing.
The torque converter is not serviceable and must be
replaced as a unit.

Figure 3. Torque Converter

SM 598,Oct ‘94 Transaxle Specs and Description l 06(S)-1-3

 Main Table of Contents
Group 06(S), Transaxle (Standard)
Charging Pump
The transaxle charging pump (Figure 4) is mounted on the
converter housing and is driven by the impeller hub gear
via the pump idler gear. The pump provides pressure for
operating the clutch packs, supplies cooled oil to the torque
converter, pressurizes the oil in the torque converter to
prevent cavitation, and circulates oil for cooling and lubri-
cating the transaxle. The truck’s hydraulic system pump is
in the same housing with the charging pump. (See Group
29 for pump details.)
Transmission
The transmission case (Figure 5) contains the clutch assem-
bly, forward/reverse drive gears, a reverse idler gear, and a
power output gear (Figure 7) that drives the differential
drive pinion.
The differential pinion gear shaft (Figure 7) is mounted in
tapered roller bearings at both ends in the transmission case
and can be adjusted for mounting distance, as well as ring
and pinion gear contact.
Forward/Reverse Clutch Packs
The clutch assembly contains two clutch packs. Each clutch
pack (Figure 6) contains alternating outer and inner discs
and a piston to press the discs together. The outer discs
have splines on their outer diameters that mesh with the
(forward or reverse) clutch drum. The inner discs have
splines on their inner diameters that mesh with the (forward
Converter
Housing
Transaxle Control
Valve
Figure 4. Components on Converter Housing
D6(S)-1-4 l TransaxleSpecs and Description
CIRRU
or reverse) drive gear. The outer discs and entire clutch
assembly, driven by the torque converter turbine, can rotate
over the hubs of the forward and reverse drive gears with-
out engaging them. However, when the inner and outer
discs are pressed together, the outer discs drive the inner
discs, which in turn drive either the forward or reverse
drive gear. The forward drive gear directly drives the power
output gear (Figure 7) mounted on the differential pinion
shaft. The reverse drive gear drives the power output gear
via the reverse idler shaft gears.
Solenoid Valves
Solenoid-operated direction control valves (Figure 5) are
mounted on the transmission case. They switch flow to the
forward or reverse clutch pack, or neither, in response to an
electrical signal from the operator’s direction control lever.
Transaxle Control Valve
The transaxle control valve (Figure 4) is mounted on the
converter housing. The valve directs flow for lubrication
and clutch pack actuation. The assembly contains an inch-
ing valve that controls the amount of pressure delivered to
the clutch pack discs and, thus, the extent of slippage
through the clutch. All components within the valve assem-
bly are described under “Operation” later in this Section.
The transaxle oil filter mounts to the transaxle control
valve.
Pump Drive Gear
&?-Pump
Idler Gear
Pump
Stator
support
SM 598,Oct ‘94
 Main Table of Contents

ClmK Group 06(S), Transaxle (Standard)

Figure 5. Transmission Components

Reverse

Differential Figure 6. Clutch Components, Reverse Drum

The differential (Figure 7) is mounted on the transmission

case. The pinion on the transmission output shaft drives a
ring gear bolted to the differential case. The differential
case is supported by opposed tapered roller bearings
mounted in the transmission case. The differential bearing
preload and ring gear clearance (backlash) is maintained
by adjustment nuts on the differential bearing carriers.

I- Pinion

Figure 7. Differential Components

SM 598,Oct ‘94 Transaxle Specs and Description l 06(S)-1-5

 Main Table of Contents

Group OS(S), Transaxle (Standard) CUWK

Drive Axle
The axle housing Figure 8) encloses the differential and
contains the axle shafts. The axle shaft ends spline into the
differential side gears (Figure 9). The rotation of the differ-
ential case drives the differential side gears and pinions,
which drives the two axle shafts at the differential rate
needed for cornering.
The axle shafts drive hub assemblies mounted at the ends
of the axle housing on opposed tapered roller bearings. A
brake shoe assembly is mounted behind each hub on the
axle end and acts on a brake drum that bolts to and encloses
the hub.

7 Hub

Bearing

Axle Shaft

c Bearing
Brake Drum

Figure 8. Drive Axle Components

Differential

.
Side / \

c0 Gear

/ //
/
/
/
/

Figure 9. Axle Shaft and Differential

/
, //

\ ‘. \ uY ,/-
\ .’ ’
\
L Pinion

06(S)-l-6 l Transaxle Specs and Description SM 598,Oct ‘94

 Main Table of Contents

CUlRK Group 06(S), Transaxle (Standard)

Operation
Transaxle operation is controlled by the transaxle control
valve (Figures 10 and 11).
The sequence of operation and the elements of the direc-
tion control valve shown below are described in the text
and schematic on the next two pages.

inching Spool Inching Balance Spring Inching Rod

7 /- r
I

1 ’ ’ Inching Return Springs

L - Lube Relief Sbool

L Oil Filter Filter Bypass Spool L Regulator

Spool

Figure 10. TransaxleControlValve

SM 598,Oct ‘94 Transaxle Specs and Description l 06(S)-1-7

 Main Table of Contents

Group 06(S), Transaxle (Standard) CUIRK

Oil from the charging pump enters the transaxle control Cooling/Lube Circuit:
valve through an internal passage. Then it flows through
Flow from the filter passes through a cooler relief valve
the filter (or if the filter is clogged, through a bypass to the
that enables oil to bypass the cooling system if clogged,
cooling/lubrication circuit) and to the pressure regulator,
then exits the transaxle valve assembly and goes to the oil
which maintains pressure for the clutch actuation circuit,
cooler. The lube relief valve maintains pressure in the
and passes a large volume of flow to the coolingjlubrication
cooling/lubrication circuit to a set pressure.
circuit. The clutch actuation circuit and the coolingjlubrica-
tion circuit are best described separately: Cooled oil returns to the transaxle control valve, where it is
directed through the external lube tube, to the end of the
clutch shaft. Bores through the length of the clutch shaft
Clutch Actuation Circuit: conduct oil to the torque converter for driving the turbine
Flow from the filter then goes through the inching valve, and to the clutch packs and various bearings for lubrication.
exits the transaxle control valve assembly, goes through the The priority lube sleeve on the clutch shaft moves with the
external pressure tube, and then to the solenoid valves. A clutch piston to increase lube oil flow to clutch discs that
small amount of flow through inching valve also goes are engaging.
through the modulating valve to sump.
From the clutch packs and torque converter, the oil drains
If one of the solenoid valves is open, it conducts oil to the back to the sump (transmission and axle housings).
corresponding clutch piston through a path that includes a
bore in the oil distributor sleeve, a groove in the clutch
shaft, and a bore in the clutch shaft that leads to the clutch
cylinder.
Fluid entering the clutch cylinder moves the piston, which
presses the clutch discs together. As the piston reaches its
end of travel, pressure builds in the circuit, but is limited to
a maximum level by the pressure regulating valve.
As the operator depresses the inching pedal, a variable
orifice in the inching valve drops pressure downstream of
the inching valve. This reduces pressure on the clutch
piston accordingly, which lets the discs slip.
When the operator puts the truck in neutral, shifts to the
opposite direction, or turns off the truck, the open solenoid
valve closes and a spring returns the clutch piston, which
releases the clutch discs and forces oil back through the
solenoid valve to sump.
When the inching valve relieves pressure, oil displaced by
the returning piston goes to sump through the modulating
valve.
The modulating valve and accumulator work together to
absorb shock caused by direction changes and to smooth

06(S)-1-8 l Transaxle Specs and Description SM 598,Oct ‘94

 Main Table of Contents

CIRRK Group 06(S), Transaxle (Standard)

Transaxle Hydraulic Schematic WE

E2
“5
+l

Figure 11

SM 596,Oct ‘94 Transaxle Specs and Description l 06(S)-1-9

 Main Table of Contents

Group 06(S), Transaxle (Standard) CIRRK

Figure 12

06(S)-l-10 l Transaxle Specs and Description SM 599,Oct ‘94

Main Table of Contents
 Main Table of Contents

CMRK Group 06(S), Transaxle (Standard)

Section 2.

Transaxle Troubleshooting

Troubleshooting Techniques .............. ..“...........................“............” ............................................ 1

Symptoms and Causes ................. .._...“.......“........................”......~..............” .............................. 2

Checks ...................................... ..“............” ..................................................................................... 3

Fluid Level Check ............................................................................................................................ 3
Fluid Leakage Checks ...................................................................................................................... 3
General Mechanical/Electrical Checks ............................................................................................ 3
Solenoid Valve Electrical Checks .................................................................................................... 3
Stall RPM Test ................................................................................................................................. 4
Transaxle Pressure Checks .............................................................................................................. 4

Troubleshooting Techniques
The following information serves as an aid to isolating
problems in a transaxle that is not functioning correctly.
When troubleshooting a “transaxle” problem, keep in mind
that the transaxle is only the central unit of a group of
related power train components. Proper operation of the
transaxle depends on the condition and correct functioning
of the other related components. Therefore, to properly
diagnose a suspected problem in the transaxle, consider the
transaxle fluid, charging pump, torque converter, transaxle
assembly, oil cooler, filter, connecting lines, controls, and
engine as a complete system.
To identify and correct a transaxle fault, consider the prin-
ciples of operation, as given in Section 1, along with symp-
toms and causes indicated on the next page.
Verification of the suspected problems usually requires
performing the stall checks, pressure checks or solenoid
electrical checks described later in this Section. Inspection
and overhaul of the suspect components is described in
various locations within this Group.

SM 598,Oct ‘94 Transaxle Troubleshooting l 06(S)-2-1

 Main Table of Contents

Group 06(S), Transaxle (Standard) CUIRK

Symptoms and Causes
The following lists typical transaxle troubles and possible
causes.
Truck Won’t Move in Either Direction
. Low or no clutch pressure. (See below.)
. Parking brake on.
. Pressure regulating valve stuck open.
. Inching valve stuck.
. Modulating valve stuck or plugged.
. No current to solenoid valves.
. Solenoid valves stuck.
. Broken inching return springs.
. Broken inching balance spring.
. Clutch disc faces severely worn or glazed.
Low or No Clutch Pressure
. Parking brake on.
. Low transaxle fluid level.
. Pressure regulating valve stuck.
. Inching valve stuck.
. Modulating valve stuck or plugged.
. InchingJxnke pedal not returned to full up position.
. Defective or worn charging pump.
. Broken or worn clutch shaft or piston sealing rings.
. No current to solenoid valves.
. Solenoid valves stuck.
High Clutch Pressure
l Faulty pressure regulating valve.

Truck Moves only in Forward or only in Reverse Low Cooler Return Pressure-Low Charging Pump
output
l No current to solenoid valve.
. Low fluid level.
. Solenoid valve stuck closed.
l Suction screen has restriction.
Defective or worn charging pump.
Truck Moves in Forward or Reverse while in Neutral
l

l Solenoid switched on due to electrical fault.

Overheating
l Solenoid valve stuck open.
l Low fluid level.
. Worn charging pump.
Clutch Slips When Not inching
l Worn oil sealing rings.
l Low clutch pressure. See “Low or No Clutch Pres-
sure.” . Dirty oil cooler.

l Brake/inching pedal overlap misadjusted l Restriction in cooler line.

l Inching linkage or rod damaged or misadjusted. l Cooler bypass valve stuck open.

l Clutch disc faces worn or glazed.

Noise in Converter
. Defective converter. Perform stall check.
Truck Will Not inch
Inching valve sticking.
Loss of Power
Inching return springs damaged or incorrect (opposite
coiling). l Low engine rpm @ converter stall. Tune engine.
Inching balance spring damaged or incorrect (opposite l Overheating - See “Overheating” above.
coiling). . Faulty converter. Perform stall check.
Excessive leakage between inching spool and valve
housing. High Oil Level on Dipstick
Inching linkage damaged. l Plugged breather.
. Hydraulic pump seal failure.

Clutch Noise or Premature Failure

l Incorrect oil in transaxle.

c%(S)-2-2 l Transaxle Troubleshooting SM 598,Oct ‘94

 Main Table of Contents

CMRK Group 06(S), Transaxle (Standard)

Checks Solenoid Valve Electrical Checks

The following checks should be performed when indicated
by troubleshooting or at the specified PM intervals.
Fluid Level Check
Check fluid level as described in the “Transaxle Drain and
Fill” Section in this Group.
Fluid Leakage Checks
Check the fluid lines and fittings between the transaxle and
the cooler located beneath the radiator. If leakage cannot be
stopped by tightening a fitting, replace the defective parts.
The cooler can be further checked for leaks by disconnect-
ing the lines from the cooler and applying 5 psi air pressure
to the fittings. If the cooler is leaking and will not hold this
pressure, it must be replaced.
To check the solenoids in the direction control valves,
operate the direction control with the truck running and
listen to or feel each solenoid to determine if it operates.
If either solenoid valve does not appear to be operating,
remove the leads from the valve and check that 12 volts are
present at the solenoid only when the truck is on, the
parking brake is off, and the appropriate direction is se-
lected at the shift lever. Also check that voltage drops to 0
when the lever is shifted to neutral or the opposite direc-
tion.
If this test or other troubleshooting indicates that a solenoid
valve is not receiving electrical current or is activating at
the wrong time, consult the wiring diagrams in Group 14
and troubleshoot the direction control circuitry.
If the valve is receiving the correct electrical signal but not
operating, replace the valve.

Inspect the transaxle drain plug. If the plug shows leakage,

torque the plug 90-110 Nom (66-81 ft-lb). If tightening does
not stop the leak, replace the plug O-ring.

IMPORTANT
This transaxle uses only Clark # 2776236
transaxle fluid.

General Mechanical/Electrical Checks

Prior to performing pressure and stall tests, the following
mechanical checks should be made:
1. Be sure all control lever linkage is properly connected
and adjusted in each segment and at all connecting
points.
2. Check wiring and electrical components that actuate
the transaxle. Reverse Solenoid Valve

3. Check the service brake and inching pedal for correct Forward Solenoid Valve
adjustment and travel. Be sure the inching pedal moves
freely and returns fully.
4. Be sure all components of the cooling system are in
good condition and operating correctly. Air clean the
oil cooler if necessary.
5. The engine must be operating correctly. Be sure it is
correctly tuned and adjusted to the correct idle and no-
load governed speed specifications.

SM 598,Oct ‘94 Transaxle Troubleshooting l 06(S)-2-3

 Main Table of Contents

Group OS(S), Transaxle (Standard) emK

Stall RPM Test Transaxle Pressure Checks

Transaxle problems can be isolated by the use of pressure
IMPORTANT tests.
Perform the stall rpm test before you make
When the stall test indicates slipping clutches, measure
transaxle pressure checks.
clutch pack pressure to determine if the slippage is due to
Stall tests are described in Group 00. Refer to the stall tests low pressure or to clutch disc material failure.
Section in Group 00 and follow the procedure given there.
Measure regulator pressure to help determine if low clutch
Stall rpm is the rpm at which the engine runs with full pressure is caused by a faulty pressure regulator, inching
power applied, the transaxle engaged, and truck movement valve, or charging pump.
stopped by an immovable object or by the service brakes Also refer to “Symptoms and Causes” on page 2 of this
(right foot pedal). Section for other suggested causes of low clutch pack
Stall test indications are as follows: pressure.
l Normal engine stall rpm: Measure cooler return pressure to determine if pressure in
LPG 1790-1890 the clutch lubrication circuit is sufficient and whether a
suspect converter is sufficiently charged (filled and pres-
Gas 1850-1950
surized). Cooler return pressure will also be low if regula-
Diesel 2150-2250 tor pressure is low.
l Low engine stall rpm: If clutch discs are glazed or otherwise failing, clutch over-
LPG 1600-1700 haul is needed to correct performance problem.
Gasoline 1650-1750 If the converter is damaged, converter replacement is re-
Diesel 1900-2000 quired to correct performance problem
A loss of engine power is indicated and an engine
tune-up or repair is required. Minimum Tools Required
l Very low engine stall rpm: Hydraulic transmission test manifold, or conventional
LPG 1100-1200 pressure gauge with O-300 psi (o-2070 kPa) pressure
range, with hose and fittings.
Gasoline 1150-1250
Tachometer
Diesel 1300-1400
Faulty stator support shaft or a convertor malfunction
Test Preparation
is indicated and replacement of converter or stator
support shaft is indicated. Preliminary checks and stall rpm test must be completed
l High engine stall rpm: prior to pressure checks.
LPG Above 1890
IMPORTANT
Gasoline Above 1950
Be sure that transaxle fluid level is correct
Diesel Above 2250
and oil warmed to operating temperature
Either slippage of the clutch pack or converter fin and that all mechanical checks have been
damage is indicated. Pressure checks (see next sub- completed.
section) will show whether the clutch pack must be
repaired or if the converter must be replaced.

06(S)-2-4 l Transaxle Troubleshooting SM 598,Oct ‘94

 Main Table of Contents

CMRK Group 06(S), Transaxle (Standard)

PressureTest Procedures 6. When each pressure check is completed, stop the

engine, remove pressure gauge, and reinstall plug or
1. Raisefrontoftruckandblocksteerwheelsasdescribed
in Croup 22.
2. Return all controls to neutral and release parking brake.
3. Connect tachometer.
4. Removeplug, or disconnect fitting, then connect pres-
sure gauge, or tee and pressure gauge, as indicated in
illustration below.
5. Operate engine at specified rpm while taking pressure
readings indicated in illustration below. Make a record
of each pressure reading.
IMPORTANT
Do not apply the inchingpeda2 while mak-
ing clutch pressure checks. Apply the inch-
ing pedal only when making inching con-
trol pressure test.
Do not apply parking brakz when making
pressure checks. The parking brake turns
off the solenoid valves.

Regulator Pressure: 1300-1650 kPa (190-240 psi) @

1800 rpm. Put direction control in neutral. Connect gage
to test port

-0 P
Regulator
Pressure

Reverse Clutch
Pressure
Cooler Return Pressure: 345-827 kPa (50-120 psi)
@ 1800 rpm. Put direction control in neutral. Connect
Forward Clutch Pressure: 1240 kPa (180 psi), mini- gauge into line with tee.
mum, @ 1800 rpm. Place direction control in forward. P Cooler Return
Connect gauge to test port. Pressure
P
Reverse Clutch Pressure: 1240 kPa (180 psi), mini- I
mum, @ 1800 rpm. Place direction control in reverse.
Connect gauge to test port.
Inching Control Pressure: Depress inching pedal while
performing forward or reverse clutch pressure test. Pres-
sure must rapidly fall from full clutch pressure to 310
kPa (45 psi) then more slowly to O-35kPa (O-5psi).
Neutral Check: When direction control is in neutral,
clutch pressure should be 0 kPa (0 psi). Also check with
parking brake applied and direction control in forward
or reverse; pressure should be 0 kPa (0 psi).

SM 598, Apr ‘98 Transaxle Troubleshooting l 08(S)-2-5

 Main Table of Contents

CUlRK Group 06(S), Transaxle (Standard)

Section 3.

Transaxle Oil and Filter

Oil Level Check

With the directional control lever in the neutral posi- IMPORTANT
tion and the parking brake on, run the engine at fast idle TRANSAXLE OIL SPECIFICATION. Use
to allow the transaxle to reach normal operating tem- only Clark transmission fluid part #
perature. 2776236.
With the directional control lever in the new&run the
engine at normal idle and check the oil level on the
dipstick. Add oil as needed to bring the level to the full
mark on the dipstick.

I)
mlu
9 0 0

Dipstick

1
Full

Mark \

SM 598,Oct ‘94 Transaxle Oil and Filter l 06(S)-3-1

 Main Table of Contents

Group 06(S), Transaxle (Standard)

Oil and Filter Replacement

Check transaxle oil every 50-250 hours or monthly. Drain
and refill transaxle oil and replace the external filter every
2000 hours or every year.
NOTE
Transaxle should be drained with truck at
NORMAL OPERATING TEMPERA-
TURE.
1. If necessary in order to obtain sufficient clearance
under the truck, safely elevate and block the entire
truck as described in Group SA.
2. Remove drain plug and allow oil to drain completely
into apan of at least 20-liter (5galIon) capacity. Clean
plug of all debris. Clean sump screen.
Plug
l Check O-rings for damage and scratches; replace
if damaged.
l Use a Stoddard-type cleaning solvent to clean the
screen.
l Allow screen to dry before reinstalling it. Do not
dry screen with rag-loose fibers could block
screen.
2. Remove the external transmission oil filter.
3. Install:
. A new external transmission oil filter
. A clean sump screen
. A clean drain plug.
4. Fill the transaxle through the dipstick opening with
transmission fluid, Clark part # 2776236. Use 18.5
liters (19.6 quarts).
5. With the directional control lever in the neutral posi-
tion and the parking brake on, run the engine at fast idle
to allow the transaxle to reach normal operating tem-
perature.
6. With the directional control lever in the neutral, run the
engine at normal idle and check the oil level on the
dipstick. Add oil as needed to bring the level to the full
mark on the dipstick.

External
Transmission

06(S)-3-2 l Transaxle Oil and Filter SM 598, act ‘94

 Main Table of Contents

CllRRK Group 06(S), Transaxle (Standard)

Section 4.

Transaxle Oil Cooler

Oil Cooling System Blockage Check

Check supply and return lines for kinks and pinches when
you suspect that flow is blocked or below normal.
Flow Check
Flow rates through cooling system lines may be checked
with a flowmeter, if one is available. Flow should be OS-
0.6 L/s (8-10 gpm).
Pressure Check
Measure the pressure at each of these points with a pressure
gauge tee’d into the line, as indicated in the illustration
below. The truck should be in neutral and running at 1800
rpm with the oil temperature at 60-105” C (140-220” F). If
the pressure diflerence between the two points is 276-414
kPa (40-60 psi), the cooler, fittings, or hoses are at least
partially blocked and causing the cooler bypass valve to
activate.
If the pressure difference is greater than 60 psi, the cooler
bypass valve is probably stuck closed.

A clog or other restriction in the system causes an abnor- If the pressure drop in the system is excessive, measure the
mal pressure drop across the inlet and outlet points on the pressure difference across each hose and the cooler sepa-
control valve. rately to locate the blockage.

r/ n

t- Return from
0P

\
Cooler
\ \

c SUPPlY
to Cooler

SM 590,Oct ‘94 Transaxle Oil Cooler . 06(S)-4-l

 Main Table of Contents

Group 06(S), Transaxle (Standard) ClmK

Oil Cooler Removal Oil Cooler Installation
The oil cooler is a separate unit located under the engine- Oil cooler installation is the reverse of removal.
cooling radiator. To remove the oil cooler.
Tighten mounting nuts and bolts to 40-45 N-m (54-61 ft-
Dram the transaxle fluid as described in Section 3 of lb). Reconnect fittings and tighten according to the hydrau-
this Group. lit fitting tightening procedure in Group 40.
Remove counterweight as described in Group 38. Fill transaxle as described in Section 3 of this Group (06).
Disconnect oil line fittings at cooler. Cap lines.
Remove the mounting nuts: The cooler is secured by a
carriage bolt at each end. The nuts for these bolts are
accessible through a hole in each wheel well.
Hold down the rear lip of the lower shroud andpull the
cooler from the back of the truck. (If necessary unbolt
the lower shroud and drop it down for clearance.)

Cooler Lines

Heat Shield

Transaxle Oil Cooler and Lines

06(S)-4-2 l Transaxle Oil Cooler SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 06(S), Transaxle (Standard)

Section 5.

Transaxle Removal
and Replacement

Transaxle Removal ....................._..........“.“.........“......~....................~............~_ ......................... 2

Transaxle Replacement .._...U.._......_.._.....-...~“...-...~..~...............~.................- ....................... 4

SM 598,Oct ‘94 Transaxle Removal and Replacement l 06(S)-5-l

 Main Table of Contents
Group 06(S), Transaxle (Standard)
TransaxleRemoval
1. Remove the upright as described in Group 34. Place a
block under the counterweight to prevent tip-back.
2. Remove the drive wheels as described in Group 22.
Leave front of truck elevated on blocks.
3. Tilt back steer column.Raise the seat deck Disconnect
the battery positive cable. Remove the floor plate as
described in Group 38.
4. Remove the dram plug and dram the transmission as
described in Section 3 of this Group (06).
A
WARNING
Hydraulic fluid is toxic to the skin, eyes,
and respiratory tract. Avoid skin and eye
contact. Good general ventilation is nor-
mally adequate.
5. Disconnect parking brake cables at cowl, as shown in
Group 23.
6. Disconnect the four lines at the hydraulic pump as
shown in Group 29.
7. Also disconnect/remove (Figure 1):
Inching cable from inching rod
Brake line at union of flexible line and metal line
Transaxle temperature sensor wire
Transaxle oil cooling lines
Electrical connectors for solenoid valves
Cables, wires, or hoses anchored to the transaxle.
Access Plate -v\T== /%+-A - Brake Line Joint
Oil Cooling
Lines
Connectors
06(S)-5-2 l Transaxle Removal and Replacement
CIRRK
A WARNING
Place a BLOCK UNDER THE COUNTER-
WEIGHT to prevent tip-back when the
transaxle is removed.
Also, make sure any lifting gear you use,
including sling, chain, hoist, or eyebolt, is
of sufficient capacity and is safety-inspected
and approved.
8. Support the flywheel-end of the engine by some reli-
able means, such as a floor jack or block under the
flywheel housing.
9. Remove the access plate (Figure 1) from the transmis-
sion and remove the bolts that hold the transmission
drive plate to the engine flywheel (Figure 2).
10. Remove the bolts that mount the transmission housing
to the engine flywheel housing (Figure 2).
11. Slide the converter away from the flywheel.
12. Remove the bolts from the suspension mounts for the
operator’s cell, as shown in Group 38.
13. Slightly hoist the front of the cell until the transaxle can
clear the cowl (Figure 3). Do not over-extend any of the
flexible lines connected to the cowl-mounted compo-
nents.
Hydraulic Pump Lines
Figure 1. Items to Disconnectfronz
Transaxle. Also disconnect:
connector from temperature sensor
(on side not shown), cables, wires,
and hoses anchored on transaxle.
SM 596, Apr ‘96
 Main Table of Contents

Group 06(S), Transaxle (Standard)

Pull the transaxle forward so that the housing

Figure 2. Tramaxle-to-Engine Mounting
14. Check that all wiring, hoses, and cables are out of the
way. Then, pull the transmission from the front of the
truck using either a jack or lift truck as follows:
Using a jack (Figure 3):
a. Place a rolling jack under the transmission hous-
ing and raise the jack until it contacts the housing.
b. Remove the four mounting bolts from each trans-
mission-to-frame mounting bracket.
n
! CAUTION
Make sure the torque converter stays with
the transaxle when you separate the
transaxle from the engine. Do not drop the
torque converter.
flanges separate andclearthe dowels. Use aprybar
if necessary.
Raise the jack so that the flange on the converter
housing can clear the frame cross-member.
Bring the transaxle slowly forward with the jack,
until the flange on the converter housing clears the
cross-member. Then lower the jack slightly and
pull the transaxle from the truck Make sure the
torque converter stays with the transaxle.
Using a lift truck:
a. Spread the forks so that the transmission case and
the axle housing can both rest stably on the forks.
b. Place the forks under the transaxle so that the tips
nearly touch the frame cross-member. Raise the
forks until they touch the transaxle.
C. Remove the four bolts from each transmission-to-
frame mounting bracket.
d. Pull the transaxle forward so that the housing
flanges separate andclearthe dowels. Use a prybar
if necessary.
e. Tilt the upright back to enable the mounting
flange on the converter housing to clear the cross-
member. Pull the transaxle for-w- adjusting
upright tilt as necessary, until the tmnsaxle is clear
of the truck Make sure the torque converter stays
with the transaxle.

Figure 3. Truck and Axle-to-Frame

engine are properly
blocked. Operator’s cell
is raised. Transaxle is
resting on jack.

FrameCross-Member1

SM 598, Apr ‘96 Transaxle Removal and Replacement l OS(S)+3

 Main Table of Contents

Group 06(S), Transaxle (Standard) ElCilw

TransaxleReplacement 7. Install the housing-to-housing mounting bolts. Torque

to 40-45 Nom (30-33 ft-lb).
1. Make sure the torque converter is installed in the
transaxle, as described in the transaxle overhaul Sec-
tion in this Group (06).
2. Install alignment studs in flywheel (Figure 5).
3. Remove the access cover from the converter housing.
4. Sightly hoist the operator cell so that the transaxle can
clear the front cowl. Do not over-extend any of the
flexible lines connected to the cowl-mounted compo-
nents.
5. Preparetoplacethetransaxleinthetruckwitharolling
jack or with a lift truck as follows:
Usinga jack (Figure 4):
a, Place a rolling jack at the front of the truck Hoist
the transaxle onto the jack.
b. Roll the transaxle up to the frame cross-member.
c. Raise the jack so the converter housing flange can
clear the cross-member.
Usinga lift truck: Housing-to-Housing Drive Plate Mounting
Mounting Bolt Bolt and Typical Align-
a Position the forks under the transaxle so that it is ment Stud
stably supported under the transmission case and
axle housing, with the converter housing beyond Figure 5. Afounting the Engine Housing and Flywheel to
the tips of the forks. the Transmission Housing and Drive Plate
6. Sting the transaxle to the engine so that converter pilot,
dowels, alignment stud, and mounting flanges mate
properly (Figure 5).

Figure 4. Truck and

engine are properly Axle-to-Frame
blocked. Operator’s cell
is raised. Transaxle is
resting on jack.

Frame Cross-Member 1

OS(S)+4 . Transaxle Removal and Replacement SM 598, Apr ‘96

 Main Table of Contents
emu
8. Install the axle-to-frame mounting bolts (Figure 4).
Torque the mounting bolts to 542-596 Nom (400440
Mb.)
9. Rotate the transmission drive plate until a vacant
flywheel hole and a drive plate mounting hole am
within the access port (Figure 6). Screw in, but do not
tighten the drive plate mounting bolt. Repeat at each
flywheel/drive plate mounting hole, removing the
alignment stud
Figure 6. Fastening the Drive Plate to the Flywheel
Access Plate -‘~~ / Brake Line Joint
Connectors
SM 598, Apr ‘96
Group 06(S), Transaxle (Standard)
10. Torque all the drive plate mounting bolts 20-25 Nom
(15-18 ft-lb).
11. Reinstall/reconnect the following items (Figure 7):
l Inching cable at control cover.
l Brake line at union of flexible line and metal line.
Torque to 16 N*m (12 f&lb).
l Transaxle temperature sensor connectors.
l Transaxle oil cooling lines. Tighten fittings per
hydraulic fitting tightening procedure in Group
40.
l Access plate
l Solenoid valve connectors.
12. InstaJl/connect all other items removed or discon-
nected in steps 1 through 6 of “Transaxle Removal,”
using the referenced Sections for specific procedures.
! CAUTION
n
Do not use old transmission fluid Use only
Clark Transmission Fluid part number
2776236. See the transmission drain and
fill Section in this Group (06) for details.
13. Fill the transaxle. Run truck until warm. Recheck fluid
level.
Hydraulic Pump Lines
Figure 7. Items to Reconnect
to Transaxle. Also reconnect
connectors to temperature
sensor (on side not shown).
Transaxle Removal and Replacement . OS(S)-64
 Main Table of Contents

clmu Group 06(S), Transaxle (Standard)

Section 6.

Transaxle Overhaul

General Practices to Follow .................................... ..“...........................~..................................... 2

Disassembling Components ............................................................................................................. 2
Cleaning Parts .................................................................................................................................. 2
Inspecting Parts ................................................................................................................................ 2
Repairing and Replacing Parts ......................................................................................................... 3
Bearings .................................................................................................................................... 3
Gears and Shafts ....................................................................................................................... 3
Splines.. ..................................................................................................................................... 3
Clutch Discs .............................................................................................................................. 3
O-Rings and Gaskets ................................................................................................................ 3
Oil Seals .................................................................................................................................... 4
Housings ................................................................................................................................... 4
Threaded Fasteners and Snap Rings ........................................................................................ .4
Reassembling Components ............................................................................................................. .4

Overhaul Procedures ..................... ..“.........................................................................................” . 5

Transaxle Disassembly ................................................................................................................... .5
Removing Transaxle Peripherals .............................................................................................. 5
Separating Converter, Transmission, and Axle Housings ....................................................... .8
Removing the Stator Support, Impeller Hub Gear and Bearing, Stator Oil Seal,
and Pump Idler Gear.. ........................................................................................................ 9
Removing Clutch Assembly and Reverse Idler Shaft ............................................................ 10
Removing the Differential and Pinion Shaft Assembly ......................................................... 10
Removing the Suction Tube ................................................................................................... 11
Removing Bearings, Cups, Shims, and Oil Distributor from Transmission
and Differential Housing ................................................................................................. 11
Differential Overhaul ..................................................................................................................... 12
Differential Disassembly ........................................................................................................ 12
Differential Reassembly ......................................................................................................... 12
Clutch Overhaul ............................................................................................................................. 13
Disassembling the Clutch ....................................................................................................... 13
Reassembling the Clutch ........................................................................................................ 14
Transaxle Control Valve Overhaul ................................................................................................ 17
Transaxle Reassembly ................................................................................................................... 18
Installing Oil Distributor Sleeve, Reverse Idler Shaft Bearing, and Clutch Shaft Bearing
into Transmission Case.. .................................................................................................. 18
Installing the Suction Tube ..................................................................................................... 18
Installing the Pinion Bearings, Pinion Shaft, and Output Gear .............................................. 19
Installing the Differential ........................................................................................................ 21
Installing the Clutch and Idler Gear.. ..................................................................................... .23
Installing the Pump Idler Gear and Bearing .......................................................................... .24
Installing the Stator Oil Seal, Impeller Hub Gear and Bearing, and Stator Support ............. .24
Joining Converter, Transmission, and Axle Housings .......................................................... .25
InstaIling Axle Shafts and Axle Ends ..................................................................................... 25
Installing Transaxle Peripherals ............................................................................................. 26
Filling and Initial Startup ....................................................................................................... .28

SM 598,Oct ‘94 Transaxle Overhaul l 06(S)-6-1

 Main Table of Contents
Group 06(S), Transaxle (Standard)
General Practices to Follow
The following procedures should be applied throughout the
process of disassembling, inspecting, cleaning, repairing,
replacing, and reassembling the transaxle components.
Specific disassembly and reassembly procedures are given
later in this Section. Follow those procedures closely.
Disassembling Components
Before disassembling the transaxle, you must drain the
transaxle fluid, disconnect the necessary controls, linkages,
and hydraulic lines, and remove the transaxle from the
truck as described in Section 5. Observe the following
practices during disassembly:
l Cleanliness - Work in a clean place. It is important
that no dirt or foreign material enters the unit during
repairs. Dirt is an abrasive and can damage bearings.
It is always good practice to clean the outside of the
unit before starting the planned disassembly.
l Assemblies - When disassembling the various assem-
blies, such as the clutches, idler shaft, and wheel ends,
lay all parts on a clean bench in the same sequence as
removed. This procedure will simplify reassembly
and reduce the possibility of losing parts.
l Using Tools to Move Parts - Always apply force to
shafts, bearings, housings, etc., with restraint. Move-
ment of some parts is restricted. Never apply force to
the part being driven after it stops solidly. The use of
soft hammers, bars and mauls for all disassembly
work is recommended.
l Bearings - Remove bearings that will be reused with
pullers designed for this purpose. Lubricate bearings
with clean oil and wrap them in a lint-free cloth or
clean paper to protect them while not in use.
l Snap Rings - Remove snap rings with pliers designed
for this purpose. Snap rings removed in this manner
can be reused, if they are not sprung or loose in the
groove.
OS(S)+2 . Transaxle Overhaul
EIRRK
Cleaning Parts
A WARNING
Gasoline is not an acceptable cleaning sol-
vent because of its extreme combustibility.
It is unsafe in the workshop environment.
Proper cleaning requires complete disassembly.
Wash steel parts with machined surfaces in a com-
mercial solvent.
Clean the inside and outside of bearing caps, hous-
ings, etc. Cast parts which do not have machined or
polished surfaces may be cleaned in hot solution.
Wash castings or other rough parts in solvent or clean
in hot solution tanks using mild alkali solutions, heat-
ing parts thoroughly before rinsing.
Rinse all parts thoroughly. Dry immediately with clean
rags, except for parts with rough surfaces. Lightly oil
parts and wrap them in corrosion-resistant paper if
they will not be used immediately. Store parts in a
clean, dry place.
NOTE
Do not use rags to dry parts with rough
surfaces, such as castings. Fibers left by
rags can restrict flow through the suction
screen.
Clean bearings thoroughly in clean, approved solvent
until completely cleaned. Dry bearings using mois-
ture-free compressed air. Be careful to direct air stream
across bearing to avoid spinning. Lubricate bearings
with clean oil and wrap them in a lint-free cloth or
clean paper to protect them until installation
Do not spin bearings when drying them. Bearings
may be rotated slowly by hand to facilitate drying.
Inspecting Parts
Closely inspect all transaxle components after cleaning and
before reassembly to determine whether they require re-
placement.
Careful and complete inspection of all parts is very impor-
tant Replacement of all parts showing indication of wear,
over-stressing, or damage will save time and money at a
later date.
Inspect:
l Steel parts for notches, visible steps or grooves. Look
for scuffing, deformation, or discoloration related to
improper lubrication.
l Bearing balls, cages or retainers, rollers, and race-
ways for pitting, discoloration, and spalled areas.
SM 598,Oct ‘94
 Main Table of Contents
CUIRK
Gear teeth for signs of excessive wear, pitting, or
cracking along contact lines. Check tooth contact pat-
tern.
Machined surfaces of cast or malleable parts for cracks,
scoring, and wear. Look for elongation of drilled holes,
wear on machined surfaces and nicks or burrs in
mating surfaces.
Fasteners for rounded heads, bends, cracks or dam-
aged threads.
All housings for cracks or leaks, loose studs, or cross-
threaded holes.
IMPORTANT
Any damage that affects the alignment or
structural integrity of the housing requires
replacement. Repair by welding or straigbt-
ening should not be attempted. Such pro-
cesses can affect the housing metallurgy
and cause it to fail completely when under
load.
Repairing and Replacing Parts
Replace lower-cost parts such as thrust washers, seals, etc.,
that protect the transaxle from premature wear and do not
add greatly to the cost of rebuild.
Replace heavily worn but unbroken parts.
Steel parts such as shafts or gears are not repairable. If
worn or damaged, replace them, along with mating parts as
necessary.
Seals and washers should be routinely replaced. Fasteners
with self-locking patches may be reused if secured with
several drops of 277 (Clark part # 1802302).
Transaxle housing repairs are limited to removal of nicks or
burrs on machined surfaces or replacement of damaged
studs.
Since the cost of a new part is generally a small fraction of
the total cost of downtime and labor, avoid reusing a ques-
tionable part which could lead to additional repairs and
expense soon after initial reassembly. To aid in determin-
ing the reuse or replacement of any transaxle part, also
consider the unit’s history, hours of use, application, etc.
When replacement is necessary, use only genuine Clark
parts to assure continued performance and extended life
from your unit.
Recommended inspection procedures for various types of
parts are as follows:
SM 590,Oct ‘94
Group 06(S), Transaxle (Standard)
Bearings
Replace bearings that are pitted, discolored, or spalled.
Always replace bearing cups and cones as a set. Do
not replace a bearing or race separately.
Replace bearings with excessive clearances.
Check bearing fits. Bearing inner races should fit tight
to the shaft; outer races slightly tight to slightly loose
in housing bore. If bearing spins freely in bore, how-
ever, housing should be replaced.
Gears and Shafts
Check gear teeth for frosting and pitting. Frosting of
gear tooth faces presents no threat of transmission
failure. Often in continued operation of the unit, frosted
gears will “heal” and not progress to the pitting stage.
And in most cases, gears with light to moderate pitted
teeth have considerable gear life remaining and can be
reused. But gears with advanced-stage pitting should
be replaced.
If the Magnaflux process is available, use it to check
parts for damage.
If gear teeth show areas where the case-hardening is
worn through or cracked, the gear must be replaced.
Inspect all shafts to be sure they are not bent or
cracked and that splines are not damaged.
Splines
l Check splines on all shafts and gears for abnormal
wear. If splines are severely worn or pitted, replace
the specific part affected.
Clutch Discs
All damaged discs must be replaced with new ones.
Inspect clutch plates for excessive wear (shown by
worn dimples or friction surfaces), excessive heating
(blue color indicates excessive heating), and warp.
Examine clutch plate internal and external teeth for
evidence of excessive wear.
O-Rings and Gaskets
l Replace all O-rings at overhaul.
l Replace all gaskets at overhaul.
l O-rings and seals should be lubricated with transmis-
sion fluid (Clark part # 2776236) before assembly.
Transaxle Overhaul l OS(S)-6-3
 Main Table of Contents
Group OS(S), Transaxle (Standard)
Oil Seals
l Replace all oil seals at overhaul.
l Use extra care when installing seals. Seal lips aud
sealing surfaces can be easily nicked and damaged,
thereby destroying the sealing ability.
Housings
l Check all housings for damage, cracks and wear.
Replace damaged housings, as needed.
l Gasket sealing surfaces should clean and free of nicks
and burrs.
Threaded Fasteners and Snap Rings
l Inspect all fasteners for damage and wear. Replace all
damaged fasteners.
l Snap rings are to be installed with flat side away from
load. Replace any damaged or suspect snap rings.
Reassembling Components
These practices should be followed during reassembly:
l CIeanliness - Be sure that interiors of all housings are
clean. It is important that dirt and other foreign mate-
rials be kept out of the uansaxle during reassembly.
Dirt is an abrasive and can damage polished surfaces
of bearings and washers.
l Removing Burrs - Make sure all lead-in chamfers for
oil seals, piston ring grooves, and O-rings are smooth
and free from burrs. Inspect at assembly.
l Initial Lubrication of Parts - Brush light coating of
transmission fluid, Clark part # 2776236, on bearings
and bushing bores.
Lubricate all piston ring grooves, clutch plates and O-
rings with transmission fluid # 2776236 before as-
sembly.
l Use of Sealing Compounds and Thread Lockers -
Use only where specified.
Make sure there is no excess or free sealing com-
pound or thread locker that could enter the oil system.
Threads should be clean and dry before application of
thread compound.
l Gaskets - Be sure all gaskets are installed. An omis-
sion of any gasket can result in oil leakage.
OS(S)&4 l Transaxle Overhaul
ElfIRK
Capscrews and Threaded Fasteners - Use only
threaded fasteners of the correct part number and
material specification. Replace all fasteners that have
a questionable condition. Threads should be clean and
dry before application of thread compound. Apply
lubricant or thread compound only as specified. Be
sure all fasteners are installed (none omitted) and
torqued to the correct specification.
Bearings - Use of the proper bearing installation tool
is recommended for the installation of bearings. The
proper tool applies equal force to both bearing races,
preventing damage to balls/rollers and races while
maintaining correct bearing alignment with bore and
shaft. Avoid using a tubular or sleeve-type driver,
whenever possible.
Torque Recommendations - Correct torque applica-
tion is extremely important to assure long transaxle
life and dependable performance. Over-tightening or
under-tightening can result in a loose installation and,
in many instances, eventually cause damage to
transaxle gears, shafts, and/or bearings. Use a torque
wrench whenever possible to attain recommended
torque ratings. Torque recommendations are given in
this Section with the specific assembly procedures.
Tool Reference - Some repair procedures in this
manual may show the use of specialized tools. Their
actual use is recommended as they make transaxle
repair easier, faster, and prevent costly damage to
critical parts.
But for the most part, ordinary mechanic’s tools such
as socket wrenches, screwdrivers, etc., and other stan-
dard shop items such as a press, mauls, and soft bars
are all that is needed to successfully disassemble and
reassemble the transaxle.
IMPORTANT
Refer to the appropriate Customer Service
Parts Book for the correct service replace-
ment parts to be used during reassembly of
the transaxle.
SM 596,Oct ‘94
 Main Table of Contents

LlflRK Group 06(S), Transaxle (Standard)

Overhaul Procedures Removing Transaxle Peripherals

Overhaul involves following the general practices given Use a chain hoist to lift the tram&e. For lifting, an eyebolt
earlier in this Section and performing the specific proce- with a 9/16-18UNF thread can be screwed into one of the
dures given in the remainder of this Section. clutch test ports, shown in Figure 12, after removing the
Please read the general practices before proceeding. port plug.
Position the transaxle in its in normal orientation. Remove
NOTICE items as described below. Locations are shown in Figure
12.
Cleanliness is of extreme importance in the
repair and overhaul of this assembly. 1. Ifthe transaxle was not previously drained, remove the
drain plug and drain the oil. Also remove strainer.
Perform all disassembly and assembly work
in a clean area. Overhaul the transaxle only
in a clean, dust-free location, using clean
tools and equipment. Dirt or grit will dam-
age the highly-machined surfaces and re-
sult in premature failure of components.
Cleanliness of interior surfaces, orifices, etc. Figure 1. Drain Plug and Strainer
is extremely important to the proper op-
eration of the hydraulic circuit. The exte-
rior surface of the unit must be thoroughly 2. Remove clutch pressure tube and clutch lube tube at
control valve cover and transmission case.
cleaned of all dirt and foreign substances
to prevent contamination of the parts dur-
ing overhaul. Protect all components from
dust and dirt while repairs are being made.
Be sure the work area is kept clean.

Figure 2. Clutch Pressure and Lube Tubes

Transaxle Disassembly
3. Disconnect brake line fittings atbrake backing plates.
Remove bolt that holds brake line tee to control valve
NOTICE cover. Lift tee and connected lines away.
Keep all parts in order as disassembly
progresses. Take care to properly identify
each part and its order of removal. If nec-
essary, keep notes and put markings on
parts using a non-destructive marker such
as a felt-tipped pen.

Figure 3. Brake Lines and Fittings

SM 598,Oct ‘94 Transaxle Overhaul - OS(S)-6-5

 Main Table of Contents

Group 06(S), Transaxle (Standard) ClRRK

Remove transaxle oil dipstick tube, if not already 7. Remove transaxle oil fdter.
removed, by disconnecting mounting bracket and fit-
ting at end of tube.

Figure 7. Transaxle Oil Filter

8. Remove transaxle control valve assembly. Remove

and dispose of control valve gasket.

Figure 4. Transaxle Oil Dipstick Tube

Remove torque converter assembly by carefully slid-

ing it off the turbine/clutch shaft and the stator support
Use care during handling and storage. Improper han-
dling could cause converter leaks.
Figure 8. Transaxle Control Valve
See the “Transaxle Control Valve Overhaul” Section
in this Group (06), for overhaul procedures.

9. Remove the solenoid valves and temperature sensor.

f?l

Figure 5. Torque Converter

Remove main hydraulic pump and gasket. The trans-

mission charging pump is in the same housing. Also
remove three O-rings from ports and pilot.
Figure 9. Solenoid Valves and Temperature Sensor

10. Remove the breather.

Figure 10. Breather

Figure 6. Hydraulic Pump and Transaxle Charging Pump

06(S)-6-6 l Transaxle Overhaul SM 598,Oct ‘94

 Main Table of Contents

ElfIRK Group 06(S), Transaxle (Standard)

11. If you intend to overhaul the axle end and/or brake

assemblies,disassemblethosecomponentsasdescribed
in the “AxleEnd Overhaul” Section in this Group (06),
and the “Service Brake Inspection and Overhaul’
Section in Group 23.

Figure 11. Axle End Assembly

r Torque Converter (In Housing)

Dipstick Tube
Transaxle
Control Valve

Transaxle
Oil Filter
Main Hydraulic
PumpflIansaxle
Charging Pump
Brake Line Tee

Drain Plug
Temp. Sensor and Strainer

Pressure Tube Axle End

Assembly

Lube Tube

Brake Drum

Brake Line Fiiing J L Solenoid L Breather LClutch Brake Line Fitting

Valves Test Ports

Figure 12. Transaxle Peripherals

SM 598,Oct ‘94 Transaxle Overhaul l OS(S)-6-7

 Main Table of Contents

Group 06(S), Transaxle (Standard) CIRRK

Separating Converter, Transmission, and Axle Transmission Case to Axle Housing
Housings
Refer to Figure 13.
Before you separate the housings, the transaxle must be 1
If the axle shaft is not already removed remove 10
removed from the truck (as described in Section 5) and .
axle-to-hub mounting bolts (G) from each axle end,
peripherals must be removed from the transaxle (as de-
and pull axle shafts (H) out of differential.
scribed above). Then, proceed as follows.
2. Remove 17 transmission-to-axle mounting bolts (E &
J) from mounting flanges.
Converter Housing to Transmission Case
3. Separate axle housing (F) from transmission case (D),
Refer to Figure 13.
tapping with rubber mallet if necessary.
1. Block under the converter housing (B) or hoist it so that 4
Remove and discard gasket (I) between housings.
it is supported as you unbolt it from the transmission
case (D).
2. Access transmission-to-converter mounting bolts (A)
and washers from inside of converter housing (B).
Remove 11 bolts.
3. Separate converter housing from transmission case
@), rapping with rubber mallet if necessary.
4. Remove and discard gasket (C) between housings.

Figure 13. Separation of Transaxle Housings

OS(S)-6-8 l Transaxle Overhaul SM S98,Oct ‘94

 Main Table of Contents
CWIRU
Removing the Stator Support, Impeller Hub Gear and
Bearing, Stator Oil Seal, and Pump Idler Gear
Refer to Figure 14.
Before you remove these items, the transmission case must
be separated from the converter housing as described previ-
ously. Then:
1. Remove 4 stator support mounting capscrews (G) aud
washers.
2. Using a soft-faced hammer, tap stator support(E) from
converter housing, Bearing (F) and bushing @I) are
pressed onto stator support and should be replaced if
worn or damaged, although it is advisable to replace
the entire assembly.
Figure 14. Converter Housing Contents (Torque Converter Removed Previously)
SM 598,Oct ‘94
Group 06(S), Transaxle (Standard)
3. Remove hook ring seal (J).
4. Lift out the impeller hub gear ( K).
5. Remove the impeller hub bearing (L) by tapping
lightly.
Rush the oil seal (A) out of the housing.
To remove the pump idler gear, install an M8- 1.25bolt
into the threaded hole in the shaft (B) of the pump idler
gear. Pull the shaft from its bore with a slide hammer
or other suitable device, gripping the installed screw.
Do not pry on machined surface.
8
Remove the pump idler gear (II) and bearing (C) from
’
the converter housing.
Transaxle Overhaul l OS(S)-6-9
 Main Table of Contents

Group 06(S), Transaxle (Standard) Emu

Removing Clutch Assembly and Reverse idler Shaft
Before you remove these components, the transmission
case must be separated from the converter housing as de-
scribed previously.
1. Remove reverse clutch outer thrust bearing set (Figure
15, A).
1. Remove the clutch assembly (Figure 15, B) and re-
verse idler shaft (H) together: Use a gear puller to
loosen the idler shaft from its rear bearing (G). Grasp
both shafts and pull from case.
2. Locate and remove forward clutch outer thrust bearing
(Figure 15, C) from transmission case or clutch shaft
(turbine shaft).
3. If the inner bearing (Figure 15, I) needs replacing, pull
it from the idler shaft.
Removing the Differential and Pinion Shaft Assembly
Before you remove these components, the torque converter
and axle housing must be separated from the transmission
case and the transmission case should be anchored to the
bench. Then:
Support the differential assembly (Figure 16,I) for
removal.
Full the lock pins (Figure 16, L) from the differential
carrier adjusting nuts.
Remove the adjusting nuts (Figure 16, M).
Remove the differential casing (Figure 16, I) and cone
bearings (Figure 16, G and K).

Figure 15. Clutch Assembly and Idler Shaft Removal

Figure 16. Differential and Pinion Removal

06(s)-6-10 l Transaxle Overhaul SM 598, act ‘94

 Main Table of Contents

ClRRK Group 06(S), Transaxle (Standard)

5. Remove output gear retaining ring (Figure 16, A)
from pinion shaft (inside transmission case).
6. Hold or block the pinion shaft (Figure 16, F) or output
gearwith abrassbarorsimilarsoftmaterialtoprevent
turning. Loosen and remove the pinion shaft nut
(Figure 16, N).
7. Use a brass bar to drive the pinion shaft (Figure 16, F)
from its bearings. Support pinion so that shaft does
not fall as it exits the case.
8. Remove the pinion shaft outer bearing (Figure 16,O)
and shims (Figure 16, Q).
Note: Wire shims to transmission case for storage
until reassembly.
9. Remove output gear (Figure 16, B).
Removing the Suction Tube
Removing Bearings, Cups, Shims, and Oil Distributor
from Transmission and Differential Housing
With all other components cleared from transmission case:
1. Pull the reverse idler shaft rear bearing. (Figure 15, G).
2. Pull the turbine (clutch) shaft rear bearing (Figure 15,
D).
3. Inspect the clutch shaft oil distributor sleeve (Figure
15, E).If it appears worn or damaged, remove the
retaining set screw (F). Then, pull the oil distributor
sleeve from the transmission case with a slide hammer
or gear puller.
4. If pinion bearings are to be replaced, drive out the cups
(Figure 16, D and P) from inside transmission case.
Remove shims (Figure 16, C) from differential side.
Note: Wire shims to transmission case for storage until
reassembly.

To remove the oil suction tube assembly from transmission

Remove the keeper from the bore with pliers (A).

Discard keeper.
Push the tube toward the converter end of case (B) to
free it from axle end of case
Rotate the tube (C) to provide clearance.
Pull the tube back toward the axle case (D)andremove
the tube.
Remove and discard O-ring.

Figure 17, Oil Suction Tube Removal

SM 598,Oct ‘94 Transaxle Overhaul l OS(S)-6-l 1

 Main Table of Contents

Group 06(S), Transaxle (Standard) CMRK

DifferentialOverhaul
Refer to Figure 18.

Differential Disassembly
1. Unbolt the ring gear (A) from the differential casing.
2. Using a small drift pin or rod, drive the differential
pinion pin lock pin (B) from the casing Q.
3. Remove pinion pin (C).
4. Remove items G-K from differential casing.
5. If bearings or cups (D, F) need replacement, drive cups
from casing.

Differential Reassembly
Before reassembly, clean, inspect and lubricate all parts.

IMPORTANT /
Replace both the pinion and ring gear as
matched set only.
1. Press bearing (D, F) cups to bottom of bores if they are
being replaced. Cups must be replaced if bearings are
being replaced.
2. Insert the side gears (H) and washers (I) into the
differential assembly.
3. Insert washers (K) into grooves in casing.
‘I
4. Insert both pinion gears (G, J) into position on the side
g-. ,J
5. Rotate the side gears and pinions until the bores in the
pinions (G, J) align with the pm (C) hole in the ,K
housing.
6. Insert the pinion pin (C) into the housing. Rotate the
pinion pin so that one of its slots can receive the lock Figure 18. Differential Casing AssemblylDisassembly
Pin 09.
7. Drive lock pm (B) into the casing so that the lock pin
engages the pinion pin (C).
8. Mount the ring gear (A) to the casing (E):
a. Use a vice with soft jaws to hold the casing.
b. Clean and dry all bolts and ring gear threads.
c. Apply Loctite primer T (Clark part #1803836)
and Loctite 271 (Clark part #1802302) to all A! CAUTION
threads. RING GEAR BOLTS. Use only new ring
gear bolts. Used bolts can failed prema-
d Use alignment studs to position the ring gear.
turely.
e. Install 12 mounting bolts with washers, and torque
to 205-250 Nom (151-185 ft-lb).

OS(S)-s-12 l Transaxle Overhaul SM 598, Apr ‘96

 Main Table of Contents

ClmK Group 06(S), Transaxle (Standard)

Clutch Overhaul 7. Slide off retainer disc (J), piston return spring (K),
sleeve (L), and shim (TV).

Disassembling the Clutch 8. Remove clutch piston (0) by turning clutch upside
down and tapping the shaft on a block of wood or by
Figure 19 shows the contents of the reverse drum (R). The applying compressed air to bore between distributor
contents of the forward clutch drum (S) are the same as the seal rings (M). (Outermost bore is for reverse piston:
and reverse clutch drum except that the forward clutch’s innermost for forward piston.)
drive gear is smaller and the outer thrust bearings differ (as
shown in Figures 15 and 38). 9. Remove from piston, and discard clutch piston seals
and O-rings (P and Q).
1. Slide off clutch drive gear(B), and inner thrust bearing
and washers (D). 10. Repeat above procedures for forward clutch drum (S)
disassembly.
2. Remove seal ring (C) from gear hub
11. Remove three oil distributor seal rings (M) at end of
3. Press the clutch gear bearings and spacer (A) from the shaft by squeezing and unlatching them.
internal bore of clutch gear hub, if they need replace-
ment. 12. Inspect turbine shaft. Check widths of sealringgrooves
by installing new seal rings (M) from kit. If side
4. Pry retainer ring (E) out of the groove in the clutch clearance exceeds 0.203 mm (0.008 in), shaft is worn
barrel (R) and remove clutch disc end plate (F). and must be replaced.
5. Withdraw the five inner clutch discs (G) and five outer
clutch discs (H).
6. Remove clutch return spring retainer clip (I) with snap
ring pliers. (To remove the clip you, must first com-
press the spring as illustrated in Figure 23.)
A CAUTION
SPRING UNDER HEAVY COMPRES-
SION. Carefully remove with press and
special tool shown in figure 23.

Figure 19. Forward Clutch Pack Contents

SM 598,Oct ‘94 Transaxle Overhaul l OS(S)-6-13

 Main Table of Contents

Group 06(S), Transaxle (Standard) ClRRK

Reassemblingthe Clutch
Forward and reverse clutch reassembly are the same. The Retainer Clip
reverse clutch is shown below.
NOTICE Retainer Disc
Before reassembly, clean, inspect and lu-
bricate all parts with a light layer of Clark-
Return Spring
Transmission Fluid, part # 2776236.

Lube Sleeve
Clutch Piston and Return Spring Reassembly
1. Install new clutch piston inner and outer O-rings and
Shim Pack
teflon oil seal rings in piston grooves. Make sure that
outer O-ring is not twisted.
Piston
Teflon
Seal

O-Ring

Groove for
Retainer Clip

Figure 20. Clutch Piston Assembly

Figure 21. Clutch Pack Assembly

IMPORTANT
NOTE
CLUTCH PISTON RINGS MUST BE
SHIM PACK THICKNESS. If you are in-
SEATED before you install the piston on
stalling a new lube sleeve, piston, or tur-
the shaft and into the clutch drum.
bine shaft, you must determine the required
Hold a cylindrical object, such as a screw- shim thickness.
driver shaft, against the new seal rings and
To do so, install the sleeve withouta shim
rotate the piston to seat the rings.
pack and check the gap (Figure 22) be-
Make sure the seal rings are seated flush tween the sleeve’s flange and the clutch
with the inner and outer diameters of the piston with a flexible feeler gauge. Then
piston. use the chart on the next page to determine
2. Position the clutch assembly so that the open end of the the thickness of the shim pack.
clutch drum faces up. (Refer to Figure 21.)
6. Recheck gap (Figure 22) after installing shims, and
3. Apply transmission fluid, Clark part # 2776236, to adjust as necessary.
piston seal and inside of drum.
7. Install piston return spring (Figure 21) over sleeve
4. Install clutch piston, with oil seals, over turbine shaft and against flange.
and into bottom of the drum. Rotate piston to check
8. Install retainer disc (Figure 21) against spring. Make
whether seals are installed properly. The piston will sure that retainer disc is properly aligned to clear steps
bind if either seal is out of position.
on turbine shaft.
5. Install shim pack and lube sleeve, with flange end of
9. With a press (Figure 23), compress the return spring
sleeve toward piston.
and install retainer clip into groove in Nbine shaft.
Make sure sharp edge of clip faces up.
10. Repeat assembly procedures for forward clutch.

06(S)-6-l 4 l Transaxle Overhaul SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 06(S), Transaxle (Standard)

Lube Sleeve Shim Chart

Measured Gap Shim Pack Measured Gap

Before Shimming Height After Shimming
(mm) (inch) (mm) (inch) (mm) (inch)
4.45-4.67 (.175-.184) 4.25 (.167) 0.20-0.42 (.008-.017)
4.19-4.42 (.165-.174) 4.00 (.158) 0.19-0.42 (.008-.017)
3.94-4.17 (.155-.164) 3.75 w8) 0.19-0.42 (.007-.016)
3.86-3.91 (.145-.154) 3.50 (.138) 0.18-0.41 (.007-.016)
3.43-3.65 (.135-.144) 3.25 (.128) 0.18-0.40 (.007-.016)
3.18-3.40 (.125-.134) 3.00 (.118) 0.18-0.40 (.007-.016)
2.92-3.15 (.115-.124) 2.75 (.108) 0.17-0.40 (.007-.016)
2.67-2.90 (.105-.114) 2.50 (.098) 0.17-0.40 (.007-.016)
2.41-2.64 (.095-.104) 2.25 (.089) 0.16-0.39 (.006-.018)
2.16-2.39 (.085-.094) 2.00 (.079) 0.16-0.39 (.006-.018)
1.91-2.13 (.075-.084) 1.75 (.069) 0.16-0.38 (.006-.018)
1.65-1.88 (.065--074) 1.50 (.059) 0.15-0.38 (.006-.018)
1.38-1.63 (.055-.064) 1.25 W9) 0.13-0.38 (.006-.018)
1.21-1.37 (.048-.054) 1.00 (.039) 0.21-0.37 (.006-.018)
0.84-1.19 (.033-.047) 0.75 (.030) 0.09-0.44 (.004-.018)
0.07-0.83 (.003-033) No Shim 0.07-0.83 (.003-.033)

li
Gap sin

Figure 23. Press and Fixture. Fixture must be at least 25

cm (10 in) long with an inner diameter of 3.5 cm (1.4 in),
an outer diameter of 6.4 cm (2.5 in), and an opening to
allow installation of a snap ring.

Figure 22. Shim and Gap Shown in Cross-Section of

Clutch Assembly

SM 598, act ‘94 Transaxle Overhaul l 06(S)-6-15

 Main Table of Contents

Group OS(S), Transaxle (Standard) CMRK

Clutch Discs Reassembly
Retainer Ring
Refer to Figure 24.
1. Soak friction discs in transmission fluid, Clark part #
2776236. End Plate

2. Install the first outer clutch disc (steel disc) against

clutch piston. Next, install first inner clutch disc (fric-
tion disc). Alternate outer and inner discs to install a
total offive standard thickness outer steel discs andfive
inner friction discs.
3. Install clutch disc end plate with stepped surface to
outside.
4. Install end plate retainer ring into groove in drum. Pull
up forcefully at two points on end plate to verify that
retainer ring is properly seated.
5. Check clutch disc clearance Inner Disc
(Friction Disc)
a. Stand the clutch assembly on end with drum open-
ing upward. The stack of clutch discs and end plate
will rest against the piston. Outer Disc
b. Set up a dial indicator as shown in Figure 25. Raise (Steel Disc)
end plate against retainer ring. Measure the dis-
Groove for
tance end plate travels. (Flexible feeler gauge may
Retainer
be used.) Ring
c. If clearance is more than 3.38 mm (0.133 in), add
an outer (steel) clutch disk.
6. Repeat assembly procedures forforward clutch.

Figure 24. Clutch Discs Installation

Figure 25. Clearance between End PIate and Retainer Ring.

06(S)-S-16 l Transaxle Overhkul SM 598,Oct ‘94

 Main Table of Contents
ElfIRK
Clutch Gear Reassembly
1. Install inner thrust bearing set (thrust bearing be-
tween two thrust washers) onto clutch shaft (turbine
shaft).
2. If removed, press clutch gear bearing set into clutch
gear. Top surface of upperbearing shouldbe just below
top surface of gear. Letters on bearing edges should be
visible after installation.
3. Install seal ring into groove in clutch gear hub.
Seal Ring
Inner Thrust
Bearing Set
Figure 26. Clutch Gear, Seal Ring, and Bearings
Clutch Gear Installation
1. Lower the gear assembly into the clutch pack and
rotate it as necessary to clear the teeth of each friction
disk. Do not force the hub into the clutch pack. Be sure
the clutch hub is fully through the entire clutch pack.
Figm 27. InstallingClutch Gear by RotatingintoClutch Pack
SM 598, Apr ‘96
Group 06(S), Transaxle (Standard)
2. Check that gear assembly is inserted correctly: The
gear seal ring must be just below the upper surface of
the end plate.
3. Repeat clutch gear assembly and installation proce-
dures for forward clutch.
Oil Distributor Rings Installation
1. After forward clutch is assembled, install three new oil
distributor seal rings on clutch shaft. Gently spread
each ring and slide it into its groove. Squeeze and latch
each ring.
2. Apply transmission fluid Clark part # 2776236 to rings
to facilitate assembly into oil distributor.
Figure 28. Oil Distributor Rings
Transaxle Control Valve Overhaul
The entire control valve should be disassembled, cleaned,
and inspected at transaxle overhaul. However, the valve-
or its various subsections-may be disassembled separately
whenever troubleshooting indicates a problem.
Procedures are given in the transaxle control valve over-
haul Section of this Group (Group 06).
Transaxle Overhaul l OS(S)-6-17
 Main Table of Contents

Group 06(S), Transaxle (Standard) CUlRK

Transaxle Reassembly

IMPORTANT Setscrew
Before proceeding, read the general prac-
tices for inspecting, cleaning, replacing, and 71
reassembling components given at the be-
ginning of this Section.
Sleeve
Notes:
l Use sealing compounds and thread lockers only where Turbine Shaft
specified. Rear Bearing
l All lead-in chamfers for oil seals, piston ring grooves
and O-rings must be smooth and free from burrs.
Inspect at assembly.
l Lubricate all piston ring grooves, clutch plates and O-
rings with transmission fluid, Clark part # 2776236,
before assembly. The Clark-specified fluid has addi- Reverse Idler Shaft Rear
tives that are especially important for conditioning Bearing
new friction disks.
l Brush a light coating of transmission fluid, Clark part Figure 29. installation of Transmission Case Rear
# 2776236 on bearings and bushing bores. Components
l After applying sealing compounds and thread lockers,
make sure there is no free or excess material that
could enter the oil system. Installing the Suction Tube
If the suction tube has been removed, install it as follows.
Installing Oil Distributor Sleeve, Reverse Idler Shaft 1. Check cleanliness of O-ring groove in suction mbe
Bearing, and Clutch Shaft Bearing into Transmission’ bore. Lubricate 0- ring and tube end with transaxle
Case fluid. Install O-ring in groove.
2. Push the tube end (A) into and through the bore in the
NOTE converter end of the transmission case.
Carefully align the oil distributor sleeve
before insertion. Use scribe marks on face 3. Rotate the tube to align (B); then push the tube into the
of sleeve to align with setscrew hole. axle end of the case (B) until the tube end is firmly
seated.
1. Install the oil distributor sleeve (Figure 29): Align the
4. With a socket, press the keeper into the bore (C) until
setscrew hole in the sleeve with the hole in the case and
it seats against the tube. The tab ends of the keeper
drive the sleeve in until the holes coincide.
should point toward you.
2. Apply Loctite #242 (Clark part++1802300) and install
the setscrew through the valve mounting base and into Suction 7
sleeve. Torque setscrew to 16-20N*m (140-175 in-lb).
3. Drive the turbine shaft rear bearing (Figure29) fully
into the transmission case.
4. Drive the reverse idler shaft rear bearing fully into
the transmission case.

Figure 30. Oil Suction Tube Installation

OS(S)-61 8 l Transaxle Overhaul SM 598,Oct ‘94

 Main Table of Contents

ClClRK Group 06(S), Transaxle (Standard)

Installing the Pinion Bearings, Pinion Shaft, and
Output Gear
IMPORTANT
REPLACE RING AND PINION AS A
SET. Pinion and ring gear must be re-
placed as a new set if either is to be re-
placed.
Determining Shim Pack Thickness
The position of the pinion along the radius of the ring gear
is called the “pinion mounting distance.” This distance
must be kept within a specified range for the ring gear and
pinion to mesh properly. Because manufacturing toler-
ances vary among ring and pinion sets, the actual pinion
mounting distance may require shimming in order to match
the specified pinion mounting distance.
The shim pack is shown in Figure 3 1A.
To determine the shim pack thickness required for the ring
gear and pinion set you are installing:
1
1. Note the number on the end of the pinion shaft.
2. Locate the number on the chart below.
3. Select the shim pack thickness next to the number you
located.
4. Check the shim pack height with a micrometer before
installation.
IMPORTANT
You must determine the thickness of and
install the required shim pack whenever
you replace the ring gear and pinion set, or
the old shim pack.

Shim Pack Thickness Chart

Mark on Shim Pack Tbickne.ss Markon Shim Pack Thicknes

l%lion (mm) @W Pinion (=I (inch)
50 0.26 0.010 0 0.76 0.030
48 0.28 0.011 -2 0.78 0.031
46 0.30 0.012 4 0.80 0.031
44 0.32 0.012 -6 0.82 0.032
42 0.34 0.013 -8 0.84 0.033
40 0.36 0.014 -10 0.86 0.034
38 0.38 0.015 -12 0.88 0.035
36 0.40 0.016 -14 0.90 0.035
34 0.42 0.016 -16 0.92 0.036
32 0.44 0.017 -18 0.94 0.037
30 0.46 0.018 -20 0.96 0.038
28 0.48 0.019 -22 0.98 0.038
26 0.50 0.020 -24 1.00 0.039
24 0.52 0.020 -26 1.02 0.040
22 0.54 0.021 -28 1.04 0.041
20 0.56 0.022 -30 1.06 0.042
18 0.58 0.023 -32 1.08 0.042
16 0.60 0.024 -34 1.10 0.043
14 0.62 0.024 -36 1.12 0.044
12 0.64 0.025 -38 1.14 0.045
10 0.66 0.026 -40 1.16 0.046
8 0.68 0.027 42 1.18 0.046
6 0.70 0.027 -44 1.20 0.047
4 0.72 0.028 46 1.22 0.048
2 0.74 0.029 48 1.24 0.049
0 0.76 0.030 -50 1.26 0.049

SM 598,Oct ‘94 Transaxle Overhaul l 06(S)-6-19

 Main Table of Contents
Group 06(S), Transaxle (Standard)
Installing Pinion Shaft and Setting Preload
Refer to Figure 3 1A.
1. Drive olcter bearing cup, if removed, fully into bore.
2. Install the inner bearing shim pack, as selectedabove.
3. Drive the inner bearing cup into the bore firmly
against the shim pack.
4. Press (or expand with induction bearing heater) the
inner pinion bearing onto the pinion shaft until it
butts against the shoulder of the pinion.
5. Position the output gear in the case with the long hub
of the gear outward as shown.
6. Insertthe pinion shaft and inner bearing into the case
and through the output gear. Seat the bearing with a
sharp blow to the pinion end with a soft-faced hammer.
7. Slip the output gear retainer ring on the pinion shaft,
but do not install it into its groove at this time.
Bearing Installation Tip: To brace the pinion shaft in
preparation for driving on the outer bearing, install the
differential assembly adjusting nuts as shown inFigure
33. Then install a T-bar bearing puller into the adjusting
nuts and tighten finger-tight against pinion.
Outer Bearing Cup
Outer Pinion Bearing
Pinion Shaft Nut
Figure 31A. Pinion Installation
06(S)-6-20 . Transaxle Overhaul
CMRK
8. Install the outer bearing shim pack. If a new pinion
shaft is, start with a nominal shim pack of 1.575 mm
(0.062 in).
9. Drive outer bearing onto the pinion shaft.
10. Install the old pinion shaft nut and torque to 270-340
N-m (200-250 ft-lb). Hold or block the pinion shaft
with a brass bar or similar soft material to prevent the
shaft from turning while tightening the nut. Anchor
case to bench if necessary,
11. Unblock the pinion shaft and use a torque wrench to
measure thepinion shaft bearing rolling-torque preload
(Figure 31B). Preload torque should be 0.8-2.3 Nom
(7-20 f&lb).
12. If the preload torque is outside the specified range, you
must add shims to increase preload or remove shims to
decrease it. To add or remove shims, remove the pinion
shaft nut and bearing and repeat steps 8 through 11.
13. After the preload torque proves to be within the speci-
fied range, rephzce the pinion shaft nut witha new
one. Do not reuse the pinion shaft nut. Torque nut
270-340 Nom (200-250 ft-lb).
14. Install the retainer ring into its groove, makingsureit
is fully seated.
15. If used, remove T-bar puller and adjusting nuts.
Inner Pinion Bearing
Inner Bearing Cup
inner Bearing Shim Pack
Figure 31B. Preload Torque Check
SM 598,Oct ‘94
 Main Table of Contents

ElmK Group 06(S), Transaxle (Standard)

Installing the Differential Setting Differential Bearing Reload

Installing Differential Cage
1. Press the left and right cups into the differential cage,
if removed.
Figure 32. Bearing Cup Installation
2. Place bearings in differential assembly (Figure 33).
3. Position differential assembly between carrier “ears.”
Block under ring gear to hold assembly in position.
4. Loosely install adjusting nuts through ears and into
bearings.
Bearing
The differential bearing preload is the bearings’ resistance
to turning, which is controlled by how tightly the bearings
are sandwiched between theirraces. The change in distance
(deflection) between the differential carrier ears caused by
tightening the differential adjusting nuts is a convenient
indicator of preload. To measure the deflection:
Securely clamp transmission case to bench and set up
a dial indicator so that it is zeroed against a flat on a
carrier ear (Figure 34).
Tighten one or both of the adjusting nuts until the
pinion appears to correctly mesh with the ring gear and
there is a small amount of play (backlash) between the
pinion and ring gear.
Read the deflection on the dial indicator.
Your goal is for this deflection to measure 0.076 mm
(0.003 in), without changing the temporary backlash
set in step 2.
To change the deflection without affecting the back-
lash, tighten both adjusting nuts equally, or loosen both
equally: Use a clockwise rotation on both adjusting
nuts to increase the deflection (Figure 34). Use a
counter-clockwise-rotation on both nuts to decrease
the deflection. When the deflection is correct, pre-
cisely set backlash as described on the next page.
NOTE
The deflection of one carrier ear should
measure 0.075 mm (0.003 in). The total
deflection measured from flat to flat should
be 0.15 mm (0.006 in).

Adjusting Nut

Figure 33. Diflerential Installation

Figure 34. Differential Bearing Preload

Decrease _
deflection.- 1c

SM 598,Oct ‘94 Transaxle Overhaul l 06(S)-6-21

 Main Table of Contents

Group OS(S), Transaxle (Standard) ClmK

Setting Ring Gear and Pinion Backlash 4. Check the resulting backlash on three teeth around the
The backlash measurement is the distance a ring gear tooth ring. Repeat adjustments until the preload and back-
can travel between pinion teeth with the pinion stationary. lash measurements are both correct.
Because the pinion and ring gear teeth are beveled, you can 5. Drive lucking pins (Figure 3, D) through the upper or
change the backlash by changing how deeply the teeth lower holes in the differential carrier ears and between
mesh into each other. To adjust backlash without changing cleats in adjusting nuts. If necessary
preload, you shift the ring gear along it axis by tightening
one adjusting nut while loosening the other an equal amount.
Checking Ring and Pinion Gear Tooth Contact Pattern
To measure and adjust backlash:
To check the ring gear and pinion for proper tooth contact
1. Set up a dial indicator on a ring gear tooth (Figure 35,
pattern (correct position):
A). Hold or block the pinion so that it cannot rotate.
Apply a thin, even coating of gear checking com-
2. Rotate the ring gear through backlash (Figure 35, B)
pound, to the ring gear teeth.
and read the measurement.
Rotate the ring andpinion gears through a minimum of
Backlash must be 0.20-0.28 mm (0.008-0.011 in).
one revolution and apply a load (hold by hand) to the
If the measurement is less than required, you need to gears as they are turned
shifttheringgearawayfromthepinion,ifmorethan
When the ring gearis turned, the compound is squeezed
required, into the pinion.
away by the contact action of the teeth, leaving bare
3. To shift thering gearposition,rotate the adjusting nuts areas that are the exact shape, size and area of the tooth
equally in opposite rotations (loosen one nut, tighten contact pattern.
the other) as shown Figure 35, C.
Check the tooth contact area on the sides of the ring
Tip: Insert a rod in the recess on the carrier ear and gear teeth. On an old
between cleats on the adjusting nut. Rotate theadjust- gearset,the contact pat-
ing nut with the rod as far as the recess allows-this is tern must match wear
one“notch.” Keep count of each “notch” you rotate the pattern. On a new gear Good
adjusting nut. Repeat on other adjusting nut using set, the tooth contact
same number of “notches.” pattern must be as
shown in Figure 36. If
the contact pattern is
incorrect, recheck the
pinion mounting pro- High
cedure and the ring-
and-pinion backlash
reading. Disassemble
theparts,addorremove
inner bearing shims as
needed to adjust pinion
positionandadjustdif- Low
ferential bearing nuts to
correct backlash.
Adding shims corrects Figure 36. Tooth
a “high” pattern. Re- Contact Pattern
moving shims corrects
a “low” pattern.
Locking Pin /o D

Figure 35. Ring Gear Backlash Adjustment IMPORTANT

_ Increase Decrease Each time the ring gear or pinion is moved,
- backlash. backlash. = the backlash and the differential bearing
preload must be checked and reset as
needed.

06(S)-6-22 . Transaxle Overhaul SM 598,Oct ‘94

 Main Table of Contents

Group 06(S), Transaxle (Standard)

Installing the Clutch and Idler Gear
The following should already be installed: oil distributor
sleeve, clutch shaft rear bearing, reverse idler shaft rear
bearing, and differential pinion shaft (with transmission
output gear). Additionally, the clutch pack should be fully
assembled, including oil distributor seal rings. Then:
1. Press the reverse idler shaft front bearing onto the idler
shaft until it is fully seated against the shoulder.
Figure 37. Installation of Front Bearing onto Reverse
Idler Shaft -
2. Apply transmission fluid to forward clutch outer thrust
bearing assembly (thrust bearing between two wash-
ers) and to reverse clutch outer thrust bearing and
install them on clutch shaft.
Forward Clutch
Outer Thrust
Bearing Reverse
Assemb Clutch
Outer
Thrust
Bearing
3. Place a soft-faced hammer within reach.
4. Hold the reverse clutch gear so that it does not
disengageany friction disks. Then, insert the end of the
clutch shaft into its bearing (Figure 39). Make sure the
forward clutch gear meshes with the output gear.
5. Insert the idler gear shaft end into its bearing while
maneuvering the clutch and idler shafts so that the
idler, clutch, and output gears mesh (Figure 39).
6. Lightly tap the idler gear shaft with a soft-faced
mallet to seat the shaft and bearing into the bearing
pocket. Lightly tap on the clutch shaft with a soft-faced
mallet to seat the shaft into the bearing pocket_
7. Check forproper clutch shaft installation depth (Fig-
ure 40):
Place a transmission case-to-converter housing
gasket on mating surface. Place a straight edge
against gasket and over clutch thrust washer.
If thrust washer touches straight edge, a clutch
disc may be out of position. Stop assembly of the
unit, remove the clutch, make sure both clutch
gears engage all five friction disks, and repeat the
clutch/idler gear installation procedure.
Measure the gap between the straight edge and the
thrust washer. If the gap is not 0.1-0.8 mm (0.004-
0.032 in) remove the clutch pack and reinstall it
with a thinner or thicker reverse clutch outer
thrust bearing (Figure 38), as needed.

Figure 38. Installation of Clutch Outer Thrust Bearings

Install gasket.

Measure
gap between
straight
edge and thrust
washer.

Idler Gear Shaft

Figure 39. Installation of Clutch and Reverse Idler

Assemblies Figure 40. Measuring Clutch Installation Depth

SM 598,Oct ‘94 Transaxle Overhaul l 06(S)-6-23

 Main Table of Contents

Group 06(S), Transaxle (Standard) ClRRK

installing the Pump Idler Gear and Bearing
1. Pressthebearingintothehubof the pump idler gear.
2. Apply clean transmission fluid Clark # 2776236 to the
bearing.
3. Insert the gear with bearing between the shaft mount-
ing holes in the converter housing. Check that holes in
housing and bearing align.
4. Insert shaft(threaded end up) into outer bore and drive
shaft in to below housing surface.
Shaft -4 1
Installingthe Stator Oil Seal, ImpellerHub Gear and
Bearing, and Stator Support
1. From converter side, drive the oil seal into its bore,
flush with the machined surface, with the beveled edge
facing the transmission case.
2 If bearing and bushing have been removed from stator
.
support:
a. Press bushing flush into splined end of stator
support.
b. Press needle bearing 4.0 mm (0.16 in) below
flange surface.
3. Tap the impeller hub bearing into the converter
housing.
4. Coat sealing ring with transmission fluid and slide it
onto stator support. Squeeze and latch sealing ring into
groove.
5. Oil the impeller hub gear. Place it in the converter
housing, and position it to mesh with the pump idler
gear.
6. Insert stator support assembly into converter housing
and through impeller hub gear and bearing and oil seal.
Make sure stator support is in pilot and that mounting
holes align with holes in converter housing. (Use of
alignment studs is advised).

7. Install four capscrews and tighten to 54-64 Nom (40-

48 ft-lb).

r Oil Seal
Figure 41. Pump Idler Gear Installation

Impeller Hub Bearing

Impeller Hub Gear

Y‘X

‘I
Bushing
Stator Support
Needle bearing
Capscrew /

Figure 42. Stator Support and Oil Seal installation

06(S)-6-24 l Transaxle Overhaul SM 598,Oct ‘94

 Main Table of Contents

ClmK Group 06(S), Transaxle (Standard)

Joining Converter, Transmission, and Axle Housings
Clean all gasket mating surfaces. If there are any nicks,
remove them with emery cloth. Then join the housings as
follows. (Refer to Figure 43.)
Transmission Case to Axle Housing
1. Place gasket over dowels on mounting flange on trans-
mission case. Do not use gasket sealer.
2. Install at least two alignment studs in mounting holes
in transmission case mounting flange.
3. With a hoist, bring the axle housing and transmission
case together, using the alignment studs for guides.
ing bore in the converter housing.
Loosely install four long mounting bolts with washers
and seven short mounting bolts with washers through
converter housing and into tmnsmission case mount-
ing flange. (Remove alignment studs.)
Gradually torque the mounting bolts, in a criss-cross
pattern, 54-65 Nom (40-48 ft-lb).
Installing Axle Shafts and Axle Ends
If axle end and/or brake assemblies were removed,
install them as described in the “Axle End Overhaul”
Section in this Group (06) and the “Service Brake
Inspection and Overhaul” Section in Group 23.

4. Loosely install sixmounting bolts with washers through Insert O-ring into groove in axle shaft (Figure 43).
the transmission case mounting flange and into the Insert axle shaft into axle assembly and torque mount-
threaded holes in the axle housing mounting flange. ing bolts 90-110 Nom (67-81 Mb).

5. Remove the alignment studs and loosely install 11

mounting bolts with washers through the axle mount-
ing flange, through the gasket, and into the threaded
holes in the transmission case mounting flange.
6. Gradually torque all of the above-mentioned mount-
ing bolts, in acriss-cross pattern, 54-65 Nom (4048 ft-
lb).

Converter Housing to Transmission Case

1. Place gasket over dowels on mounting flange on trans-
mission case. Do not use gasket sealer.
2. Install at least two alignment studs in mounting holes
in transmission case mounting flange. Figure 44. Axle End

3. Hoist the converter housing so that

its mounting flange comes to-
gether with the transmission case
mounting surface. Make surethe
reverseidlergearclearsthebear-

Shaft

Figure 43. Joining the TransaxleHousings.

SM 596,Oct ‘94 Transaxle Overhaul l 06(S)-6-25

 Main Table of Contents

Group 06(S), Transaxle (Standard) CICIRK

Installing Transaxle Peripherals 5. Install clutch pressure tube and clutch lube tube by
connecting fittings and O-rings on tube ends and to
Locate peripherals on Figure 53. control valve cover and transmission case.
1. Thoroughly clean the transmission sump oil strainer
with an approved cleaning solvent. Dry with com-
pressed air. Install strainer and drain plug. Tighten Lube Tube
plug 90- 110 Nom (66-8 1 ft-lb).

Pressure
Tube kQ b O-Rings

Figure 45. Drain Plug and Strainer Figure 49. Clutch Pressure and Lube Tubes
Clutch pressure tube torque specs: Tube End: 33-42
2. Install transaxle control valve with gasket and 10
Nom (24-30 ft-lb); Boss End: 42-53 Nom (3 l-39 ft-lb).
fasteners. Torque fasteners to 28-35N*m (21-26) ft-lb.
Clutch lube tube torque specs: 73-90 Nom (54-66 ft-
lb).

6. Install oil dipstick tube. Connect fitting and O-rings

on tube end and to transmission case: torque 171-209
Nom (126-154 ft-lb). Fasten bracket to transaxle hous-
ing.

Figure 46. Tramaxle Control Valve B

3. Install oil filter cartridge. Tighten per instructions on
filter. ,

Figure 47. Transaxle Oil Filter

O-Rings
“i, . 69
(P

_@’ ”
ti
4. Installhydraulicpump: ReplacethreeO-rings. Install
two mounting bolts and washers. Torque 90- 110 N*m Figure 50. Transaxle Oil Dipstick Tube
66-8 1 ft-lb).

.. 7. Mount the solenoid valves; torque 30.5-37 N*m (22.5-

27.5 ft-lb). Mount temperature sensor and gasket:
torque 45-55 Nom (33-40 ft-lb).

Figure 48. Hydraulic Pump and Transaxle Charging

Pump Figure 51. Solenoid Valves and Temperature Sensor

OS(S)+26 l Transaxle Overhaul SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 06(S), Transaxle (Standard)

8. Mount brake line tee and connected brake lines to 9. Install torque converter assembly by carefully slid-
control valve cover with mounting bolt. Connect brake ing it onto the turbine/clutch shaft and the stator
lines to fittings on brake backing plates. Torque fitting support. Use care during handling. Improper handling
15-19 Nom (11-14 ft-lb). could cause converter leaks.

Figure 52. Brake Lines Figure 54. Torque Converter

r Torque Converter (In Housing)

Dipstick Tube
Transaxle
Control Valve

Transaxle
Oil Filter
Main Hydraulic
Pump/Transaxle
Charging Pump
Brake Line Tee

Drain Plug
and Strainer

Axle End
Assembly

Brake Drum

Brake Line Fiiingl L Breather I- Solenoid Brake Line Fiiing

Valves

Figure 53. Transaxle Peripherals

SM 598,Oct ‘94 Transaxle Overhaul l 06(S)-6-27

 Main Table of Contents

Group 06(S), Transaxle (Standard) CUlRK

10. Install the breather: Apply Loctite 17009 to threads
and torque 45-50 N-m (33-37 ft-lb).
Filling and Initial Startup
Follow the fluid replacement procedures in Section 3 of
this Group. Also, be-sure to bleed brake lines before operat-
ing the truck as described in Group 23.

Figure 55. Breather NOTICE

Be sure to use Clark transmission fluid,
part # 2776236, after rebuilding clutch
packs. This fluid contains additives that
condition clutch friction discs and extend
their life.

06(S)-6-28 . Transaxle Overhaul SM 598,Oct ‘94

 Main Table of Contents

CWRU Group 06(S), Transaxle (Standard)

Section 7.

Drive Axle Ends

Overhaul

Drive Wheel Removal

The drive axle ends can be overhauled with the drive axle
in the truck. If the drive axle is to be left in the truck:
1. Safely raise and properly block the front of the truck
as described in the lifting and jacking Section of
Group SA.
2. Remove the drive wheels as described in Group 22.

Drive Axle Shaft Removal and

Replacement 7 Axle Shaft
1. Remove 10 mounting bolts and washers from each
axle shaft flange. O-Ring
1. Pull axle shaft out of axle housing.
3. Remove O-Ring from hub.
4. Reverse steps 1 through 3 for installation. Use new O-
Ring, Torque mounting bolts to 90-l 10 N-m (66-81
ft-lb).

L Mounting Bolt

SM 598,Oct ‘94 Drive Axle Ends Overhaul l 6(S)-7-1

 Main Table of Contents
Group 06(S), Transaxle (Standard)
Axle End Removal
The following procedures refer to the illustration on the
next page.
1. Separate brake drum from hub. If necessary, screw
jackscrews though holes in drum to force drum apart
from hub. Remove drum.
2. Bend back tab on locking washer to clear slot in lock
nut.
3. Remove locknut from spindle. Special wrench, con-
struction shown on page 4, may be used.
4. Remove tongued washer from spindle.
5. Remove outer bearing from spindle.
6. Remove hub from spindle.
7. Remove inner bearing.
8. Remove and discard oil seal from hub.
9. Extract inner and outer bearing cups from hub if
bearings are to be replaced.
Axle Mounting Bracket Removal and
Installation
1. Remove or install the brake assembly as described in
“Service Brake Overhaul” in Group 23.
2. Remove or install the axle mounting bracket by sliding
it off or on the axle housing. Use anti-seize compound,
Clark part #1802307, on the contact surfaces before
installing the bracket.
Inspection, Cleaning, and Repair
Inspect bearings and cups for wear. Replace bearing and
cup as a set if either is worn. Clean parts with a Stoddard-
type solvent.
6(S)-7-2 . Drive Axle Ends Overhaul
EICIRK
Axle End Assembly
1. Press new cups into hub, if cups were removed.
2. Lube inner bearing with transmission fluid, Clark part
# 2776236, and install bearing.
3. Prepare surfaces and install oil seal:
a. Remove nicks, scratches, and burrs from hub and
spindle surfaces that will receive the seal.
b. Apply alight coat of Loctite Primer N, Clark part
#1803267, and Loctite Gasket Maker, Clark part
#1802303 to seal outer diameter and hub inner
diameter.
c. Press new oil seal into hub with special driver,
which can be constructed from drawing on page4.
IMPORTANT
OIL SEAL LEAKS. The oil seal must be
replaced with a new one each time the hub
is removed. Use extreme care not to dam-
age the seal during installation. Use the
proper seal driver, shown on page 4.
4. Install hub.
5. Lube outer bearing with transmission fluid, Clark part
# 2776236, and install.
6. Install tongued washer, locking washer, and locknut
(hand-tight) .
7. While turning hub, torque locknut to 200-245 Nom
(147-181 ft-lb) with special wrench shown on page 4.
Loosen locknut- then hand-tighten locknut until bear-
ing has no end-play.
8. Loosen locknut until tab on washer lines up with slot
in locknut. Bend tab on washer into slot on locknut.
9. Align inspection slot on brake drum with inspection
slot on hub. Install brake drum by sliding it over studs
mounted on hub. Tap drum with a soft-faced hammer
to seat it against the hub. Remount the wheel as
described in Group 22.
SM 598,Oct ‘94
 Main Table of Contents

CUIRK Group 06(S), Transaxle (Standard)

Housing

- Axle Mounting Bracket

_ Spindle

- Brake Assemblv

_ Brake Mounting Bolt

- Hub

Outer Bearing
and Cup

Inner Bearing
and Cup

Tongue Washer
Lock Washer

SM 598,Oct ‘94 Drive Axle Ends Overhaul l 6(S)-7-3

 Main Table of Contents

Group 06(S), Transaxle (Standard) CWIRU

-
f

z
3

2.5

Hub Oil Seal Driver. Construct as shown.

Drive Socket

Square /
Stock

\*< x 1" Long

Hub Locknut Wrench. Construct as shown.

6(S)-7-4 . Drive Axle Ends Overhaul SM 590,Oct ‘94

 Main Table of Contents

ClRRK Group 06(S), Transaxle (Standard)

Section 8.

Transaxle Control Valve

Overhaul

NOTE
A description of transaxle control valve func-
tion is given in Section 1, ‘Transaxle Speci-
fications and Description.”
Problem diagnosis and pressure checks that
indicate control valve performance are given
in Section 2, “Transaxle Troubleshooting.”

Service Requirements Parts Cleaning, Inspection, and

The control valve should be disassembled, cleaned, and
inspected whenever the transaxle is overhauled or when-
ever indicated by troubleshooting.
Lubrication
Clean all parts with a safety-approved commercial solvent
before inspection.
Inspection includes:
. Checking bores and spools for scratches, nicks, burrs,
and wear
l Making sure inching rod is not bent
l Making snre springs are not bent or cracked
l Checking the oil filter adaptor for thread damage
l Making sure all orifices are free of blockage.
Lubricate all components with transmission fluid, Clark
part #2776236, before reassembly. Lubricate and wrap parts
if reassembly will not be done immediately.

SM 598,Oct ‘94 Transaxle Control Valve Overhaul l 06(S)-8-1

 Main Table of Contents
Group 06(S), Transaxle (Standard)
Assembly and Disassembly Procedures
The necessary procedures are generally obvious from the
illustration given below, with thefollowing notes:
Separator Pin (G): This pin separates the cooler bypass
spool from the lube relief spool. To install it:
1. Insert the spool, spring, and washer that make up the
oil cooler bypass (F) into their bore.
2. Push against the washerwith asmall flat-tippedscrew-
driver to compress the spring. The flat of the blade
should face the pin bore.
3. When the washer clears the pin bore, insert the sepa-
rator pin (G), withdraw the screwdriver, and tighten
the pin to 5.5-6.5 Nom (49-58 in-lb).
06(S)-6-2 . Transaxle Control Valve Overhaul
CIRRK
O-Ring (C): Lubricate O-ring with transmission oil before
assembly.
Seal, Inching Rod (E): Replace with new seal (E). Press
fit.
Guide (A), Inching Rod: The bore through the inching rod
guide has a chamfered edge on one side. This side of the
guide must face the retaining ring.
Filter Adaptor (L): Apply Loctite #242, (Clark Part
#1802300) to adaptor threads at installation. Tighten to 90-
110 Nom (66-81 ft-lb).
Caps: Torque caps (H, K, M, and N) to 58-72 Nom (43-53
ft-lb). Torque caps (D, I, and J) to 138-165 N*m (102-122
ft-lb).
SM 598,Oct ‘94
 Main Table of Contents

GROUP 06(H)

GROUP 06(H)

HYDROSTATIC TRANSMISSION

Transmission Specifications and Description ............... Section 1

Control System Troubleshooting and Adjustment

Troubleshooting Charts ......................................... Section 2A
Hand-Held Diagnostic Control ............................. Section 2B

Components Removal and Replacement ...................... Section 3

Hydrostatic Drive Pump Service ................................... Section 4

Hydrostatic Drive Motors Service ................................. Section 5

Drive Axle Ends Overhaul ............................................. Section 6

SM 598, Dee ‘94 Hydrostatic Transmission

 Main Table of Contents

clmu Group 06(H), Transmission (Hydrostatic)

Section 1.

Hydrostatic Transmission
Specifications and Description

Specifications Electrical Diagrams

See Sections 4 and 5 for detailed drive pump and drive See Group 40 for wiring and circuit diagrams for the hydro-
motor specifications. static truck.
Drive Pump:
Type: Axial piston, variable displacement Hydraulic Diagrams
Max. Displacement: 75 cm3/rev (4.57 in3/rev)
Max. Pressure: 480 bar (7000 psi) See Group 30 for a complete hydrostatic truck hydraulic
Rated Pressure: 420 bar (6000 psi) schematic diagram.
Engine-to-Pump Drive Ratio: 1:1
Dry Weight: 52 kg (115 lb)
Charge Pump: Service Requirements
Displacement: 20 cm3/rev (1.20 in3/rev)
Pressure Setting: 26 bar (375 psi) Spin-on filter mounted on top of drive pump should be
changed every 2000 hours.
Drive Motors and Axle:
Type: Radial piston: two integrated into drive axle. Main hydraulic system fluid and filters should be serviced
Max. Displacement: 2x565 cm3/rev (2x34.5 in3/rev) as described in Group 29.
Max. Pressure: 450 bar (6500 psi) Axle ends should be cleaned and replaced during brake
Rated Pressure: 420 bar (6000 psi) repairs.
Flush Relief Setting: 24 bar (350 psi) @ 3.8 L/min
(1 gpm) @ 49” C (120’ F) Pump pressure checks (Section 4) should be performed
Drive Motor-to-Axle Drive Ratio: 1:1 every 2000 hours.
Axle Dry Weight: 238 kg (525 lb)
Control Type: SUSMIC 12 microprocessor. Programming Fastener Torques
and diagnostics: SUSMIC-DIA 2 or PC laptop.
Drive Axle Mounting Bolts: 542-596 Nom (400440 ft-lb)
Microprocessor Inputs:
Engine Actuator Sensor: O-5 volts Drive Pump-to-Adaptor Mounting Bolts: 70-80 Nom (52-
Accelerator Pedal Sensor: O-5 volts 59 ft-lb)
Brake Pedal Sensor: O-5 volts
Drive Pump-to-Frame Mounting Bolt: 70-80 Nom (52-59
Lift Lever Sensor: O-5 volts
ft-lb)
Engine Speed Sensor: O-9.9 kHz
Microprocessor Outputs: Fitting Torques: See Group 40 from hydraulic fitting tight-
Engine (Throttle) Actuator: O-12 volts ening procedure.
Electrical Displacement Control: O-100 mA.

SM 598, Dee ‘94 Hydrostatic Transmission Specs and Description l 06(H)-1-l

 Main Table of Contents
Group 06(H), Transmission (Hydrostatic)
Description
In the hydrostatic drive truck, power is transmitted to the
drive wheels by hydraulic-powered motors, rather than by
gears and clutches. The entire system is depicted on the
next page. The control system is depicted below.
The hydrostatic truck’s conventional spark-ignited or die-
sel engine rotates a hydraulic pump, the “hydrostatic drive
pump.” that supplies fluid to two hydraulic motors in the
drive axle. Each motor drives a drive wheel.
The hydraulic fluid is drawn from the same sump that
supplies the load handling system. [Incidentally, the pump
for the load-handling system (covered in Group 29) is
mounted on, and mechanically driven by, the hydrostatic
drive pump.]
The hydrostatic drive pump is a variable displacement
axial piston pump. (See Section 4 of this Group for a
complete description of the pump and its subassemblies.)
Pump output volume and direction of flow are governed by
the pump’s swashplate. The angle at which the swashplate
is tilted controls the length of the piston strokes as the
pistons rotate past inlet/outlet ports. Swashplate angle is
controlled by an electrical displacement control (EDC).
The EDC hydraulically varies the angle of the swashplate
in response to the electrical signal level received from the
computer.
The fluid displaced by the drive pump flows through exter-
nal plumbing to the radial piston drive motors in the drive
axle. The volume and direction of the fluid determines the
speed and direction of the truck. Each drive motor is con-
nected to an axle shaft that drives an axle end and wheel
identical to those used on the standard truck. (See Section 5
Tilt Aux l&2 Parking Brk Act. Pedal
Switch Switches Switch Sensor
COMPUTER (SUSMIC 12 MICROPROCESSOR)
:;
: :
:,.+
.:
,::;
: :
::
,-.-..-.- t ________
i Diagnostic i Engine
Actuator
: Control
_-.--.._.--:
ThrbtUe
06(H)-1 -2 l Hydrostatic Transmission Specs and Description
CMRK
of this Group for a complete description of the drive mo-
tors.) Parallel circuitry to the drive motors allows a speed
differential between the motors when the truck is cornering.
The diagram below shows the flow of information into and
out of the computer that controls the drive system-the
SUSMIC 12 microprocessor.
The inputs consist of signals from the various sensors and
switches that are affected by positioning of the truck’s
manual controls.
The signals from the switches consist of either an open or
closed circuit. The signal from the engine speed sensor
consists of pulses ranging from 0 to 9.9 kH2 (cycles per
second), increasing as engine speed increases. The signals
from the other sensors consists of 0 to 5-volt levels that
vary according to the position of the associated control.
The outputs consists of electrical power to the engine ac-
tuator and to the EDC. Zero to 12 volts are supplied to the
engine actuator and 0 to 100 mA are supplied to the EDC.
As the truck operates, the computer monitors the positions
of the various manual controls in order to sense the desired
performance; while at the same time, the computer monitors
engine speed and engine actuator position in order to sense
the actual performance.
To make the actual performance match the desired perfor-
mance, the computer varies the engine throttle position via
the engine actuator and the drive pump output via the EDC.
The system can be diagnosed and adjusted with a diagnos-
tic control, usually the SUSMIC-DIA 2, that connects to
the SUSMIC 12 computer.
Eng. Actuator Engine Speed Brake Pedal Lift Lever
Sensor Sensor Sensor Sensor
Electrical
Displacement
Control
Drive’ Pump
SM 598, Dee ‘94
 Main Table of Contents

CUlRU Group 06(H), Transmission (Hydrostatic)

I DRIVE DRIVE

Drive
Axle

+-xl
Tilt and Aux Pump

Diagnostic
Interface

Hydraulic Control
Valve sensor (Wuj

Displacement

Control (EDC)j&+~aptor

Engine (Throttle) Actuator

andFeedbackSensor
Coupling &0

Accelerator Pedal
Sensor

Brake
Pedal
Sensor

+ = Control Signal 4&f? n

,-, q Hydraulic Line I
y-J--
Direction Lever

SM 598, Dee ‘94 Hydrostatic Transmission Specs and Description l 06(H)-1-3

 Main Table of Contents

Group 06(H), Transmission (Hydrostatic) CUIRU

Schematic Diagram of Drive Pump and Drive Axle

DRIVE AXLE ASSEMBLY

NOTE
See Sections 4 and 5 for
component descriptions.

3-E
-- E - HYDROSTATIC
1 r--1
DRIVE PUMP
ASSEMBLY

MAIN HYDRAULIC SYSTEM:

To From

I-

A Drive Motors
B Loop Flushing Valve G Charge Circuit Relief Valve
C Cooler Bypass Valve H DrivePump
D Electrical Displacement Control I Charge Pump
E Multi-Function Valves J Oil Cooler +& = Gauge Port
F Charge Circuit Pressure Filter K Sump

06(H)-1 -4 . Hydrostatic Transmission Specs and Description SM 598, Dee ‘94

 Main Table of Contents

ClRlW Group 06(H), Transmission (Hydrostatic)

Section 2A.
Control System Troubleshooting and Adjustments

Troubleshooting Charts

Vehicle Does Not Move U....“.......................“......~.............“.................................................._ ....... 2

Vehicle Does Not Reach Maximum Speed .......... .._ ..................................................................... 4
Driving Behavior Abnormal .........“.I”......................~...” ............................................................ 6

NOTE
HIGH IDLE SPEED. The hydrostatic truck electronic con-
trol system limits maximum engine rpm. A mechanical
governor, however, is installed on the intake manifold and
set to a higher rpm. The procedure for checking the me-
chanically governed maximum r-pmis on page 4.

Introduction

The charts on the following pages each begin with one of The charts then lead you through a problem isolation pro-
three general symptoms: cess.
l Vehicle does not move Control system faults can be further diagnosed using the
l Vehicle does not reach maximum speed diagnostic control described in Section 2B (or 2C).
l Driving behavior abnormal.

SM 596, Dee ‘94 Control System Troubleshooting Charts l 06(H)-2A-1

 Main Table of Contents

Group 06(H), Transmission (Hydrostatic) CMRK

Vehicle Does Not Move

1 Diagnostic LED RED

SUSMIC 12
2 Diagnostic LED YELLOW
Microprocessor
3 Diagnostic LED GREEN
4 Diagnostic LED GREEN
LED:

Vehicle does not

move

-T-

A CAUTION Operate the

- Manual

-rl
transmission using the
Override
MANUAL OVERRIDE.
manual override on the
Operation of the manual Electrical Displacement
override causes the drive Control (EDC)
wheels to turn. Raise the
drive wheels and block the
EDC
truck as described in
Group 22 before operat-
ing the manual override.
Follow
troubleshooting

pump
Service Manual

Check power supply

on

N Replace SUSMIC 12

\ \

06(H)-2A-2 l Control System Troubleshooting Charts SM 598, Dee ‘94

 Main Table of Contents

CUIRK Group 06(H), Transmission (Hydrostatic)

flashes Setup the control

N Replace SUSMIC 12 l system with the
fast diagnostic control

\ \ \
flashes
slow

I
\ \

, A periphery error is Use the diagnostic

detected * control to analyze

4 \ I
4

no Repair/Replace
l

\ \

*Checking EDC Coil Resistance

Disconnect EDC connector. Mea-
sure resistance through pins A and
B. Value should be about 25 ohms.

Connector

Check the wiring to the

Electrical Displacement

SM 598, Dee ‘94 Control System Troubleshooting Charts l 06(H)-2A-3

 Main Table of Contents

Group 06(H), Transmission (Hydrostatic) CWRK

Vehicle Does Not Reach Maximum Speed

Vehicle does not

reach the maximum
speed

operate the
n ! CAUTION
MANUAL OVERRIDE.
transmission using the
manual override on the
Electrical Displacement
Operation of the manual Control (EDC)

override causes the drive

wheels to turn. Raise the
drive wheels and block the
truck as described in
Group 22 before operat-
ing tbe manual override.

*Checking High Idle Speed

To check the high idle setting of the mechanical governor:
I 1. Install taihometer.
Disconnect the linkage between the engine actuator
1 Check hig ; speed. ( 1: and throttle.
With engine running, manually operate throttle to
full-open position and read rpm.
4. Perform engine acuator set-up procedure after recon-
necting liige.

06(H)-2A-4 l Control System Troubleshooting Charts SM 598, Dee ‘94

 Main Table of Contents

CWW Group 06(H), Transmission (Hydrostatic)

Use the diagnostic

control to check the
output current to the
EDC

Perform the sensor

check procedure with
the diagnostic control

troubleshooting

E Repair/Replace

+
‘r

Check the
brake/inching
pedal sensor
with the
diagnostic control
\ \

Repair/Replace

1
Use the diagnostic
control to check yes
the output current
to the EDC
I-

SM 598, Dee ‘94 Control System Troubleshooting Charts l 06(H)-2A-5

 Main Table of Contents

Group 06(H), Transmission (Hydrostatic) CMRK

Driving Behavior Abnormal

LEDs 1 to 4

Use the diagnostic

control to check
the Performance
Level

Set the Performance

no Level with the
>
diagnostic control

Run the complete

set-up procedure
with the
diagnostic control

no
l Problem solved

The problem must be

Check all sensors,

actuators, and switches
with the diagnostic
control

06(H)-2A-6 l Control System TroubleshootingCharts SM 598, Dee ‘94

 Main Table of Contents
CMRK Group 06(H), Transmission (Hydrostatic)

Section 2B.
Control System Troubleshooting and Adjustment
Using the SUSMIC DIA-3
Hand Held Diagnostic Control

Forklift Truck Operation Manual for the

SUSMIC-DIA 3, Software Version 6.4

SM 598, Sept ‘98 SUSMIC-DIA 3 Hand-Held Diagnostic Control l 06(H)-2B-1

 Main Table of Contents

Table of Contents
1. Safe Maintenance Practices ............................................................................................................ 3
2. Introduction .................................................................................................................................... 4
3. Battery Life ..................................................................................................................................... 4
4. Connection of the DIA-3 ................................................................................................................ 5
5. Activation of the SUSMIC-DIA 3 .................................................................................................. 5
5.1 Deactivation of the SUSMIC-DIA 3 ..................................................................................... 5
6. Sensor Set-up .................................................................................................................................. 5
6.1 To Access the Sensor Set-up Menu ....................................................................................... 6
6.1.1 Flow Chart Sensor Set-up ................................................................................................... 7
7. Sensor Set-up Procedures ............................................................................................................... 8
7.2.1 Set-up 00 Software Version Number Indication .............................................................. 9
7.2.2 Set-up 01 Throttle Pedal Sensor Calibration .................................................................. 10
7.2.3 Set-up 02 Brake Pedal Sensor Calibration ..................................................................... 11
7.2.4 Set-up 03 Lift Valve Sensor Calibration ........................................................................ 12
7.2.5 Set-up 04 Setting the Parameter for the Engine Type .................................................... 13
7.2.6 Set-up 05 Setting the Parameter for the Type of Driving Controls ................................ 14
7.2.7 Set-up 06 Setting the Parameter for the Driving Characteristics.. .................................. 15
7.2.8 Set-up 07 Engine Actuator Caliration ............................................................................ 16
7.2.9 Set-up 08 EDC Minimum Calibration.. .......................................................................... 17
7.2.10 Set-up 09 EDC Maximum Calibration ......................................................................... 18
7.3 Custom Adjustment of Driving Characteristics, Software Version 64 Only ........................ 19
7.3.1 Set-up 10 Deceleration-accel pedal released, forward ................................................... 20
7.3.2 Set-up 11 Deceleration-accel pedal released, reverse ..................................................... 21
7.3.3 Set-up 12 Engine speed, tilt and auxiliary functions ...................................................... 22
7.3.4 Set-up 13 Max. engine speed, lift function ..................................................................... 23
7.3.5 Set-up 14 Speed limitation, forward ............................................................................... 24
7.3.6 Set-up 15 Speed limitation, reverse ............................................................................... 25
7.4 Custom Adjustment of Driving Characteristics, Software Version 22,23 and 63 ............... .27
7.4.1 Set-up 10 Deceleration-Shifting from Forward or Reverse to Neutral .......................... 28
7.4.2 Set-up 11 Deceleration-accel pedal released .................................................................. 29
7.4.3 Set-up 12 Deceleration-Shifting from Forward or Reverse to Reverse or Forward ....... 30
7.4.4 Set-up 13 Engine speed, Tilt and Auxiliary Functions ................................................... 31
7.4.5 Set-up 14 Maximum Engine Speed, Lift Function ......................................................... 32
8. Sensor/Actuator Error Diagnosis .................................................................................................. 33
8.1 Select the Sensor/Actuator Error Procedure ........................................................................ 33
8.1.1 Sensor/Actuator Error Listing .......................................................................................... 33
8.1.2 Flow Chart Sensor Error Procedure .................................................................................. 34
9. Sensor Check Procedure ............................................................................................................... 35
9.1 Select the Sensor Check Procedure ........................................................................................ 35
9.2. Sensor Check Procedures ...................................................................................................... 35
9.2.1 Check 00 Throttle Pedal Sensor ........................................................................................ 36
9.2.2 Check 01 Pulse Pick-Up (PPU) on the Hydrostatic Pump ................................................ 37
9.2.3 Check 02 Brake Pedal Sensor ............................................................................................ 38
9.2.4 Check 03 Directional control ............................................................................................. 39
9.2.5 Check 04 Parking Brake Switch ....................................................................................... 40
9.2.6 Check 05 Lift Sensor ......................................................................................................... 41
9.2.7 Check 06 Tilt and Auxiliary Switch .................................................................................. 42
9.2.8 Check 07 Engine Actuator Feedback ................................................................................ 43
10. Hydrostatic Drive Micro-Processor, LED’s .................................................................................. 44
11. DIA-3, Quick Reference w/Limits ............................................................................................... 45

06(H)-2B-2
 Main Table of Contents
Cl!‘!‘Rli
1. Safe Maintenance Practices

1. Refer to Clark service manuals for a complete listing of safe maintenance practices and for procedures
to perform safe lifting, jacking and blocking of the lift truck.

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

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

4. Before starting work on truck:

A. Raise drive wheels off of floor and use blocks or other positive truck positioning devices.

5. Operation of the truck to check performance must be conducted in an authorized, safe, clear area.
Before starting to drive the truck:

A. Be in operating position.
B. Be sure parking brake is engaged.
C. Put directional control in neutral.
D. Start engine.
E. Check functioning of directional and speed controls, steering, brakes, warning devices, and
anyload handling attachments.

l Safe Parking

Before working on truck:

1. Park truck on a hard, level, and solid surface, such as a concrete floor with no gaps or breaks.

2. Put upright in vertical position and fully lower the forks or attachment.

3. Put all controls in neutral. Turn key switch OFF and remove key.

4. Apply the parking brake and block the wheels.

5. Make sure there is sufficient overhead clearance for raising the upright.

l Hydrostatic Truck Fleets

Clark recommends for companies with multiple hydrostatic trucks that all the trucks be set with the same
driving parameters so they drive the same.

06(H)-2B-3
 Main Table of Contents

2. Introduction
SUSMIC DIA-3 DIAGNOSTIC TOOL
FOR HYDROSTATIC DRIVE TRUCK
DIA3 P/N 4334183
Includes the Diagnostic Unit, Cable with On.Off Switch, and Jumper Cable
What is the DIA-3?
l The SUSMIC DIA-3 is a tool needed to service Clark’s Hydrostatic truck. The tool communicates
with the microprocessor which controls the hydrostatic drive system.
DIA-3 Functions:
l Driving Parameter Selection and Custom Drive Characteristic Programming.
l Sensor and Acuator Set-Up.
. Error Diagnostics
l Sensor and Acuator Operation Check.
DIA-3 OPERATION: The DIA-3 instruction manual must be followed precisely when using it.
Changing driving parameters is accomplished with procedure 06 of the Sensor Set-Up menu.

LCD Display

Green and Yellow LED’s

S&Ii UD

and ON/OFF

(4 334 167)

\Connector SO-42 (at the Forkliftwiringharness)

/
Adapter cable 4 334 166
/

A NOTICE: The SUSMIC-DIA 3 is a sensitive electronic service tool and it must be

handled with care and protected from water, shocks and dust.
Not operating the DIA-3 correctly may cause the microprocessor on the
truck to go into the ERROR mode. This is a safety feature where the
computer will not let the truck go anywhere if there is a problem with the
programming. The memory and the programming cannot be marmed
permanently and skillful operation of the DIA-3 can correct the error.

3. Battery Life
The DIA-3 uses 2 AA batteries. It is shipped with zink type batteries. You should experience the
following approximate battery life when using the DIA-3 . Note that the DIA-3 shuts itself off when not
used to conserve battery life.
l Zink - 20 min. l Akaline - 250 min. l Lithium - 550 min.

06(H)-2B-4
 CMRK
Main Table of Contents

4. Connection of the SUSMIC-DIA 3 (see illustration a 2. Introduction)

Before starting the SUSMIC-DIA 3 disconnect the cable of the horn.
Connect the SUB-D Diagnostic connector with the chip card to the adapter cable
4 334 168.
Connect the adapter cable 4 334 168 with the connector SO-42 at the Forklift Truck.
Insert the chip card into the SUSMIC-DIA 3 - the SUSMIC-DIA 3 will switch on. The display
shows:

The SUSMIC-DIA 3 service device 4 334 167 and the adapter cable 4 334 168 are available as a KIT
under part-number: 4 334 183.

5. Activation of the SUSMIC-DIA 3

1. Disconnect the horn cable.
2. Ignition ,,OFl?‘.
3. After the SUSMIC-DIA 3 is connected to the controller the display shows: 1 SUSM,C_D,A 3 1

Version number of the SUSMIC-DIA 3 ~ 1 Version X.X I

Now you switch on the ignition. The display shows:

To start the communication between the SUSMIC 12 and the service device SUSMIC-DIA 3 the
button @ must be pushed. Now you are in the ,,Communication Procedure“.
The display shows for a second: -1

After that the display shows:

To select any special procedure (sensor set-up, sensor error, sensor check) use the buttons @ and
0. Push the @ button (ENTER) to start the selected procedure.

If the DIA 3 displays the message ,,BATTERIE SWACH -> = WEITER“, this means that the
batteries should be replaced.

A NOTICE: When the hydrostatic truck’s computer system is accessed with the DIA3
instrument, the computer quits controlling the truck driving functions.
When this occurs, the truck will not respond to inputs from the accelerator
pedal, directional control, and the service and parking brakes until the DIA
3 is correctly disconnected.

5.1 Deactivation of the SUSMIC-DIA 3

. The main menu or all other menus can be left by pushing the @ button (EXIT).
After pushing the @ button, the display shows:
. The communication link may only be unplugged, if the display shows: F(

-1
. After 3 minutes of inactivity, the SUSMIC-DIA 3 will switch off automatically. To reactivate the
display remove and reinsert the chip card.

06(H)-2B-5
 Main Table of Contents
CMRK
6. Sensor Set-up
The following procedures are needed for the first set-up of the lift truck, such as when replacing the
hydrostatic controller (SUSMIC), or after the replacement of a sensor or actuator. Also the procedures
allow adjustment of the driving characteristics to fit a particular application.

Features:
The following service can be performed with the DIA 3 instrument in the SENSOR SETUP menu.
l Indication of the version of software loaded into the truck’s hydrostatic controller
l Calibration of the sensors and actuator
l Setting the default parameters for vehicle driving controls, engine type, and adjustment of the
driving characteristics

6.1 To Access the Sensor Set-up Menu

When the hydrostatic controller is accessed with the DIA 3 instrument, the computer quits controlling
the truck driving functions. When this occurs, the truck will not respond to inputs from the accelerator
pedal, directional control, and the service and parking brakes until the DIA 3 is correctly disconnected.

l Activate the main menu, the display shows:

l Select with the buttons @ or @ the

procedure until the display shows:

. Push @ to enter the procedure.

LCD Display

Green and
Yellow LED’s

Scroll Up

Exit Enter/Save

Scroll Down

SOlCOla

06(H)-2B-6
 Main Table of Contents
CLSRK
6.1.1 Flow chart sensor set-up

l Push 0F to activate the main

menu.

l Push @ or @ to select the’

sensor set-up procedure.

l Push @ to activate the set-up

procedure.

Push @ or @ to select the

menu number.
l----- -----1

Push @ to activate the set-up

------------_
procedure for the selected
sensor.

The sensor set-up procedures are described in detail in the following chapters.

A NOTICE: The maximum and minimum positions of all the sensors must be taught to

the hydrostatic controller for the system to work correctly.

06(H)-2B-7
Cl!!RK
Main Table of Contents

7. Sensor Set-up Procedures

The Forklift Truck Control System defines the following sensor set-up procedures:
00 : Software version number indication
01 : Throttle pedal sensor calibration
02 : Brake pedal sensor calibration
03 : Lift cylinder sensor calibration
04 : Setting the parameter for the engine type

05 : Setting the parameter for driving controls

06 : Setting the parameter for driving characteristics

07 : Engine actuator calibration

08 : EDC minimum calibration

09 : EDC maximum calibration

$stom Adjustment of Driving Characteristics, Software Version 64 Only.

: Deceleration-accel pedal released, forward
11 : Deceleration-accel pedal released, reverse
12 : Engine speed, tilt and auxiliary functions
13 : Max engine speed, lift function
14 : Speed limitation, forward
15 : Speed limitation, reverse

Custom Adjustment of Driving Characteristics, Software Versions 22, 23 and 63

10 : Deceleration-forward or reverse to neutral.
11 : Deceleration-accel pedal released.
12 : Deceleration-forward to reverse / reverse to forward.
13 : Engine speed, tilt and auxiliary functions.
14 : Maximum engine speed, lift function.
* + Input Error
If a number is selected other than a number contained in the
above list, the LCD shows:

and the buzzer sounds for a short time. After the buzzer stops, then another selection can be made with
the @ or @ buttons.

A NOTICE: Set-up procedure 08 requires for the engine to be running and the truck must
be raised with the drive wheels off of the ground. Review the safe lifting and
blocking procedures located in the Clark Service Manual. Set-up procedures
00 through 07 and 09 through 15 require that the engine is NOT running.

Disconnect the DIA 3 instrument after exiting the procedures with

the exit button @ until the display shows:

All newly entered data will be lost if the DIA 3 is switched off before the DISCONNECT prompt is
displayed.

06(H)-2B-8
 Main Table of Contents
El!!RK
7.2.1 Set-up 00 Software version number indication procedure
Accessing this menu will indicate which version of software is loaded into the hydrostatic controller on
the truck. This information can be important when adjusting driving characteristics or resolving sensor

A NOTICE:

The engine must NOT be

running and set the parking
brake for this procedure.

-> Main Menue

l Push 0) to activate the main
menu.

l Push @ or @ to select the

sensor set-up procedure.

Selected menu F
number 1I Q l Push @ to activate the set-up
procedure.
+ 00 t
Sensor Set-up

l Select with the buttons @ or

Decrease @ the menu number 00.

---L------b--,

i Select sensor number 1

I------------- 1
9 Push @ to see the Forklif
Trucksofhvare version number

Forklift Truck software version number 1 1 on the display. The green LED
lights.

1
l Push @ or @go back to the
set-up procedure.
S00976a

06(H)-2B-9
 Main Table of Contents

7.2.2
7.2.2 Set-up 01 Throttle pedal sensor calibration procedure
When replacing the throttle pedal sensor or adjusting the throttle pedal linkage, the maximum and
minimum sensor values must be set into the hydrostatic controller’s memb:y for the engine to respond
to the throttle properly. The following procedure allows for proper setting of these values.

A NOTICE:

The engine must NOT be

running and set the parking
brake for this procedure.
Also, the foorplate must be in
place.
Push @ to activate the main
menu.
Push @ or @ to select the
+ t sensor set-up procedure.
Sensor Set-up \ Push @ to activate the set-up
procedure.
Selected menu
number Select with the buttons @ or
@ the menu number 01.
Push@ to activate the throttle
Sensor Set-up
sensor procedure.
The green LED lights.
Push @ if you want to leave
the set-up without setting the
f Select menu number I sensor.
I---------____ 1
Push @ to start the sensor set-
up. The number indicated is the
minimum value. As the throttle
pedal is moved, the value
indicated will rise and fall
corresponding to the position
of the pedal verifying proper
Current sensor voltage sensor operation.
in Vno x 10 l Q) Maximum position:
Push and hold the throttle pedal
flat to the floor.

Current sensor voltage I

inV,oxlO -
0w Push 0.
The number indicated is the
maximum value.
@ Minimum position:
Release the throttle pedal. The
number indicated is the
minimum value.
SOO977a Push @ to save the new set-up.

06(H)-2B-10
 CL!‘RK
Main Table of Contents

7.2.3 Set-up 02 Brake pedal sensor calibration procedure

When replacing the brake pedal sensor or after adjusting the brake linkage, the maximum and minimum
sensor values must be set into the hydrostatic controller’s memory for the brake system to operate
properly. The following procedure allows for the proper setting of these values.

A NOTICE:

The engine must NOT be

running and set the parking
brakeforthisprocedure. (With
the parking brake set, the
brakepedalwillnotmovefully
which is fine and allows pro-
per adjustment of the
maximum position value).
. Push @ to activate the main
+ t
Sensor Set-up menu.
. Push @ or @ to select the
Selected menu sensor set-up procedure.
number . Push @ to activate the set-up

procedure.
Sensor Set-up . Select with the buttons or
@ the menu number 0 9 .
. Push @ to activate the set-up
Decrease
brake pedal sensorprocedure.
. The green LED lights.
1 Select menu number i . Push @ if you want to leave
I
-------------I
the set-up without setting the
sensor.
-3 02 t Status . Push @to start the sensorset-
r._._._._._._._._._.-.-. up. The number indicated is
1 LED: green
the released position value.
. @ Push and hold the brake

Current sensor voltane-

in VDc x 10
0 PT pedal to the mechanical brake
start position. (firm)
. Push 0.

The number indicated is the

new start position.
. @ Release the brake pedal.
Current sensor voltage
in V,, x 10 Push and hold the brake pedal

02 -. to set the minimum value. The

pedal must be pushed in a
minimum of l/2” and the
Save )
0 display must read 7 or higher.
. Push @ to save the new set-

up*
06(H)-2B-11
 Main Table of Contents

7.2.4 Set-up 03 Lift valve sensor calibration procedure

When the lift function to raise the forks is operated, the engine speeds up proportionally to how far the
lift lever is moved. When replacing the lift sensor or any adjustment of the lift lever mechanism occurs,
the neutral and maximum lever position values must be set into the hydrostatic controller’s memory for
the lift function to operate properly. The following procedure allows for the proper setting of these values.

The engine must NOT be

running and set the parking
brake for this procedure.
l Push 0) to activate the main
menu.
l Push @ or @ to select the
sensor set-up procedure.
8 Push @ to activate the set-up
procedure.

10 *
l Select with the buttons @ or
Selected menu
number @ the menu number 03.
l Push @ to activate the set-up
*- lif cylinder sensor procedure.
l The green LED lights.

Increase @ 6 Decrease l Push Q if you want to leave

the set-up without setting the
i sensor.
1 Select menu number ,
I------------_I
Push @ to start the sensor set-
up. The number indicated is the
-303 t Status current neutral position of the
-.-.-.-.-._._._._._.-.-.- lever.
LED: green
@ Move and hold the lift lever
to max. raise position.
Current sensor voltage Push 0. The number indicated
in VDc x 10 is the new maximum raise lever
position.
@ Slowly move the lift lever to
released position and hold the
Current sensor voltage
in VDc x 10 lever about l/8 to l/4 inch in
2 __ -+ XX+ Set Min the raise position.
0 -_
Push @ to save the new set-
up. The number indicated is the
new neutral position of the lift
S00979a
lever.

06(H)-2B-12
 CL!lRK
Main Table of Contents

7.2.5 Set-up 04 Setting the parameter for the engine type

The hydrostatic controller must
performed when the hydrostatic
when errors occur, under certain
selection. Before using the other
Set-up Procedures 04 and 05.
know which engine is installed in the truck. This procedure must be
controller is replaced or the software in the controller is changed. Also
conditions the computer may lose the proper engine and vehicle control
set-up procedures, select the proper engine and vehicle controls using-

+I~
A NOTICE:

The engine must NOT be

running and set the parking
brake for this procedure.

l Push 0w to activate the main

menu.
l Push @ or @ to select the
sensor set-up procedure.
Push @ to activate the set-up
procedure.
Selected menu
Select with the buttons @ or
number
@ the menu number 04.
Push @ to activate the selec-
tion procedure.
The yellow LED lights.
Push @ ifyou want to leave the
set-up without changes.
1 Select menu number )
I-------------I Push @ to start the set-up.
The display shows the current

+ 04 t Status engine type saved into memory.

-.-._._._._._._._._.-.-.- The green LED lights.
LED: yellow
Select with the buttons @ or
Current engine type number @ the engine type:
)k
00 : Diesel
0
Leave without saving
01 : LP-Gas
I + XX t Status 02 : Diesel Perkins
Save -._._._._._._._._._.-.-.-
(onlyfor CD(G)P20-30H)
03 : Natural Gas

Decrease
. Push @to save the new set-up.
. Push @ to leave the procedure
1 Select engine type /
S00980b I_______ ------I without changes.

06(H)-2B-13
 Main Table of Contents

7.2.6 Set-up Menu 05 Setting the parameter for the type of driving controls
The hydrostatic controller must know which driving controls are installed on the truck (column
directional control, Unitrol pedal system, Two Pedal system). This procedure must be performed when
the hydrostatic controller is replaced or the software in the computer is changed. Also when errors occur,
under certain conditions the computer may lose the proper engine and vehicle control selection. Before
using the other set-up procedures, select the proper engine and vehicle controls using Set-up Procedures
04 and 05.

A NOTICE:

The engine must NOT be

running and set the parking

.
brake for this procedure.
Push @ to activate the main

.
menu.
Push @ or @ to select the

.
sensor set-up procedure.
Push @ to activate the set-up

.
1QP
procedure.

Selected menu Select with the buttons @ or

. 05.
number @ the menu number
Push @ to activate the selec-

.
tion procedure.

.
The yellow LED lights.
Push @ if you want to leave
_-- L------L--,
the set-up without changes.

.
1 Select menu number 1
I------------_I

+ 05 t Status
.
Push @ to start the set-up.
The display shows the current
_._._._._._._._._._.-.-.- type of vehicle controls saved
LED: yellow
in the memory. The green LED

Current vehicle type number-1 9

.
lights.
Select with the buttons @ or
@ the vehicle type:
00 : Column Directional
control/Unitrol.
01 : Two pedal system
Decrease Push @ to save the new set-
up*
I Select vehicle type 1 Push @ to leave the procedure
SO0981 b I-------------I
without changes.

06(H)-2B-14
 Main Table of Contents
CMRK
7.2.7 Set-up Menu 06 Setting the parameter for driving characteristics
The driving characteristics can be adjusted to suit the material handling application or to the individual
operator’s preference. There are three driving characteristics available:
,,Smooth“-Generally used for handling fragile loads or when the truck must be driven smoothly.
,,Standard“-Useful for typical material handling applications.
,,Aggressive“-Good for fast shuttle applications or skilled operators.
,,Extra“-Smooth (only software version 64) - used when minimum dynamic braking is desired
Testing is recommended after changes are made to assure the desired driving characteristic is attained.
Perform testing in a clear, pedestrian free area. Clark recommends for companies with multiple
hydrostatic trucks that all the trucks be set with the same driving parameters so they drive the same. When
selecting the desired driving characteristics, perform the following procedure.

A NOTICE:

The engine must NOT be running

and set the parking brake for this

..procedure.
Push @ to activate the main menu.
Push @ or to select the sensor set-

.up procedure.
Push @ to activate the set-up

. procedure.
Select with the buttons @ or @ the

Selected menu . menu number 06.

Push @to activate the set-up default

.. parameter procedure.
The yellow LED lights.
Push @ ifyou want to leave the set-

.. up without changes.
Push @ to start the set-up.
The display shows the current drive
parameter list saved in the memory.

-+06 t Status
. The green LED lights.
Select with the buttons @ or @ the
_._._._._._._._._._.-.-.- parameter list:
LED: yellow
00: Smooth
Current drive parameter list number
01: Standard
02: Aggressive
03: Extra smooth (version 64 only)
Leave without saving .
,ic + XX t Status Push @ to save the new set-up.
Save -.-._.-._._._._._._.-.-.- . Push @ to leave the procedure
LED: green
without changes.
t
Increase Q Q Decrease A NOTICE:
_-- ~~~~~~~l-~~~ By installing a new driveparameter
i Select drive parameteri
S00982b list number
I---------_--_I ’ list, the values from the set-ups 10
- 21 will be reset.
06(H)-2B-15
 Main Table of Contents

7.2.8 Set-up 07 Engine actuator calibration

The engine actuator controls the position of the throttle on the engine. Whenever the actuator is replaced
or the throttle linkage at the engine is adjusted, the following procedure will calibrate the engine actuator
to the hydrostatic controller. Note: The correct engine parameter must be set as described in Sensor Set-
up menu 04 for proper calibration of the engine actuator.

A NOTICE:

The engine must NOT be

running and set the parking
brake for this procedure.

. Push @ to activate the main

menu.

. Push @ or @ to select the

sensor set-up procedure.

+ c
Sensor Set-up
. Push @ to activate the set-up
procedure.
Selected menu
number . Select with the buttons @ or
@ the menu number 07.

. Push @ to activate the set-up

combustion engine actuator

Decrease
procedure. Zfthe hood is raised,
you can see the engine actuator
y--L ____ --L--, move. When the acturatorstops
i Select menu number ( moving, this procedure is
I-------------I
finished. The numbers indicated
are the positions of the actuator
andwill rise to a maximum value
Current value and stop when the procedure is
feedback Dotentiometer
done.
in VDc x i0

9 Wait until the set-up procedure

is done (- 20 - 30 sec.).

l The values will be saved

automatically.

06(H)-2B-16
 Main Table of Contents

7.2.9 Set-up 08 EDC minimum calibration procedure

The hydrostatic controller must be calibrated with the electrical current value at which the truck just begins to move in both
forward and reverse. This procedure must be performed whenever the hydrostatic pump, the EDC (Electronic Displacement
Control) on the pump, or the hydrostatic controller is replaced. This procedure must be performed for both forward and reverse
for the truck to accelerate and drive properly at low ground speeds.

A NOTICE: The engine must run during this procedure and the hydrostatic controller system will not
respond to directional control, service and parking brake inputs. The truck must be supported with the drive wheels
off of the ground and the work area must be adequately ventilated. Refer to Clark service manuals for a complete
listing of safe maintenance practices and for procedures to perform safe lifting, jacking and blocking of the lift
truck.
+ c . Push @ to activate the main menu.
Disconnect I .
1 ------7 Push @or @ to select the sensor set-up procedure.
------
I Starttheengine . Push @ to activate the set-up procedure.
. Select with the buttons @ or @ the menu number 08.
The number indicated is the output current. 10 is the
point where this adjustment starts. The number
indicated is the output current. 10 is the point where
this adjustment starts.
. Push @ to activate the EDC-deadband forward
procedure. The yellow LED lights.
. Push @ if y ou want to leave the set-up without
changes.
. Push @ to start the set-up. The green LED lights.
The number indicated is the output current. 10 is the
point where this adjustment starts.
. @With@or@ you can increase or decrease the
output current until the charge pressure decreases
+ 10 t Status
appr. l-l.5 bar or until you can hear a flow noise in
the axle. The vehicle is trying to move forward.
. Push @ to save the new current value.
. Push @ ifthe new current value should not be saved.
. The EDC-deadband reverse procedure is active. The
Save
yellow LED lights.
. Push @ if y ou want to leave the set-up without
_._._._._._._._._._.-._
LED: vellow changes.
. Push @ to start the set-up. The green LED lights.
Current output to the EDC
in mA The number indicated is the output current. 10 is the
point where this adjustment starts.
. @With@or@ you can increase or decrease the
output current until the charge pressure decreases
appr. I- 1.5 bar or until you can hear a flow noise in
Save the axle. The vehicle is trying to move reverse.
. Push @ to save the new current value.

A
. Push @ ifthe new current value should not be saved.
NOTICE: the maximum allowed difference between EDC-deadband forward and reverse is 10
mA. If the difference is higher than 10 mA the EDC must be adjusted mechanically.

06(H)-2B-17
 Main Table of Contents

7.2.10 Set-up 09 EDC maximum calibration procedure

The hydrostatic controller must be calibrated with the electrical value when the hydrostatic pump has reached maximum
displacement which produces the maximum speed of the truck. This procedure must be performed whenever the hydrostatic
pump, theEDC (Electronic Displacement Control) on the pump, or the hydrostatic controller is replaced. The maximum speed
of this truck at factory settings is 11 MPH corresponding to an EDC value of 95.

A NOTICE: The engine must not be running and set the parking brake for this procedure.
-3 t
Disconnect
I
------ 1 ------7 . Push @ to activate the main menu.
. Push @ or @ to select the sensor set-up
procedure.
Push @ to activate the set-up procedure.
Select with the buttons @ or @ the menu
number 09.
Push @ to activate the max. EDC current

Selected menu forward procedure. The yellow LED lights.

. Push Of i you want to leave the set-up without
changes.
l Push @ to start the set-up. The green LED
lights. The number incicated is the output
current.
9 aWith @ or @ you can increase or de-
Current output to the EDC crease the output current until the display
in mA
. -3 10 t Status indicates 95 or other desired value.
_._.~_._._._._._._._._.~
LED: green
I 0
9 Push F to save the new actual current value.
l Push Of i the new max. EDC current should
not be changed.
l The max. EDC current reverse procedure is
active. The yellow LED lights.

-+lO+ Status 4
. Push Of i you want to leave the set-up without
_._._._._._._._._._._.~_ changes.
LED: yellow

Current output to the EDC

l Push 0) to start the set-up. The green LED
in mA lights. The number indicated is the output
+ 10 t Stat&l
current.
l @With @ or @ you can increase or de-
crease the output current until the display indi-
cates 95 or other desired value.

0
9 Push F to save the new actual current value.
l Push @f i the new max. EDC current should
not be changed.

06(H)-2B-18
 CMRK
Main Table of Contents

7.3 Custom Adjustments of Driving Characteristics

Version 64 Software

A NOTICE:

Use sensor set-up procedure 00 to determine the version of software in the truck.

06(H)-2B-19
 Main Table of Contents

7.3.1 Set-up IO Adjustment of deceleration time (Forward direction)

When operating the truck, the time for the truck to slow to a stop when the accelerator pedal is released can be adjusted (Set-
up menu 10 for forward, 11 for reverse).
Normally this parameter is set with the selection of the driving characteristics parameter (Set-up menu 06). If
operator preference or the application demands a different length of time for the truck to stop then this parameter
can be adjusted for longer or shorter time intervals with the following procedure. Testing is recommended after
changes are made to assure the desired driving characteristic is attained. Perform testing in a clear, pedestrian free
area. Clark recommends for companies with multiple hydrostatic trucks that all the trucks be set with the same
driving parameters so they drive the same.

A NOTICE:
The engine must NOT be
running and set the parking
brake for this procedure.
Push @ to activate the main
menu.
Push @ or @ to select the
sensor set-up procedure.
Push @ to activate the set-up
Selected menu number procedure.
Adjustment of the deleceration time Push (@to activate the adjust-
in Forward direction ment.
12 = Shifting from forward to neutral The yellow LED lights.
13 = Release accelerator pedal Push @ ifyou want to leave the
set-up without changes.
Push @ to start the set-up.
The display shows the current
deceleration parameter saved.
The green LED lights.
. Select with the buttons @ or
@ the deceleration para-
meter: I . ..20
* XX t Status 20 = the slowest deceleration
-._._._.-.-._._._._.-.-.~ time
LED: yellow
1 = the fastest deceleration
Current deceleration parameter time
The value 0 will be saved as 1.
Leave without saving Push ) to save the new set-up.
+ XX + Status
Push 8 to leave the procedure
Save without changes.

_-- L ------ L ---I

1 Select deceleration 1
parameter
I__- em-- ------I I

SO1 369a

06(H)-2B-20
 Main Table of Contents

7.3.2 Set-up 11 Adjustment of deceleration time (Reverse direction)

When operating the truck, the time for the truck to slow to a stop when the accelerator pedal is released can be adjusted.

Normally this parameter is set with the selection of the driving characteristics parameter (Set-up menu 06). If
operator preference or the application demands a different length of time for the truck to stop then this parameter
can be adjusted for longer or shorter time intervals with the following procedure. Testing is recommended after
changes are made to assure the desired driving characteristic is attained. Perform testing in a clear, pedestrian free
area. Clark recommends for companies with multiple hydrostatic trucks that all the trucks be set with the same
driving parameters so they drive the same.

A NOTICE:
The engine must NOT be

.
running and set the parking
brake for this procedure.

.
Push @ to activate the main
menu.

.
Push @ or @ to select the
sensor set-up procedure.

.
+ t Push @ to activate the set-up
Sensor Set-up procedure.
Selected menu number
Push @ to activate the adjust-

.
Adjustment of the deleceration time ment.
in Reverse direction The yellow LED lights.
15 = Shifting from reverse to neutral

.
Push @ if you want to leave
16 = Release accelerator pedal the set-up without changes.
17 = Shifting from reverse to forward Push @ to start the set-up.
The display shows the current

.
deceleration parameter saved.
The green LED lights.
Select with the buttons @ or
@ the deceleration para-
meter: l-20
.
20 = the slowest deceleration
+ XX t- Status time
_._,_._._._._._._._.-.-.- 1 = the fastest deceleration
LED: yellow
time
I
The value 0 will be saved as 1.
Current deceleration parameter ------l @
Push @ to save the new set-
up.
Push @ to leave the procedure
without changes.

Increase @ @ Decrease
_-- L--,-_-L-_,
; Select deceleration I
parameter
I---___------_I I

SO1 370a

06(H)-26-21
CMRK
Main Table of Contents

7.3.3 Set-up 12 Adjustment of the Engine RPM’s when the Tilt or Auxiliary Mast Functions
are operated
When operating the tilt or auxiliary levers controlling the mast, a switch tells the computer to speed up
the engine to supply proper hydraulic flow to that mast function. Some operators or auxiliary devices may
require a faster or slower response. The following procedure will allow adjustment of the engine RPM’s
to increase or decrease the hvdraulic nump flow. Note that the tilt function and all auxiliary functions are
d L

controlled with this same parameter and the engine will speed up the same amount for all of these
functions.

A
+ c
’ Disconnect NOTICE:
I
The engine must NOT be
running and set the parking
brake for this procedure.
. Push @ to activate the main
menu.
. Push @ or @ to select the
sensor set-up procedure.
. Push @ to activate the set-up
procedure.
. Select with the buttons @ or
Selected menu
@ the menu number 12.
. Push @ to activate the
adjustment.
. The yellow LED lights.
. Push @ ifyou want to leave the
set-up without changes.
. Push @ to start the set-up.
. The display shows the current
tiltfixedRPA4value saved. The
_._._._._._._._._._.-.-.- green LED lights.
LED: yellow . With the @ or @ button it is
Current engine RPM possible to adjust the tilt fixed
in l/mid 00
RPM between 1200...2000
Leave without saving RPM. The value is indicated on
+ XX 4-- Status
the display in 100 RPM
Save _._._._._._._._._._.-.-,-
increments.
9 Values lower than 12 will be
saved as 1200 RPM.
l Push @to save the new set-up.
l Push @ to leave the procedure
S01371a
without changes.

06(H)-2B-22
 Cl!!RK
Main Table of Contents

7.3.4 Set-up 13 Adjustment of the Maximum Engine RPM’s when the Lift Lever is Moved
to the Maximum Raise Position
When operating the lift lever controlling the raising of the forks, a sensor tells the computer how far
the lift lever has been moved and the computer will speed up the engine proportionally to supply proper
hydraulic flow. Some operators or applications may require a faster or slower response. The following
procedure will allow adjustment of the maximum engine RPM’s when the lift lever is moved to the
maximum raise position.

rr A NOTICE:

The engine must NOT be

running and set the parking
brake for this procedure.
. Push @ to activate the main
menu.
. Push @ or @ to select the
sensor set-up procedure.
. Push @to activate the set-up
procedure.

.k
. Select with the buttons @ or

10
Selected menu
number @ the menu number 13.
.

&- .
Push @
adjustment.
to activate

The yellow LED lights.

the

. Push @ if you want to leave

Increase @ @ Decrease
_-- A_____-I_--,
the set-up without changes.
I
i Select menu number I . Push @ to start the set-up.
I-------------I
. The display shows the current
lift maximum RPM value
+ 13 t Status
-.-.-.-._._._._._._.-.-.- saved. The green LEDlights.
LED:yellow . With the @ or @ button it is
Current engine RPM possible to adjust the lif max.
in l/min/lOO RPM between 1200...2500
Leave without saving RPM The value is indicated
,i( + XX t Status
on the display in 100 RPM
Save _._._._._._._._._._._._._
increments.
Values lower than 12 will be
saved as 1200 RPM.
Push @ to save the new set-up.
Push @ to leave the
SO1372a
procedure without changes.

06(H)-26-23
 Main Table of Contents

7.3.5 Set-up Menu 14 Adjustment of the EDC Current Limitation (Speed Limitation) Forward
Where local applications or plant regulations require that the maximum truck speed be less than 11 MPH,
values can be entered for correspondingly lower truck speeds. Entering a lower value results in slower
maximum speed and testing is recommended to assure the entered value results in desired maxiumum
speed. Perform testing in a clear, pedestrian free area.
l Push 0k to activate the main
menu.
l Push @ or @ to select the
sensor set-up procedure.

l Push @ to activate the set-up

procedure.

l Select with the buttons @ or

@ the menu number 20.
&lso-L-up I
Push @ to activate the

1
Selected menu
number adjustment.
The yellow LED lights.

Increase

_--
\
Q QYe Decrease
Push @ ifyou want to leave the
set-up without changes.
Push @ to start the set-up.
------ --‘I
I Select menu number 1 b
The display shows the current
I-------------I
limitationof the max.EDC
P current (vehicle speed).
w
+ 14 t Status The green LED lights.
_.-.-._._._._.-.-.-.-.-
LED: yellow
With the @ or @ button it is
Max. EDC current possible to adjust the max. EDC
,/&
in %A0 current between O...
10. The
0
value is indicated on the display
in Yo/lO.

0 = No vehicle speed
lO= 100%

Decrease
. Push @to save the new set-up.
Push @ to leave the procedure
,__-l---_--L--,
.
I Select max. !
SO1 373a
EDC current
1_____________1 without changes.

06(H)-2B-24
 Main Table of Contents

7.3.6 Set-up Menu 15 Adjustment of the EDC Current Limitation (Speed Limitation) Reverse
Where local applications or plant regulations require that the maximum truck speed be less than 11 MPH,
values can be entered for correspondingly lower truck speeds. Entering a lower value results in slower
maximum speed and testing is recommended to assure the entered value results in desired maxiumum
speed. Perform testing in a clear, pedestrian free area.
Push @ to activate the main
menu.
Push @ or @ to select the
sensor set-up procedure.
Push @ to activate the set-up
procedure.

. Select with the buttons @ or

@ the menu number 15.

Push @ to activate the

adjustment.
Selected menu
The yellow LED lights.

Push @ if you want to leave

the set-up without changes.

Increase Q Q Decrease
. Push @ to start the set-up.
The display shows the current
,-_L_--___L--,

i Select menu number 1 limitationof the max.EDC

I-------------I
current (vehicle speed).
The green LED lights.

+ 15 +- Status
i _._._._.-._._._._.-.-. . With the @ or @ button it is
t’ LED: vellow
possible to adjust the max. EDC
current between O...
10. The
value is indicatedon the display
in o/o/10.
0 = No vehicle speed
lO= 100%

Push @ to save the new set-

Increase q 9 Decrease
up.
-_---- LB_,
Push @ to leave the procedure
FsBLSelect max. 1
SO 1374a ;__ -----------
EDC current ; without changes.

06(H)-26-25
 Main Table of Contents

7.4 Custom Adjustments of Driving Characteristics

For Version 22,23 and 63 Software

A NOTICE:

Use sensor set-up procedure 00 to determine the version of software in the truck.

06(H)-2B-27
 Main Table of Contents

7.4.1 Adjustment of the Deceleration Time When Shifting From Forward or Reverse to Neutral.

When operating the truck, the time for the truck to slow to a stop when the directional control is shifted
from forward or reverse to neutral can be adjusted. Normally this parameter is set with the selection of
the driving characteristics parameter (SENSOR SET-UP Menu 06). If operator preference or the
application demands a different length of time for the truck to stop when shifted to neutral, then this
parameter can be adjusted for longer or shorter time intervals with the following procedure. Testing is
recommended after changes are made to assure the desired driving characteristic is attained. Perform
testing in a clear, pedestrian free area. Clark recommends for companies with multiple hydrostatic trucks
that all the trucks be set with the same driving parameters so they drive the same.

A NOTICE: The engine must not be running and set the parking brake for this procedure.

. Push @ and @ at the same time

to activate the main menu.
. Push @ or @ to select the sensor
set-up procedure.
. Push @ to activate the set-up
procedure.
. Select with the buttons @ or @
the menu number 10.
Push @to activate the adjustment.
The yellow LED lights.
Push @ if you want to leave the
set-up without changes.
. Push @ to start the set-up.
. The display shows the current
decelerationparametersaved. The
green LED lights.
1 Select menu number 1 .
L-_____------2 Select with the buttons @ or @
the deceleration para-meter:
lCL.60:
10 = the longest deceleration time
60 = the fastest deceleration time
l Values lower than 10 will be saved
Leave without saving I + as 10.
+ XX t Status . Push @ to save the new set-up.
Save
l Push @ to leave the procedure
without changes.
Increase A 7 Decrease

QQ
r 3&Ft TleC~l~rYtiOn 1
IL------------A
parameter 1

06(H)-26-28
 CMRK
Main Table of Contents

7.4.2 Adjustment of the Deceleration Time When the Accelerator Pedal is Released.

When operating the truck, the time for the truck to slow to a stop when the accelerator pedal is released
can be adjusted. Normally this parameteris set with the selection of the driving characteristics parameter
(SENSOR SET-UP Menu 06). If operator preference or the application demands a different length of
time for the truck to stop, then this parameter can be adjusted for longer or shorter time intervals with
the following procedure. Testing is recommended after changes are made to assure the desired driving
characteristic is attained. Perform testing in a clear, pedestrian free area. Clark recommends for
companies with multiple hydrostatic trucks that all the trucks be set with the same driving parameters
so they drive the same.

A NOTICE: The engine must not be running and set the parking brake for this procedure.

Push @ and @ at the same time

to activate the main menu.
Push @ or @ to select the sensor
set-up procedure.
. Push @ to activate the set-up
procedure.
. Select with the buttons @ or @
the menu number 11.
Push @ to activate the adjust-
ment.
1' b
Selected menu
number
The yellow LED lights.
Push @ if you want to leave the
set-up without changes.
. Push @ to start the set-up.
~~~~~~~~~~L__ . The display shows the current
1
) Selectmenunumber 1 b decelerationparametersaved. The
I-----________A
0 green LED lights.
. Select with the buttons @ or @
the new deceleration para-meter:
1 Actual deceleration parameter 7 A lCL.60:
10 = the slowest deceleration time
IY
Leave without saving 60 = the fastest deceleration time
I$ + XX t Status
. Values lower than 10 will be saved
Save
as IO.
. Push @ to save the new set-up.
. Push @ to leave the procedure
I parameter
L-___------__J I without changes,

06(H)-2B-29
 Main Table of Contents
CMRK
7.4.3 Adjustment of the Deceleration TimeWhen Shifting From Forward to Reverse or Reverse
to Forward.

When operating the truck, the time for the truck to slow to a stop and reverse direction when the
directional control is shifted from forward to reverse or reverse to forward can be adjusted. Normally
this parameter is set with the selection of the driving characteristics parameter (SENSOR SET-UP Menu
06). If operator preference or the application demands a different length of time for the truck to reverse
direction, then this parameter can be adjusted for longer or shorter time intervals with the following
procedure. Testing is recommended after the changes are made to assure the desired driving character-
istic is attained. Perform testing in a clear, pedestrian free area. Clark recommends for companies with
multiple hydrostatic trucks that all the trucks be set with the same driving parameters so they drive the
same.

A NOTICE: The engine must NOT be running and set the parking brake for this procedure.

. Push @ and @ at the same time to

+ t
Disconnect
I
I activate the main menu.
. Push @ or @ to select the sensor set-
up procedure.
. Push @ to activate the set-up
procedure.
. Select with the buttons @ or @ the
menu number 12.
Push @ to activate the adjustment.
The yellow LED lights.
Selected menu
Push @ if you want to leave the set-up
without changes.
. Push @ to start the set-up.
. The display shows the current
deceleration parameter saved. The
green LED lights.
. Select with the buttons @ or @ the
deceleration para-meter:
10...60:
Actual deceleration parameter -1 6
10 = the slowest deceleration time
I 4 60 = the fastest deceleration time
Leave without saving
A + XX t Status l Values lower than 10 will be saved as
Save
10.
. Push @ to save the new set-up.
Increase @ @ Decrease
. Push @ to leave the procedure without
changes.

06(H)-26-30
 Main Table of Contents
CMRK
7.4.4 Adjustment of the Engine RPM’s When the Tilt or Auxiliary Mast Functions are Operated.

When operating the tilt or auxiliary levers controlling the mast, a switch tells the computer to speed up
the engine to supply proper hydraulic flow to that mast function. Some operators or auxiliary devices
may require a faster or slower response. The following procedure will allow adjustment of the engine
Rpm’s to increase or decrease the hydraulic pump flow. Note that the tilt function and all auxiliary
functions are controlled with this same parameter and the engine will speed up the same amount for all
of these functions.

A NOTICE: The engine must NOT be running and set the parking brake for this procedure.

. Push @ and @ at the same time

to activate the main menu.
l Push @ or @ to select the sensor
set-up procedure.
. Push @ to activate the set-up
procedure.
l Select with the buttons @ or @
the menu number 13.
. Push @ to activate the adjustment.
l The yellow LED lights.
l Push @ if you want to leave the
Selected menu b set-up without changes.
number 10
. Push @ to start the set-up.
l The display shows the current tilt
jixedRPMvaluesaved. The green
Increase v Decrease
LED lights.
Q ------0 __
r-- 1
1 Select menu number 1 l With the @ or @ button it is
L---__-------J
possible to adjust the tiltj?xedRPM
between 1200...2000
--f 13 t Status
l/min. The value is indicated on the
-.-.-.-._._._._.-.-.-.-.-
LED: yellow display in 100 RPM’s.
l Values lower than 12 will be saved
as 1200 RPM.
. Push @ to save the new set-up.
l Push 0 to leave the
Save
procedureithout changes,

1 Select engine RPM i

L_----------_A

06(H)-2B-31
WIRK Main Table of Contents

7.4.5 Adjustment of the Maximum Engine RPM’s When the Lift Lever is Moved to the Maximum
Raise Position.

When operating the lift lever controlling the raising of the forks, a sensor tells the computer how far the
lift lever has been moved and the computer will speed up the engine proportionally to supply proper
hydraulic flow. Some operators or applications may require a faster or slower response. The following
procedure will allow adjustment of the maximum engine Rpm’s when the lift lever is moved to the
maximum raise position.

A NOTICE: The engine must NOT be running and set the parking brake for this procedure.)

. Push @ and @ at the same time to

activate the main menu.
. Push or to select the sensor set-
up procedure.
. Push to activate the set-up
procedure.
. Select with the buttons or the
menu number 14.
. Push to activate the adjustment.
. The yellow LED lights.
. Push if you want to leave the set-up
without changes.
. Push to start the set-up.
. The display shows the current lift
maximum RPM valuesaved. The
green LED lights.
r-_l_-----L__, . With the or button it is possible
1 Select menu number I
L--___------_J to adjust the lift max. RPM between
1200...2500 l/min. The value is
+ 14 t Status indicated on the display in 100 RPM’s.
_._._._.-.-._._._._.-.-.- . Values lower than 12 will be saved as
LED: yellow
1200 RPM.
Actual engine RPM .
in l/min/1OO
Push to save the new set-up.
. Push to leave the procedure without
Leave without saving
+ XX t Status changes.
_.-.-._._._._._._.-.-.-.-
Save
LED: green

1 Select engine RPM /

I-___---------J

06(H)-2B-32
 Main Table of Contents
CMRK
8. Sensor/Actuator Error Diagnosis
If an error exists which prevents the software from running, the following procedure will indicate which
component is causing the problem. After the problem component is identified, the Sensor Check
Procedures may be valuable for checking operation of the component. For some error conditions, the
computer will lose the selection for the engine type and vehicle control (menu 04 and 05 of the Sensor
Set-up Procedures). These must be reset to the proper configuration before the other sensors and
parameters are adjusted in the Sensor Set-up Procedures.

A NOTICE: The engine must NOT be running and set the parking brake for this procedure.

8.1 Select the sensor/actuator error procedure

Activate the main menu, the display shows:
Select with the buttons @ or @ the
procedure until the display shows:
Push @ to activate the error procedure.
The display shows: -1
and the green LED lights.
. After pushing the @ button, the software checks the system for errors.
. Errors are displayed with the error number on the display:
and the yellow LED lights. -1

. If no error remains, the system switches back to the main menu automatically.
The display shows:
. Push @ to search for the next error.
. Push @ to stop the searching process.

8.1.1 Sensor/Actuator Error Listing

Sensor power
EDC Pump (+)
EDC Pump (-)
Start RPM pump c Low Idle
Inch/brake pedal sensor
Speed sensor (Attention: if engine is not running, this will indicate as an
error because the RPM is too low. This is normal.)
Acceleration pedal sensor
Lift cylinder sensor
Engine actuator
EDC-deadband (use sensor set-up menu 08 and 09 to adjust minimum and
maximum EDC correctly)
EDC-deadband tolerance (minimum EDC for forward and reverse are too
far apart - Maximum difference is 9.)
Engine actuator set-up error
Minimum lever position too high
Start current is higher than max. current
Difference between min. and max. lever position too low
Lever does not go back into min. position

06(H)-2B-33
 Main Table of Contents

8.1.2 Flow Chart Sensor Error Procedure

+ t
) Disconnect .
I Push @ to activate the main
I
menu.

. Push @ or @ to select the

sensor error procedure.
-> Main Menue

. Push @ to activate the sensor

error menu. The green LED
lights.
[ &nscL:rror 1

. Push @ if you want to leave

the procedure without
searching for errors.

. Push @ to start the procedure.

Q
;e The system checks for errors.

. If a
r------ ------

! Systemchecks for ! sensor error is indicated,

i errors automaticallyf
I------‘------ ,
the display shows the sensor
Error I No error I error number and the yellow
! found ! I
LED lights.
. Push @ again, to see another

Sensor
+
XX t Status
Error
_._._._._._._._._._._
.
error.
Push @ to leave the proce-
LED: vellow dure.

r-------------
0
‘p
w
. If no error remains, the green
LED lights.
) System checks for )
I . If no error remains, the system
next error
i------,------j
Error 1 No error I switches back to the main menu
Y I
L------ ! ------d automatically.

. Check the type of error with the

listing of 8.1.1.
. Solve the problem.
SO1 002a

06(H)-2B-34
 Main Table of Contents

9. Sensor Check Procedure

The following procedures allow checking the operation of the sensors and switches used in the
hydrostatic computer system with the DIA-3 instrument.

A NOTICE:

When the hydrostatic truck’s computer system is accessed with the DIA 3 instrument, the
computer quits controlling the truck driving functions. When this occurs, the truck will not
respond to inputs from the accelerator pedal, directional control, and the service and parking
brakes until the DIA 3 is correctly disconnected.

9.1 Select the sensor check procedure

l Activate the main menu, the display shows:

l Select with the buttons @ or @ the

sensor check procedure, the display shows:

l Push @ to enter the procedure.

9.2 Sensor Check Procedures

The Forklift Truck Control System provides in conjunction with the SUSMIC-DIA 3 the following
sensor check procedures:

Throttle sensor
:: : Speed sensor
02 i Inch/braking pedal sensor
03 : Direction switch
Parking brake (switching signal)
i/i: : Lift cylinder sensor
06 i Tilt cylinder and auxiliary function (switching signal)
07 : Engine actuator feedback sensor

If a number is selected other than a number contained in the above list, the LCD shows:

and the buzzer sounds for a short time. After the buzzer stops, then another selection can be made with
the @ or @ buttons.

A NOTICE: Set-up procedures

running.
00,02 through 07 requires that the engine is NOT

Set-up procedure 01 requires for the engine to be running with the

directional control in neutral and the parking brake set.

06(H)-2B-35
Cl!!RK
Main Table of Contents

9.2.1 Check 00 Throttle Pedal Sensor Procedure

A NOTICE:

The engine must NOT be

running and set the parking
brake for this procedure.

l Push @to activate the main menu.

l Push@or@toselectthesensor
set-up procedure.

l Push @ to activate the sensor

check procedure.

l Select with the buttons @ or @

Selected sensor the sensor number 00.
number

l Push @ to activate the throttle

+ 00 t
sensor.
Sensor Check
l The green LED lights.

l Push the throttle pedal - The

voltage output of the sensor is
indicated on the display (in V,c x
I
Select sensor i
10). As the pedal is moved, the
I number
L------,-----,--4 I
display will change which indicates
proper operation of the sensor.
Sensor value (0-5V) ---
in VDC x 10 I v The number indicated when the
+ XX t Status pedal is released is the minimum
_._._._._._._._._._.-.-.-
LED: green value, andwhen thepedal ispushed
flat to the floor is the maximum
r------- -------1
value.
Push throttle 1
I
I pedal
I.-----,---,--,--- I
* Push @ to leave the procedure.

SO0991 a

06(H)-2B-36
 Main Table of Contents
CMRK
9.2.2 Check 01 Pulse pick-up (PPU) on the Hydrostatic Pump Procedure
The PPU measures the RPM’s that the engine is turning the hydrostatic pump for the hydrostatic system
computer. This procedure allows a coarse reading of the engine RPM’s and the following procedure
allows verification that the PPU is operating correctly.

A NOTICE:

The engine must run during this procedure and the hydrostatic controller system will not respond
to directional control, service and parking brake inputs. The truck must be in neutral, the parking
brake set, the wheels blocked, and the work area must be adequately ventilated. Refer to Clark
service manuals for a complete listing of safe maintenance practices and for procedures to perform
safe lifting, jacking and blocking of the lift truck.

+I[ Push @ to activate the main

menu.

Push @ or @ to select the

sensor check procedure.

Push @ to activate the sensor

check procedure.

I
&&Check
Select with the buttons @ or
@ the sensor number 01.

Push @ to activate the speed

sensor.

The green LED lights.

Move the engine actuator by

hand - The output of the sensor
is indicated on the display in
increments of 100 RPM (12
corresponds to 1200 RPM.
When the engine is not running,
+ XXt Status
_.-._._._._._._.-.-.-.-.- 00 is displayed.
LED: green

. Push @ to leave theprocedure.

S00992a

06(H)-28-37
 Main Table of Contents
CWRK
9.2.3 Check 02 Brake Pedal Sensor Procedure
The following procedure allows checking of the voltage output of the sensor which indicates the position
of the brake pedal to the hydrostatic system computer.

A NOTICE:

The engine must NOT be

running and set the parking
brake for this procedure.

. Push @ to activate the main

menu.

. Push @ or @ to select the

sensor check procedure.

. Push @ to activate the sensor

check procedure.

. Select with the buttons @ or

Selected sensor
number @ the sensor number 02.

+ 02 t . Push @ to activate the brake

+ Sensor Check
pedal sensor.

The green LED lights.

Increase A.\ ‘7
Decrease

Push the brake pedal - The

r---66- -------
_ ---, _
Select sensor ; voltage output of the sensor is
I
I
L-----------
number ----_ I indicated on the display (in V,c
x 10). As the pedal is moved,
Sensor value (O-W) ‘-1 _ the display will change which
in VDCx 10 I v
+ XX c Status indicates proper operation of
_._._._._._._._._._.-.-.- the sensor.
LED: green
Push @ to leave the
t -L-_-y ---,
.
procedure.
r---‘-._

1 Push mcb/brakmg 1
I pedal
L-__------------- I

06(H)-2B-38
 Main Table of Contents
CMRU
9.2.4 Check 03 Directional Control Procedure
The direction the truck travels in controlled by two switches connected to the direction control lever on
the steering colunrin, or two switches connected to the Unitrol pedal, or two switches connected to the
pedals of the Two Pedal control. One switch indicates forward, one switch indicates reverse, and neither
switch actuatedforneutral. The following procedure will indicate which direction the hydrostatic system
computer is reading when the directional control is operated.

A
+ t
Disconnect NOTICE:
I
The engine must NOT be
running and set the parking
brake for this procedure.

Push @ to activate the main

menu.

+
Push @ or @ to select the
sensor check procedure.

9
Selected sensor
number
SensoYCheck Push @ to activate the sensor
check procedure.

Select with the buttons @ or

@ the sensor number 03.

Push @ to check the direction

switch. The color of the LED
Decrease indicates the Direction the
control is in. Changing
r_---L--__-_-_-L-__, direction will illuminate the
I
Select sensor ;
I number I corresponding LED.
I.-,,---,----,----

Reverse = yellow LED

+ 03 t Status Neutral = no LED
Forward = green LED
LED-! yellowj ; i green!

Push @ to leave the procedure.

I Switch
f
I
L--,,_,------,a-- switch
direction I
S00994a

06(H)-2B-39
 Main Table of Contents

9.2.5 Check 04 Parking Brake Switch Procedure

When the parking brake is actuated, a switch tells the hydrostatic controller to go into neutral. The
following procedure indicates what the hydrostatic controller is reading when the parking brake is
actuated and released.

The engine must NOT be

running and set the parking
brake for this procedure.

l Push 0F to activate the main

menu.

l Push @ or @ to select the

sensor check procedure.

+ t Sensor Check I
0
9 Push F to activate the sensor
check procedure.

b
19
Selected sensor l Select with the buttons @ or
number @ the sensor number 04.

\P
9 Push @ to check the parking

L-------
brake switch. The green LED

0
will indicate if the switch is
active. Applying and releasing
the parking brake will show
operation of the switch.

Parking brake active =

green LED
Parking brake inactive =
no LED

------,&& t -------1
l Push @to leave theprocedure.
I I
I brake switch
I.-------_--------
I

S00995a

06(H)-26-40
 Main Table of Contents
CMRK
9.2.6 Check 05 Lift Sensor Procedure
The following procedure allows checking of the voltage output of the sensor which indicates the position
of the lift lever to the hydrostatic controller. This procedure is useful when the engine will not increase
speed when the lift lever is actuated or when the engine will not idle properly in the case where the lift
sensor may be indicating that the lever is actuated when it is not.

The engine must NOT be

running and set the parking
brake for this procedure.

l Push @ to activate the main

+ Main Menue menu.

l Push @ or @to select the sensor

check procedure.

l Push @ to activate the sensor

check procedure.

l Select with the buttons @ or @

Selected sensor the sensor number 05.
number l The green LED lights.
l Push @ to check the lift cylinder
signal.

8 Operate the lif cylinder lever -

The voltage output of the sensor is
indicated on the display (in V,c x
10). As the lever is moved the
display will change which
indicates proper operation of the
sensor. The number indicated
when the lever is released is the
Sensor value (0-5V) neutral position value, and when
in VDCx 10
+ XX t Status the lever is moved to the maximum
-.-.-.-.-.-._._._._.-._.- raise position is the maximum
LED: green value.

-------1 l Push @ to leave the procedure.

I
Pull lift
I
S00996a
I cylinder
L--,------,-----,
lever I

06(H)-2B-41
CMRK
Main Table of Contents

9.2.7 Check 06 Tilt and Auxiliary Switch Procedure

The following procedure allows checking of the switches which indicate operation of the tilt and
auxiliary functions to the hydrostatic controller. This procedure is useful when the engine will not
increase speed when the tilt or auxiliary lever is actuated or when the engine will not idle properly in the
case where the switch may be indicating the lever is actuated when it is not. Note that there is a separate
switch for the tilt and each auxiliary function.

+ t
- Disconnect
A NOTICE:

The engine must NOT be

running and set the parking
brake for this procedure.

l Push 0F to activate the main

menu.

Push @ or @ to select the

sensor check procedure.

Push @ to activate the sensor

Selected sensor check procedure.

number

Select with the buttons @ or

@ the sensor number 06.

Push to check the tilt cylinder

switch. Operation of the tilt and
auxiliary levers will indicate
operation of the switches. When
the levers are in neutral, the
switches should not be active.
* 06 c Status Switch status active = g r e e n
-._._._.-._.~._._‘_._‘-‘_ LED
Switch status tilt cylinder- not active i active
LED- off i green Switch status inactive = n o
LED

tilt cylinder lever

-----_----------~,
I
Push @ to leave theprocedure.

S00997a

06(H)-28-42
 Cl!!RK
Main Table of Contents

9.2.8 Check 07 Engine Actuator Feedback Procedure

The following procedure allows checking of the voltage output of the engine actuator which indicates
the position of the engine throttle to the hydrostatic controller.

NOTICE:

The engine must NOT be

running and set the parking
brake for this procedure.

Push @ to activate the main

menu.

Push @ or @ to select the

sensor check procedure.

Selected sensor
Push @to activate the sensor
check procedure.

Select with the buttons @ or

@ the sensor number 07.
Increase
Push @ to check the engine
r--- L-m_----L---,
Select sensor i actuator feedback sensor.
f
I number I
L----------v----,
l The green LED lights.

l Move engine actuator by hand

from low idle to high idle -The
voltage output of the sensor is
r------- t
-------I
indicated on the display (in
! Move engine actuator I
; lever-by hand 1 VDCx 10).
L--------------,,

l Push @ to leave the

procedure.
S00998a

06(H)-2B-43
 Main Table of Contents

10. Hydrostatic Drive Microprocessor

LED INDICATORS

The hydrostatic drive system in the Clark CGC 20/25/30H, the CGP 20/25/30H, and the CDP 20/25/30H
is controlled by a microprocessor. The microprocessor is mounted on the left side frame rail in the engine
compartment. The microprocessor has a program loaded in it which analyzes the data inputted from the
sensors and switches located on the truck. From this data, the engine speed and the displacement of the
pump are controlled to provide drive capabilities and higher engine speeds for the mast functions.

The memory of the microprocessor cannot be damaged by using the DIA-3 service tool or by
disconnection of the battery. The internal components can be damaged or the memory can be affected
by electric arcs so disconnection of the microprocessor from the wire harness prior to welding is required.

Located on top of the microprocessor are four light emitting diodes (LED’s), two green, one yellow, and
one red. Looking down on the microprocessor in the truck, the rear most LED is green and indicates the
12 volt power from the trucks electrical system. If this LED is dim or not illuminated when the ignition
switch is on, then a connection or low voltage problem exists.

The next LED is also green and it indicates the microprocessor’s internal 5 volt power supply. If this
LED is dim or not illuminated when the ignition switch is on and the first LED is illuminated, than an
internal problem with the microprocessor exists. This condition is not serviceable at the dealership.

The LED third from the rear is yellow and indicates when the program is running. It flashes slow
(approximately once per second) when the program is running and fast if the program is not running.

The forward most LED is red and indicates when an error condition exists. When the truck is in an error
mode, the truck is programmed to not allow driving until the error is corrected. The DIA-3 diagnostic
instrument must be used to diagnose and correct the error.

Red Error Indication

Yellow-Application Status

Green-5 Volt Power Supply

Green-12 Volt Power Supply

06(H)-26-44
 EMRK
Main Table of Contents

DIA-3 Quick Reference

Use this page when you are thoroughly familiar with the operation of the DIA-3.

+SENSOR SET-UP+
00 Software Version Number Indication <VERSION XX>
01 Throttle Pedal Sensor Calibration Maximum (38), Minimum (14)
02 Brake Pedal Sensor Calibration Maximum (43), Minimum (7)
03 Lift Valve Sensor Calibration Maximum (43), Minimum (15)
04 Setting the Parameter for the Engine Type Diesel COO>,LPG <Ol>, Perkins Diesel <02>,
CNG <03>
05 Setting the Parameter for Driving Controls Column ShiftKJnitrol COO>,Two Pedal cOl>
06 Setting the Parameter for Driving Characteristics Smooth COO>,Standard cOl>, Aggressive cO2>
Extra Smooth <03>
07 Engine Actuator Calibration Automatic
08 EDC Minimum Calibration Forward and Reverse, Max Difference is 10,
(Approximately 19 for F. and R.)
09 EDC Maximum Calibration Set to c95>

Custom Adjustment of Driving Characteristics, Software Version 64 Only:

10 Deceleration-Accel Pedal Released, Forward <l> (Fast) to <20> (Slow)
11 Deceleration-Accel Pedal Released, Reverse cl> (Fast) to <20> (Slow)
12 Engine Speed, Tilt and Auxiliary Functions <12> (1200 RPM) to <20> (2000 RPM)
13 Max Engine Speed, Lift Function <12> (1200 RPM) to <25> (2500 RPM)
14 Speed Limitation, Forward CO> (No Speed) to <lo> (100%)
15 Speed Limitation, Reverse <O> (No Speed) to <lo> (100%)

Custom Adjustment of Driving Characteristics, Software Version 22,23, and 63:

10 Deceleration- F or R to N. <lo> (Slow) to c60> (Fast)
11 Deceleration-Accel Pedal Released clO> (Slow) to c60> (Fast)
12 Deceleration-F to FUR to F <lo> (Slow) to <60> (Fast)
13 Engine Speed, Tilt and Auxiliary Functions <12> (1200 RPM) to <20> (2000 RPM)
14 Max Engine Speed, Lift Function <12> (1200 RPM) to <25> (2500 RPM)

+Sensor Error+
01 Sensor Power 22 Engine Actuator Feedback Signal
05 EDC Pump (+) 23 EDC Deadband
06 EDC Pump (-) 24 EDC Deadband Tolerance
17 Start RPM Pump c Low Idle 25 Engine Actuator Set-Up Error
18 Inch/Brake Pedal Signal 26 Minimum Lift Lever Position Too Hi
19 Speed Sensor Signal 27 Start Current is Higher than Max.
20 Acceleration Pedal Signal 28 Lift Lever Min/Max Difference Too Low
21 Lift Sensor Signal 29 Lift Lever Does Not Return to Min.

+Sensor Check+
00 Throttle Pedal Sensor 04 Parking Brake Switch
01 Pulse Pick-Up (PPU) 05 Lift Sensor Check
02 Brake Pedal Sensor 06 Tilt and Aux. Switch
03 Direction Control Switch 07 Engine Actuator

06(H)-2B-45
 Main Table of Contents

elfIRK Group 06(H), Transmission (Hydrostatic)

Section 3.

Hydrostatic Transmission Components

Removals and Replacements

Hydrostatic System Plumbing .._....._........U..._............_...............~...................~.....~..._._.._ ..... 2

Drive Axle ......“.“..._..“........“.....“......_ .......................................................................................... 3
Drive Pump ..___“.~..“...“I.....“..._........__...........“..........~.........“.............~ ................................. 4
Engine ....W.~.......“.““.......“.““..............................”...............“............“.................“_ ..................... 4
Pump Adaptor and Couplings .._..........I......._.....~..................................”...~ ............................ 4
Coupling Hub ................................................................................................................................... 4
Adaptor and Coupling ...................................................................................................................... 4
Control System ................ .._...“...........“.....~.......~...............~...~............_........~ ........................... 6
Computer .......................................................................................................................................... 6
Engine (Throttle) Actuator ............................................................................................................... 7
Lift . Tilt, and Aux Control .............................................................................................................. 8
Direction Control ............................................................................................................................. 9
Brake Pedal ...................................................................................................................................... 9
Accelerator Pedal(s) ....................................................................................................................... 10

IMPORTANT
CLEANLINESS. Extreme cleanliness is required when you ser-
vice a hydrostatic transmission. Do repairs in a clean, dust-free
environment. Keep all openings covered. Clean all parts thor-
oughly and dry them with a lint-free cloth before reassembly.
Change all filters at the intervals prescribed in Group PM.

SM 598, Dee ‘94 TransmissionRemovalsand Replacements l 06(H)-3-1

 Main Table of Contents

Group 06(H), Transmission (Hydrostatic) LlllRK

IMPORTANT Hydrostatic System Plumbing
CLEANLINESS. Extreme cleanliness is re-
quired when you service a hydrostatic trans- The illustration below shows removal and replacement of
mission. the hydraulic plumbing for the hydrostatic system.
--------------_- 1 Not shown is the plumbing for the main hydraulic system
as a whole (load handling and steering systems). See Groups
29 and 30 for main hydraulic system information.
Service notes:
l Lower shroud must be in position before installing oil

l Hydraulic fitting tightening procedure:

a. Tighten fitting finger-tight until it stops turning,
whiie moving the fitting lightly side to side to
prevent cocking or thread damage.
b. Using finger tips, lightly snug fitting with wrench
until the fitting bottoms out on the seat or port. Do
not overtighten. Over-tightening can crack the

rolL&LERF&-
! PNEUMATIC-TIRE
’ TRUCK
I
- -
-_----_-
a:- Lower Radiator Shroud

Drive Motor Drive Motor

r Return Line r Supply Line

Toraue

(30-33 ft-lb)

Oil Temperature
Sender

Torque, 16 bolts,
57-58 Nom (42-50 ft-lb)

HydrostaticSystemPlumbing

06(H)-3-2 l TransmissionRemovalsand Replacements SM 598, Dee ‘94

 Main Table of Contents

CWRK Group 06(H), Transmission (Hydrostatic)

Drive Axle
1. With the truck safely blocked, remove the drive wheels 4. Disconnect the hydraulic fittings to the drive axle.
as described in Group 22. (See “Hydrostatic System Plumbing” in this Section
for information on disconnecting and connecting the
fittings.)

2. Disconnect the parking brake cable at the front cowl as

described in Group 23(H).

5. Securely support the axle on a rolling jack.

6. Remove the mounting bolts from the axle mounting

brackets and roll the axle from under the frame.
3. Disconnect the service brake line at the tee on the drive Toraue
_- -- __
axle. When replacing line, tighten fitting per hydraulic
fitting tightening procedure in Group40. Bleed brakes
as described in Group 23(H) after installing the drive
axle.

IMPORTANT
CLEANLINESS. Extremecleanliness is re- 7. Replacement is the reverse of removal.
quired when you service a hydrostatic trans-
mission.

SM 598, Dee ‘94 TransmissionRemovalsand Replacements l 06(H)-3-3

 Main Table of Contents

Group 06(H), Transmission (Hydrostatic) ClClRK

IMPORTANT Pump Adaptor and Couplings
CLEANLINESS. Extreme cleanliness is re-
quired when you service a hydrostatic trans-
mission. Coupling Hub
The coupling hub may be removed for replacement or
pump repairs. To remove the hub from the pump shaft,
loosen the clamp bolt (or bolts) and pull the hub off. Install
Drive Pump hub prior to reassembly.

1. Remove the lift pump (shown on next page) as de-

scribed in Group 29.
2. Label and disconnect all hydraulic fittings and electri-
cal connections to the drive pump. (See “Hydrostatic
System Plumbing” earlier in this Section.) Cap hy-
draulic lines.

Mount hub at
62 mm (2.44 in) max. 1

Coupling Hubfor Gas Engine

Toraue to 50-55 Nom-

(37-41 ft-lb).

Mount hub flush

with end of shaft.

Coupling Hub for Diesel Engine

3. Attach a hoist to the drive pump.
4. Remove the four pump mounting bolts shown in the
illustration on the next page. Adaptor and Coupling
5. Remove the pump-to-frame-mounting bolt shown in If it is necessary to access the engine flywheel or repair the
the illustration on the next page. drive coupling, refer to the illustrations on the next page.
6. With the hoist bearing the pump’s weight, slide the
pump toward the front of the truck until the splined
coupling hub clears the adaptor.
7. Installation is the reverse of removal.

Engine
To remove the engine, it is first necessary to remove the
drive pump as described here. Then remove the engine as
described in Group 00.

06(H)-3-4 . TransmissionRemovalsand Replacements SM 590, Dee ‘94

 Main Table of Contents

Group 06(H), Transmission (Hydrostatic)

Toraue
Coupling to 70-80 N-m
i\ r- L-
(52-59 ft-lb).

\ Coupling Hub Drive Pump-to-Frame Mount

f-

‘sb Toraue
20-25 N-m Adaptor
1177421 in-lb).

(52-59 Alb).
-Toraue v
70-80 Nom
Pump-to-Engine Mounting Arrangement (52-59 ft-lb).

SM 598, Dee ‘94 Transmission Removals and Replacements l 06(H)-3-5

 Main Table of Contents

Group 06(H), Transmission (Hydrostatic) CUIRK

Control System
The following control system components are mounted in
various locations:
l Computer IMPORTANT
l Engine (throttle) actuator After the computer or sensors are replaced,
l Brake pedal sensor you must perform the “set-up” procedures
l Accelerator pedal(s) and sensor described in Section 2 of this Group.
l Direction control switches
l Lift control sensor
l Tilt and aux control sensors.
Location and mounting of these controls are illustrated on
the following pages. Service notes are provided where
special procedures are necessary.

Computer
Toraue
20-23 N-m NOTE
(S-17 ft-lb).--,
See wiring diagrams in Group 14 for elec-
trical hookups.

06(H)-3-6 l TransmissionRemovalsand Replacements SM 598, Dee ‘94

 Main Table of Contents

EMRK Group 06(H), Transmission (Hydrostatic)

Engine (Throttle) Actuator

Toraue ,4 bolts,

(71-88 in-lb)

IMPORTANT
After sensors are re-
placed, you must per-
form the “set-up” pro- NOTE
cedures described in See wiring diagrams iu
Section 2 of this Group. Group 14 for electrical
Actuatorfor LPG Engine hookups.

Actuator for Diesel Engine

SM 598, Dee ‘94 Transmission Removals and Replacements l 06(H)-3-7

 Main Table of Contents

Group 06(H), Transmission (Hydrostatic) CMRK

Lift , Tilt, and Aux Control

IMPORTANT
After sensors are replaced, you
must perform the ‘set-up” proce-
dures described in Section 2 of this
Group.

Tilt/ Aux

NOTE
Seewiringdiagrams iu Group
14 for el&ricaI hookups.

(63-94 in-lb) L Lift Sensor

\
Bottom View Y-. Toraue
9.4-I 0.6 N-m
(83-94 in-lb)
Switch(es)

06(H)-3-8 l TransmissionRemovalsand Replacements SM 598, Dee ‘94

 Main Table of Contents

ClaRK Group 06(H), Transmission (Hydrostatic)

Brake Pedal

Full brake pedal removal and installation information is

given in Group 23(H).
IMPORTANT
After sensors are replaced, you
must perform the “set-up”
procedures described in Sec-
tion 2 of this Group.

20-25 Nom
(177-221 in-lb)

5-6 N-m
(44-53 in-lb)

NOTE
Seewiring diagrams in Group 14 for elec-
trical hookups.

Direction Control
The single-accelerator pedal hydrostatic truck uses the stan-
dard direction control lever and switch to provide a direc-
tion signal to the computer. This control is covered in
Groups 25 and 14.
The two-pedal truck uses two pedals and two switches to
control direction. These components are depicted in “Two-
Pedal System-Pedals and Direction Switches” on page
12.

SM 598, Dee ‘94 Transmission Removals and Replacements . 06(H)-3-9

 Main Table of Contents

Group 06(H), Transmission (Hydrostatic) CMRK

Accelerator Pedal(s)

Single-Accelerator Pedal System

Toraue
20-25 N-m
(177-221 in-lb),:,4

Accelerator Sensor

IMPORTANT
After sensors are re-
placed, you must per-
form the “set-up” pro-
cedures described in
8-10 N-m Section 2 of this Group.

(124-142 in-lb)

Accelerator Sensor

Bottom View

06(H)-3-10 l Transmission Removals and Replacements SM 598, Dee ‘94

 Main Table of Contents

CUlRK Group 06(H), Transmission (Hydrostatic)

Two-Pedal System-Pedal Lever and Sensor

_Toruue ,6 bolts,

Sensor

IMPORTANT
After sensors are re-
placed, you must per-
form the ‘set-up” pro-
cedures described in
Section 2 of this Group.

Accelerator Sensor

Lever
Bottom View

SM 598, Dee ‘94 Transmission Removals and Replacements l 06(H)-3-l 1

 Main Table of Contents

Group 06(H), Transmission (Hydrostatic) CIRRK

Two-Pedal System-Pedals and Direction Switches

NOTE
The single-accelerator
pedal hydrostatic truck
uses the standard direc-
tion control lever and
switch to provide a direc-
tion signal to the com-
puter. This control is cov- With floorplate installed,
adiust the tab to contact
ered in Groups 25 and 14.
the pedal roller (previous
The two-pedal truck uses page) when the pedals
the two pedals and two are in the neutral posi-
switches shown here and \ tion.
on next page to control Torque fasteners 20-25
\ _..
direction. N-m ( 177-221 in-lb).

NOTE
SeeGroup 38 for furtherin-
formationon removingand
insMing the floorplate.

Mount 3 mounting
plates to floorplate.
Toraue, 4 fasteners,
Toraue, 12 fasten-
12-14 Nom(106-124 in-
ers, 12-14 N-m
lb).
(106-124 in-lb).
Toraue, 2 fasteners,
20-25 Nom(177-221 in- -
Y
lb).

05(H)-3-1 2 . Transmission Removals and Replacements SM 590, Dee ‘94

 Main Table of Contents

EmI6 Group 06(H), Transmission (Hydrostatic)

Mounts to
floorplate. See

Mounts to floorplate. See

previous page.

Route switch

Direction

Toraue, 4 fasteners, -I
20-25 N-m (177-221 in-
lb).

L Direction SwitchJ
Switch harness
routing shown
on next page.

SM 598, Dee ‘94 TransmissionRemovalsand Replacements l 06(H)-3-13

 Main Table of Contents

Group 06(H), Transmission (Hydrostatic) CIMW

Two-PedalSystem-Wiring

Direction Switches Wiring Harness.

Route as shown.

SM 598, Dee ‘94

06(H)-3-14 . Transmission Removals and Replacements
 Main Table of Contents

EmK Group 06(H), Transmission (Hydrostatic)

Section 4.

Hydrostatic Drive Pump Service

Two Sauer-Sunstrand manuals are inserted behind this page:

l The Series 90 Arid Pumps and MotorsSERVICE Manual. This manual
includes pump description, troubleshooting. adjustment. and minor re-
pairs.
l The Series 90 Axial Pumps and Motors REPAIR Manual. This manual
includes pump major repairs, overhaul, and complete disassembly/assem-
bly.

IMPORTANT
PUMP FILTRATION. The hydrostatic drive pump has a spin-
on t.ype filter mounted on it. This filter must be replaced after
the first 50 hours of truck oueration and every 2000 hours
thereafter. If truck performance is sluggish, a clogged filter
could be the problem.

for Hydrostatic Drive Pump

SM 598, Dee ‘94 Hydrostatic Drive Pump Service l 06(H)-4-1

 Main Table of Contents

elmI Group 06(H), Transmission (Hydrostatic)

Section 5.

Hydrostatic Drive Motors Service

SM 598, Dee ‘94 Hydrostatic Drive Motors Service l 06(H)-6-I

 Main Table of Contents

DO 800/LEX1/11.94

Notice
Designations ,descriptions and presentations correspond to the state of information
at the date of impression of this manual. Modifications may influence the product service without
any obligations for us arising there from . Methods and set-ups are recommendations only, no
liability is undertaken by Rexroth for the results.

For service instructions relating to the wheel hub and brake assemblies refer to
Clark Material Handling No 2804045.

Contents :
Page
...
Safety Instructions . . . . . .. . .. .. . . . . . .. .. . . . . . .. .. . .. . .. .. .. . .. .. .. .. . . . . . . . . .. . . . . . . .. . . .. . . . . . . . . .. .. . . . . . . . . . . . . . . . . . . .. . .III
Installation . .. . .. . . .. . . . . . . . .. . . . . .. . . . . . .. . . . . . . . . . . .. .. .. .. .. . ... . .. . . . . . . . . .. .. . . .. .. . . . . . .. . . . . . .. .. . . . . . . . . .. . . .. . . . . . . . . . . iv
Commissioning .. . .. . .. . .. . .. . . .. . . . .. . .. . . .. . . . . . .. .. .. .. .. . .. . .. . .. . . . . . . . . . . .. . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . .V
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Dismantling . . . . . . . . . . . . . . . . . .. . .. . . . . . . . .. . . . .. . . .. . . .. ... ... .. .. . ... . . . . . . . . .. . . . . . .. . . . .. . . .. . . . . .. . . . . . . . . . . . .. . . ._. . .._.... vii

1. Dismantling Instructions . . . . . . . . . .. . . . . .. . .. .. .. .. . .. .. .. . . . . . . . . .. . . . . . . . . .. . .. .. . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . ..1

1 .I Axle Unit Assembly.. ............................................................................. .l

1.2 Mid Casing Assembly.. .......................................................................... .I
1.3 Flushing Assembly.. .............................................................................. .2
1.4 Rotating Assembly.. .............................................................................. .3
1.5 Front Case Assembly.. .......................................................................... .3

2. Reassembly Instructions . . . . .. . . . . .. . . .. . .. .. . ... . . ... . .. . . . . . . . . .. . . .. .. . . .. . . . .. ..___.__......................... 4

2.1 Flushing Assembly.. .............................................................................. .5

2.2 Mid Case Assembly.. ............................................................................. -6
2.3 Rotating Assembly.. .............................................................................. .6
2.4 Front Case Assembly.. .......................................................................... .7
2.5 Axle Unit Assembly.. ............................................................................. .7

Appendices
Page

A. Assembly Drawing . . .. .. . .. . . .. . . . .. . . . .. .. . . .. ... .. . ... ... . . . . .. . . . .. . . .. .. .. . .. .. . . .. . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . .8

B. Tooling . . . . . . . . .. . . . . . . . .. .. .. . . . . .. .. . .. . . . . . .. . . .. .. . ... . .. .. . .. . . . . . . . .. . . . . .. . .. . . . .. . . . .. . . .. .. . . . . . . . . . .. . . . . . . . . . . .. . .17

C. Grease Specification .. . . . .. . . . . .. . . . . . . . . .. .. . .. .. .. .. .. .. . . . . . . . .. . .. . . . . . . . .. . . . . . . . . . . . . .. . . .. . . . . . . . .. . . . . . . . . . . 20

D. Fault finding . .. . . . . . . . . .. . . .. . . . . . . . . . . . .. . . . . .. . ... . .. ... ... . .. . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . ..21

Rexroth Scotland ii
 Main Table of Contents

DO 800/LEXi /I 1.94

SAFETY INSTRUCTIONS

WARNING : Damage or injury may result if any of the instructions in this manual are not
followed. If in doubt contact an authorised Rexroth agent.

a. All shipping plugs shall be removed prior to connection of hydraulic lines to motor.

b. Prior to attempting any maintenance work on motor ensure all pressure sources
have been disconnected.

C. Motor output shafts rotates on supply of pressure to the motor. Ensure personnel
do not contact shaft.

d. Motors shall be fully supported as specified in installation instructions prior to

application of pressure.

e. Maximum pressures , speeds, and shaft loads applied to motor shall not exceed
relevant data sheet limits. If in doubt consult authorised Rexroth agent.

f. When lifting motors use slings/ shackles rated for motor weight. Ensure motor
is secure and gives a balanced lift.

GENERAL

The following repair instructions are intended to assist in inspections and repairs
to be carried out. Prerequisite is that this work is carried out only by qualified
personnel. These units are manufactured with great care and with adherence
to defined tolerances to the highest manufacturing accuracy, and therefore the
following points must be given particular attention.

Rexroth Scotland
iii
 Main Table of Contents

DO 800/LEXl/li .94

INSTALLATION

a. Ensure all packing / shipping plugs are removed prior to use.

b. Hydraulic fluid used shall is mineral oil ( HL, HLP) to DIN 51524 or
environmentally acceptable hydraulic fluid. (HTG, HPG, HE to RE90221)
are acceptable subject to reduced guarantee.

For acceptability of other fluids please refer to authorized Rexroth agent.

Viscosity shall be greater than IO mm2/s under all conditions to prevent serious
wear. Operational limits for full functionality are 16 mm2/s < a < 100 mm2/s with
optimum results obtained at 16 mm2 /s c a c 36 mm2/s.

C. Oil cleanliness is vital to obtaining long service life, therefore well maintained
filtration is essential.

Oil contamination shall not exceed NAS 1338 class 9 ( or SAE class 6,
IS0 / DIS 4406 class 18/l 5).

The required level of cleanliness may normally be achieved by filters with a

minimum retention rate of B10 > 75.

Care should be taken in placement of filters in the system and pressure

drops across filters. The maximum permissible interval between system oil
changes, shall be every 2,000 hours running time or yearly , whichever is the
shortest.

Note. Motors are tested with mineral oil and system shall be fully flushed prior
to use of any alternative fluid type.

d. Motor connections shall be rated for maximum system pressure and be in

accordance with relevant international standards. Connection lines shall be
designed such as to impose minimum loading on motor due to vibration,
movement, temperature changes of system ,etc..

All connections shall be completed prior to motor operation.

Connections shall be sized to minimise pressure losses. Recommended

minimum bore of hydraulic lines is 8 mm.

Pressure at leakage port shall not exceed 10 bar. Hydraulic line should be sized
accordingly, using the maximum motor leakage flow in the relevant data sheet.

Rexroth Scotland
iv
 Main Table of Contents

DO 800/LEXl /I 1.94

e. Prior to operation the motor shall be securely mounted using all the body
mounting holes with an arrangement capable of withstanding maximum torque
and all external loads placed on motor shaft.

Ensure mounting face is flat and square, allowing no distortion of motor mounting
flange.

Leakage port shall be mounted at the top to ensure motor is permanently oil
filled. Alternatively a check valve may be placed in drain line to ensure motor is
permanently oil filled. Ensure case pressure does not exceed 10 bar.

f. Shaft connection to mechanical drive shall use all mounting holes specified on
output shaft care must be taken to ensure no loading is generated by eccentric
mounting of motor to a load. Suitable flexible coupling shall be used if this loading
cannot be avoided.

COMMISSIONING

a. Ensure system is completely flushed to rated oil cleanliness levels prior to

commissioning.

b. WARNING : During the running in period ( minimum 24 hour) the motor should
not be run unloaded at greater than 50% of maximum speed.

C. On completion of run in check motor is free from leaks.

d. Under operating conditions confirm:

- Oil temperature does not exceed 80 OC ( 176 OF)

- Case pressure is less than IO bar.
- Boost pressure (P2) is greater than case pressure by at least 2 bar.
- Boost pressure is recommended to be set at > 15 bar.
- Confirm operating speeds, pressure and power are within datasheet
recommendations.

Rexroth Scotland
V
 Main Table of Contents

DO 800/LEX-I /I 1.94

OPERATION

a. Monitor oil cleanliness at regular intervals

b. Periodically check motor is still securely mounted and running at normal

temperature, sound level and leakage. Confirm unit is oil tight.

C. during extended storage motor should be filled with hydraulic oil.

Rexroth Scotland
vi
 Main Table of Contents

DO 800/LEXl /l 1.94

DISMANTLING

a. When dismantling the unit from the machine, immediately close openings with plugs
to prevent ingress of dirt.

b. Make note of the details on code plate such as serial number, type number and
running time of unit (for ordering spare parts).

C. Remove external dirt (cleaning spirit or trichlor solution).

d. Have ready a clean work place, lay out tools ready.

e. Use only non-threading cleaning rags.

f. Before dismantling components, mark parts to ensure correct reassembly.

9. Carry out step by step dismantling.

h. The appearance of the parts removed often gives an indication of the condition of the
system. For example :-

Scored sliding surfaces, -contaminated operating fluid.

heavy abrasion

Discolouration of components - overheating of operating

with heavy loading fluid, incorrect choice of
viscosity or inadequate
specification of operating
fluid.

-insufficient oil.

Rexroth Scotland
vii
 Main Table of Contents

DO 800/LEX1/11.94

1 .I Axle unit Dismantlinu Instructions

Refer to Appendix A P.9 and Pl 1

1.1.1 Remove hose line from port ‘L’ allowing oil to be drained from motor.

1.1.2 Remove ( 12 off ) capscrews, item 73.

1.1.3 Separate mid casing, rotational groups and front cases.

1.1.4 Remove washer ( 12 off ), item 78, from capscrew ( 12 off ), item 73.

1.15 Remove O-ring, item 72, from mid case, item 58

1.1.6 Remove O-ring, item 72, from front case, item 2 or 3.

1.1.7 Repeat for other side.

1.2 Dismantlina the Mid Casina Assembly

Refer to Appendix A P.14

Take care not to damage timing face.

1.2.1 Mark position of distributor, item 59, in relation to rear case, item 58. This mark will
be required on reassembly.

1.2.2 Drop mid case, item 58, from approximately 8 cm onto a clean plastic or wooden
surface. This shock will release distributor, item 59.

I .2.3 Remove seal ring, item 63, from distributor, item 59.

1.2.4 Remove seal ring, item 62 & 64, from mid section, item 58.

1.2.5 Remove springs ( 6 off ), item 61, from distributor, item 59.

1.2.6 Check timing face of distributor. If necessary lap timing face.

1.2.7 Remove dowel pin, item 60 , from mid case, item 58 .

1.2.8 Repeat for other side.

Rexroth Scotland 1
 Main Table of Contents

DO 800/LEXl/i 1.94

1.3 Dismantlina flushina assembly

Refer to Appendix A P.9, P. 15 & P.16

1.3.1 If flushing assembly is working satisfactorily do not dismantle.

1.3.2 Remove plug, item 100, from mid case, item 58.

1.3.3 Remove and discard O-ring, item 101.

1.3.4 Remove spring, item 99, and washer , item 98.

1.3.5 Depress spool, item 96.

1.3.6 Spool should move freely back and forth.

Spool sticking

1.3.7 Remove spool, item 96, and inspect for scoring of machine surface.

1.3.8 Remove second plug, item 100, from mid case, item 58.

1.3.9 Remove and discard O-ring, item 101.

1.3.10 Remove second spring, item 99, and second washer, item 98.

1.3.11 With mid assembly completely dismantled flush mid case, item 58 .

1.3.12 Dip spool, item 96, into clean hydraulic oil.

1.3.13 insert spool, item 96, into spool bore then move back and forth.

Relief valve

1.3.14 Remove plug, item 102, from mid case, item 58.

1.3.15 Remove and discard, O-ring , item 103.

1.3.16 Remove spring, item 105.

1.3.17 Remove valve poppet assembly, item 104,106 and 107.

1.3.18 Check orifice, item 106, is clear.

1.3.19 Flush valve poppet assembly thoroughly

Rexroth Scotland 2
 Main Table of Contents

DO 800/LEX1/11.94

1.4 Dismantlina Rotatina Assemblv

Refer to Appendix A P.13

1.4.1 Remove O-ring, item 42, from cylinder block, item 15

1.4.2 Each piston assembly, item 16 & 17, can be removed under gravity or by low air
pressure applied to the ports in the cylinder block, item 15.

1.4.3 Remove rollers , item 16, from piston assembly and check for wear on rollers
piston seats

1.4.4 Check timing face of cylinder block. If necessary lap timing face.

1.4.5 Repeat for other side.

1.5 Front Case Assemblv

Refer to Appendix A P.12 & 10

1.5.1 Remove hex head screws ( 10 off ), item 22.

1.5.2 Remove washers, item 23, from hex head screws.

1.5.3 Remove shaft, item 1, from front case assembly.

1.5.4 Remove O-ring, item 21.

1.5.5 Remove axle sleeve, item 6. This will also remove rear bearing cone, of item 7, from
front case assembly.

1.5.6 Support rear bearing cone, of item 7, at it’s edges and separate from axle sleeve
, item 6, using bench press and assembly tool 1.

1.5.7 With a soft steel drift lever rear bearing cone, of item 7, from front casing , item 2
or 3.

1.5.8 Remove shaft seal, item 8, from front case, item 2 or 3.

1.5.9 Repeat for other side.

Rexroth Scotland 3
 Main Table of Contents

DO 800/LEX1/11.94

REASSEMBLY

a. Use only genuine Rexroth Spare Parts. We recommend the use of

preassembled, co-ordinated and tested component groups. The required
component groups and seal kits should be selected from the spares list and
ordered by quoting the code plate details.

b. Assembly should be carried out observing the maximum cleanliness.

C. Assembly is carried out in reverse order to dismantling unless otherwise stated,

d. Do not re-use old seals.

e. Oil components before assembly (hydraulic mineral oil).

f. Tighten screws with torque wrench according to specification. If there is any suspicion
of stripping of threads, use new screws.

IMPORTANT

On completion of repair, close all openings with plugs. Should difficulties arise, please
contact your nearest service centre.

Rexroth Scotland 4
 Main Table of Contents

DO 800/LEXi /I 1.94

2.1 Reassemblina flushina assemblv

Refer to Appendix A P.9, P.15 & P.16

Relief valve

2.1 .l Insert valve poppet assembly.

2.1.2 insert spring, item 105.

2.1.3 insert O-ring, item 103, to plug, item 102.

2.1.4 Insert plug, item 102, to mid case, item 58. Start by hand.

2.1.5 Torque plug, item 102, to 60-70 Nm ( 44-52 1bf.f-t).

Flushing spool

2.1.6 Insert washer, item 98.

2.1.7 Insert spring, item 99.

2.1.8 Fit O-ring, item 101, to plug, item 100.

2.1.9 Fit plug, item 100, to mid case, item 58. Start plug by hand.

2.1 .I0 Torque plug, item 100, to 35-40 Nm ( 26-30 Ibf.ft )

2.1.11 Dip spool, item 96, into clean hydraulic oil.

2.1.12 insert spool, item 96, into spool bore. Check spool moves freely.

2.1.13 Insert second washer, item 98.

2.1.14 insert second spring, item 99.

2.1.15 Fit O-ring, item 101, to plug, item 100.

2.1.16 Fit second plug, item 100, to mid case, item 58. Start plug by hand.

2.1.17 Torque plug, item 100, to 35-40 Nm ( 26-30 Ibf.ft )

Rexroth Scotland 5
 Main Table of Contents

DO 800/LEX1/11.94

2.2 Reassemblina Mid Case Assembly

Refer to Appendix A P.14

2.2.1 Insert Dowel pin, item 60, to mid case.

2.2.2 Check all components are clean and free from debris.

2.2.3 Place distributor ring, item 59, and springs, item 61 ( 6 off ), on bench.

2.2.4 Place springs,

item 61, into recesses in distributor ring, item 59, using a small amount
of G3 grease to hold springs in position.

2.2.5 Place mid casing, item 58 and seal rings, items 62,63 & 64 on bench

2.2.6 Insert seal rings, items 62 & 64, into correct grooves in mid case, item 58, with
minimum distortion of seals. Lightly smear G3 grease over the seals. Use alignment
mandrel, assembly tool 2, to stretch and align seals.

2.2.7 Insert seal ring, items 63, into correct groove in distributor, item 59, with minimum
distortion of seal. Lightly smear G3 grease over the seals. Use alignment mandrel,
assembly tool 3, to compress and align seal.

2.2.8 Insert distributor ring, item 59. Use assembly tool 4 to re-align marks made when
dismantling distributor from mid case. When correctly fitted distributor, item 59,
will locate on dowel pin, item 60.

2.2.9 Repeat for other side.

2.3 Reassemblina Rotatina Assembly

Refer to Appendix A P.13

Take care not to damage timing face

2.3.1 Check all components are clean and free from debris.

2.3.2 Place cylinder block, item 15, piston assemblies (8 off), item 17, and rollers, (8 off),
item 16.

2.3.3 Fit roller ,item 16, to piston assembly, item 17. Dip piston assembly into clean oil.

2.3.4 Fit piston, item 17 and roller, item 16, to piston bore in cylinder block, item 15.

2.3.5 Repeat for each piston bore in cylinder block, item 15

2.3.6 Insert O-ring, item 42, to cylinder block, item 15.

2.3.7 Repeat for other side.

Rexroth Scotland 6
 Main Table of Contents

DO 800/LEXl /I 1.94

2.4 Front Case Assembly

Refer to Appendix A P.12 & 10

2.4.1 Fit shaft seal, item 8, to front case, item 2 or 3, with assembly tool 5

2.4.2 Smear lip of seal , item 8, with G3 grease

2.4.3 Press rear bearing cup, of item 7, to front case, item 2 or 3, with assembly tool 6.

2.4.4 Heat rear bearing cone, of item 7, then fit to axle sleeve, item 6.

2.4.5 Fit rear bearing cone, of item 7, with axle sleeve, item 6, to front case assembly.

2.4.6 Fit O-ring, item 21.

2.4.7 Fit shaft , item 1, to front case assembly.

2.4.8 Fit washers, item 23, to hex head screw, item 22.

2.4.9 Fit hex head screws ( 10 off ), item 22, and start by hand.

2.4.10 Torque hex head screws ( 10 off ), item 22, to 100-l 10 Nm (74-81 Ibf.ft ).

2.4.11 Repeat for other side.

2.5 Axle unit Assembly

Refer to Appendix A P.11

2.5.1 Fit O-ring, item 72, to front case, item 2 or 3.

2.5.2 Fit O-ring, item 72, to mid case, item 58.

2.5.3 Fit washers ( 12 off ), item 78, to capscrews ( 12 off ), item 73.

2.5.4 Grease shaft spline , item 1, with G3 grease

2.5.5 Combine mid section, rotational group and front case.

2.5.6 Thoroughly degrease all mating parts of capscrews, item 73.

2.5.7 Apply Loctite 243 to capscrews ( 12 off ), item 73.

2.5.8 Fit capscrew, item 73, and start by hand.

2.5.9 Torque capscrews, item 73, to 195-200 Nm ( 144-147 Ibf.ft )

2.5.10 Repeat for other side.

Rexroth Scotland 7
 Main Table of Contents

D0/800/LEXl /l1.94

APPENDIX A

ASSEMBLY DRAWINGS

1. Axle General Arrangement.. ............................................................................. -9

2. Axle Genaeral Arrangement Left Side.. ............................................................ 10

3. Motor Assembly.. .............................................................................................. 1I

4. Left Side Part Assembly.. ................................................................................. .I2

5. Rotational Assembly.. ...................................................................................... .13

6. Mid Case Assembly.. ........................................................................................ 14

7. Relief Valve ....................................................................................................... 15

8. Flushing Spool . .. . . . . . . . . .. . . . . . .. . . .. . . . . . . .. . . . . . . . . . . . .. . .. . .. . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . .. . . .. . . . .. .. . 16

Rexroth Scotland 8
Main Table of Contents

DO 800/LEXl /I 1.94

Axle General Arrangement

Rexroth Scotland 9
 Main Table of Contents

DO 800/LEX1!11.94

Axle General Arrangement Left Side

Rexroth Scotland IO
 Main Table of Contents

DO 800/LEXi /1 1.94

Motor Assembly

GREASE SHAFT SPLINE PRIOR TO FITTING

TO CYLINDER BLOCK WITH G3 GREASE

)
SMEAR SEAL LIP WITH G3 GREASE

r
TORQUE TO 195-200 Nm ( 144-147 Ibf.ft
ASSEMBLE USING LOCTITE 243
xl2

Rexroth Scotland 11
Main Table of Contents

DO 800/LEX1/11.94

Left Side Part Assembly

r SMEAR SEAL LIP WITH G3 GREASE

Rexroth Scotland 12
Main Table of Contents

Rotational Assembly

x16 x2 x16

V,M/
I /
,,/I
-_-_ _

Rexroth Scotland 13
Main Table of Contents

DO 800/LEX1/11.94

Case

x2 x2 2
59 z- 1
!ja ( >

r;

Rexroth Scotland 14
Main Table of Contents

DO 800/LEXl /l1.94

Relief Valve ( Part Section A-A )

Rexroth Scotland 15
 Main Table of Contents

DO 800/LEX1/11.94

Flushing Spool ( Part Section B-B )

o-
96

x2@-

n/ nn\

Ih

Rexroth Scotland 16
 Main Table of Contents

D0/800/LEXl /I 1.94

APPENDIX B

TOOLING

Rexroth Scotland 17
 Main Table of Contents

D0/800/LEXl/l1.94

EauiDment (Assemblv and Dismantling)

General

1. Allen Key

a.SW12 DIN 911

2 Double Ended Ring Spanner

a.SW18-i9 DIN 838

3 Bearing Heater

4. Soft Mallet

a. Mallet Size 40

5. Torque Wrench(es) covering the ranges

a. 195-200 Nm 144-l )
b.lOO-110 Nm ( 74-81 Ibf.ft
Nm ( Ibf.ft
d.35-40
 Main Table of Contents

D0/800/LEX1/11.94

Special

1. Axle Sleeve Assembly Tool RF 6281

2. Mid Case Seal Stretch Mandrel RF 6282

3. Distributor Seal Compression Mandrel RF 6283

4. Distributor Alignment Tool RF 6147

5. Shaft Seal Assembly Tool RF 6284

6. Rear Bearing Cup RF 6141

N.B. Special tools can be obtained from G.L. Rexroth (Scotland).

State full motor code and RF numbers

Rexroth Scotland 19
 Main Table of Contents

D0/80O/LEXl /l1.94

APPENDIX C

GREASE SPECIFICATION

Grease Specification

CODE TYPE

G3 A high performance industrial grease of

medium/hard consistency (NLGI No 3). Temperature
range -30” C to 150° C. (-22 OFto 302 OF)

eg. Shell Alvania G3

Rexroth Scotland 20
 Main Table of Contents

D0/800/LEXi/l1.94

APPENDIX D

FAULT FINDING

a. Motor does not rotate :-

- For braked motors ensure brake is released.

- Confirm pressure is being applied to motor.
_ Lift axle unit clear of ground ( ensure no pressure is applied to motor during
disconnection ). Then confirm motor rotates.
- If still jammed confirm pump is out putting a flow of oil.
- Strip and inspect motor for damage.

b. External oil leaks :-

- Check pressure to brake port exceeds brake release pressure and is stable
- Check connections are secure and oil tight.
- Check oil cleanliness and motor pressure.
- Strip inspect motor. Replace necessary seals.
- Ensure all bolts are torqued to correct setting.
- Confirm leakage line is unblocked and case pressure is less than 10 bar.

C. High temperature / Noisy operation :-

- Check P2 pressure is above case pressure by at least 2 bar.

- Check motor mounting is correct. ( see installation ).
- Strip motor and inspect cam, rollers, pistons and main bearings for wear.

d. Motor speed incorrect :-

- Check pump flow sufficient for desired motor speed.

- Check motor leakage flow. If high, inspect motor.
- Check motor pressure is correct.

Rexroth Scotland 21
 Main Table of Contents

Emu Group 06(H), Transmission (Hydrostatic)

Section 6.

Drive Axle Ends

Overhaul

Drive Wheel Removal

The drive axle ends can be overhauled with the drive axle
in the truck. If the drive axle is to be left in the truck:
1. Safely raise and properly block the front of the truck
as described in the lifting and jacking Section of
Group SA.
2. Remove the drive wheels as described in Group 22.

Drive Axle Shaft Removal and

Replacement
1. Remove 10 mounting bolts and washers from each
axle shaft flange.
2. Pull axle shaft out of axle housing.
3. Remove O-ring from hub.
4. Reverse steps 1 through 3 for installation. Use new O-
ring. Torque mounting bolts to 90- 110 Nom (66-8 1 ft-
lb).

L Mounting Bolt

SM 598, Dee ‘94 Drive Axle Ends Overhaul l 6(H)-6-l

 Main Table of Contents
Group 06(H), Transmission (Hydrostatic)
Axle End Removal
The following procedures refer to the illustration on the
next page.
1. Separate brake drum from hub. If necessary, screw
jackscrews though holes in drum to force drum apart
from hub. Remove drum.
2. Bend back tab on locking washer to clear slot in lock
nut.
3. Remove locknut from spindle. Special wrench, con-
struction shown on page 4, may be used
4. Remove tongued washer from spindle.
5. Remove outer bearing from spindle.
6. Remove hub from spindle.
7. Remove inner bearing.
8. Remove and discard oil seal from hub.
9. Extract inner and outer bearing cups from hub if
bearings are to be replaced.
Axle Mounting Bracket Removal and
Installation
1. Remove or install the brake assembly as described in
“Service Brake Overhaul” in Group 23.
2. Remove or install the axle mounting bracket by sliding
it off or on the axle housing. Use anti-seize compound,
Clark part #1802307, on the contact surfaces before
installing the bracket.
Inspection, Cleaning, and Repair
Inspect bearings and cups for wear. Replace bearing and
cup as a set if either is worn. Clean parts with a Stoddard-
type solvent.
6(H)-6-2 . Drive Axle Ends Overhaul
CWRIC
Axle End Assembly
1. Press new cups into hub, if cups were removed.
2. Lube inner bearing with transmission fluid, Clark part
# 2776236, and install bearing.
3. Prepare surfaces and install oil seal:
a. Remove nicks, scratches, and burrs from hub and
spindle surfaces that will receive the seal.
b. Apply a light coat of Loctite Primer N, Clark part
#1803267, and Loctite Gasket Maker, Clark part
#1802303 to seal outer diameter and hub inner
diameter.
C. Press new oil seal into hub with special driver,
which can be constructed from drawing on page4.
IMPORTANT
OIL SEAL LEAKS. The oil seal must be
replaced with a new one each time the hub
is removed. Use extreme care not to dam-
age the seal during installation. Use the
proper seal driver, shown on page 4.
4. Install hub.
5. Lube outer bearing with transmission fluid, Clark part
# 2776236, and install.
6. Install tongued washer, locking washer, and locknut
(hand-tight) .
7. While turning hub, torque locknut to 200-245 Nom
(147-181 ft-lb) with special wrench shown on page 4.
Loosen loclmut; then hand-tighten locknut until bear-
ing has no end-play.
8. Loosen locknut until tab on washer lines up with slot
in locknut. Bend tab on washer into slot on locknut.
9. Align inspection slot on brake drum with inspection
slot on hub. Install brake drum by sliding it over studs
mounted on hub. Tap drum with a soft-faced hammer
to seat it against the hub. Remount the wheel as
described in Group 22.
SM 598, Dee ‘94
 Main Table of Contents

CIRRK Group 06(H), Transmission (Hydrostatic)

,/~ZlLlount ing Bracket

Assembly

Brake Mounting Bolt

Outer Bearing
and Cup

and Cup

Brake Drum

SM 598, Dee ‘94 Drive Axle Ends Overhaul l 6(H)-6-3

 Main Table of Contents

Group 06(H), Transmission (Hydrostatic) EUlRK

0 0

:
3

2.5

O-RING -
25K40428

Hub Oil Seal Driver. Construct as shown.

Drive Socket

3/S" square/

L---c
Stock
X 1" Long
l/4"

l/4"

Hub Locknut Wrench. Construct as shown.

6(H)-6-4 l Drive Axle Ends Overhaul SM 598, Dee ‘94

 Main Table of Contents

SAUER s SUNDSTRAND

Series 90
 Main Table of Contents

Introduction

The purpose of this manual is to provide information
necessary for the normal servicing of the Series 90
family of hydrostatic pumps and motors. This manual
includes unit and component description, trou-
bleshooting, adjustments, and minor repair proce-
dures. Following the procedures in this manual, the
minor repairs may be performed without affecting the
unit warranty.
Sauer-Sundstrand provides a complete repair service for
its products. Contact any Sauer-Sundstrand Authorized
Service Center for details.
The torque values, pressure settings and dimensions
used throughout this manual are given in English and
metric measurements.

A Series 90 transmission does occasionally require

servicing and the transmission has been designed with
this in mind. Many of the parts on these transmissions
are interchangeable among certain frame sizes within
the Series 90 family. This includes such items as the
controls, charge system, multi-function valves, loop
flushing valves and auxiliary mounting pads. In addi-
tion, many repairs or adjustments can be accomplished
without the necessity of removing the unit from the
vehicle provided the unit is accessible and can be
thoroughly cleaned before beginning any procedures.
Since dirt or contamination is the greatest enemy of
any type of hydraulics, the greatest possible cleanli-
ness is necessary.

Variable Displacement Pump Fixed Displacement Motor

 Main Table of Contents
,,,, ,,,,

I I ,, ,,
~~~~r~~~~~~
‘~~~~r~l
,,,,, ,,,, ,,,,, ,, ,j ,, ,,,,,,,
‘,
,, ,, ,~,,,

General Description of the Series 90 Hvdrostatic Transmission

The Series 90 hydrostatic pumps and motors can be Two (2) unique multi-function valves are designed in
applied separately or combined in a system to transfer the pump to provide the check valve, pressure limiter,
and control power. high pressure relief valve, and bypass functions.

The Series 90 pump and motor combined in a system
provide an infinitely variable speed range between
zero and maximum in both forward and reverse modes
of operation.
Series 90 variable displacement pumps are a compact,
high power density unit with state-of-the-art design,
using the parallel axial piston/slipper design in conjunc-
tion with a tiltable cradle swashplate to vary the pump’s
displacement. Reversing the direction of tilt of the
swashplate reverses the flow of oil from the pump and
thus reverses the direction of rotation of the motor
output.
The pump includes the charge pump and associated
valving to provide the necessary flow for makeup oil, to
operate the control system, and provide cooling for the
system. It also features a range of auxiliary mounting
pads to accept an auxiliary hydraulic pump for use with
complementary hydraulic systems.
The fixed displacement motors also use the parallel-
axial piston/slipper design in conjunction with a fixed
displacement swashplate. Valving options are
included in the motor to provide cooling and flushing
functions.

The variable displacement pump is controlled by a

compact, responsive hydro-mechanical, closed loop
control system which can be controlled by either a
mechanical, hydraulic, or electric input signal.

r Control
Handle

Suction Flow
0 Control Pressure

Pump Motor

Fig. 1 - Typical Series 90 Variable Pump - Fixed Motor Transmission Schematic

2
 Main Table of Contents

The Series 90 Pumps and Motors are easy to install,

CASE I 1
requiring no adjustments and few auxiliary compo-
nents. They have their own hydraulic support system
which is discussed in this section.

Basic Closed Circuit

The main ports of the pump are connected by
hydraulic lines to the main ports of the motor. Fluid
PUT flows, in either direction, from the pump to the motor
then back to the pump in this closed circuit. Either of
the hydraulic lines can be under high pressure. The
position of the pump swashplate determines which line
is high pressure as well as the direction of fluid flow.
AT EXCHANGER W/BYPASS
Case Drain and Heat Exchanger
1
-RESERVOIR
The pump and motor require case drain lines to
Fig. 2 - Basic Closed Circuit remove hot fluid from the system. The motor should be
drained from its topmost drain port to insure the case
CHARGE RELIEF remains full of fluid. The motor case drain is then con-
CASE DRAIN
nected to the lower drain port on the pump housing
and out the top most port. A heat exchanger, with a
bypass valve, is required to cool the case drain fluid
before it returns to the reservoir.

Charge System and Inlet Filter

A fixed displacement (gerotor type) charge pump is
installed in the variable displacement pump and driven
off the main pump shaft. The charge pump supplies
INLET FILTER
cool fluid to the system, keeps the system charged,
and supplies fluid to operate the control system.
Charge pressure, with the pump in neutral (zero flow),
Fig. 3 - Charge System is limited by a relief valve (nominal settings of 290, 350,
and 405 PSI [20, 24, and 28 BAR] above case pres-
sure at 1800 RPM, are available).

Since either of the main hydraulic lines can be high

pressure, two (2) charge check valves are used to
direct the charge supply into the low pressure lines.
The check valves are contained in the multi-function
valves located in the pump end cap.

The charge pump draws the fluid from the reservoir.

An inlet filter is required to insure that only clean fluid
enters the system.

Fig. 4 - Variable Displacement Pump

3
 Main Table of Contents

MULTI-FUNCTION VALVE
Pressure Limiter and High Pressure
Relief Valve
J L (Includinq
Press& Limiter
and High Pressure The Series 90 pumps are designed with a pressure
Relief Valves) limiter system and sequenced system relief valves.
When the preset pressure is reached in the main loop,
the pump will destroke to limit the system pressure.
For unusually rapid load application, the relief valve is
available to also limit pressure. The pressure limiter
sensing poppets also act as pilot valves for the relief
valve spools, such that the relief valves are sequenced
to operate at pressures above the pressure limiter
destroke pressure level. Both the pressure limiter
sensing valves and relief valves are built into the multi-
function valves in the pump end cap.

Fig. 5 - Pressure Limiter and High

Pressure Relief Valve
Loop Flushing Valve

A shuttle valve and charge relief valve can be assem-

bled in the motor end cap to provide the loop flushing
function. The shuttle valve provides a circuit between
the low pressure side of the closed loop and the
charge relief valve in the motor end cap.

This charge relief valve is normally set at approximately

the same pressure as the pump charge relief valve
(nominal settings of 290, 350, and 405 PSI [20, 24,
and 28 BAR], at 1 GPM flow over the valve are avail-
able). This relief valve regulates the charge pressure
level when there is a pressure differential in the main
loop. The shuttle valve is spring centered to the closed
CHARGE RELIEF VALVE _j_j
position so that during transition of reversing pres-
sures in the closed circuit, no high pressure fluid is lost
from the circuit.
Fig. 6 - Loop Flushing Valve
Safety Precautions
 Main Table of Contents

Technical Data - Variable Displacement Pump

.” _ “~..-“: <_.___“.” _” “.
x1* ^I_.^,_ ,I”,,,_, .^ ” ~.“)

Frame Size 075 ( 100 180 250

-- -_,_
/_”“X_.“_
_‘I,_“.__^..
I- I,_ .“__)_”
Product Status
X X

4.57 6.10 10.98 15.25

75 100 180 250
_ ” “xII.~~.ll,
;_ x ._,_ _

5000 5000 4700 4300 4000 3500 3100

- RPM 4200 4200 3900 3600 3300 2900 2600
Minimum - RPM 500 500 500 500 500 500 500
9i;essu~e __.^“““I1- “. _ “-1”-1
1. - - ..I, . .._l^^l I”.“.. I

Maximum PSI 7000

BAR 480 ALL SERIES 90 PUMPS #
Continuous PSI 6000
BAR 420
_II I- ” llI,-“. “I‘*“l”“,ll,“_ ...)“i.,j ll_x
_ ,,11”
Case Pressure
Continuous PSI 40
BAR 3 ALL SERIES 90 PUMPS *
Maximum PSI 75
(Cold Start) BAR 5 >
_,I - __Ii_ ,__
..”__~~ll_“____ “_,”_.,. _“_
” ““,xIII._ l-_^I^I _.f,~.___ _^. ‘. ^, “. - _,,_. ^I_ “_l_“)_“_I,_^
““,“Ix,l“. I” l” “.^
_)_ .““”
.,/,-_. ” -x1_”

Input Mounting Flange

(per SAE J744) ,SAE B SAE B SAE C SAE C SAE C SAE D SAE D SAE D
_“~“,“ll-“-*,,x_l -_,-,__,__
^_ “l.““_ _^“_ I.I-. _ ,I_l^“-“lf__. _~_
I ll”l_ “_ “,_“,I _“__ __x_II. .” “tl,“,~,.l”_._^.>
111~~ _“” Il”__I. _Y__ _”__,,,__l^_“_
I .-~,//x
Input Shaft (Std. Spline)
Number of Teeth and Pitch 15 T 16/32P 15T 16/32P 14T 12/24P IT 12/24P 13T 8/16P +T 8/16P 13T 8/16P 3T 8/l 6P
.^ _.“._
,,,..r “.__ “_,“_“.i_/__.))“x- _i-- < I I I”^ _ __ll”

62 75 88 108 150 195 260 300

28 34 40 49 68 88 118 136
Mass Mome;~_“~~“G”;_’ _.“. “““~“_,~” -_.““,I1_I” I _“““l-l~__l;”_““/)“”
l”_1111” I_,,_ I ,___)_^_“I.
“^^^. _ (W”_““,_
I_ .“_

bf the internal rotating parts

Ib.ft. - Sec2 1.0017 0.0029 0.0044 0.0071 0.0111 0.0170 0.0280 0.0470
Nm - Sec2 1.0023 0.0039 0.0060 0.0096 0.0150 0.0230 0.0380 0.0640
)__I./“_“”_I”_”I_I -
l_I~“_^II~“~_.“._Ix~-~lxx~~_
““..,“_(, “1.“~_
_,_- _I_ I_ II”I.-___ )“,.“~l__i_^,l -I-.“r - Ix-
Charge Inlet Vacuum
Bt Sea Level
Normal in. Hg
BAR (abs.)
Cold Start in. Hg
BAR (abs.)
,
_._“_“_ ,,-_- _^“”
_,,-_.
“__ x_“lx(_^_,I
.I-- 111,1.~
),~,
“~

* Specifications for products in development are projectea.

5
 Main Table of Contents

Technical Data
II- ,_,“-*,,~_ - Fixed
_-wl_“.__”
_.,IIy_^I Displacement
_I _I,_--“_^,
^r_-_
Motor .__ _ -__c1_-^___4.”
- -- “_,__l,,x__I___
I.1,,”1xII,X1X,11xI~ _.II-” ” _,,x_,““^I
1x”*11I1,~xI,*ll
_i- II ““l-““-mlml^l-“. ^”)_“)~I_/)__,
“-_-- _..-

055 075 100 130 180 250

-.,--l”^i^. _I” - .._.
._I_ )__“_l_,-^ll__l__“___l^“l”l”l.,_ll”l,,” ““-“-l_“l”““-l^~ _;Ix__I”11” )“”_“I ,“_xII”c”_-I^I
“I_-__ __._.I ^_,__ __“..,*
u”__I-“x_l,___,“l_^Ii
-41~1-1111
~~~~
Product Status
Available X X X X
In Development* X X
,“_.~_^“l”l____
.---.- “l_““l-
i-_i_” -__“___.__ Ir I_”I- .i- ____
” )“~I”- _,_,,
“_,~
_~/_,
,_ _,l_“__*_.“,____l_“”
XXlfX_I-.“._.I_“I___
- ...i_in_;
r --- _-.,,-10I__^“_- ---I-1”-_l”-_
Displacement
in3/Rev : 3.35 4.57 6.10 j 7.93 10.98 15.25
cc/Rev 55 75 100 130 180 250
.ll_lll_“_~l_~_.““_..”“_ _x”,_,_“_^__~“_i_mlx”,__,I-III”l”__~_” _^ l”._“-___l .--,ll”~_~~--^ ““_)_““““““..~“^II.xI1xx~
x_ “1-“-----” -l”l-----“~~- __- -““- _o_
Output Speed
Maximum - RPM 5300 4800 4400 4000 3800 3400
Continuous - RPM 4200 3800 3500 3200 2900 2600
.ll” II “_ __“l_“l,_.,__
,_“,__“__”
_^“I___“___ I_“-“_ _ _‘ __^_“_”
l-l xI”“_“._x _“ll”n_ /i ._(.I--~----*1x- II ” “I.I- I _ ___.- “_-l_*___ll”l-” I--l-li~
.3 ._-- II-” _1_^
Pressure
Maximum PSI 7000
BAR 480 ALL SERIES 90 MOTORS #
Continuous PSI , 6000
BAR 420 >
.”,,,,
f,,_, xI^II -. ~_i_“I“l”~“l_m___~I_ _,)_._-,_____-_lll”,,~ll,‘/~ll”__l^“~“”
xI_l”“l”-“l”ll”ll” _,,_“,l_”__^,,_ .I”.---- -__(- -. _“.__
“__xxII-llI” -~,
11xIXI-xIIX
~._“x.“^ _I--IxIx”l,~~*~~~-.
“111”
“”
Case Pressure
Continuous PSI 40
BAR 3 ALL SERIES 90 MOTORS *
Maximum PSI 75
(Cold Start) BAR 15
I_“,_,_,~_~_~_
“l “_____”l”l_““1”____
_____”_“_“__““__
__”.A l”_x_,._I ““1”1”1””
X”_“_“-.“_“_tll_~I_
._-_i^A,x_w- 1- ~,~““1_ I _I-,.~--_
- -“-..lt--1XI--I”I”-
-_-I--” ^ -=-=-
Output Mountiqg Flange
{per SAE J744) ; SAE C : SAE C SAE C SAE D SAE D SAE D
I____“_,_““__l___ _._” _l__.“_“_____^_
“_,~X1_I,__C,_t”__~_“~
)__
l_l--_)_ ,“.,,._ IX _t-ll”“,.l”l”--^
__--_ IXI__,_;.; -(Ix i”-i”.-.“.“Ix-1-) .-.._I--.-\-x- )_. “”_ - _1-“-1”--
Output Shaft (Std. Spline)
Number of Teeth and Pitch t4T 12/24P ’ 14T 12/24P 13T 8/16P i 13T8/16P 13T 8/16P 13T 8/16P
“_i_;_;x__ll,_-^“I___““~
_ _^“_ _“_-*,_*.__-_ -_- “1__Y//I”.
__^,___ If I_ I _..“^-.“l-l. “_.Il--i_ ““_ll ” ,-i; I” -_l_“lll_l’I, l_“l”__lr_,XI,/ ))I_ __x”.__-. “.__“__“___
_. .__l.”
Weight
Ibs 48 57 74 99 137 190
kg 22 26 34 45 62 86
_““___ _l,__i__”______:“,_,_ ^__l_
_.- “_ll__ll,IlfX_ll_““_-.;__l_- I _”.~“_“~~.._~_.I
_I_,___. _ _ __i__l__“^____/_
,I”~_““_,I,-~“Xi”X”,-tXI.
I”x“l”- -^ I--__, -” - -.-----
Mass Moment of Inertia
of the internal rotating parts
Ib.ft. - Set* 0.0044 0.0071 j 0.0111 0.0170 0.0280 0.0470
Nm - Sec2 0.0060 0.0096 0.0150 0.0230 0.0380 0.0640
_I ))_,-.
llil -“x”,II-^
.--_-~_1”1_ I-II-I”- ^ ““~I-” I-l-.,-x,~ll”“l-II.
-~1”- I-~ n-eP
_- “-l_-___ ^xI)I”_-_____.d~*m_*~~______-“-:
--,;,, ,-“---_-.“” “_ ”-*,___“.Il_l__n
* Specifications for products in development are projected.

Technical Data - All Series 90 Pumps and Motors “_“__“_lll_l_,_”_ill n__““.~_“____,e_l_“;_-~~~,-~,~~~.”””. -_;-“-
Temperature at tlottest Point in Fluid Contamination Levels -
Transmission (normally at case drain) IS0 Code
Maximum “F 240 Recommended Limit - Continuous Operation 18113
“C 115 Limit for Machine Assembly (at roll off) 21115
Continuous 220
1;
104
” __^_~_~___--
_“_“_xxI”I_,_--___” -.--~~,y^y~_-_- __I, -. ___^I”-.-.~,II,,*,x**Ix
“11, .~
Suggested Filtration
Optimum 70 (13) Dedicated Reservoir (Beta IO) 1.5 to 2.0
Minimum Continuous ’ 47 (6.4) Common Reservoir (Beta IO) 10to20
Minimum Intermittent 42 (5.0)
Maximum Continuous 500 (110)
Ivlaximum Cold Start 7500 (1600)
-- “------_._~._~.~_
i__;___l__,___~ll~l _i- -“,,_1((-- __~ _IX_
___“_ _i__l_ ---_-~_
6
 Main Table of Contents
Controls and Options
Fig. 7 - Variable Displacement Pump with
Manual Displacement Control
Fig. 8 - Variable Displacement Pump with
Manual Displacement Control and
Neutral Start Switch
Fig. 9 - Variable Displacement Pump with
Hydraulic Displacement Control
Fig. 10 - Variable Displacement Pump
with Electric Displacement Control
7
Manual Displacement Control (MDC)
The manual displacement control converts a mechani-
cal input signal to a hydraulic signal using a spring cen-
tered 4-way servo valve which ports hydraulic pressure
to either side of a double acting servo piston. The
servo piston rotates the cradle swashplate through an
angular rotation of fl7”, thus varying the pump’s dis-
placement from full displacement in one direction to full
displacement in the opposite direction.
A solenoid override option is available for the manual
displacement control. This option consists of a DC
solenoid operated valve which connects the sides of
the servo piston to each other when no current is sup-
plied to the solenoid. This maintains the pump in a
zero displacement condition. When current is sup-
plied to activate the solenoid, the control acts as a
standard manual displacement control.
Manual Displacement Control with
Neutral Start Switch
The neutral start switch is a feature available with the
manual displacement control. When connected prop-
erly with the vehicle’s electrical system, the neutral start
switch assures that the prime mover can be started
only when the control is in a neutral position.
Hydraulic Displacement Control
The hydraulic displacement control uses a hydraulic
input signal to operate a spring centered 4-way servo
valve, which ports hydraulic pressure to either side of a
double acting servo piston. The servo piston rotates
the cradle swashplate through an angular rotation of
k17”, thus varying the pump’s displacement from full
displacement in one direction to full displacement in
the opposite direction.
Electric Displacement Control (EDC)
The electrical displacement control is similar to the
hydraulic displacement control with the input signal
pressure controlled by a 12 volt D.C. pressure control
pilot (PCP) valve. The PCP valve converts an electrical
input signal to a hydraulic signal to operate a spring
centered 4-way servo valve which ports hydraulic pres-
sure to either side of a double acting servo piston. The
servo piston rotates the cradle swashplate through an
angular rotation of fl7”, thus varying the pump’s dis-
placement from full displacement in one direction to full
displacement in the opposite direction.
 Main Table of Contents
Fig. 11 - Variable Displacement Pump
with Auxiliary Mounting Pad
Fig. 12 - Variable Displacement Pump
showing location of Multi-Function
Valves
Fig. 13 - Variable Displacement Pump
showing location of Displacement
Limiters
Fig. 14 - Variable Displacement Pump
with Charge Pump
Auxiliary Mounting Pads
Auxiliary mounting pads are available on all Series 90
pumps. This pad is used for mounting auxiliary
hydraulic pumps and for mounting other Series 90
pumps to make tandem pumps.
Multi-Function Valve _
All Series 90 pumps are designed with multi-function
valves. The multi-function valve incorporates the main
loop check valve, the pressure limiter valve, the high
pressure relief valve, and the bypass valve in a
replaceable cartridge. There are (2) multi-function
valve cartridges in each Series 90 pump.
Displacement Limiters (Option)
All Series 90 pumps are designed for optional mechan-
ical displacement (stroke) limiters. The displacement of
the pump can be adjusted to any displacement to zero
displacement.
Charge Pumps
The charge pump is necessary to provide for cooling,
to maintain positive pressure in main circuit, to provide
control pressure and to make-up internal leakage.
Charge pressure must be at its specified pressure
under all conditions of driving and braking to prevent
damage to the transmission. The standard charge
pumps will be satisfactory for most applications: how-
ever if the charge pump sizes available for this size
pump are not adequate, a gear pump may be mounted
to the auxiliary pad and supply the required additional
charge flow.
 Main Table of Contents

Filtration

All Series 90 pumps are available with provisions for

either suction or charge pressure filtration (integral or
remote mounted) to filter the fluid entering the charge
circuit.

The suction filter is placed in the circuit between the

reservoir and the inlet to the charge pump.

The pressure filter may be integrally mounted directly

on the pump or a filter may be remotely mounted for
Fig. 15 - Variable Displacement Pump ease of servicing.
with Integral Charge Pressure Filtration
A non-bypass filter is preferred on all types of filtration.

Fig. 16 - Variable Displacement Pump

with Remote Charge Pressure Filtration

Loop Flushing Valve

All Series 90 motors are designed to accept a loop

flushing valve. The loop flushing valve is used in instal-
lations which require additional fluid to be removed
from the main hydraulic circuit because of transmission
cooling requirements, or unusual circuits requiring
additional loop flushing to remove excessive contami-
nation in the high pressure circuit.

Fig. 17 - Fixed Displacement Motor

showing location of Loop Flushing Valve
 Main Table of Contents
Fluids
Hydraulic fluids used with Sauer-Sundstrand products
should be carefully selected with assistance from a repu-
table supplier, following the guidelines presented in the
“Fluid Quality Requirements” bulletin, BLN-9887.
Start-Up Procedure
The following start-up procedure should always be
followed when starting-up a new Series 90 installation
or when restarting an installation in which either the
pump or motor had been removed from the system.
Prior to installing the pump and/or motor, inspect the
units for damage incurred during shipping and han-
dling. Make certain all system components (reservoir,
hoses, valves, fittings, heat exchanger, etc.) are clean
prior to filling with fluid.
Fill the reservoir with recommended hydraulic fluid
which should be passed through a 10 micron (nominal,
no bypass) filter prior to entering the reservoir. The
use of contaminated fluid will cause damage to the
components, which may result in unexpected vehi-
cle/machine movement.
The inlet line leading from the reservoir to the pump
must be filled prior to start up. Check inlet line for
properly tightened fittings and make sure it is free of
restrictions and air leaks.
Be certain to fill the pump and/or motor
housing with clean hydraulic fluid prior to
start up. Fill the housing by pouring filtered oil into
the upper case drain port.
Install a 0 to 500 PSI (35 BAR) pressure gauge in the
charge pressure gauge port to monitor the charge
pressure during start-up.
It is recommended that the external control input signal
(linkage for MDC, hydraulic lines for HDC, or electrical
connections for EDC) be disconnected at the pump
control until after initial start-up. This will allow the
pump to remain in its neutral position.
“Jog” or slowly rotate prime mover until charge pres-
sure starts to rise. Start the prime mover and run at the
lowest possible RPM until charge pressure has been
established. Excess air may be bled from the high
pressure lines through the high pressure gauge ports.
10
Once charge pressure has been established, increase
speed to normal operating RPM. Charge pressure
should be 320 PSI (23 BAR) minimum. If charge pres-
sure is incorrect, shut down and determine cause for
improper pressure.
Shut down prime mover and connect external control
input signal. Start prime mover, checking to be certain
pump remains in neutral. With prime mover at normal
operating speed, slowly check for forward and reverse
machine operation.
Charge pressure should remain at 320 to 340 PSI (23
to 24 BAR) minimum during forward or reverse opera-
tion. Continue to cycle slowly between forward and re-
verse for at least five (5) minutes.
Shut down prime mover, remove gauges, and plug
ports. Check reservoir level and add fluid if necessary.
The transmission is now ready for operation.
Maintenance
To insure optimum service life on Series 90 products,
regular maintenance of the fluid and filter must be per-
formed.
Check the reservoir daily for proper fluid level, the
presence of water (noted by a cloudy to milky appear-
ance, or free water in bottom of reservoir), and rancid
fluid odor (indicating excessive heat).
It is recommended that the fluid and filter be changed
per the vehicle/machine manufacturer’s recommenda-
tions or at the following intervals:
l System with a sealed type reservoir - 2000 hrs.
l System with a breathing type reservoir - 500 hrs.
It may be necessary to change the fluid more fre-
quently than the above intervals if the fluid becomes
contaminated with foreign matter (dirt, water, grease,
etc.) or if the fluid has been subjected to temperature
levels greater than the maximum recommended.
Never reuse fluid.
The filter should be changed whenever the fluid is
changed or whenever the filter indicator shows that it is
necessary to change the filter.
 Main Table of Contents

Gauge Installation

Various pressure and vacuum gauge readings can be a

Fig. 18 - Gauge Connections --
Variable Pump with Radial Port End. Cap
great asset in troubleshooting problems with the
Series 90 transmission or support system.
It will be necessary to install a high pressure gauge into
the system pressure gauge ports to check the high
pressure setting of the multi-function valves.
Measuring the charge pump inlet vacuum will help
locate restrictions in the inlet lines, filter, etc.
Case pressure readings can help locate restrictions in
the return lines, oil cooler, and return filter.

Fig. 19 - Gauge Connections --

Variable Pump with Twin Port End Cap

IMEGRAL

SUCTION FILTRATION PRESSURE FILTRATION

SIDE VIEW END VIEW

Fig. 20 Gauge Connections --

Variable Pump

Snubbers are recommended to protect pressure

gauges. Frequent gauge calibration is necessary to
insure accuracy.
21 Gauge Connections --
Fixed

11
 Main Table of Contents

Neutral Difficult
Or
Impossible To Find

SYSTEM OPERATING HOT

TRANSMISSION OPERATES IN
ONE DIRECTION ONLY

12
 Main Table of Contents

LOW IN NEUTRAL & FORWARD

OR REVERSE
SYSTEM RESPONSE IS SLUGGISH

OR REVERSE

SYSTEM WILL NOT OPERATE IN EITHER DIRECTION

 Main Table of Contents

Manual Displacement Control (MDC)

There are no adjustable elements in the manual dis-

placement control. ‘All functions are preset at the fac-
tory.

Fig. 22 - Variable Displacement Pump

with Manual Displacement Control

Hydraulic Displacement Control (HDC)

Neutral Adjustment

The neutral adjustment is the only adjustment that can

be made on the hydraulic displacement control, all
other functions are pre-set at the factory. The neutral
adjustment of this control must be made on a test
stand or on the vehicle with the prime mover operating.

Fig. 23 - Variable Displacement Pump

with Hydraulic Displacement Control

Disable vehicle or machine. Install two (2) 500 psi (35

BAR) gauges in the servo gauge ports (one in each
side). Start the prime mover and operate at normal
speed.

For earlier production controls, loosen the lock nut on

the neutral shaft with a 17 mm hex wrench. For later
production controls, loosen the lock nut on the neutral
adjusting screw with a 10 mm hex wrench.

Fig. 24 - Gauges in Servo Gauge Ports

14
 Main Table of Contents

Use a 5 mm internal hex wrench to turn the neutral

shaft on earlier production controls, or a 3 mm internal
hex wrench to turn the neutral adjusting screw on later
production controls.

Rotate the neutral shaft or neutral adjusting screw

clockwise until the pressure increases in one of the
two (2) pressure gauges. Note the location “A”
(angular position) of the internal hex wrench.

Without removing the internal hex wrench, rotate the

Fig. 25 - Rotating Fig. 26 - Rotating neutral shaft or adjusting screw counter-clockwise until
Neutral Adjustment Neutral Adjustment the pressure increases in the other gauge. Note the
Shaft (Early Screw (Later location “B” (angular position) of the internal hex
Production Control) Production Control) wrench.

Rotate the neutral shaft or adjusting screw clockwise

half the distance between location “A” & “B”. The con-
trol should now be in a neutral position. In this position
the gauges should read the same pressure (case
pressure).

While holding the shaft or screw stationary with the

internal hex wrench, tighten the neutral shaft lock nut
(earlier production controls) to 16 ftlbsf. (22 Nm) or the
neutral adjusting screw lock nut (later production con-
trols) to 60 in.lbsf. (7 Nm). Do not overtorque the lock
nut.

If the pump does not consistently return to neutral,

stop the prime mover and refer to the trouble shooting
procedure in the Troubleshooting Section. With the
neutral position set, stop the prime mover, remove the
Fig. 27 - Tightening Fig. 28 - Tightening two (2) gauges, and install the gauge port plugs.
Neutral Shaft Neutral Screw
Locking Nut (Early Locking Nut (Later
Production Control) Production Control)

Electric Displacement Control (EDC)

Neutral Adjustment

The adjustment procedures for the Electric Displace-

ment Control are the same as the procedures for
adjusting the hydraulic displacement control listed
above.

Fig. 29 - Variable Displacement Pump

with Electric Displacement Control

15
 Main Table of Contents

MDC Neutral Start Switch Removal and

Installation
Replacement of the neutral start switch may be accom-
plished with the control on the machine providing a
space of .38 in. (9.85 mm) is available for switch
removal.

Fig. 30 - Loosen Neutral Start Switch

Lock Nut

Using two (2) l-1/8 inch wrenches, hold the switch

Fig. 31 - Neutral Start Switch Removed

After the locknut is loose, remove the switch.

NOTE: An assist spring and disc were installed
CONTROL IN NEUTRAL POSITION between the earlier production neutral start
switch and the eccentric plug. If the current
production switch is installed, the spring and
disc are not required.
Install the new switch into the special lock nut, finger
CAM SLOT tight. Leave the switch lock nut loose. Perform the
Neutral Start Switch Adjustment as outlined in the fol-
lowing section

MDC Neutral Start Switch Adjustment

Make certain the control is in the neutral position. If the
Fig. 32 - Cam Slot and Neutral Start switch is being replaced with the control removed from
Switch Pin the unit, neutral can be verified by rotating the control
link assembly until the neutral start switch pin is
engaged in the slot on the cam.
Attach a continuity checker to the two screws on the
end of the switch. With the control in the neutral posi-
tion, turn the switch counter-clockwise until electrical
continuity is obtained. Turn switch counter-clockwise
an additional l/4 turn after continuity has been
obtained.
Hold the switch in place and tighten the locknut to 20
ftlbsf. (27 Nm) torque.
With the continuity checker attached to the switch,
Fig. 33 - Checking Continuity of Neutral rotate the control lever (or the control link) in each
Start Switch direction to assure continuity is broken when the con-
trol is not in the neutral position.

16
 Main Table of Contents

Fig. 34 - Variable Displacement Pump

with Neutral Start Switch

ECCENTRIC LOCKNUT

CAM SLOT circuit. The continuity

SWITCH PIN should be interrupted with an equal amount of handle
rotation in both directions. If the continuity is obtained
in neutral and satisfactorily interrupted in each direc-
tion, proceed to check the switch with the prime mover
running.

Fig. 35 - Neutral Start Switch Showing If continuity can not be verified in neutral, determine
Special Lock Nut for Eccentric Plug the direction of handle rotation (clockwise or counter-
clockwise ) necessary to establish continuity.

The pin which engages the cam slot is mounted in an

1" 1"
k- MIN. j +-- MIN. -d eccentric plug which allows for adjustment. The
accompanying drawing provides dimensions for alter-
nate designs for an eccentric plug adjustment tool.

*. -
1116"
1116" '/n"

ECCENTRIC ADJUSTMENT

While holding the switch from turning, loosen the

switch lock nut and remove the neutral start switch.
Note the slots on the eccentric plug for the adjustment
tool. Loosen the special eccentric plug lock nut while
holding the eccentric in place with the adjustment tool.

17
 Main Table of Contents

If it was necessary to rotate the control handle clock-

wise to obtain continuity, turn the eccentric plug to
move the pin down (or toward the pump). If a counter-
clockwise rotation of the handle was necessary to
obtain continuity, rotate the eccentric plug to move the
pin up (or away from the pump). Only a small amount of
adjustment in either direction is needed to center the
pin in the internal mechanism cam slot.

Fig. 38 - Neutral Start Switch Removed -

Showing Start Switch Pin

Turn the eccentric plug a maximum of l/4 of a turn

ECCENTRIC while frequently stopping to check maximum pin depth
EUTRAL START SWITCH PIN
into the eccentric collar. In most cases it can be deter-
mined that the pin has engaged in the slot, either by
feel or depth gauge, within the first l/4 turn.

Fig. 39 - Adjust Eccentric Plug to move

pin toward pump or away from pump as
required

While holding the eccentric plug in place, tighten the

eccentric plug lock nut to 20 ft. Ibsf. (27 Nm). Reinstall
the switch as outlined in the neutral start switch
removal / installation and adjustment headings of this
section.

Recheck switch continuity to determine whether addi-

tional adjustment of the eccentric is necessary. If fur-
ther adjustment is required, continue rotation up to l/4
additional turn.

Fig. 40 - Tighten Lock Nut

112 turn total or Ths

NOTE: The eccentric plug is normally installed into the

control housing between 5-l/2 and 6-l/2
turns.

If too much adjustment was made, turn the eccentric

plug l/8 turn in the opposite direction. Again, install
the switch and check for continuity.

18
 Main Table of Contents
Fig. 41 - Checking Continuity of Neutral
Start Switch (Gauges Installed in Servo
Gauge Ports)
Fig. 42 - Multi-Function Valves
19
Install two (2) 500 psi (35 BAR) gauges in the servo
gauge ports (one in each side). Energize the starter
circuit, and start the prime mover.
While operating at normal speed and with the pump in
the neutral (zero flow) position, note the pressure
reading on the gauges. This reading should be noted
as the base pressure.
Slowly move the control handle in one direction while
observing the pressure gauges and the continuity
checker. Continuity must be broken before the pres-
sure on either gauge increases more than 12 PSI (0.9
BAR) from the base pressure obtained at neutral.
Slowly move the control handle in the opposite direc-
tion. Again, continuity must be broken before the
gauge pressure increases more than 12 PSI (0.9 BAR)
from base pressure.
Continuity must again be verified when the control is
returned to neutral.
If continuity is not broken at base pressure plus 0 to 12
PSI (0 to 0.9 BAR) in either direction, stop the prime
mover and readjust the eccentric plug as described
previously. If the pressure difference is equal in each
direction but greater than 12 PSI (0.9 BAR), loosen the
switch locknut and turn the switch clockwise 1/16 of a
turn to increase the sensitivity. Retighten the locknut
and recheck pressure differences and continuity.
After verifying proper control and switch operation,
stop the prime mover. Remove the continuity checker
and pressure gauges. Reinstall the servo pressure
port plugs and reconnect the electrical leads from the
machine starter circuit to the neutral start switch. Install
and adjust, if necessary, the external control linkage.
Multi-Function Valve Pressure
Adjustment
Adjustment of the pressure limiter and high pressure
relief valve pressure setting is accomplished by the
same procedure.
In order to set the pressure setting on the pressure
limiter or high pressure relief valve, the motor output
shaft must be locked so it does not rotate. This may be
accomplished by locking the vehicle’s brakes or rigidly
fixing the work function so it cannot rotate.
 Main Table of Contents

Install two (2) 10,000 PSI (690 BAR) pressure gauges

in the high pressure gauge ports. Install a 500 PSI (35
BAR) pressure gauge in the pump charge pressure
gauge port.
Start the prime mover and operate at normal speeds.
Loosen locking nut (smallest hex on multi-function
valve) with a 10 mm wrench for earlier 042 through 100
frame size units, a 19 mm wrench for later 042 through
100 frame size units, or a 13 mm wrench
Fig. 43 - Loosen Pressure Adjusting
Screw Lock Nut

not
over-torque.
Activate or move the input signal so pump returns to
the neutral position. The pressure in the high pres-
sure circuit should return to the charge pressure set-
ting. To verify the actual pressure setting, actuate or
move the input signal to the control such that the
pump again develops pressure in the high pressure
circuit to the newly adjusted pressure limiter pressure
setting. Then allow the pump to return to its neutral
position.
The same procedure is used for setting the pressure
of the other multi-function valve, but the input control
signal must be activated or moved in the opposite
direction so that the pressure develops in the opposite
high pressure side of the closed circuit.
Shut down the prime mover and remove the gauges
and install the gauge port plugs. Replace the plastic
dust plugs (if used).

20
 Main Table of Contents
Fig. 46 - Charge Pressure Gauge Port
(Variable Displacement Pump with
Suction Filtration)
Fig. 47 - Charge Pressure Gauge Port
(Fixed Displacement Motor)
21
Charge Pressure Relief Valve Adjustment
To measure pump charge pressure, install a 500 PSI
(35 BAR) pressure gauge in the pump charge pres-
sure gauge port. Install a gauge to measure case pres-
sure. Operate the system with the pump in neutral
(zero angle) when measuring pump charge pressure.
The following table shows the acceptable pump
charge pressure range for the nominal charge relief
valve settings. These pressures assume 1775 pump
RPM and a reservoir temperature of 120°F (49”(Z), and
are referenced to case pressure. Smaller displace-
ment charge pumps will produce charge pressure
readings in the lower portion of the range, while larger
charge pumps will produce readings in the higher por-
tion of the range.
To measure motor charge pressure, install a 500 PSI
(35 BAR) pressure gauge in the motor charge pres-
sure gauge port. Install a gauge to measure case pres-
sure. Operate the system with the pump in stroke
(forward or reverse) when measuring motor charge
pressure.
The following table shows acceptable motor charge
pressures for the nominal charge relief valve settings.
These pressures assume a reservoir temperature of
120°F (49”(Z), and are referenced to case pressure.
 Main Table of Contents

Earlier production Series 90 pumps and motors are

equipped with a shim adjustable charge pressure relief
valve. Adjustment of the charge pressure is accom-
plished by changing the shim thickness behind the
spring. The plug for this type charge relief should be
torqued to 50 ftlbsf. (68 Nm).

Fig. 48 - Shim Fig. 49 - Shim

Adjustable Charge Adjustable Charge
Pressure Relief Pressure Relief
Valve (Pump) Valve (Motor)
Later production Series 90 pumps and motors are
equipped with an external screw adjustable charge
pressure relief valve. Adjustment of the charge pres-
sure is accomplished by loosening the lock nut (with a
l-l/l 6” hex wrench for 042 through 100 units, or a l-
5/8” hex wrench for 130 units), and turning the
adjustment plug with a large screwdriver. Clockwise
rotation of the plug increases the setting, and counter-
clockwise rotation decreases the setting (at a rate of
approximately 50 PSI [3.4 BAR] per turn). The lock nut
for this type charge relief should be torqued to 38
Fig. 50 - Screw Fig. 51 - Screw ftlbsf. (52 Nm).
Adjustable Charge Adjustable Charge
Pressure Relief Pressure Relief Once the desired charge pressure setting is achieved,
Valve (Pump) Valve (Motor) remove the gauges.

Bypass Valve

The bypass function is performed by the multi-function

valve cartridges. The prime mover should be shut
down when opening or closing the bypass valves.

Using a 1 -l/l 6” (042 through 100) or l-3/8” (130)

Fig. 52 - Loosening and Rotating Bypass
Hex on Multi-Function Valve
wrench on the middle size hex of the multi-function
valve cartridge, and a l-1/4” (042 through 100) or l-
5/8” (130) wrench on the large hex to prevent rotation
of the cartridge assembly, rotate the middle hex three
(3) revolutions counterclockwise to open the bypass
valve. Do not rotate more than 3-l/2 revolutions, as
additional rotation will permit external leakage.
Prior to moving the vehicle or otherwise causing the
motor shaft to turn, move the control handle of the
manual displacement control on the pump to the
maximum full forward position. Hold the handle in this
position during bypass valve operation.

To close the bypass valve, rotate the middle hex

clockwise until it is seated. Then torque the middle
hex to 30 ftlbsf. (41 Nm.).

22
 Main Table of Contents
Fig. 53 - Loosen Displacement Limiter
Lock Nut
Fig. 54 - Rotate Adjusting Screw
Fig. 55 - Tighten Lock Nut
23
Displacement Limiter Adjustment
(Option)
Using a 13 mm wrench for 042 through 100 frame size
pumps or a 17 mm wrench for 130 frame size pumps,
loosen the lock nut retaining the displacement limiter
adjusting screw.
Using a 4 mm internal hex wrench for 042 through 100
frame size pumps or a 5 mm internal hex wrench for
130 frame size pumps, rotate the adjusting screw to
limit the displacement of the pump.
NOTE: Rotating the adjusting screw clockwise will de-
crease the maximum displacement of the
pump while rotating the adjusting screw coun-
terclockwise will increase its max. displacement
up to the max. designed displacement of the
pump.
After establishing the desired maximum displacement
setting, tighten the lock nut on the adjusting screw to
18 ft.lbsf. (24 Nm) for 042 through 100 frame size
pumps, and 35 ft.lbsf. (48 Nm) for 130 frame size
pumps.
The maximum displacement can be limited in either
direction. Use the above procedure to set either or
both displacement limiters.
For each full revolution, of the adjusting screw, the
displacement will change according to the following
chart.
 Main Table of Contents

Minor Repair and Replacement

Controls_ Displacement Limiter

Charge Pressure Relief Valve

Control Orifices
Auxiliary Mounting Pad

Filter

-Charge Pump

p).yJq_
Multi-Function Valve

Variable Displacement Pump

Charge Pressure Relief Valve,

Seal

Fixed Displacement Motor

Fig. 56 - Minor Repairs

Minor Repairs may be performed, following the proce-
dures in this section, without voiding the unit warranty.
Although specific products are illustrated, these pro-
cedures apply to all series and types of units in the
Series 90 Family.
Geneyal
Protect all exposed sealing surfaces and open cavities
from damage and foreign material.
It is recommended that all gaskets and O-rings be
replaced. All gasket sealing surfaces must be cleaned
prior to installing new gasket. Lightly lubricate all O-
rings with clean petroleum jelly prior to assembly.

Cleanliness is a primary means of insuring satisfactory

transmission life, on either new or repaired units.
Cleaning parts by using a solvent wash and air drying is
adequate, providing clean solvent is used. As with any
precision equipment, the internal mechanism and
related items must be kept free of foreign materials and
chemicals.

24
 Main Table of Contents

Lip type shaft seals are used on the Series 90 pumps

and motors. These seals can be replaced without
major disassembly of the unit. However, replacement
of the shaft seal usually requires removal of the pump
or motor from the machine.
Remove the screws holding the retainer plate and seal
carrier to the housing, using a 10 mm hex wrench (042
pumps), a 5 mm internal hex wrench (055 through 100
units), or a 6 mm internal hex wrench (130 units).
Remove the retainer plate.
NOTE: Certain units use a one piece retainer plate
and seal carrier.
After removing the screws, the seal carrier may move
out of its bore by approximately l/4 in. (6 mm). An
outward spring force on the shaft will tend to overcome
Fig. 57 - Remove the friction from the O-ring on the seal carrier O.D. If
the seal carrier does not move from its bore upon
removal of the screws, pry it from its bore as shown
and/or lightly tap the end of the shaft with a soft mallet.
NOTE: After the seal carrier is removed, the shaft and
bearing assembly may be free in the housing.
Do not remove shaft unless unit is positioned
with the mounting flange UP. If the unit is posi-
tioned horizontally when the shaft is removed,
the cylinder block could move out of place,
making shaft installation difficult.
Place seal carrier and seal in arbor press and press out
old seal.
Inspect the seal carrier, the new seal and the O-ring for
any damage or nicks.
Using the arbor press, press the new seal into seal car-
rier. Be careful not to damage seal.
NOTE: The outside diameter of the seal may be lightly
coated with a sealant (such as Loctite High
Performance Sealant #59231)prior to installa-
tion. This will aid in preventing leaks caused by
damage to the seal bore in the seal carrier.
Inspect the sealing area on the shaft for rust, wear, or
contamination.
Wrap spline or key end of shaft with plastic film to pre-
vent damage to the sealing lip on the seal during instal-
lation.
Prior to assembly, lubricate the O-ring on the O.D. of
the seal carrier and the I.D. of the seal with petroleum
jelly.
Assemble the seal carrier and seal over the shaft and
into the housing bore. Install the retainer plate (if
used).
Install the screws and torque to 10 ftlbsf. (13.5 Nm) for
042 through 100 pumps, 24 ft.lbsf. (32 Nm) for 130
pumps, 7 ftlbsf. (9.5 Nm) for 055 through 100 motors,
and 16.6 ftlbsf. (22.5 Nm) for 130 motors.

25
 Main Table of Contents

Multi-Function Valve Cartridges

The multi-function valve cartridge is removed with a l-
l/4” (042 through 100 pumps) or a l-5/8” (130 pumps)
hex wrench on the largest hex on the cartridge.
Inspect cartridge for damage to parts and O-rings.
Install cartridge in multi-function valve cavity and torque
to 66 ft.lbsf. (89 Nm) for 042 through 100 pumps and
206 ft.lbsf. (279 Nm) for 130 pumps.

Fig. 63 - Remove Fig. 64 - Install and

Multi-Function Torque Cartridge
Valve Cartridge

Fig. 65 - Multi-Function Valve Cartridge

Components (Earlier Production)

’ Fig. 66 - Multi-Function Valve Cartridge

Components (Later Production)
Charge Pressure Relief Valve (Variable
Pump)
Remove the shim adjustable charge relief valve plug
with a 1” hex wrench.
Before removing the screw adjustable relief valve plug,
mark the plug, lock nut, and housing so as to approxi-
mately maintain the original adjustment when assem-
bling. Remove the screw adjustable charge relief valve
plug by loosening the lock nut with a l-l/l 6” wrench
Fig. 67 - Remove Fig. 68 - Remove and unscrewing the plug with a large screwdriver.
Charge Relief Valve Charge Relief Valve Remove the spring and relief valve poppet.
(Shim Adjust) (Screw Adjust)
Inspect the poppet and mating seat in the end cap for
damage or foreign material. When inspecting shim
adjustable valves, do not alter the shims or interchange
parts with another valve.
Install the poppet and spring. For shim adjustable
valves, install the plug and torque to 50 ftlbsf. (68 Nm).
For screw adjustable valves, install the plug with its lock
nut, aligning the marks made at disassembly, and
torque the lock nut to 38 ftlbsf. (52 Nm).

Fig. 69 - Shim Check and adjust, if necessary, the charge pressure.

Fig. 70 - Screw
Adjustable Charge Adjustable Charge
Relief Valve Relief Valve

26
Main Table of Contents

For pumps with an auxiliary mounting pad, remove the

four (4) screws holding the auxiliary mounting pad to
the end cap and remove auxiliary mounting pad.

Using a 10 mm (042 through 100 pumps) or a 13 mm

(130 pumps) hex wrench, remove the six (6) screws
holding the charge pump cover retainer.

Remove the retainer and the charge pump cover. For

pumps with an auxiliary mounting pad, remove the aux-
iliary drive coupling.

Remove the charge pump shaft and charge pump

drive key.

Remove the spacer plate(s) (which may be present in

later production pumps).

Remove the charge pump outer port plate.

Remove the charge pump gerotor assembly.

Remove the outer eccentric ring and alignment pin.

Remove the inner port plate.

Inspect the port plates, gerotor assembly, bushings,

and charge pump shaft, for abnormal wear, damage or
foreign material.

NOTE: If a different displacement charge pump is

being installed, the gerotor assembly, gerotor
outer. eccentric ring, and inner port plate
(earlier production pumps) or outer spacer
plate(s) (later production pumps) must be
replaced together. If different thickness port
plates are included in an earlier production
charge pump assembly, the thicker plate is the
inner port plate (installed next to the pump end
cap).

Prior to installation, apply a small quantity of petroleum

jelly to the I.D., O.D., and side faces of the gerotor
assembly.

27
 Main Table of Contents

Note: The charge pump rotation is determined by

the orientation of the gerotor assembly outer
eccentric ring and the location of the alignment
pin in the end cap.

Fig. 76 - Orienting Fig. 77 - Orienting

Gerotor Outer Ring Gerotor Outer Ring
and Alignment Pin and Alignment Pin
(CCW Rotation) (CW Rotation)

install the inner port plate and the gerotor assembly

outer ring.

Fig. 78 - Install Fig. 79 - Install

Inner Port Plate Gerotor Assembly
Outer Ring

Install the alignment pin to properly orientate the port

plates and outer eccentric ring for correct pump rota-
tion.

Install the gerotor assembly.

Fig. 80 - Install Fig. 81 - Install

Alignment Pin Gerotor Assembly

Install the outer port plate.

Install the spacer plate (if used).

Fig. 82 - Install Fig. 83 - Install

Outer Port Plate Spacer Plate

28
 Main Table of Contents

Install the charge pump drive key into the charge pump
shaft.

NOTE: The 75 cc and 100 cc pumps use the same

charge pump drive shaft. Two (2) keyways are
provided in the drive shaft for the later produc-
tion charge pumps used in these units. The
rear keyway (with identifier groove) is used in
75 cc pumps. The front keyway (closest to the
internally splined end of the shaft) is used in
100 cc pumps.
Fig. 84 - Keyway Fig. 85 - Install
Locations in Charge Pump Shaft Install the charge pump shaft. The internally splined
Charge Pump Shaft end of the shaft is installed next to the end cap.
(075 and 100)
NOTE: The outer diameter of the front (internally
splined) end of the earlier production charge
pump shafts is chamfered. Earlier production
pump end caps may not be machined to
accept the current (non-chamfered) shaft.
Always use a chamfered end shaft in units with
the earlier end cap.

For pumps with an auxiliary mounting pad, install the

auxiliary drive coupling.

Carefully remove alignment pin from cavity without dis-

turbing aligned parts. Using petroleum jelly place pin in
charge pump cover.

Install charge pump cover with aligning pin into the

aligned parts in the cavity, taking caution not to dam-
age the cover O-ring during assembly.

Fig. 86 - Install Fig. 87 - Install

Aligning Pin in Charge Pump
Charge Pump Cover Cover

Install the charge pump cover retainer and the six (6)
hex screws and torque the screws to 10 ftlbsf. (13.5
Nm) for 042 through 100 pumps, and 24 ft.lbsf. (32
Nm) for 130 pumps.

For pumps with auxiliary mounting pads, install the O-

ring and auxiliary mounting pad adaptor onto the end
cap. Refer to the Auxiliary Pad Installation instructions
for details.

Fig. 88 - Install Fig. 89 - Torque

Cover Retainer Retainer Screws

29
 Main Table of Contents

Auxiliary Pad Installation

The following procedure should be followed when

converting a pump which has no auxiliary mounting
pad to a pump with an auxiliary mounting pad.
Using a 8 mm internal hex wrench for 042 pumps, a 19
mm hex wrench for 055 pumps, a 24 mm hex wrench
for 075 and 100 pumps, or a 14 mm internal hex
wrench for 130 pumps, remove the four (4) large
screws which fasten the end cap to pump housing.

Fig. 90 - Remove Fig. 91 - Remove Using a 10 mm (042 through 100 pumps) or a 13 mm

(130 pumps) hex wrench, remove the six (6) screws
Screws and Charge Pump
holding the charge pump cover retainer.’ Remove the
Retainer Cover retainer.
Remove the charge pump cover.
Note: The original charge pump cover will not be
used when installing the auxiliary pad.
Install the auxiliary drive coupling onto the pump drive
shaft spline (small outer diameter of coupling must be
toward rear of pump).

Fig. 92 - Remove Fig. 93 - Install

Large Screws Coupling
Remove alignment pin from valve plate in cavity. Place
pin in correct hole in the new charge pump cover. Use
petroleum iellv to hold pin in place.

Install new charge pump cover (with hole for auxiliary

Fig. 94 - Install Fig. 95 - Install New shaft) and O-ring in end cap cavity, aligning pin to hole
Alignment Pin in Charge Pump in valve plate.
Charge Pump Cover
Cover (shown for
CCW Rotation)
Install the charge pump cover retainer and the six (6)
hex screws and torque the screws to 10 ftlbsf. (13.5
Nm) for 042 through 100 pumps, and 24 ft.Ibsf. (32
Nm) for 130 pumps.
Take care to assure the surfaces are clean and free of
any foreign material prior to assembly of the mounting
pad.

Fig. 96 - Install Fig. 97 - Torque

Screws and Cover Retainer Screws
Retainer

30
 Main Table of Contents

Install O-ring on end cap pilot.

InstaH the auxiliary mounting pad adaptor on external

pilot on rear of end cap.

Fig. 98 - Install Fig. 99 - Install

O-Ring on End Cap Auxiliary Pad
Pilot Adapter

Position mounting pad and install four (4) new large

screws (and washers, if used) through mounting pad
adaptor and end cap into the housing. Torque per
table below.

Fig. 100 - Install Fig. 101 - Torque

Auxiliary Pad Pad Adapter
Adapter Screws Screws Install the O-ring and flange’cover or auxiliary pump.

Fig. 102 - Pump Fig. 103 - Install

with Auxiliary Pad Cover
Mounting Pad O-Ring
Auxiliary Pad Conversion

To convert an auxiliary mounting pad to a different size

mounting pad, use the above procedure with the fol-
lowing additions:

In addition to removing the charge pump cover retainer

and the charge pump cover, remove the old auxiliary
drive coupling.

In addition to removing the four (4) large end cap

Fig. 104 Auxiliary
- retaining screws, remove the old auxiliary mounting
Auxiliary Pad Cover Mounting Pad Parts pad adapter.

31
 Main Table of Contents

Filtration Options

Suction Filtration

Install the hydraulic fitting to connect the external suc-

tion filter to the charge pump inlet port.

The reducer fitting (with charge pressure gauge port) is

torqued to 120 ftlbsf. (165 Nm) using a 1-l/4” wrench
on 042 frame size pumps, or torqued to 140 ft.lbsf.
(190 Nm) using a 1-l/2” wrench on 055 through 130
Fig. 106 - Charge Fig. 107 - Fitting frame size pumps. The gauge port plug is torqued to
Pump Inlet with Gauge Port 20 ftlbsf. (27 Nm).
(Suction Filtration)
Remote Charge Pressure Filtration (Option)

The following procedures are required to install the

remote charge pressure filter manifold.

Remove the reducer fitting, located at charge pressure

gauge port, from pump end cap. (This part will not be
used with the remote charge pressure filter option).

Fig. 108 - Remote Pressure Filtration

Manifolds
Install the filter manifold into the port on the side of the
housing. The hydraulic tube should enter its mating
bore in the pump end cap with a low force.

Rotate filter manifold clockwise between 6 and 7 revo-

lutions after the filter manifold threads engage the
threads in the end cap.

Note: Failure to install the filter manifold to a sufficient

depth in the end cap will result in insufficient
engagement of the tube in the end cap bore.
This may allow unfiltered oil to bypass the filter
Fig. 109 - Install Fig. 110 - Tighten and enter the charge system.
Remote Pressure Remote Pressure
Filter Manifold into Filter Manifold Lock After the filter manifold is installed to the proper depth,
End Cap rotate the manifold to the desired position.
Nut
While holding the filter manifold in the desired position,
use a l-3/8” open end wrench to tighten the swivel
lock nut to 52 ft.lbsf. (70 Nm) on 042 frame size
pumps, or a l-5/8” open end wrench to tighten the
swivel lock nut to 90 ftlbsf. (122 Nm) on 055 through
130 frame size pumps.

32
 Main Table of Contents

Integral Charge Pressure Filtration (Option)

The following procedures are required to install the

integral charge pressure filter assembly.

Remove the reducer fitting, located at the charge

pressure gauge port, from pump end cap. (This part
will not be used with the integral charge pressure filter
assembly).

Fig. 111 - Integral Pressure Filter Head

Assembly

Install the filter assembly into the port on the side of the
housing. The hydraulic tube should enter its mating
bore in the pump end cap with a low force.

Rotate filter head clockwise between 6 and 7 revolu-

tions after the filter head threads engage the threads in
the end cap.

Note: Failure to install the filter head to a sufficient

depth in the end cap will result in insufficient
engagement of the tube in the end cap bore.
Fig. 112 - Install Fig. 113 - Tighten This may allow unfiltered oil to bypass the filter
Integral Pressure Integral Pressure and enter the charge system.
Filter Head into End Filter Head Lock
Nut After the filter head assembly is installed to the proper
Cap depth, rotate the assembly to the desired position.

While holding the filter head in the desired position,

use a l-3/8” open end wrench to tighten the swivel
lock nut to 52 ft.lbsf. (70 Nm) on 042 frame size
pumps, or a l-5/8” open end wrench to tighten the
swivel lock nut to 90 ftlbsf. (122 Nm) on 055 through
130 frame size pumps.

After installing the filter head assembly, install the filter

canister per the instructions on filter canister.

Fig. 114 - Install Fig. 115 - Pump

Filter Canister with Pressure Filter
Installed

33
 Main Table of Contents

Manual Displacement Control (MDC)

Thoroughly clean external surfaces prior to removal of
control.
Using a 5 mm internal hex wrench, remove the eight (8)
control mountina screws. Remove the control and
gasket from housing.

Fig. 116 - Remove Fig. 117 - Remove

In preparation for installing the control, place a new
Mounting Screws Control gasket on the housing. Inspect to assure that the con-
trol orifice check valve and spring are in their proper
position in the control.
Engage the pin on the control linkage in the mating
hole in the link attached to the swashplate.
Set control into place and move control lever both
directions to check proper engagement of control link-
age pin. Proper engagement will be indicated by cen-
tering torque as the lever is moved from center. Non-
engagement of control linkage pin is indicated by lack
of centering torque as the lever is moved. In case of
non-engagement remove the control and repeat the
Fig. 118 - Inner Fig. 119 - Assemble above procedure.
Face of Control Control to Linkage
Move the control into place against the pump housing,
align the gasket, and install the screws.
NOTE: For 042 pumps, the rear / center control
mounting screw installs into a “thru” hole, and
has a sealing washer installed under its head.
Torque the screws to 12 ftlbsf. (16 Nm).
NOTE: If the control being removed or replaced is
equipped with a neutral start switch, refer to
the “Neutral Start Switch Removal and Installa-
tion” instructions in the Component Adjust-
ment section.
Fig. 120 - Assemble Fig. 121 - Torque
Control to Pump Mounting Screws Solenoid Override Valve for MDC
(Option)
Thoroughly clean external surfaces prior to removal of
valve.
Using a 5 mm internal hex wrench, remove the two (2)
screws and remove solenoid manifold from housing.
Remove the old gasket.
The solenoid may be removed from the valve by
removing the nut with a 3/4” hex wrench. The
solenoid valve may be removed from the manifold with
a 718” hex wrench.
When installing the solenoid valve into the manifold,
the valve should be torqued to 13.8 ft.lbsf. (18.6 Nm).
When installing the solenoid onto the valve, torque the
nut to 25 in.lbsf. (2.8 Nm).
In preparation for installing the solenoid manifold, place
a new gasket on the control housing. Install the mani-
fold onto the control housing, align the gasket, and
install the screws. Torque screws to 10 ftlbsf. (13.5
Nm).
34
 Main Table of Contents

Hydraulic and Electric Displacement

Control (HDC and EDC)
Thoroughly clean external surfaces prior to removal of
control.
Using a 5 mm internal hex wrench, remove screws and
lift control away from housing.

Fig. 122 - Remove Fig. 123 - Remove

Mounting Screws Control
In preparation for installing the control, place new gas-
ket on the housing. Inspect to assure that the control
orifice and spring are in the proper position in the con-
trol.
Engage the pin on the control linkage in the mating
hole in the link attached to the swashplate.

Fig. 124 - Inner Fig. 125 - Assemble

Face of Control Control to Linkage
Move control back and forth to check engagement of
pin in the link. Proper engagement will be indicated by
an increasing spring force as the control is moved away
from center position. Non-engagement of pin will be
indicated by lack of spring force. In case of non-
engagement, remove control and repeat the above
procedure.
Position the control in place on the pump housing,
align the gasket, and install the screws.
NOTE: For 042 pumps, the rear / center control
Fig. 126 - Assemble Fig. 127 - Torque mounting screw installs into a “thru” hole, and
has a sealing washer installed under its head.
Control to Pump Mounting Screws
Torque the screws to 12 ftlbsf. (16 Nm).

Displacement Control Filter Screens

If the pump is equipped with control filter screens in
the pump housing, they should be pressed into posi-
tion (with the rounded edge of the filter screens facing
the control) until they are flush to 0.08 in. (2.0 mm)
below the surface of the housing.

Displacement Control Adapter Plate

(130 Pumps Only)
The screws retaining the control adapter plate to the
housing may be removed with a 6 mm internal hex
wrench.
When installing the adapter plate, ensure the O-rings
are in the proper position and torque the screws to 24
ftlbsf. (32 Nm).

35
 Main Table of Contents

Electric Displacement Control PCP

(Pressure Control Pilot)

Thoroughly clean external surfaces of control

Using a 4 mm internal hex wrench, remove the four (4)

screws and remove the PCP.

Fig. 128 - Remove Fig. 129 - PCP

PCP Mounting Components
Screws

Check surfaces for nicks or damage. Clean internal

screens.

Install new O-rings in PCP Housing. Place PCP against

EDC housing and install the screws. Torque to 48
inlbsf. (5.4 Nm).

Fig. 130 - Install Fig. 131 - Torque

PCP onto Control PCP Valve Screws

Orifice Check Valve

Remove the control assembly as described in the

instructions for the specific control.

The orifice check valve is located at the surface of the

pump housing face, in the control assembly. Remove
the spring retainer and spring from the orifice check
valve cavity and then remove the orifice check valve.

Fig. 132 - Remove Fig. 133 - Orifice

Spring Retainer Check Valve
Components

Install the desired orifice check valve in the cavity and

then install the spring and spring retainer to hold orifice
check valve in position.

Assemble the control onto the pump. Refer to the

instructions for the specific control.

Fig. 134 - Orifice Check Valve Installed

36
 Main Table of Contents

Loop Flushing Valve (Fixed Motors)

Using an 1 l/l 6” wrench, remove hex plugs from both
sides of valve.
Remove springs, washers, and flushing valve shuttle
spool. Note orientation of washers.
Remove flushing valve spool.
Inspect parts for damage or foreign material.
NOTE: Earlier production motors used a l/4” (6.4 mm)
nominal diameter shuttle valve spool. Later
motors use a 3/8” (9.5 mm) diameter spool.
Fig. 135 - Remove Fig. 136 - Remove
install flushing valve spool in end cap, then install the
Plugs, Springs and Shuttle Spool
washers (the step on the washers should face out,
Washers toward the springs) and springs on each end of the
spool. Install the hex plugs and torque to 30 ft.Ibsf. (41
Nm) on 055 through 100 motors, or 50 ftlbsf. (68 Nm)
on 130 motors.

Defeating Loop Flushing Valve

Remove loop flushing valve per above instructions
(these parts will not be used).
Install defeating spool into spool bore in end cap.
Install hex plugs provided and torque to 30 ft.lbsf. (41
Nm) on 055 through 100 motors, or 50 ftlbsf. (68 Nm)
on 130 motors.
Fig. 137 - Install Fig. 138 ‘- Install
Remove charge relief valve (these parts are not neces-
Flushing Valve Washers, Springs,
sary). Replace with hex plug provided and torque to
Shuttle Spool and Plugs, and 30 ftlbsf. (41 Nm) on 055 through 100 motors, or 50
Torque Plugs ftlbsf. (68 Nm) on 130 motors.
Charge Pressure Relief Valve (Fixed
Motor)
Remove the shim adjustable charge relief valve plug
with a 718” hex wrench.
Before removing the screw adjustable relief valve plug,
mark the plug, lock nut, and housing so as to approxi-
mately maintain the original adjustment when assem-
bling. Remove the screw adjustable charge relief valve
plug by loosening the lock nut (with a 1-l/16” hex
wrench for 042 through 100 units, or a l-5/8” hex
Fig. 139 - Remove Fig. 140 - Remove wrench for 130 units), and unscrewing the plug with a
Charge Relief Valve Charge Relief Valve large screwdriver.
(Shim Adjust) (Screw Adjust) Remove the spring and relief valve poppet.
Inspect the poppet and mating seat in the end cap for
damage or foreign material. When inspecting shim
adjustable valves, do not alter the shims or interchange
parts with another valve.
Install the poppet and spring. For shim adjustable
valves, install the plug and torque to 50 ftlbsf. (68 Nm).
For screw adjustable valves, install the plug with its lock
nut, aligning the marks made at disassembly, and
torque the lock nut to 38 ftlbsf. (52 Nm).
Check and adjust, if necessary, the charge pressure.

Fig. 141 - Shim Fig. 142 - Screw

Adjustable Charge Adjustable Charge
Relief Valve Relief Valve

37
 Main Table of Contents

General Parts ldentif ication

The following information is for general parts identifica-

tion ONLY. Refer to the applicable Service Parts List
when ordering service parts.

Series 90 Variable Dispkement Pump (Minor Repair)

 Main Table of Contents

Series 90 Variable Displacement Pump (Minor Repair)

END CAP (PORT COVERS)

ITEM 1 DESCRIPTION IQTY \

I J70A
THRU I
J7OV
WASHER

CHARGE SYSTEM J80A SCREW 4

ITEM DESCRIPTION QTY THRU
HOOB CHARGE PUMP - 11,14,17, J8OV
THRU 20. 26.34 CC/REV J90A O-RING 1
HOOG ’ ’ THRU ’
HOOL EXTERNAL (NO CHARGE PUMP) J9OV
HO58 CHARGE PUMP ASSY - 11.14.17. 1 J92A/T PLATE COVER A 1
THRU 1 20, 26,34 CUREV J92BlV PLATE COVER B 1
H05G 1 J92C PLATE COVER C 1
H&i 1 SPACER (NO CHARGE PUMP) 1 1 J92D PLATE COVER D 1
H30 1 PLATE, PORT - INNER (THIN) 1 1 J95A SCREW HEX HD 214
THRU

CHARGE PRESSURE REGULATION

ITEM 1 DESCRIPTION IQTY
K020 1 CHARGE PRESSURE RELIEF I
1 THRU 1VALVE - PV - 20,243 28 BAR 1
AUXILIARY MOUNTING PAD
K028
ITEM DESCRIPTION QTY
KlO PLUG ASSY CHG RELIEF 1
JOOA AUX MTG A FLG, W/COVER
K50 O-RING 1
JOOB AUX MTG B FLG, W/COVER
K70 SPRING HEL COMP 1
JOOC AUX MTG C FLG, W/COVER
K80 POPPET CHG RELIEF 1
JOOD AUX MTG D FLG, W/COVER
K90 NUT-SPECIAL 1
JOON AUX MTG FLG- NONE
JOOT AUX MTG A FLG (11T), W/COVER
SHAFT CONFIGURATION
JOOV AUX MTG B-B FLG, W/COVER
ITEM DESCRIPTION QTY
JlOA COUPLING 1
1 THRU 1 L30 CARRIER SEAL 1
JlOV L35 CARRIER SEAL (1 PIECE) 1
J15N COVER CHARGE PUMP- W/O AUX 1 L40 SEAL LIP 1
J15A/B COVER CHARGE PUMP - W/AUX 1 L50 C-RING 1
/C/D L60 PLATE RETAINING 1
/T/V L70 SCREW METRIC 3
J30A BUSHING-CHARGE PUMP 1
THRU COVER CONTROL
J3OV ITEM DESCRIPTION QTY
J40A O-RING, CHARGE PUMP COVER 1 MOCA CONTROL-COVER PLATE
THRU MlCA PLATE - COVER 1
J4OV MllC GASKET - CONTROL 1
J50A O-RING, ADAPTOR FLANGE 1 M87C WASHER - SEAL (042) 1
THRU
M90C SCREW 6
J5OV
MODC CONTROL- 3 POS F-N-R 12V
JGOA/T ADAPTOR FLANGE A .I MODD CONTROL- 3 POS F-N-R 24V
JGOB/V ADAPTOR FLANGE B 1 Ml DC CONTROL 3 POS F-N-R 12V 1
Ml DD CONTROL 3 POS F-N-R 24V 1
MllD GASKET - CONTROL 1
SCRFW 6
 Main Table of Contents

Series 90 Variable Displacement Pump (Minor Repair)

\‘.‘V,

IF IPAf?KARn\ FILTRATION
ITEM DESCRIPTIO
NOOL FILTRATION-IN1
N40L FILTER ELEM
NOOM FILTRATION-IN1
NOOP FILTRATION-IN1 , v, Iv, . a mm_m_m.
N40P FILTER ELEMENT ASSY SHORT 1
,vt, n,r, , vv,. , ROL HDC 1 NOOR FILTRATION-REMOTE MANIFOLD
hli 1 l-l 1 CACKFT _ f?nhlTRnl 1 NOOS FILTRATION-SUCTION
._._. _____. ._. __. ._ _ ~ 1 Nl OS Fl-lTING REDUCER 111
M90H SCREW N35S PLI IG STR THn Ill
MOMA CONTROL- MDC W/O NSS N15 O-RI1
MOMB CONTROL- MDC W/NS.S
. ., .
m-v I

MOMC CONTROL- MDC ‘.WNISfM

.,___ W/n
. ., NSS 1 I PRESSURE REGULATION
MOMD CONTROL- MDC W/SOL W, ITEM DESCRIPTION QTY
MOME CONTROL- MDC W/2 POS ! PO01 M-FCTN V-PL W/HPRV PORT A/B
MOMF CONTROL- MDC W/SOL2 V”n ‘lPC\ P2Al M-FCTN VALVE ASSY PORT A
THRU
P2A8
P2Bl M-FCTN VALVE ASSY PORT B
THRU

CONTROL ORIFICE
1 THRU 1
M7MG ITEM DESCRIPTION Or/
MSME 2 POSITION SOLENOID VALVE 1 TOO2 CONTROL ORIFICE
MllM GASKET - CONTROL 1 THRU
1 TO09
M71 M WASHER
T202 VALVE, ORIFICED CHECK 1
M72M NUT HEX 1
THRU
M74M SOL VLV - OVERRIDE (1 POLE) 1
T209
M75M MANIFOLD - OVERRIDE VALVE 1 1
T302 SPRING
M76M SOL VLV - OVERRIDE (2 POLE) 1
THRU
M77M GASKET - OVERRIDE MANIFOLD 1 T309
M78M SCREW - OVERRIDE MANIFOLD 2 T402 RETAINER, SPRING 1
M87M WASHER - SEAL (0421 1 THRU

41
 Main Table of Contents

KOOO

H6qW

H66W.4

HSON
REF -&-q’-
\

H50W
REF

RFF

END CAP (PORT COVERS) CHARGE PRESSURE REGULATION

ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
G61 GASKET - SHIPPING 2 KOOO CPRV-MF, LP FL DEFEAT
G62 COVER, PORT - SHIPPING 2 Kl 00 CPRV-MF, LP FL DEFEAT PLUG 1
G63 CLAMP, SPLIT 1” (CODE 61) 4 KOlO CHARGE PRESSURE RELIEF
G64 SCREW, HEX HEAD (SHIPPING) 4 THRU VALVE (SHIM ADJUST) - MF - 10,
K028 20, 24,28 BAR
KlO PLUG ASSY CHG RELIEF 1
K50 Q-RING 1
K610 SHIM CHARGE RELIEF - 1
THRU 10,203 24. 28 BAR
K628
K70 SPRING HEL COMP 1
K80 POPPET CHG RELIEF 1

SHAFT CONFIGURATION
ITEM DESCRIPTION QTY,
L30 CARRIER, SEAL 1
L35 CARRIER, SEAL (1 PIECE) 1
L40 SEAL LIP 1
L.50 O-RING 1
L60 PLATE RETAINING 1
L70 SCREW METRIC 3

42
 Main Table of Contents

Unit Identification

Name Plate
Each Series 90 pump and motor will have a name plate
affixed to the housing. The name plate will include the
9OLO55 EA 1 N following information:
6 S 3 C6 C 03 Model (Identification) Number
HNN 35 35 24 The Model Number is used by the factory in manufac-
turing. On repeat orders, a complete unit can be
ordered by the Model Number. The Model Number is
cross referenced to the specific Model Code
(Nomenclature) for the unit.

Model Code
Name Plate (U.S.A. Production) The Model Code for the Series 90 pumps and motors
is defined on the following pages. The Model Code
completely defines the specific unit and must be used
when ordering the complete unit for the first time or for
ordering parts to service the product.

Serial Number
9OLO55 EA 1 N The Serial Number is used to identify the manufactur-
6 S 3 C6 C 03 ing (assembly) location, the build date, and the unit
HNN 35 35 24 sequence in the build. The Serial Number is also used
to identify the unit’s warranty time period, and MUST
be referenced when ordering service parts.

A “Manufacturing Location” letter code was added to

the Serial Number during 1988. This code indicates
the location of original manufacture (assembly). “A”
indicates the unit was originally assembled in Ames,
Name Plate (West German Production) Iowa, U.S.A. “N” indicates the unit was originally
assembled in Neumtinster, West Germany.

NOTE: Since design configuration changes (such as

product improvements) may be implemented
at different manufacturing locations at different
times, the Manufacturing Location code must
be used with the Serial Number Date Code to
identify a particular unit when ordering service
parts.

The first four (4) digits in the Serial Number indicate the
SAER-sums- Build Date Code. The first number (2 digits) indicates
Ames, Iowa, U.S.A. Neumiinster. W.-Germony the year of manufacture. The second number (2 digits)
indicates the calendar week of manufacture. For
example, “88-26” indicates a unit which was manufac-
tured in the twenty sixth calendar week of the year
1988.

The final five (5) digits in the Serial Number represent a

sequential number used to identify a specific unit.

Bar Coding - Tag

87-24-l 2346
A Universal Bar Code, representing the Identification
Number and the Serial Number, will also be affixed to
later production units so these items can be read elec-
Bar Coding - Tag tronically.

43
 Main Table of Contents

Model Code
Series 90 Variable Displacement Pump - PV
R M PJGN
ir
PRODUCT OR SERIES
90 = Series 90, Closed Circuit

R: TYPE AND ROTATION

L = Pump, Left Hand (CCW)
R = Pump, Right Hand (CW)

DISPLACEMENT

042 = 42 cc/rev (2.56 in%ev)

055 = 55 cc/rev (3.35 in%ev)
075 = 75 cc/rev (4.57 in%ev)
100 = 100 cc/rev (6.10 in%ev)
130 = 130 cc/rev (7.93 in%ev)

M: CONTROL

CA = Cover Plate
DC = 3 Position (F-N-R) Solenoid - 12V DC
MA = Manual Displacement (MDC)
MB = Manual Displ (MDC) w/Neutral Start (NS)
MC = Manual Displ (MDC) w/DC Sol Override - 12 V DC
MD = Manual Displ (MDC) w/NS and DC Sol Override
HA = Hydraulic Displ (HDC)(l - 11 BAR)
HC = Hydraulic Displ(HDC)(3 - 11 BAR)
EA = Electrical Displ (EDC) w/MS Connector
EP = Electrical Displ (EDC) w/Packard Connector
NOTE: MC and MD Controls require ,018, .022, or .026 in. Dia. Control Orifice

P: PRESSURE REGULATION
1 = Pressure Limiter (PL) Range 1 (140-420 BAR) in Port A 8 B (Standard)
2 = High Pressure Relief Valves (HPRL) in Port A & B - No PL

6 = Pressure Limiter (PL) Range 2 (450-520 BAR) in Port A & B

J: AUXILIARY MOUNTING PAD

A = SAE A w/Sealed Cover

B = SAE B w/Sealed Cover
C = SAE C w/Sealed Cover
D = SAE D w/Sealed Cover
N = No Auxilary Pad
T = SAE A w/Sealed Cover, 11 T Shaft
U = SAE B w/Sealed Cover, 19 T Shaft
V = SAE B-B w/Sealed Cover

G: END CAP PORTS (SAE J518c Code 62)

1 = Twin Ports w/Special Code 61 Flange Halves*

2 = Side Ports w/Special Code 61 Flange Halves*
6 = Side Ports
8 = Twin Ports

N: FILTRATION
S = Suction (Standard)
R = Remote Pressure
P = Pressure Integral (Short Filter)
L = Pressure Integral (Long Filter)

F: DISPLACEMENT LIMIITATION
3 = No Limiters (Standard)
4 = Limitation Both Sides (Factory set at maximum displacement)

44
 Main Table of Contents

Series 90 Variable Displacement Pump (PV)

LHT W V Z K

K: CHARGE PRESSURE SETTING**

18 = 18 BAR (260 PSI)
20 = 20 BAR (290 PSI)
24 = 24 BAR (350 PSI)
28 = 28 BAR (400 PSI)

2: HIGH PRESSURE SETTING PORT B**

14 = 140 BAR (2030 PSI)
17 = 170 BAR (2460 PSI)

23 = 230 BAR (3300 PSI)

26
29 =
= 260
290 BAR
BAR (3770
(4200 PSI)
PSI) Range 1 (Standard)

32 = 320 BAR (4640 PSI)

35 = 350 BAR (5070 PSI)
38 = 380 BAR (5510 PSI)
20 = 200 BAR (2900 PSI) >
42 = 420 BAR (6090 PSI)

48 = 450
45 480 BAR (6530
(6960 PSI) > Range 2

Y: HIGH PRESSURE SETTING PORT A**

(Same setting ranges as above)

W: SPECIAL HARDWARE FEATURES

NNN = None (Welded Pistons)
HNN = Hollow Pistons
NBN = Downhill Kit

CONTROL ORIFICE
00 = No Orifice
01 = .018 in. Dia.
22 = .022 in. Dia.
02 = .026 in. Dia.
03 = .032 in. Dia. (Standard)
04 = .040 in. Dia.
05 = .054 in. Dia.
06 = ,062 in. Dia.
09 = ,092 in. Dia

H: CHARGING SYSTEM

B = 11 cc/rev (.69 in%ev)

C = 14 cc/rev (36 in%ev)
D = 17 cc/rev (1.03 in%ev)
E = 20 cc/rev (1.20 in%ev)
F = 26 cc/rev (1.60 ins/rev)
H = 34 cc/rev (2.07 inVrev)
L = Ext. Charge w/ Int. Relief

L: SHAFT CONFIGURATION
042~055~075~100~130
Sl = 14T 12/24 P N/AkTDkTDI 0+ 1N/A
S3 = 16T 12/24 P
C3 = 15T 16132 P
C6 = 21T 16/32 P
C7 = 23T 16132 P
C8 = 27T 16132 P
Fl =13T8/16P
Kl = 1.375 in. Str. Key
STD = Standard K2 = 1.500 in. Srt. Key
0 = Optional Tl = 1.375 in. Tapered
N/A = Not Available T2 = 1.50 in. Tapered
* Patent pending T3 = 1 .OO in. Tapered
** All Pressure settings are nominal set pressure at factory test TF = 13T 8/16P, Taper Spl
conditions. Actual pressures will vary due to actual conditions. + = Not recommended for front pump in tandem configurat )ns.
45
 Main Table of Contents

Series 90 Fixed Displacement Motor (MF)

R M PJGNF L H T W Y Z K

PRODUCT OR SERIES 2
90 = Series 90, Closed Circuit

R: TYPE AND ROTATION

M = Motor, Bi-directional

DISPLACEMENT
055 = 55cc/rev (3.35 in%ev)
075 = 75cc/rev (4.57 ha/rev)
100 = lOOcc/rev (6.10 in%ev)
130 = 130 cc/rev (7.93 in%ev)

M: NC = Not Applicable
P: 0 = Not Applicable
J: N = Not Applicable

G: END CAP PORTS (SAE J518c Code 62)

1 = Twin Ports, w/Special Code 61 Flange Halves’

3 = Axial Ports, w/Special Code 61 Flange Halves*
7 = Axial Ports
8 = Twin Ports

N: N = Not Applicable
F: 0 = Not Applicable

L: SHAFT CqNFlGURATlON

Sl =14T12/24P
C6 = 21 T 16132 P
C7=23T16/32P
C8=27T16/32P
Fl =13T8/16P
F2 = 13 T 8/l 6 P (Long)
Kl = 1.375 in. Str. Key
K2 = 1.50 in. Str. Key
K3 = 1.75 in. Str. Key
Tl = 1.375 in. Tapered
T2 = 1.50 in. Tapered

H: CHARGING SYSTEM
N = No Loop Flushing (defeated) (Use Charge Pressure Setting 00)
W = Loop Flushing Valve (Use Charge Pressure Setting 18 thru 28) (Standard)

T: 00 = Not Applicable

W: SPECIAL HARDWARE FEATURES

NNN = None
HNN = Hollow Pistons

Y: 00 = Not Applicable
2: 00 = Not Applicable

K: CHARGE PRESSURE SElTlNG*’

18 = 18 BAR (260 PSI) Nominal
20 = 20 BAR (290 PSI) Nominal
24 = 24 BAR (350 PSI) Nominal
28 = 28 BAR (400 PSI) Nominal
00 = None
NOTE: Motor charge pressure setting should be the same as pump setting.
STD = Standard * Patent pending
0 = Optional l* All Pressure settings are nominal set pressure at factory test
N/A = Not Available conditions. Actual pressures will vary due to actual conditions.

46
 Main Table of Contents

Authorized Service Centers - North America

United States
ALASKA HAWAII MINNESOTA PENNSYLVANIA

Alaska Hydraulics, Inc. Hawaiian Fluid Power Fauver Company West Penn Hydraulics, Inc
500 West Potter 803 Ahua Street 10290 West 70th Street R.R. #3, Box 228
Anchorage, AK 99518 Honolulu, HI 96819 Eden Prairie, MN 55344 Johnstown, PA 15904
(907)562-2217 (808)833-4516 (612)943-1707 (814)269-4994

ARKANSAS IDAHO MISSOURI Donegal Hydraulics

Route 230 West
Fluid Components Inc. Rucker Fluid Power, Inc. Fauver Company Mount Joy, PA 17552
7600 Fluid Drive 2033 Century Way 3939 33rd Terrace NE. Suite H (717)653-2298
Little Rock, AR 72206 Boise, ID 83709 Kansas City, MO 64117
(501)490-0222 (208)377-4822 (816)452-4444 PUERTO RICO

CALIFORNIA Rucker Fluid Power, Inc. MONTANA H-an-D Caribbean Inc.

1901 Main Street P.O. Box 2318
Zemarc Corporation Lewiston, ID 83501 Rucker Fluid Power, Inc. Toa Baja, Puerto Rico 00759-2318
2240 Gaspar Avenue (208)746-9677 3723 Grant Creek Road (809)251-l 865
Los Angeles, CA 90040 Missoula. MT 59802
(213)721-5598 ILLINOIS (406) 549-4181 TEXAS

Rucker Fluid Power, Inc. Fauver Company NEVADA Hydraquip Corporation

15095 Wicks Blvd.-Branch Office 275 Commonwealth Drive 1119 lllthstreet
San Leandro, CA 94577 Carol Stream, IL 60188 Reno Hydraulic & Rebuild, Inc. Arlington, TX 76011
(415)895-7100 (708)682-5010 1400 Marietta Way (214)660-7230
Sparks, NV 89431
Rucker Fluid Power, Inc. Rucker Fluid Power, Inc. (702)356-2703 Rucker Fluid Power, Inc.
11021 Greenstone Ave. 28192 North Ballard Drive 2120 Hutton, Suite 500
Santa Fe Springs, CA 90670 Lake Forest, IL 60045 NEW JERSEY Carrollton, TX 75006
(213)946-1010 (708)680-0050 (214)243-1722
Powertech Hydraulics
COLORADO IOWA 459 Route 17 North Hydraquip Corporation
Mahwah, NJ 07430 7230 Wynnpark Drive
Rucker Fluid Power, Inc. Sauer-Sundstrand Service Center (201)934-9354 Houston, TX 77008
4675 Joliet 2800 East 13th Street (713)869-9471
Denver, CO 80239 Ames, Iowa 50010 NEW YORK
(303)373-4840 (515)239-6000 Rucker Fluid Power, Inc.
Fitzsimmons Hydraulics Company 15401 W. Vantage Parkway, Suite
CONNECTICUT Fauver Company 4400 Shisler Road 120
955 33rd Avenue S.W. Clarence, NY 14031 Houston, TX 77032
Hydro Air of Connecticut Cedar Rapids, IA 52404 (716)759-8389 (713)987-2117
243 State Street (319)366-6437
North Haven, CT 06473 NORTH CAROLINA UTAH
(203)248-8863 LOUISIANA
Rucker Fluid Power, Inc Rucker Fluid Power, Inc.
FLORIDA Rucker Fluid Power, Inc. 4030 Yancey Road 2251 West California Avenue
404 Commerce Point Charlotte, NC 28217 Salt Lake City, UT 84104
Action Hydraulics, Inc. Harahan, LA 70123 (704)525-1354 (801)977-0123
7541 N.W. 54th Street (504)734-0270
Miami, FL 33166 OHIO VIRGINIA
(305)591-7273 MARYLAND
Fauver Company Dees Corporation
Rucker Fluid Power, Inc. Dees Corporation 4149 Weaver Court South 7611 Whiteoine Road
1529 North A Street 8860 Kelso Drive Hilliard, OH 43026 Richmond, VA 23237
Tampa, FL 33606 Baltimore, MD 21221 (614)876-1261 (804)275-9222
(813)253-2837 (301)574-2900
OKLAHOMA WASHINGTON
GEORGIA MICHIGAN
Fluid Components Rucker Fluid Power, Inc.
Rucker Fluid Power, Inc. Fauver Company 6526 East 40th Street 365 Upland Drive South
75-D Mendel Drive S.W. 4550 40th Street Tulsa, OK 74145 Seattle, WA 98188
Atlanta, GA 30336 Kentwood, Ml 49508 (918)622-3781 (206)575-3736
(404)691-9678 (616)957-5177
OREGON Rucker Fluid Power, Inc.
Advanced Fluid Systems Fauver Company North 202 Lee
751 Hurricane Shoals Road 1500 East Avis Drive Rucker Fluid Power, Inc. Spokane,WA99202
Lawrenceville, GA 30245 Madison Heights, Ml 48071 6350 N.E. Halsey (509)535-4281
(404)963-6164 (313)585-5252 Portland, OR 97213
(503)288-6061

47
 Main Table of Contents

Canada
ALBERTA NEW BRUNSWICK QUEBEC SASKATCHEWAN

Rucker Products Ltd. Rousseau Controls Inc. Rousseau Controls Inc. Midwest Hydraulics
711 48th Avenue SE. Unit 8 300 Baig Boulevard 271 Labrosse Avenue 1137 Weaver Street
Calgary, Alberta T2G 4X2 Moncton, New Brunswick El E 1C8 Pointe Claire, Quebec H9R lA3 Regina, Saskatchewan S4N 5Y2
(403)243-4533 (506)859-8992 (514)695-l 240 (306)721-2277

Rucker Products, Ltd. ONTARIO Rucker Products, Ltd. Midwest Hydraulics

8503 Davies Road 2860 Halpern Street 2210 Speers Avenue
Edmonton, Alberta T6E 4N3 J N Fauver Canada, Ltd. St. Laurent, Quebec H4S 1 P8 Saskatoon, Saskatchewan S7L
(403)465-7536 6535 Mill Creek Drive, Unit 48 (514)337-9412 5x7
Mississauga, Ontario L5N 2M2 (306)244-2011
BRITISH COLUMBIA (416)821-4230 S. Huot, Inc.
1000 rue Ste-Therese, Centre
Industrial Equipment Co. Ltd. Feldcamp Equipment, Ltd. lndustriel
7462 Progress Way 1234 Brookes Street St-Malo, Quebec Gl N 4N3
Delta, British Columbia V4G 1 El North Bay, Ontario Pl B 2Pl (418)681-0291
(604)946-i 675 (705)472-5885

Rucker Products, Ltd. Rousseau Controls Inc.

2-3331 Viking Way 34 Leading Road
Richmond. British Columbia V6V Rexdale. Ontario M9V 3S9
1x7 (416)745-3945
(604)278-4411
Vulcan Machinery & Equipment,
MANITOBA Ltd.
915 Memorial Avenue, P.O. Box
Midwest Hydraulics (Man.) Inc. 2810
823 Sanford Street South Thunder Bay, Ontario P7B 5G3
Winnipeg, Manitoba R3H OE4 (807)623-4422
(204)783-2277

For Sales and Service outside of North America, please refer to the following international headquarters locations
for the specific sales office closest to you.

Sauer-Sundstrand Company
2800 East 13th Street
Ames, IA 50010

Sauer-Sundstrand Company
Krokamp 35
2350 Neumtinster
West Germany

Daikin Industries, Ltd.

Yodogawa Plant
700-l Hitotsuya
Settsu-City
Osaka 546, Japan

48
 Main Table of Contents

Description Page
INTRODUCTION.. ......................................................................................................................................................... 1
GENERAL DESCRIPTION.. .......................................................................................................................................... 2
Hydraulic Schematic ............................................................................................................................................ 2
TRANSMISSION HYDRAULIC SUPPORT SYSTEM ...................................................................................................... 3
Basic Closed Circuit ............................................................................................................................................. 3
Case Drain and Heat Exchanger.. ........................................................................................................................... 3
Charge System and Inlet Filter.. .............................................................................................................................. 3
Pressure Limiter and High Pressure Relief Valve.. ...................................................................................................... 4
Loop Flushing Valve.. ........................................................................................................................................... 4
SAFETY PRECAUTIONS .............................................................................................................................................. 4
PRODUCT SPECIFICATIONS ....................................................................................................................................... 5
Technical Data - Variable Displacement Pumps .......................................................................................................... 5
Technical Data - Fixed Displacement Motors ............................................................................................................. 6
CONTROLS AND OPTIONS .......................................................................................................................................... 7
Manual Displacement Control (MDC)........................................................................................................................ 7
Manual Displacement Control with Neutral Start Switch.. .............................................................................................. 7
Hydraulic Displacement Control (HDC) ..................................................................................................................... 7
Electric Displacement Control (EDC) ........................................................................................................................ 7
Auxiliary Mounting Pads ..;. .................................................................................................................................... 8
Multi-Function Valve ............................................................................................................................................. 8
Displacement Limiters .......................................................................................................................................... 8
Charge Pumps .................................................................................................................................................... 8
Filtration ............................................................................................................................................................ 9
Loop Flushing Valve.. ........................................................................................................................................... 9
START-UP & MAINTENANCE ........................................................................................................................................ 10
Fluids. ............................................................................................................................................................... 10
Start-Up Procedure. ............................................................................................................................................. 10
Maintenance.. ..................................................................................................................................................... 10
TROUBLESHOOTING ................................................................................................................................................... 11
Gauge Installation.. ............................................................................................................................................. 11
Fault Logic Diagrams ........................................................................... . ................................................................ 12
INSPECTIONS AND ADJUSTMENTS ............................................................................................................................ 14
Manual Displacement Control (MDC) ........................................................................................................................ 14
Hydraulic Displacement Control (HDC) Neutral Adjustment ........................................................................................... 14
Electric Displacement Control (EDC) Neutral Adjustment.. ........................................................................................... 15
MDC Neutral Start Switch Removal and Installation.. ................................................................................................... 16
MDC Neutral Start Switch Adjustment ...................................................................................................................... 16
MDC Neutral Start Switch Check and Eccentric Plug Adjustment ................................................................................... 17
Multi-Function Valve Pressure Adjustment ................................................................................................................ 19
Charge Pressure Relief Valve Adjustment ................................................................................................................. 21
Bypass Valve ..................................................................................................................................................... 22
Displacement Limiter Adjustment (Option) ................................................................................................................ 23
MINOR REPAIR & REPLACEMENT ............................................................................................................................... 24
General ............................................................................................................................................................. 24
Shaft Seal.. ........................................................................................................................................................ 25
Multi-Function Valve Cartridges.. ............................................................................................................................ 33
Charge Pressure Relief Valve (Variable Pump) ........................................................................................................... 26
Charge Pump.. .................................................................................................................................................... 27
Auxiliary Pad Installation.. ..................................................................................................................................... 33
Auxiliary Pad Conversion ....................................................................................................................................... 31
Filtration Options.. ............................................................................................................................................... 22
Manual Displacement Control (MDC). ....................................................................................................................... 34
Solenoid Override Valve for MDC (Option) ................................................................................................................. 34
Hydraulic and Electric Displacement Control ............................................................................................................. 35
Displacement Control Filter Screens ........................................................................................................................ 35
Displacement Control Adapter Plate (130 Pumps Only) ............................................................................................... 36
Electric Displacement Control PCP (Pressure Control Pilot). ......................................................................................... 33
Orifice Check Valve.. ........................................................................................................................................... 36
Loop Flushing Valve (Fixed Motor) ........................................................................................................................... 37
Charge Pressure Relief Valve (Fixed Motor) .............................................................................................................. 37
GENERAL PARTS IDENTIFICATION ............................................................................................................................ 39
Series 90 Variable Displacement Pump - PV .............................................................................................................. 39
Series 90 Fixed Displacement Motor - MF.. ................................................................................................................ 42
UNIT lDENTlFlCATlON.. ............................................................................................................................................... 43
MODEL CODE.. ............................................................................................................................................................. 44
Series 90 Variable Displacement Pump - PV.. ............................................................................................................ 4
Series 90 Fixed Displacement Motor - MF .................................................................................................................. 46
SAUER - SUNDSTRAND SERVICE CENTERS - NORTH AMERICA .............................................................................. 47
49
 Main Table of Contents

CLqRK M$ertet&Handling
GROUP 12

GROUP 12

IGNITION SYSTEM

(STANDARD
ELECTRONIC IGNITION)

Ignition System Specifications and Description.. ......... Section 1

Ignition System Troubleshooting ................................... Section 2

Ignition System Inspection, Adjustments,

and Timing ...................................................................... Section 3

Ignition Timing for 3.OL GM Engine .......................... Section 3a

Distributor Overhaul ...................................................... Section 4

SM 598, Feb’98 Ignition System

 Main Table of Contents

CUIRK Group 12, Ignition System

Section 1.

Ignition System
Description and Specifications
(Standard Electronic Ignition)

specifications ..._...““._..“..._....“.~.“-~.~~.~....~.~-~”~~”..~...~....~..-~..~“..-.“..“~ 1

IgnitionSystem Overview ..““.._..-...“.“._...-....-....“...-...”....”.-“....“...-”.-”.~.-....~... 2

Schematic Drawing of Ignition Circuitry ..“..““....U..._..-....~..“~..........~..~~.”~...“.~“...~.. 3

Distributor Components and Function ..“...._...._....U...~...~..~.~.~.”.~.~.~..-.~~~.“....~..~~ 4

Specifications
Ignition Type: Non-contact, electronic
Firing Order: l-342
Rotation (viewed from cap): Clockwise
Ignition Timing: Gasoline 4” BTDC @ 500 rpm; LPG
9” BTDC @ 500 rpm
Centrifugal Advance: Beginning: 0” at 600 rpm (en-
gine). En& 6.5” at 2600 rpm (engine)
Vacuum Advance: Beginning: 0” at 80 mmHg (3.14
inHg.) End: 11So at 280 mmHg (11 .O inHg.)
Type I Distributor and Ignition Coil
- Pick-Up Air Gap: 0.8 mm (0.031 in)
- Primary Coil Resistance: 1.08-l-32 Q between ter-
minals (+) and (-)
- Secondary Coil Resistance: 22.1-29.9 k!Z!between
terminals (-) and center
- Ignition Coil Resistor Resistance: 1.22-1.49 S2
l Type II Distributor and Ignition Coil
- Pick-Up Air Gap: 0.35 mm (0.014 in) minimum
- Pick-up Coil Resistance: 430450 SL
- Primary Coil Resistance: 10.8-14.1 Q between ter-
minals (+) and (-)
- Secondary Coil Resistance: 22.1-29.9 S2 between
terminals (-) and center
l spark Plug Type:
Gas Engine: NGK BP4ES, Champion NY1 6
LPG Engine: NGK BPSES, Champion NY12
l Spark Plug Gap: 0.7-0.8 mm (0.028-0.031 in)
l Spark Plug Tightening Torque: 25 Nom (18.4 f&lb)
l Plug Wire Resistance: 8,000 ohms per foot

SM 598, Apr ‘96 IgnitionSystemSpecificationsand Description l 12-1-l

 Main Table of Contents
Group 12, Ignition System
IgnitionSystem Overview
The purpose of the ignition system is to deliver a spark of
the proper intensity and duration to each cylinder at the
proper moment in the piston’s stroke.
The ignition system consists of the distributor, ignition
coil, spark plugs, and primary (low tension) and secondary
(high tension) wiring circuits.
The primary circuit is the low voltage circuit and is com-
posed of the ignition coil primary winding, distributor elec-
tronics, and associated wiring, including battery, ignition
switch, starter relay and neutral start relay.
The secondary circuit is the high voltage section and is
composed of the ignition coil secondary winding, the dis-
tributor cap, the rotor, the spark plug cables (wires), and the
spark plugs.
Firing Order = 1,3,4,2
/ Spark Plug
Cables
Ignhion System Components
12-1-2 l Ignition System Specifications and Description
ellFlRK
The battery supplies the voltage for producing current
through the ignition circuit.
‘The ignition switch is an OFF/ON switch. Current flows
only when this switch is closed and returns by the ground
through the engine or frame. The resistance of the primary
winding of the ignition coil restricts the primary current
flow.
The ignition coil consists of two windings, a primary wind-
ing and a secondary winding. The function of the ignition
coil is to transform the low voltage supplied by the battery
in the primary winding into the high voltage output of the
secondary winding required to jump the spark gap at a
spark plug.
The distributor conducts and interrupts the primary wind-
ing current in the ignition coil at the correct time and
distributes the resulting high tension secondary current to
the correct spark plug.
Vacuum Hose
L Ignition Coil
SM 598, Apr ‘96
 Main Table of Contents

EmK Group 12, Ignition System

When the distributor interrupts the primary current, the
collapsing field in the primary winding of the coil induces a
very high voltage in the secondary winding. This voltage is
carried by the high tension wire (cable) to the center termi-
nal of the distributor cap. The rotor co~ect~ this center
terminal to the distributor cap terminals, which in turn are
co~ected to the proper spark plug by high tension cables
(wires).
The spark plugs provide a spark gap in the combustion
chamber. The compressed air and fuel mixture is ignited
when the high voltage jumps across this gap.
The distributor incorporates a mechanical (centrifugal) ad-
vance mechanism that varies the timing by advancing the
breaker plate as the engine speed increases. This mecha-
nism consists of weighted levers that revolve with the
distributor rotor and act against a set of springs. As the
speed of rotation increases, the weights are moved out and
the timing is advanced. With this arrangement, it is pos-
sible to have a retarded spark for idling and obtain a gradual
advance in spark tuning as the engine speed is increased.
The distributor also includes vacuum advance for optimum
part-throttle economy. With this system, spark timing is not
only adjusted for the rotating speed but also for the load
applied to the engine. As load is decreased, timing is ad-
vanced, and as load is increased, timing is retarded until
only the mechanical advance is used.

Schematic Drawing of Electronic Ignition Circuitry

SPARK PLUG I

ALTERNATOR

SOLENOID VALVE FUEL OUTII yr,

=
(GASOLINEONLYJ - -

SM 598, Apr ‘96 Ignition System Specifications and Description l 12-l-3

 Main Table of Contents

Group 12, Ignition System GLCIRK

Distributor Components and Function

Components
The distributor consists of the ignitor (with self-contained
pick-up, on Type I distributor), a separate pick-up coil on
the Type II distributor, breaker plate, signal rotor, distribu-
tor rotor, and ignition advance mechanisms.
Ignition advance mechanisms include a mechanical cen-
trifugal-weight type governor, and a diaphragm-type
vacuum set.
Function
The signal rotor is mounted on the distributor shaft, which
rotates in sync with the engine crankshaft As the distribu-
tor shaft rotates, each tooth of the signal rotor passes in
close proximity to the ignitor on the Type I distributor or to
a separate pick-up coil on the Type IL The ignitor or coil
senses the position of the passing tooth much as a metal
detector detects the presence of metal.
When the tooth is sufficiently close to the pick-up, this
causes the power transistor in the ignitor to switch off. This
Off condition blocks the flow of the primary current, which
collapses the magnetic field that built up during the On
time. The collapsing field cuts across the coil secondary
winding, inducing the high voltage that fires the spark plug.
The clearance (air gap) between the teeth and the pick-up
basically determines the duration of current flow, and thus
the duration of the spark. The wider the clearance or air gap
between the teeth and the pick-up, the stronger the cut-off
and the longer the duration of the spark. This duration is
equivalent to the dwell angle in a contact-type distributor
and can be adjusted as shown in Section 3.

,- Housing

Pick-Up

“‘AirGap”-Clearance between Signal Rotor Tooth and

Pick-Up. Type I distributor shown.

Timing is controlled by precisely setting the position of the

Typical Distributor Components. Type I distributor shown. ignitor (or pick-up coil on Type II distributor) along the
circular path made by the signal rotor’s teeth. You make
A. Breather this adjustment by rotating the distributor housing while
L. Drivegear
B. Distributor cap M. o-ring observing the engine timing marks under a timing light
C. Contact carbon N. Leadwire
D. Rotor 0. Rotor shaft
E. Signal rotor P. Spring retainer
F. Groundingwire Q. Governor spring
G. Ignitor R. Governor weight
IL Breaker plate S. Distributor shaft
L Vacuum control T. Lock pin
J. Packing U. Washer
K. Distributor housing

12-l-4 l Ignition System Specifications and Description SM 598, Apr ‘96

 Main Table of Contents

CMRK Group 12, Ignition System

Section 2.

Ignition System
Troubleshooting
(Standard Electronic Ignition)

Troubleshooting Tests “.m...“.“.UU..“...U...~“~....“....”....~.~”~..~.....“.“~....””..“.-“...“.~ ...” 2

Spark Test ........................................................................................................................................ 2
Spark Plug Test ................................................................................................................................ 2
Insulation Test of Distributor Cap and Rotor .................................................................................. 3

Troubleshooting Chart .._.“_..“~..““““U.“.~...........~...”.”-..~.~.”.....“...~...~~~.~.“~-.. 3

SM 598, Apr 36 Ignition System Troubleshooting l 12-2-l

 Main Table of Contents

Group 12, Ignition System CMRK

TroubleshootingTests
The following tests should be used along with the trouble-
shooting chart on the next page to isolate ignition system
problems.
Refer to Group 14 for complete electrical system schemat-
ics, if needed.
2. If no spark appears in step 1, remove the secondary
(high-tension) cable from the center terminal of the
distributor. Hold the wire terminal tip 6-10 mm
(0250.38 in) from the engine block (ground). Crank
the engine and check for spark across the gap.

Spark Test
A WARNING
GASOLINE OR LPG FUEL. Park truck in DISTRIBUTOR
a well-ventilated area. Check for leaks and fuel
spills before performing these tests. Sparks can SPARK PLUG

ignite gasoline or LPG fuel vapors. Do not per-

form maintenance near open flame or other
sources of ignition, or while smoking. LP gas is PRIMARY
highly flammable. CABLE

n ! CAUTION
While the engine is cranking or running,
keep away from belts and fan and do not
touch bare end of spark plug wire.
1. Remove the spark plug wire from a spark plug. Hold
thebootend6-1Omm (0.25 to 0.38 in)fromtheengine
block (ground). Crank the engine and check for spark
across the gap. Repeat for each plug. If you

If spark appears, the problem is with the distributor.

Perform the “Insulation Test” below and consult the
troubleshooting chart on the next page.
If no spark appears, suspect the coil, coil power supply,
SPARK PLUG WIRE
or coil resistor. Consult the troubleshooting chart on
the next page and the inspection procedures in the next
Section.

PlugTest
DISTRIBUTOR
If there is spark from the boot end of the plug wire, but you
still suspect the plug may not be firing sufficiently, remove
the spark plug to be tested from the engine. Reconnect the
plug to the plug wire. Crank the engine, and sparks should
form between electrodes. If the spark plug is defective
(worn, leaky or poorly insulated), no spark will form. Re-
place the spark plug.

EL IMPORTANT
When removing spark plug wires from the
spark plug terminal, hold the cable cap or
boot frrmlg. Do notpull on the wire.

12-2-2 l Ignition System Troubleshooting SM 598, Apr ‘96

 Main Table of Contents

ElRRlC Group 12, Ignition System

Insulation Test of Distributor Cap and Rotor TroubleshootingChart

1. Remove the distributor cap with the secondary (high-
tension) wire installed. Crank the engine. If sparks
form along the cap surface, this is an indication of a
breakdown in the insulating quality of the cap. Clean
or replace the cap.
Verification of suspected problems usually requires per-
forming the spark test, insulation test, and spark plug test.
The following lists typical ignition troubles and possible
causes and remedies.

Engine Does not Crank

Starter, battery, or other electrical system fault. See Croup
14 troubleshooting.

Engine Cranks, But Does Not Start

Spark Test Shows No Spark

l Distributor
DISTRISUTOR Carbon tracking in cap or rotor. Replace.
CAP
Broken or loose primary lead wire. Repair or
replace.
Broken or damaged rotor. Replace.
IGNITION COIL
Distributor out of time. Retime distributor.
Faulty electronic ignition unit Replace.
Pick-up gap too wide. Adjust.
Broken wire or shorted circuit. Replace coil.
Carbon tracking on tower. Clean or replace.
Dii or wet connections in coil & distributor cap
towers. Clean or replace.
2. Remove the distributor cap. Remove and put the high-
tension (secondary) wire terminal close to the rotor. l Coil to Distributor High Tension Cable
Crank engine. If sparks form, this is indication of a - Loose or disconnected. Repair/install.
breakdown in the insulating quality of the rotor. Clean - Faulty wire or insulation. Replace.
or replace the rotor.
- Corrosion.
l wiring
- Bad secondary wire to distributor. Replace.
- Poor negative ground to block Clean, repair,
tighten.
- Fuse.
- Fiig order incorrect_ Rearrange wires.
SECONDARY
CABLE l Timing belt
- Broken.
IGNITIONCOIL
C - Jumped timing cog.
-4
Fuel System Fault
Refer to fuel system troubleshooting in Croup 02.

Instrument Pod Fault

Refer to instrument pod troubleshooting in Croup 13

SM 598, Apr ‘96 Ignition System Troubleshooting l 12-2-3

 Main Table of Contents

Group 12, Ignition System ElfIRK

Engine Runs, But Does Not Run Smoothly

Engine Fault
l See Croup 00 Troubleshooting

Engine Misses and/or Backfires

Distributor
- Worn or loose distributor drive shaft Replace
assembly.
- Carbon tracking on cap or rotor. Clean or replace.
- Broken primary lead wire. Repair or replace.
- Faulty electronic unit. Replace.
- Distributor installed 180” out of position.

Ignition Coil Fault

Coil to Distributor High Tension Wire
- Break in wire or wire loose. Replace, tighten.
- Faulty insulation. Replace.
spark Plugs
- Plugs fouled or worn out.
- Flashover on porcelain insulator. Clean or re-
place.
spark Plug wires
- Faulty.
- Firing order incorrect.

Engine Knocks
l Distributor
- Incorrect ignition timing (too far advanced).
- Disengaged or broken centrifugal advance spring.
Repair or replace.
- Worn centrifugal advance mechanism. Replace.
l Spark Plugs
- Incorrect heat range. Replace.
- Fuel. Use correct spec.

Engine Does Not Deliver Enough Power

l Distributor
- Incorrect ignition timing (retarded). Adjust.
- Faulty centrifugal advance mechanism. Replace.
- Ignitor air gap out of adjustment
. Spark plugs fouled or worn.
l Spark plug wires contaminated or defective.

12-24 . Ignition System Troubleshooting SM 598, Apr ‘98

 Main Table of Contents

ElmK Group 12, Ignition System

Section 3.

Ignition System
Inspection, Adjustment, and Timing
(Standard Electronic Ignition)

Distributor Inspection and Air Gap Adjustment ........_...._..........~.“.~..~~..~~~..~...~....~.”.” .. 2

Distributor Cap.. ............................................................................................................................... 2
Rotor ................................................................................................................................................ 2
Centrifugal Advance ........................................................................................................................ 2
Vacuum Advance Control.. .............................................................................................................. 3
Pick-Up Air Gap .............................................................................................................................. 3

Spark Plug Wire Inspection .._.........m...._....~.~~-..~..~~....~..........~....~...~.~......~.~.~~..~ ..... 3

Spark Plug Inspection and Replacement ._...._.._U....“....~....~........~~..~...~...~....~~..~...~~ .3

Removing Spark Plugs ..................................................................................................................... 3
Inspecting Spark Plugs .................................................................................................................... .4
Installing spark Plugs ...................................................................................................................... 4

Ignition Coil Inspection ..“._.~.........._....“...“....~~..~..........~....“~.““..~~....~.~.~.~“.~.~~~~ .4

specifications ““.U........“_.......~....~....“....~.........~.....~....~....”....“...“.~..~.~.“....~.~~...~.~”.~ .” 5

Ignition Coil Tests ..““.-...I....“...._“~.....~....”...~.........~....~.~~....~..””“~~....“....~...“..““.” .5

Pick-Up Coil Tests U”...._..._...“_..“..-....“.“.............”....“..““....“.--.-”..“...-..~-~.“..- - 5

Ignition Timing Checks and Adjustment ..__.._.““...._....““..-...~“““....~...-...-.~-..“.- ..- 5

Checking Ignition Timing ................................................................................................................ 5
Adjusting Ignition Timing ............................................................................................................... 6
Checking Spark Advance ................................................................................................................. 7
Centrifugal Advance ................................................................................................................. 7
Vacuum Advance ...................................................................................................................... 7

SM 598, Apr ‘96 IgnitionSystem Inspection,Adjustment,and Timing l 12-3-l

 Main Table of Contents

Group 12, Ignition System GICIRK

DistributorInspectionand Air Gap

Adjustment

Distributor Cap
1. Remove the distributor cap and check its condition for: Signal
cracks Rotor
Carbon tracking or flashover burn marks Rotor
Corrosion, rusting or damage of terminals Distributor Cap I I
Burned center terminal or side inserts
Center terminal pushed up inside cap and not free
in socket
Moisture
Dirt inside and outside.
It is very important for the cap to be clean. Moisture
and dirt make a good path for flashover. Once a carbon
track has started, the cap must be replaced.
2. Remove the spark plug wires from the distributor cap.
Inspect the cable socket terminals in the cap for corro-
sion and burn damage. Clean the towers and terminals,
asneeded.
3. Clean the distributor cap and terminals, or replace, as
needed.

Rotor
Remove the rotor and inspect it for:
l Carbon tracking or flashover burn marks
l Burned, pitted, bent or worn terminal tip
l Moisture, contamination, and dirt buildup
Clean or replace the rotor, as needed.

Centrifugal Advance
Install the rotor. Turn the rotor in the direction of rotation Typical Distributor Components. Type I shown.
and release it to confirm that the rotor returns to the original
position smoothly. If rotor sticks, distributor overhaul is
required

12-3-2 l Ignition System Inspection,Adjustment,and Timing SM 598, Apr ‘96

 Main Table of Contents

ClmK Group 12, Ignition System

Vacuum Advance Control Spark Plug Wire Inspection

Check the diaphragm in the vacuum advance unit and the
1. Check spark plug cables and boots for cuts, cracking,
line to the manifold for leakage. If the diaphragm is rup- brittleness, bums or excessive corrosion of the termi-
tured, the vacuum advance housing and linkage must be nals on both ends, and general deterioration. If the
replaced.
cables are three years old or more, replace them.
When removing a spark plug wire, be sure to hold the
Pick-Up Air Gap cap or boot. Do not pull on the wire.
1. Check the pick-up air gap. The air gap must be correct
to properly check timing.

2. Check plug wire resistance. Resistance should be

about 8,000 ohms per foot
Pick-Up Air Gap Setting. Type I.
3. To install new cables, remove one old wire at a time
and match it to a new one. Use all looms and separators
and route the wires exactly as the old ones.
The use of a dielectric silicone grease at high-voltage con-
necting points such as coil and distributor cap towers and
spark plugs is recommended to ensure good electrical con-
nection and prevent corrosion.

Gap-b- Spark Plug Inspection and

Replacement
Pick-Up Air Gap Setting. Type II.

Standard Pick-Up Air Gap Setting:

Removing Spark Plugs
Type I distributorz 0.8 mm ( .031 in)
Type II distributor: 0.35 mm (0.014 in) minimum 1. Remove the spark plug wires and move them out of the
NOTICE way.
Always check and adjust ignition timiug 2. Useanairnozzletoblowdirtandcontaminationoutof
after insWing new ignitor module or pick- the spark plug wells.
up coil, or after adjusting air gap.
2. With a clean feeler gauge, measure the maximum air IMPORTANT
gap (at the position where a projection of the signal Do not allow dirt and contaminauts to en-
rotor is aligned squarely with the pick-up). Rotate the ter spark plug openings when the plugs are
engineasnecessaryusingthecrankpulleyandfanbelt. removed.
If the measurement is not within specification, adjust
3. Loosen, but do not remove, all of the spark plugs.
the air gap setting.
Again blow dirt and contamination out of the wells.
3. Toadjusttheairgap,loosentheignitormoduleorpick-
4. Remove and inspect the spark plugs.
up coil mounting screws (varies between Type I and
Type 11). Then move the ignitor module or coil to
adjust to specification the air gap between the pick-up
and a projection on the signal rotor. After adjustment,
tighten the mounting screws.

SM 598, Apr ‘96 Ignition System Inspection, Adjustment, and Timing l 12-3-3
 Main Table of Contents
Group 12, ignition System
Inspecting Spark Plugs
1. Inspectsparkplugsforthefollowingconditions. Ifany
abnormality is found replace the plugs:
l Damage to insulator
l Wear of electrodes
l Carbon and lead deposits
l Damage and deterioration to ‘gasket
l Arcing or flashover tracking and burning of por-
celain insulator.
If spark plugs are:
l Fouled with carbon deposits, check for too rich
air-fuel mixture, dirty (clogged) air filter, or mis-
fire due to excessive spark gap.
l Burned but white, check for too lean air-fuel
mixture, excessive spark advance, or insufficient
plug tightening torque.
Installing Spark Plugs
1. Check the spark gap and adjust to the correct specifica-
tion. Use proper gauge and gapping tool.
(0.023-0.031 in)
IMPORTANT
New spark plugs do not always have cor-
rect spark gap. Always check and adjust
the spark gap of new plugs. Use proper
gauge and gapping tooI. Tighten spark
plugs to the specified torque.
2. Clean the spark plug seat in the cylinder head.
IMPORTANT
Lubricate threads on spark plugs with
ANTI-SEIZE grease, Clark part #1802307.
3. Use new seat gasket and screw plug in by hand
4. Tighten to correct torque specification.
5. Correctly install the spark plug cables (wires).
12-3-4 l Ignition System Inspection,Adjustment,and Timing
CIRRU
IgnitionCoil Inspection
Ignition coils do not normally require any service except
keeping all terminals and connections clean and tight. The
coil should be kept reasonably clean; however, it must not
be subjected to steam cleaning or similar cleaning methods
that may cause moisture to enter the coil.
Check the ignition coil tower for tracking and obvious
damage. Be sure the tower is clean and dry. Check coil
boot nipple for correct sealing and insulating qualities.
If flashover occurs here, the engine probably won’t
Start,
Check primary circuit wires for tight connections and
correct polarity. When the ignition coil is wired up
incorrectly with the distributor, it can cause high speed
“missing” with loss of power and performance under
heavy loads.
h I
PRlMARY
‘I
SECONDARY
CABLE
CABLE
IGNITIONCOIL
&
0
3. Check the coil to distributor cap high-tension (second-
ary) cable. Check the fit of the boot on the coil and
distributor cap towers. A high voltage leak atthis point
will cause the engine not to start.
SM 598, Apr ‘96
 Main Table of Contents
EmK
1. a defective coil
l Measuring the resistance of
a circuit
tester. If of resistance
as shown
If
incorrect
as necessary.
I Distributor:
Primary Coil Resistance: 1.08-1.32
between terminals (+) and (-)
Secondary Coil Resistance: 22.1-29.9 kQ
between terminals (-) and center
- Coil Resistor Resistance: 1.22- 1.49 Q
Type II Distributor:
- Primary Coil Resistance: 10.8-14.1 f2
between terminals (+) and (-)
- Secondary Coil Resistance: 22.1-29.9 ZL
between terminals (-) and center
l Measuring the insulating resistance between the
primaryterminalandcasewitha5OOVmegger(if
available) or a volt-ohmmeter. It is considered
normal if the reading is 10 megohms or above.
Replace coil, as necessary.
2. When the coil is suspected of being faulty, remove it
and check its operation on a coil tester and replace it if
inoperative. Most coil testers compare the operation of
the coil being tested with one known to be in good
condition. This test should be made first with the coils
at room temperature and then after warming the coils
five minutes by connecting the primary to a battery of
the same voltage rating as the coils. Recheck the
comparison test to see if the expansion due to heating
has caused some defect
+B- ?3?
4-- 1
0 0
ts Of
Type II Ignition Coil
SM 598, Apr ‘96 Ignition System Inspection, Adjustment, and Timing
Group
Pick-UpCoil Tests
(For Type II distributor only.) Measure resistance; value
should be 430450 Q. Make sure that ohm meter needle
moves when screw driver passes near core of coil.
IgnitionTiming Checksand Adjustment
A WARNING
ENGINE FAN. Be careful of rotating fan
blades when using a timing light.
NOTICE
Correct ignition timing is vital to the proper
and efficient operation of the engine. In-
correct timing can result in engine over-
heating, with resultant reduced piston and
valve life, and lowered fuel economy.
It is important that the ignitor air gap is set
correctly before checking and adjusting the
timing. Checking timing is counterproduc-
tive if the gap is not set to specification.
Checking Ignition Timing
1. Check and adjust ignitor air gap as explained earlier in
this Section.
2. Install a tachometer, or a combination test instrument,
such as the Clark Dynamic Engine Analyzer, Part No.
1802047.
NOTE
Tachometer must be connected directly to
battery terminals. Other grounds are not
suitable.
3. Install a timing light.
NOTE
An ignition timing light, Clark Part No.
1801971,or equivalent, with inductive spark
pickup is recommended. Install per
manufacturer’s recommendations.
4. Clean the timing pointer or indicator and timing mark
or notch on the crsnk pulley to make the mark more
legible under the timing light.
5. Start the engine and warm it up until it runs smoothly.
l 12-3-5
 Main Table of Contents
Group 12, Ignition System
6. Disconnect vacuum hose from vacuum advance on
distributor. Plug or clamp the open end of vacuum hose
to carburetor or manifold.
Vacuum Hose
7. Lower the engine speed by adjusting the carburetor
idle screw to obtain 500 rpm idle speed See Group
02, “Fuel System” for idle adjustment.
It is standard practice to check engine initial timing
with engine idling at 500 rpm so that the automatic
advance of the distributor is completely retarded and
not affecting timing. THIS IS VERY IMPORTANT
TO OBTAIN CORRECT TIMING.
n ! CAUTION
ENGINE FAN. Be sure to hold the timing
light to avoid rotating fan blades. Be care-
ful to stay away from the fan when leaning
over to see the timing marks.
8. The engine timing indicator (1) is located near the
crankshaft pulley (2) and may be seen from the right-
hand side of the truck.
12-3-6 l Ignition System Inspection, Adjustment, and Timing
CICIRK
9. With engine running at the noted idle speed, aim the
timing light at the crankshaft pulley and timing indica-
tor. Note timing marks as light flashes.
The initial ignition timing is correct when the timing
mark on the crankshaft pulley is aligned with the
correct position on the timing indicator, at idle speed.
Initial Timing Specification:
l Gasoline: 4” BTDC @ 500 rpm
l LPGz9”BTDC@5OOrpm
If ignition timing is not correct, adjust as necessary.
See “Adjusting Ignition Timing” below.
10. Adjust timing as shown below. Iftiming is OK, check
spark advance.
Adjusting Ignition Timing
Adjust timing with the engine warm and the vacuum ad-
vance hose disconnected and plugged.
Loosen but do not remove the clamp bolt at the base of
the distributor.
With the engine running at 500 rpm, adjust the timing
by slowly rotating the distributor in one direction or the
other. Turn the distributor:
l Clockwise to retard timing
l Counterclockwise to advance timing.
SM 598, Apr ‘96
 Main Table of Contents

elmI Group 12, Ignition System

3. Turn distributor body until the timing mark and indica-
tor are aligned correctly.
4. Tighten nut or clamp bolt at the base of the distributor.
5. Recheck the timing to be sure that it did not change
when distributor mounting bolt was tightened.
VacuumAdvance
1. Connect the vacuum hose and check the total advance
while engine speed is increased gradually to no-load
governed rpm.
2. Vacuum advance is obtained by subtracting centrifir-
gal advance from the measurement_

Checking Spark Advance Total advance - centrifugal advance =

After checking (and adjusting, if necessary) ignition tim-
ing, check the centrifugal advance, then the vacuum ad-
vance.
Centrifugal Advance
1. Make sure the engine is warm, the vacuum advance
line is removed and plugged, and idle is still set at 500
rpm.
2. Slowly accelerate the engine speed from idle to maxi-
mum no-load governed rpm. Check the advance while
engine speed is being increasecL
Centrifugal Advance SpeciEcation:
l Beginning: 0” at 600 rpm (engine).
l End: 6.5’ at 2600 rpm (engine).
vacuum advance
Vacuum Advance Specification:
l Beginning: 0”at 80 mmHg (3.14 inHg).
l End: 11.5Oat 280mmHg (11.0 inHg).
3. Analyze the results:
l Excessive advance. Vacuum advance control
spring is weak. If spring is broken, abrupt rising of
advance will occur.
l Insufficient advance. Breaker plate is faulty or
diaphragm is broken in the vacuum advance
control.
4. Repair or replace component parts as required. (See
distributor overhaul Section in this Croup.)

NOTE
Distributor rpm = l/2 engine rpm
3. Analyze the results:
l Excessive advance: Centrifugal advance spring is
weak. If the spring is broken, abrupt rising of
advance will occur.
l Insufficient advance. Centrifugal advance weight
or cam is faulty.
4. Repair or replace the centrifugal advance mechanism
(mainshaft and weight assembly), as required. (See
distributor overhaul Section in this Croup.)
5. Reset idle to 650 r-pm.

SM 598, Apr ‘96 Ignition System inspection, Adjustment, and Timing l 12-3-7
 Main Table of Contents

CMRK Group 12, Ignition System

Section 3a.

3.OL GM Ignition System

Timing
(High Energy Ignition)

Ignition Timing .. ..... .... ..... ... ... ... ..... ...... ..... ... .. .... ..... ..... ..... ... .. ... .... ..... ... .... ... .. ... .... ... ... ... ... ... .. .. ....... 2

SM 598, Feb’98 HEI Ignition Timing l 12-3a-1

 Main Table of Contents

Group 12, Ignition System ClllRlQ

A CAUTION
While the engine is cranking or running, keep To 12 Volt positive (+)
away from belts and fan and do not touch
bare end of spark plug wire.

A CAUTION
Do not connect alligator clip lead of Initial
Timing Connector to battery positive (+)
source until after engine is started. If initial
timing connector is connected to battery posi-
tive (+) source while engine is started, the Initial Timing Connector
ignition control module (ICM) in the distribu-
tor may be damaged. If engine must be re- 4. Connect alligator clip on long lead of Initial Timing
started while Initial Timing Connector is in- Connector to convenient battery positive (+) source.,
stalled detach alligator clip lead from B+ such as battery terminal on starter solenoid.
source to avoid damage.
This removes all advance from electronic spark timing.
Engine will probably slow down when connection is
1. Start engine and allow to warm to operating tempera- made. Engine speed should be around 6.50 RPM.
ture.
Note: Initial timing for LPG 3.OL GM - 0”
2. Remove terminal plug from distributor.
5. Loosen distributor clamp screw just enough to rotate
distributor, and set base timing to new specification.

6. When timing is set to specification, secure distributor in

position with clamp screw.
7. Recheck timing to assure that distributor did not move
during tightening.

8. Disconnect initial timing connector from battery posi-

tive source and remove connector from distributor. La-
bel initial timing connector. Store connector in safe
place.

3. Install initial timing connector to terminal connector on

distributor. (Be sure connector is seated in distributor).

12-3a-2 l HEI Ignition Timing SM 598, Feb’98

 Main Table of Contents

ClmK Group 12, Ignition System

Section 4.

Distributor Overhaul
....... 1
Replacingthe Ignitor and Pick-Up Coil.._....U....“....~....“..........~.~~....~....”..“““.~....~~

... 2
Removingthe Distributor........“..“_....~....“....~...~~..~.......~.~..........~...~...~~..~~~~~~~“~

I&all& the Distributor..~_.._..““.“_..~...~~~...““..“....”....~~~....~..~....~“. M.-W 2

DistributorDisassemblyand Assembly.._.........“....“..““...~....~...~....”..~-..”...~...~...”.~ .. 3
Type I Distributor ............................................................................................................................ 3
Type II Distributor ........................................................................................................................... 5

Replacingthe lgnitorand Pick-UpCoil

The ignitor (with self-contained pick-up) on the Type I Signal
distributor can be replaced without removing the distribu- Rotor
tor. On the Type II distributor, the pick-up coil assembly @ 0
and ignitor are separate and can be replaced. To replace Q
these components:
=ap+..-_ 0
, A
1. Remove signal rotor from the distributor drive shaft
with an ordinary bearing puller.
,,,e
-WC-_ xs
lgnitor m
2. Disconnect the wire leads from the terminals of the IgnitorPick-Up. Type I.
ignitor module (Type I) or pick-up coil assembly
(Type II) and remove two mountingAdjusting screws.
To remove the Type II ignitor, remove the mounting
screws and the other leads as well.

IMPORTANT
Do not wipe off the grease on the back of
the ignitor unit because it is needed for
heat radiation of the unit.
3. When remstallmg, set the pick-up air gap as shown in
Section 3 of this Group.

Pick-UpCoil and Igniter. Type II.

SM 598, Apr ‘98 Distributor Overhaul l 12-4-l

 Main Table of Contents

Group 12, Ignition System CulRK

Removing the Distributor Installing the Distributor

1. Rotate the engine crankshaft to put the #l cylinder
piston at top dead center.
2. Disconnect the spark plug cables and the primary and
secondary cables from the distributor.
3. Remove the vacuum hose from the vacuum advance
control on the distributor.
4. Loosen and remove the distributor locking nut from
the base of the distributor. Remove the distributor from
the engine.
1. Rotate the engine crankshaft to put the #l cylinder
piston at top dead center.
2. Align the match mark on the distributor drive pinion
gear with the match mark on the distributor housing,
shown on figure below.
3. With the match marks facing up, put the distributor
into the cylinder head so that the distributor pinion
meshes with the distributor drive gear.

Match Mark on Housing

r Locking Nut

Match Mark on Gear 1

4. Fit the distributor assembly to the engine and align the

match mark on the distributor mounting flange with
the center of the distributor installation stud.

L Vacuum Hose

Match Mark
on Mounting
Flange

5. Install and tighten the distributor locking nut.

6. Install the vacuum hose.

12-4-2 l Distributor Overhaul SM 598, Apr ‘96

 Main Table of Contents

EMRK Group 12, Ignition System

DistributorDisassemblyand Assembly Service Notes:

Type I Distributor Removingthe Signal Motor Shaft/Signal Rotor

Drive the signal rotor shaft from the signal rotor.

Removingthe Drive Gear

Putmatchmarksonthedistributorshaftanddrivegear.
To remove the lock pin, place the drive gear on a soft
block (such as a wooden block).
Drive the lock pin out with a pm punch.

Pin Punch

Installingthe Drive Gear

DisassemblySteps (Type I) Inset the drive gear into the distributor shaft so that match
marks placed before removal are aligned with each other.
1. Breather 12. Breaker plate
2. Distributor cap 13. Spring retainer
3. Packing 14. Governor spring n! CAUTION
4. Contact carbon When the pin is driven in, the slit must be
15. Governor weight
positioned at right angles to the shaft.
5. Rotor 16. Lock pin
6. Vacuum control 17. Drive gear
7. Groundingwire 18. Washer
8. Leadwire 19. o-ring
9. Ignitor 20. Distributor shaft
10. Rotor shaft 21. Distributor housing
11. Signal rotor

SM 598, Apr ‘96 Distributor Overhaul l 12-4-3

 Main Table of Contents

Group 12, Ignition System ClRRK

installingthe BreakerPlate
Install the breaker plate with its projection A seated in
groove B.

Installing the Signal Rotor

Install the signal rotor over the rotor shaft, making sure that
the rotor dowel pin is seated in the groove.

IMPORTANT
AtIer reassembly, set the pick-up air gap as
shown in Section 3 of this Group.

12-44 l Distributor Overhaul SM 598, Apr ‘96

 Main Table of Contents

ClmK Group 12, Ignition System

Type II Distributor
DisassemblySteps (Type II)
1. Breather
2. Distributor cap
3. Rotor
4. Cover
5. Signal rotor 3
6. Pick-up coil assembly
7. Ignitor
8. Heat sink
9. Breaker assembly
10. Vacuum control 1

0
11. Connector
12. o-ring
13. Distributor housing

IMPORTANT
After reassembly, set the pick-up air gap as
shown in Section 3 of this Group. 6

SM 598, Apr ‘96 Distributor Overhaul l 12-4-5

 Main Table of Contents

GROUP 13

GROUP 13

INSTRUMENT POD

Instrument Pod Description and Specifications.. ......... Section 1

Instrument Pod Troubleshooting .................................. Section 2

Instrument Pod Removal and Installation ................... Section 3

NOTE

The truck electrical system, in general, is

covered in Group 14.

SM 598,Oct ‘94 Instrument Pod

 Main Table of Contents

ClRRK Group 13, instrument Pod

Section 1.

Instrument Pod Description

and Specifications

Specifications Service Requirements

Indicator lights: LEDs integral with circuit board. Service is required only when indicated by troubleshooting
Buzzer: Integral with circuit board (which is covered in Section 2). The only service that can
be performed is to:
Fuel gauge: Analog.
l Replace the fuel gauge
Engine Coolant Temperature Gauge: Analog. l Replace the coolant temperature gauge
Hour Meter: Analog, with running indicator. Integral to l Replace the printed circuit board.
circuit board. l Replace the entire instrument pod.
Fastening Torques: Pod-to-dash mounting bolts: 8-10 Nom
(71-88 in-lb); Connector jack screw: 2.5 Nom (22 in-lb).
Pinout Locations and Circuit Diagrams: See Section 2,
“Troubleshooting,” in this Group for pinouts. Also see
Group 14, “Electrical System,” for detailed schematics.

Engine
Temperature
Gauge 7

Printed Circuit uoara

Knockouts H
for Optional
Switches Instrument Pod

SM 598, Jun ‘94 InstrumentPod Description& Specifications l 13-l-l

 Main Table of Contents
Group 13, Instrument Pod
Description
General Function
The instrument pod consists of indicator lights, an hour
meter, a printed circuit board, and attached gauges that,
together. provide the operator with important information
about truck condition and shut down the truck in the event
that certain critical conditions are present.
Information about the necessary sensors and external elec-
trical connections is in Group 14. “Electrical System.”
Engine Shutdown Function
The instrument pod circuit board receives signals from
sensors in various locations and shuts down the truck when
coolant temperature is excessive. engine oil pressure is low,
or transaxle fluid temperature is excessive.
Before shutting down the truck. the instrument pod sounds
a 30-second alarm (buzzer). After shutdown. the truck may
be restarted, but if the fault condition persists, the truck
shuts down again in 30 seconds.
Key-On Alarm
The instrument pod circuit board monitors ignition switch
position. If the key is left on with the engine not running for
30 seconds, the horn will sound.
Gauges and indicators
Coolant Temperature Gauge
Indicates whether engine coolant is in cool. normal, or hot
range. If the indicator registers in the “cool” zone after the
engine has had time to warm-up. there is a problem with the
gauge, sender, or wiring harness. If the indicator registers in
the “hot” zone. shut down the truck and service it. (Cooling
system troubleshooting information is in Group 01.) If the
engine temperature reaches 114 “C (235 OF)a buzzer will
sound. At 118 “C (245 OF)the truck will go into shutdown
mode. The gauge does not return to “0” when the power is
off.
Fuel Gauge
Indicates quantity of fuel remaining in the tank in fractions
of the whole. (Fuel level light is used on LPG/CNG.) The
gauge does not return to “0” when the power is off.
13-1-2 l Instrument Pod Description & Specifications
CWRU
Hour Meter
Indicates total engine operating time in hours and tenths.
Operating time is recorded only when the engine is run-
ning. The running indicator show that the hour meter is
operating. The indicated hours are used for planned mainte-
nance. Record the hours on the PM Report Form.
Indicator Lights and Symbols
When the truck is first started, the indicator lights should
come on for a two seconds to show that they are working.
Then, they should go off, except when indicating the con-
ditions described below.
4 Ammeter
Indicates that the alternator is not charging the battery. If
the light is on, troubleshoot the alternator charging system.
+(& Engine Oil Pressure
Indicates engine oil pressure is too low. If the light is on,
shut down the truck and service it. The truck will go into
shutdown mode after the light is on for 30 seconds.
0-3 Diesel Fuel Filter
Indicates water in the fuel filter. Drain filter.
E3 LPG Fuel Level
Indicates that LPG fuel tank is nearly empty. Proceed to
refueling station immediately. Only a few minutes of oper-
ating time is left. Actual times varies according to ambient
temperature.
m Glow Plug Preheat
Indicates diesel glow plugs are in the process of preheating
the engine. In a cold start..the engine cannot crank for a six-
second period-at which time the light goes out. In a warm
start, the six-second delay is overridden .
F Seat Belt:
4
At start-up, this light and a buzzer come on for four sec-
onds to remind the operator to fasten the seat belt. There is
no start interlock.
SM 598, Jun ‘94
 Main Table of Contents

CIRRIC Group 13, Instrument Pod

Fuel

1
Temperature Indicator Lights
Gauge and Symbols Gauge
1

Diesel Truck Display

Gas Truck Display

LPG Truck Display

I- Running Indicator
i Hour Meter

69
* - Air Filter
Indicates that the air filter element is dirty. restricting air
flow. If the light stays on. change the filter element. Occa-
sional flickering of the light does not indicate a problem.
Transaxle Oil Temperature
(8r
Indicates that the transaxle oil temperature is excessive. If
the light is on, shut down the truck and service it. The truck
will go into shutdown mode after the light is on for 30
seconds.
Hydraulic Oil Filter
Indicates that the main hydraulic system filter is dirty,
restricting fluid flow. If the light stays on, change the filter
element. Occasional flickering of the light does not indi-
cate a problem.
(@IParking Brake
Indicates that the parking brake is engaged. Anytime the
parking brake is on. the transaxle solenoid valves switch
off, disengaging the transaxle (transmission in neutral).

SM 598, Jun ‘94 Instrument Pod Description & Specifications l 13-l-3

 Main Table of Contents

CWIW Group 13, Instrument Pod

Section 2.

Instrument Pod Troubleshooting

Fuel Gauge Failure ................ ..I...........“...........................~ .......................................................... 2

Coolant Temperature Gauge Failure ........................................................................................... 3

Icon Light Failure ........................................... ..~................................................_ ......................... 4

Hour Meter Failure ................ .._.......................................~ .......................................................... 5

Buzzer Failure ......”.............................................................................................. . ........................ 6

Key-On Horn Failure ..... ..U............“........~...............~........................_.......~....................~ ......... 7

Shut-Down Mode Failure ................ ..U............................“............~.............................................. 8

06
12

;“4
23
Wiring Harness Connector to Instrument Pod. 22 05
04
Troubleshooting charts on following pages reference
these pin numbers. 21
20
19
13
07
01

1. Open (Gas/LPG Truck); Tachometer Input (Diesel) 13. Horn

2. Open 14. Park Brake Light
3. Open 15. Transaxle Temperature Warning
4. Power In 16. Open
5. Open 17. Air Filter Light
6. Engine Temperature Gauge 18. Ignition
7. Ground 19. Fuel Level Gauge
8. Open 20. Hydraulic Filter Light
9. Open (Gas/LPG Truck); Preheat Light (Diesel Truck) 21. Open
10. Low LP (Gas/LPG Truck); Fuel Filter Light (Diesel Truck) 22. Open
11. Engine Oil Pressure Light 23. Transaxle Temperature Warning Light
12. Charge Light 24. Ignition

SM 598,Oct ‘94 InstrumentPod Troubleshooting l 13-2-1

 Main Table of Contents

Group 13, Instrument Pod Emu

Fuel Gauge Failure

Remove fuel gauge.

Fuel gauge is not working insert new fuel gauge

into socket.

Replace housing and

reinstall screws.

v Connect connector to
instrument pod.

I Disconnect connector
from rear of housing. I

Turn on ignition and check for

v correct gauge operation.
i

1 Attach ohmmeter to terminals 6 1

Turn off ignition.

Reinstall instrument pod.

Fuel gauge sender is bad or

there is a problem in wiring
harness.

13-2-2 . Instrument Pod Troubleshooting SM 598,Oct ‘94

 Main Table of Contents

ElmK Group 13, Instrument Pod

Coolant Temperature Gauge Failure

4
55
START Remove coolant temperature
gauge.

I
1 lnsert;;;cooI+gauge 1

Remove instrument pod from

forklift.

Connect harness connector

to instrument pod.
Disconnect connector from
rear of housing.

Turn on ignition and check for

Attach ohmmeter to terminals

7 and 19 on harness connector
and measure resistance.

Turn off ignition.

I

Reinstall instrument pod.

Replace instrument pod.

Coolant temperature sender is

bad or there is a problem in
wiring harness.
23 End

SM 598,Oct ‘94 Instrument Pod Troubleshooting l 13-2-3

 Main Table of Contents

Group 13, instrument Pod CMRK

Indicator Light Failure

One or more indicators

Turn ignition on.

Do all indicators light

>
Replace instrument pod. for first two seconds? Repair sensor or wiring.

End.
:

13-2-4 l Instrument Pod Troubleshooting SM 598,Oct ‘94

 Main Table of Contents

ClmK Group 13, Instrument Pod

Hour Meter Failure

your meter does not work.)

Is oil psi indicator on? ) Repair oil pressure or sensor

problem.

No

Replace instrument pod.

.

23 End.

SM 598,Oct ‘94 Instrument Pod Troubleshooting l 13-2-5

 Main Table of Contents

Group 13, Instrument Pod

ClRRK

Buzzer Failure

I Buzzer does not sound with high coolant

temperature reading, high trans temp indicator,
low oil psi indicator shutdown warning
\ or shutdow:dition. ’ )

Turn ignition on.

I

Replace instrument pod. for four seconds? * Repair appropriate sensor.

End.

13-2-6 l instrument Pod Troubleshooting SM 598,Oct ‘94

 Main Table of Contents

clam Group 13, Instrument Pod

Key-On Horn Failure

Key-on warning does not work.

Honk horn.

Does horn sound?

Repair faulty horn circuitry. *

Does horn sound?

Key-on warning works correctly.

Is seatbelt icon lit?

Replace instrument pod. Repair faulty horn circtuiry.

SM 598,Oct ‘94 Instrument Pod Troubleshooting l 13-2-7

 Main Table of Contents

Group 13, Instrument Pod CMRK

Shut-Down Mode Failure

START

Engine will not run

Disconnect connector from rear

of housing.

v
Attach jumper lead between
pins 18 and 24 on harness
connector.

Start engine.

Repair engine problem. Replace instrument pod.

cd3 End.

13-2-8 . Instrument Pod Troubleshooting SM 598,Oct ‘94

 Main Table of Contents

CMRK Group 13, Instrument Pod

Section 3.

Instrument Pod Removal and Installation

Instrument Pod
Wiring harness
connector is keyed
to fit into pod one
way only.

Torque connector
jackscrew to 2.5
Nom(22 in-lb). Do
not over-torque.

Torque to 8-10 N-m (71-88 in-lb)

(3 bolts).

SM 598,Oct ‘94 Instrument Pod Removal and Replacement l 13-3-1

 Main Table of Contents

GROUP 14

GROUP 14

ELECTRICAL
SYSTEM

Electrical Specifications and Wiring Diagrams ........... Section 1

Starter and Battery Troubleshooting ......................... Section 2A

Alternator Troubleshooting ........................................ Section 2B

Starter Maintenance and Overhaul .............................. Section 3

Alternator Maintenance and Overhaul ........................ Section 4

SM 598,Oct ‘94 Electrical System

 Main Table of Contents

Group 14, Electrical

CIRRU

Section 1.

Electrical Specifications
and Wiring Diagrams

Electrical System Specitications ....~...~U..m”~~...“~........~~.....~.......~.~...~........”~.......~~~ .... 1

wiring Color codes ....“.~.._..U...“_..~~“.~.........”.~..~~...~~~”........“...~..~.~~.“..“...~...~...~ .. 2

Circuit and Wiring Harness Diagrams for Standard Transaxle LPG/Gas Trucks _............. -3

Circuit and Wiring Harness Diagrams for Standard Transaxle Diesel Trucks .._................ .. 5

Circuit and Wiring Harness Dims for Hydrostatic Transmission Trucks . .... . .. . ... . .. .

Electrical System Specifications

Voltage and Ground

System Voltage: 12 volt GaslLPG:
System Ground: Negative Type: Positive engagement, planetary gear reduction,
offset.
Alternator Voltage: 12 volts
Type: 12 volt Outputz 1.2 kW

Diesel:
Battery Type: Positive engagement, offset gear reduction.

GaslLPG: Voltage: 12 volts

Type: 12 volt Output: 2.2 kW

Cold Crank CurrenC 420 amps at 0’ F (-18” C)

Reserve Capacity: 80 minutes at 80” F (27” C) System Protection
Fuse: SA Direction Control
Diesel:
Fuse:lSA Ignition, Horn, and Options
Type: 12 volt
Fuse: 15A Headlights
Cold Crank Current: 625 amps at 0” F (-18” C)
Reserve Capacity: 160 minutes at 80” F (27’ C) Fuse: 15A Brake Lights

SM 598,Oct‘94 Electrical Specifications and Wiring Diagrams l 14-l-l

 Main Table of Contents

Group 14, Electrical ClRRK

Wiring Color Codes

Black Dark Blue

All ground wires. l Fuel gauge.
l Headlights.
Brown
l Engine coolant temperature gauge. Purple
l Reverse alarm. l Transmission temperature.
l Starter solenoid to ignition coil (Gas and LPG only).
Red
All positive battery wires. Gray
l Directional control power.
Orange l Taillights.
Direction control-reverse.
White
Yellow l Ignition.
l Direction control-forward. l Engine Oil Pressure.
l All wires for tell-tale lights on instrument pod.

Dark Green
l All horn wires.
l Strobe light.

14-l-2 l Electrical Specifications and Wiring Diagrams SM 598,Oct ‘94

Main Table of Contents
Main Table of Contents
Main Table of Contents
Main Table of Contents
Main Table of Contents
Main Table of Contents
 Main Table of Contents

ClmK Group 14, Electrical System

Section 2A.

Starter and Battery

Troubleshooting
General Information ......................................................................................................................
1

Minimum Tools Required .............................................................................................................

1

Starting System Inspection ............................................................................................................

2

Problem 1: Slow or Sluggish Cranking ................................................................................... 3

Problem 2: Nothing Happens When Start Attempt Is Made .................................................... 4

Volt Drop Tests ..............................................................................................................................

6

General Information
A
! CAUTION
When troubleshooting an engine cranking or starting Remove all jewelry (watch, rings, brace-
system, keep in mind that more than the starter is lets, etc.) before working on electrical sys-
involved. The cranking motor is only one of the ele- tems. Severe burns can result from contact
ments in the starting system. The motor, battery, wir- with electrical circuits.
ing and switches all make up the system and each
contributes to the proper functioning of that system. A
WARNING
Battery service must be done by trained
It will be helpful to have a good understanding of
solenoid, motor and circuit operation. personnel. Battery acid can cause severe
burns and injury. Do not smoke or have
The following is an important point. The starter de-
open flames around batteries.
mands high current flow from the battery to perform
its job. It is essential that the switches, wiring, and
connections do not have high resistance which can
MinimumTools Required
cause arcing or heat damage to components and ex-
cessive battery current use during starter operation. Digital voltmeter, Clark Part No. 1801989, or equiva-
lent.
All electrical connections must be clean and tight for
minimum resistance. This is especially important for Volt-ohm meter (V-O-M), such as Dynamic Engine
the battery cable connections at the battery terminals. Analyzer, Clark Part No. 1802047; Simpson 260-6P;
or equivalent.
The starter is a special type electric motor that oper-
ates on low dc voltage and must be able to withstand Carbon pile control or battery tester, such as SUN
extremely high current. The high current carrying VAT 40, or equivalent.
requirement means that the motor can be operated for
only short periods of time. To prevent overheating,
periods of operation of more than 30 seconds in dura- IMPORTANT
tion are not recommended. Always follow the manufacturer’s instruc-
tions for the test instrument being used
Before performing electrical system service procedures: when making connections and tests on elec-
l Park truck safely. trical circuits.
l Apply parking brake and block drive wheels.
l Return all controls to neutral and turn ignition key
OFF, except as otherwise noted.

SM 598, Ott ‘94 Starter and Battery Troubleshooting l 14-2A-1

 Main Table of Contents

Group 14, Electrical System CUIRK

Starting System Inspection 2. Check starter mounting bolts.

The bolts which mount the starter motor to the fly-

1. Check the battery.
wheel housing must be kept tightened to the correct
Be sure that the battery is in good condition and fully torque. Starter mounting bolt should be torqued to 26
charged before attempting to test the starter and wiring Nom (19.25 ft-lb).
circuit for problems. It is recommended that you per-
form a voltmeter test and a battery load test.

(BREAKERLESS TYPE)

SPARK PLUG
DISTRIBUT’X

T; 0
BATTERY
0

ST

t
IG

DIODE

ALTERNATOR

SOLENOID VALVE FUEL OUT--/ CARBURETOR

(GASOLINE ONLY)

Ignition and Charging System

14-2A-2 l Starter and Battery Troubleshooting SM 598,Oct ‘94

 Main Table of Contents

ClRRK Group 14, Electrical System

3. Check the wiring.

Inspect the wiring for damage. Inspect all co~ections
to starter motor, solenoid, starterrelay, ignition switch,
neutral start switch or any other control switch, and
battery, including ground co~ections. Clean and
tighten all co~ections as needed.

4. Check starter relay, neutral startrelay and ignition key

switch.

Inspect all switches to determine their condition. With

switches closed, use a voltmeter to check the circuit for
continuity. Replace defective switches and wiring as

Ground high tension (voltage) coil wire before performing

checks.
Ml

1
NOTE
NEUTRAL STARTER
RELAY When servicing the starting system, never
remove a component until tests have shown
it to be defective.

The following describes typical troubleshooting procedures

for two of the most common starting system problems.

Problem 1: Slow or Sluggish Cranking

Slow or sluggish cranking is one of the more complex
problems to solve. The battery, wiring, switches, starter
motor and engine are all factors that must be checked to
Starting System Schemutic determine where the problem is.
5. Check fuses. 1. Perform a battery load test. Temperature should be
70-80°F (21-27°C). Connect a voltmeter across the
battery terminals. Crank the engine for 15 seconds.
ElectricalChecks Measure the voltage on the voltmeter.
Before performing checks, ground the ignition system:
Disconnect the high tension (voltage) coil wire from the
distributor cap and connect it to a jumper wire that is
co~ected to ground on the engine. This will prevent the
engine from accidentally being started and also prevent
damage to electrical components while performing starting
system electrical checks and cranking tests.

If voltage is less than 9.6 volt go to step 2.

If voltage is above 9.6 volts got to step 3.

SM 598,Oct ‘94 Starterand BatteryTroubleshooting l 14-2A-3

 Main Table of Contents
Group 14, Electrical System
2. Ifvoltage measured in step 1 is less than 9.6 volts,
check battery and connections.
l Test the battery with a voltmeter. If the battery is
discharged or suspected ofbeing defective, charge
it and test it per recommended procedures.
l Replace the battery, if necessary.
l Be sure that the correct battery (size and rating) is
installed in the truck.
l Check for bad connections at battery terminals.
l Clean and tighten all battery connections.
3. Ifthe voltage measured in step I is above 9.6 volts,
check motor current draw:
a. Be sure all battery connections are clean and tight.
Connect an ammeter and carbon pile (e.g., a
battery load tester) in parallel with the battery
terminal of the starter solenoid and ground (frame
or battery negative terminal). Be sure that the
carbon pile control, or tester, is turned OFF. (Clip-
on inductance tester may be used.)
Battery Load Tester
b. Increase the load (current) until the same voltage
is reached as measured when cranking the engine.
Note the ammeter reading. Turn OFF the load.
The ammeter reading indicates the cranking sys-
tem current draw.
142A-4 ’ Starter and Battery Troubleshooting
EUlRu
c. Compare the measured system draw with the
typical current requirements of the gasoline/LPG
engine lift truck system.
Typical starter current draw: 180-220 amps.
If current draw is low go to step 4.
If current draw is high go to step 5.
Ifthe current draw measured in step 3 is low, it means
high circuit resistance. Measure the voltage drops in
the starter motor circuit (see “Additional Starting Sys-
tem Electrical Checks” below ) while cranking the
engine. Large drops of over 0.4- 1 volt indicate the need
to clean and tighten connections or replace wiring in
that portion of the circuit.
Use volt-drop test to find source of high resistance.
Refer to “Additional Starting System Electrical
Checks”, below.
Ifthe current draw measured in step 3 is high, it means
high mechanical resistance. Either a poor engine con-
dition exists, such as tight rings, or tight bearings, or
lack of lubrication, or the starter motor needs to be
removed and repaired. The starter motor should be
checked for tight bearings, pole shoe rubbing, shorted
or grounded armature or field coils. Use torque wrench
to measure force required to turn engine over or check
by hand.
Problem 2: Nothing Happens When Start
Attempt Is Made
If the starter motor won’t crank the engine, it may be
simply a poor electrical contact that is the problem. Loose
or corroded battery connections can slow down or stop a
starter motor. A loose connection may allow enough cur-
rent to pass to operate some electrical accessories but not
the starter motor. Or, the problem may be either a defective
or discharged battery.
But the problem may be an open circuit, loose connection
or other defect in the starter motor, solenoid switch, starter
relay, neutral start relay, ignition switch, or the wiring.
The best procedure in diagnosing this type of starting prob-
lem is to systematically check the possible trouble points,
starting with the easiest. See following.
1. Check the neutral start relay.
Try moving (jiggling) the directional control lever in
the NEUTRAL position, or shifting into NEUTRAL
while turning the ignition key switch to the START
position. The key switch must be turned back to the
OFF position each time before turning to the START
position.
SM 598,Oct ‘94
 Main Table of Contents
.clmu
A! CAUTION
To be safe when checking or removing bat-
tery connections for cleaning, first discon-
nect the negative battery cable at the end
where it is attached to the engine or frame
ground connection. Then, try to move
(twist) the cable connectors at the battery
back and forth to be sure that they are
tight.
2. Check the connections at the battery. They should be
free from corrosion and securely tightened. If heat is
felt at any of the connections, this is an indication that
a poor connection exists.
3. Perform a volt drop test on the battery post terminal
connections, as described in “Volt Drop Test” later in
this Section,
If the connections are tight but need cleaning, remove
the cables and clean the battery posts and the inside of
the cable connectors, using a wire brush or a special
battery terminal cleaning tool to remove the oxidation
film. Also, remove any contamination and sulfate
deposits that may have formed on the battery. Clean
the battery with a solution of baking soda and water.
Rinse with clean water. Be careful not to get any
cleaner or dirt in the battery vent holes.
SM 598,Oct ‘94
Group 14, Electrical System
Reconnect the battery cables in reverse order of re-
moval, by connecting positive (+) cable first, then
negative (-) cable, and attaching the negative cable to
the engine or frame ground last. This way, any spark
that’s produced will be far from the battery. Wipe the
battery clean with a cloth or paper towel.
Try starting the engine again.
If the starter still does not operate, check the charge
condition of the battery with a hydrometer or digital
voltmeter.
If battery is discharged and the case is not cracked or
damaged and otherwise appears to be in good condi-
tion, recharge the battery and see whether it holds the
charge. If the battery does not hold a charge, check the
charging system. Refer to “Charging System Trouble-
shooting,” Section.
Check the fan/alternator drive belt for damage and
correct tension. Replace or adjust the belt, as neces-
sary. Refer to “Cooling System and Alternator Belt
Servicing” in Group 01.
NOTE
Just as a discharged battery isn’t necessar-
ily bad, a charged battery isn’t necessarily
good. An old, or defective battery may show
a full charge but be unable to produce ad-
equate electrical energy to meet the heavy
load demand of the starter motor. The only
way to tell is with a load test.
Battery must be fully charged to perform
load test.
Starter and Battery Troubleshooting l 14-2A-5
 Main Table of Contents

Group 14, Electrical System EMRK

6. Perform a load test to determine whether the battery is

good or defective. -1 ram @
IGNITION (
SWITCH NEWRAL STARTER
START RELAY
RELAY

Disconnect the battery cables at the terminals. Either

remove the battery for testing, or connect the tester to
the battery in the truck. Refer to the manufacturer’s
instructions for recommended load test procedure us-
ing a battery tester.
If the battery is defective, replace battery. Reconnect
the battery cables in the correct order of installation
(ground cable last).
If the battery is good, continue in service and go to step
7.
7. If the battery and its connections are good as deter-
mined in step 3, but the starter still won’t crank the
engine, the problem is probably in the starter motor, the
solenoid switch, the starter relay, the ignition switch,
or the wiring.
Check voltage at the starter solenoid S terminal, while
attempting to crank the engine.
Connect the voltmeter between the “switch” terminal
and the frame (body) of the starter motor or the battery
negative terminal, and try to crank the engine.
If voltage is less than 7.0 volts, go to step 8.
If voltage is over than 7.0 volts, go to step 9.
If voltage measured in step 7 is 0 or less than 7 volts,
check for wiring continuity (broken, loose or discon-
nected wire) or defective switches such as the ignition
key switch, starter relay, or neutral start relay. Also,
check the starter motor-to-engine block ground con-
nection and the battery negative (ground) cable con-
nections.
Ifthe voltage measured in step 7 is over 7 volts, the
starter solenoid is defective and must be repaired or
replaced.
NOTE
The ignition switch has a circuit through
the starter relay (magnetic switch) and neu-
tral start switch, separate from the circuit
through the starter relay to the starter so-
lenoid.
Volt Drop Tests
The objective of volt drop tests is to check circuit resis-
tances of wiring and starter motor circuit in order to locate
trouble spots.
Check voltage drops with engine cranking. The procedure
is to look at resistance in terms of the voltage drop across a
portion of the circuit while the engine is being cranked.

NOTE
The following tests assume that the engine
is in good operating condition and the bat-
tery is at or close to full charge.

14-2A-6 l Starter and Battery Troubleshooting SM 598,Oct ‘94

 Main Table of Contents

Group 14, Electrical System

CUIRK
Rule of thumb formula for measuring volt-
age drops: Maximum circuit voltage drop=
0.20 volts per 100 amps.
To check positive post battery terminal connection,
connect voltmeter from the battery post to the terminal
on cable. Crank the engine. A voltage reading above 0
volts indicates a poor connection. Clean the terminal
post and cable end. Tighten bolt.

A! CAUTION
For safety when checking or removing bat-
tery connections, always first disconnect
the negative battery cable at the engine
ground connection. Do not smoke or allow
open flames around batteries.
To prevent engine from starting when
cranking, ground the ignition system. See
“Electrical Checks”, above.

IMPORTANT 2. Check battery negative (ground) cable and connec-

Never operate the starter motor more than tions. To check negative post battery terminal connec-
30 seconds at a time without pausing to tion, connect voltmeter from the battery post to the
allow it to cool for at least 2 minutes. Over- terminal on cable. Crank the engine. A voltage reading
heating caused by excessive cranking will above 0 volts indicates a poor connection. Clean the
seriously damage the starter motor. terminal post and cable end. Tighten bolt.
Crank engine and read voltage.

r’
rum @
1. Check battery positive cable and connections. IGNITION , , 1
SWITCH NEUTRAL STARXR
START RELAY I I
Connect a voltmeter from the positive (+) battery RELAY

terminal to the “Battery” terminal on the starter sole-

noid. With the voltmeter set on its lowest scale, crank
the engine for 15 seconds, and measure the voltage. A
reading higher than 0.4 volts indicates high resistance.
Check the cable for loose connections or the battery
terminal connection for corrosion.
BATTERY

IGNITION -
SWITCH NEmAL STARTER
START RELAY
RELAY

BAllERY

SM 598, Ott ‘94 Starter and Battery Troubleshooting l 14-2A-7

 Main Table of Contents

Group 14, Electrical System CUIRK

To check negative post battery terminal connection,
connect voltmeter from the battery post to the terminal
on cable. Crank the engine. A voltage reading above 0
volts indicates a poor connection. Clean the terminal
post and cable end. Tighten bolt.
5. Check starter ground circuit.
Connect a voltmeter from the frame (body) of the
starter motor, to either a point on the engine flywheel
housing or the bolt that mounts the battery negative
cable to the ground connection on the engine or frame.
While cranking the engine, a reading higher than 0.2
volts indicates excessive resistance. Clean the starter
mounting bolts and flange.

Check key switch, starter relay and solenoid circuit.

Connect a voltmeter across the “Battery” terminal of

the solenoid and the “Switch” terminal of the solenoid.
A voltmeter reading of 1.O-2.0 volts is expected with
the engine cranking. A reading of more than 2 volts BATl-ERY

indicates excessive resistance. Check the wiring, con-

nections, and switches in this portion of the circuit.

Alternate Method. Connect the voltmeter from the

frame of the starter motor, to the battery negative
terminal post. While cranking, a reading higher than
0.4-0.6 volts indicates excessive resistance. Clean
starter mounting flange and bolts, check battery nega-
tive cable for damage, clean and tighten battery cable
connections.
Check the starter solenoid disc contact.

Connect a voltmeter across the solenoid “Battery”

terminal and the solenoid motor terminal. With the
engine cranking, a voltage reading of less than 0.2 volts
should be measured. A reading higher than 0.2 volts
indicates excessive resistance within the solenoid.
Check the solenoid contact disc and terminals.

142A-8 l Starter and Battery Troubleshooting SM 598, Ott ‘94

 Main Table of Contents

Group 14, Electrical System

ClaRK
Section 2B.

Alternator
Troubleshooting

Alternator Maintenance Precautions ........................................................................................... 1

2
Troubleshooting Procedures .........................................................................................................
Abnormal Operation of Charge Indicator Light .............................................................................. 3
Abnormal Operation of Charging System ....................................................................................... 3

Symptoms, Causes, and Remedies ................................................................................................ 3

Do not short across or ground any of the terminals on

Alternator Maintenance Precautions
Disconnect the battery, before connecting or discon-
necting test instruments (except voltmeter) or before
removing or replacing any unit or wiring. Accidental
grounding or shorting at the regulator, alternator, am-
meter or accessories, will cause severe damage to the
units and/or wiring.
the alternator or in the charging circuit, except as
specifically instructed in a troubleshooting procedure.
The alternator must not be operated on open circuit
with the rotor winding energized. Check all terminals
for tight connections.
Be sure the alternator and battery have the same ground
polarity.

NOTE Reversed battery connections may damage the rectifi-

Disconnect the negative (-) battery cable
first.
Always follow the manufacturer’s instructions for the
test instrument being used when making connections
and tests on electrical circuits.
To avoid damage to the regulator, do not at any time,
connect battery to the regulator field terminal.
The field circuit must never be grounded on this sys-
tem, between the alternator and the regulator. Ground-
ing of the field terminal either at the alternator or
regulator will damage the regulator.
Grounding of the alternator output terminal may dam-
age the alternator and/or circuit and components.
If it is necessary to solder any lead to a rectifier lead,
use a pair of pliers as a heat dam between the solder
joint and the rectifier.
Do not attempt to polarize the alternator. No polariza-
tion is required. Any attempt to do so may result in
damage to the alternator, regulator, or circuits.
ers, wiring or other components of the charging sys-
tern. Battery polarity should be checked with a
voltmeter before connecting the battery.
If a booster battery or a fast charger is used, its polar-
ity must be connected correctly to prevent damage to
the electrical system components. Connect positive to
positive, negative to negative. Connect the negative
cable ground connection last (but not to the battery
because an explosion could result).
A CAUTION
SAFE PARKING. Before working on truck:
Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
Put upright in vertical position and fully
lower the forks or attachment,
Put all controls in neutral. Turn key switch
OFF and remove key.
Apply the parking brake and block the
wheels.

SM 598,Oct ‘94 Alternator Troubleshooting l 14-2B-1

 Main Table of Contents

Group 14, Electrical System ClRRK

A basic charging system wiring diagram showing charging

Troubleshooting Procedures circuit connections for gas/LPG/CNG trucks and diesel
trucks are shown below.

NOTE For complete details of truck wiring, refer to the schematics

Following these procedures in the order appearing in Section 1.
presented will lead to the location and cor- Trouble in the charging system will show up as either or
rection of charging system defects in the both of the following conditions:
shortest possible time. Usually only a por-
l Abnormal charge indicator lamp operation.
tion of these procedures will need to be
performed. It will never be necessary to l Abnormal charging system operation.
perform all the procedures in order to lo-
cate the trouble.

BAllERY

STARTING SWITCH

ALTERNATOR
‘\“AL~~~NAT~~ )

OIL
PRESS. WATER TEMP
SWITCH SENDER

Basic GadLPGKNG Charging System Diagram Basic Diesel Charging System Diagram

14-28-2 l Alternator Troubleshooting SM 598,Oct ‘94

 Main Table of Contents
CICIRK
Abnormal Operation of Charge indicator
Light
Check the indicator lamp for normal operation as shown
below.
Ignition Switch Lamp Engine
OFF
OFF STOPPED
ON STOPPED
ON
ON OFF RUNNING
If the (ammeter) charge indicator lamp operates normally,
proceed to “ Abnormal Charging System Operation”. Oth-
erwise, proceed to one of the following three abnormal
conditions.
Switch Off, Lamp On. In this case, disconnect the two
leads from the alternator terminal L and terminal S. If the
lamp stays on, there is a short between these two leads. If
the lamp goes out, remove and repair the alternator rectifier
bridge. This condition will cause an undercharged battery.
Switch On, Lamp Off, Engine Stopped. This condition
can be caused by the defects listed in “Switch Off, Lamp
On” above, or by an open circuit. To determine where a
break exists, proceed as follows:
l Check for a blown fuse, a bad indicator light (refer to
“Instrument Pod Troubleshooting” in Group 13), or a
break in terminal L lead circuit between alternator and
ignition switch.
l If no defects have been found, proceed to “Abnormal
Charging System Operation”.
Switch On, Lamp On, Engine Running. Possible causes
of this condition are covered in “Abnormal Operation of
Charging System.”
If a defect has been found and corrected at this point, no
further checks need be made.
Abnormal Operation of Charging System
Be sure that an undercharged condition (discharged
battery) has not been caused by ignition key switch or
other accessories having been left on for extended
periods.
Check the alternator drive belt for damage and proper
tension.
If a battery defect is suspected, check condition of the
battery.
Inspect the wiring for defects. Check all connections
for tightness and cleanliness, including the connectors
at the alternator and connections at the battery.
SM 598,Oct ‘94
Group 14, Electrical System
With ignition switch ON and all wiring harness leads
connected, connect a voltmeter from:
l Alternator BAT terminal to ground.
l Alternator terminal L to ground.
Alternator terminal S to ground.
l
A zero reading indicates a break between voltmeter
connection and battery. Repair as required.
With all accessories turned off, connect a voltmeter
across the battery. Operate engine at moderate speed
(1500- 1800 r-pm). If voltage is 15.5 volts or more (12-
volt system), remove alternator for repair.
If previous Steps 1 through 6 check satisfactorily,
check alternator as follows:
a. Disconnect battery ground cable.
b. Connect an ammeter in the circuit at the BAT
terminal of the alternator.
C. Reconnect battery ground cable.
d. Connect a carbon pile across the battery. Turn on
all accessories.
e. Disconnect ignition coil. Crank engine for 15
seconds with coil disconnected. Connect coil.
Start engine and operate engine at maximum no-
load governed speed. Adjust carbon pile as re-
quired to obtain maximum current output. Amme-
ter should read within 10 amps of rating.
f. If ampere output is within 10 amps of rated output
as stamped on alternator frame, alternator most
likely is not defective. Recheck Steps 1 through 6.
IMPORTANT
If output in amperes is correct, but charge
indicator lamp stays on, check diode trio
and rectifier bridge.
Symptoms, Causes, and Remedies
Battery Undercharged-Indicator Lamp Remains On
Defective cables, dirty posts, corroded terminals, etc.
Check, clean, repair or replace as needed.
Loose or broken belt. Check belt.
Worn or broken brushes. Replace brush assembly.
Defective alternator system. Repair or replace alter-
nator.
Alternator Troubleshooting l 14-2B-3
 Main Table of Contents

Group 14, Electrical System CICIRK

Battery Undercharged-Indicator Lamp OFF With Key Battery Charges At Idle, But Discharges Under Load
On And Engine Stopped (Normal Condition Is Lamp Conditions
ON) l Slipping belts. Check belts and adjust tension or re-
. Indicator lamp burned out or defective wiring har- place, as necessary.
ness. Check bulb & harness.
l Alternator defective. Repair or replace alternator.
Plug at rear of alternator. Check plug to ensure it is
fully seated.
Indicator Lamp Glows Slightly Under Moderate Load;
Broken brush. Replace brush assembly. Battery Appears Charged
Defective alternator system. Replace regulator. Defective diode trio. Replace diode trio.

Battery Overcharges;
Excessive Use Of Water;
Voltmeter Indicates Greater Than 14.5 Volts
(Connected Across Battery With No Load) With
Engine Idling
l Defective alternator system. Repair or replace regula-
tor.

14-2B-4 l Alternator Troubleshooting SM 598,Oct ‘94

 Main Table of Contents

ClmK Group 14, Electrical

Section 3.

Starter Maintenance and Overhaul

Installation and Removal .............................................................................................................. 2

Bench Tests and Adjustments ....................................................................................................... 3

Pinion Gap Adjustment.. .................................................................................................................. 3
Pull-In Test of Solenoid ................................................................................................................... 3
Hold-in Test of Solenoid.. ................................................................................................................ 3
Return Test of Solenoid ................................................................................................................... 4
No-load Test ..................................................................................................................................... 4

Overhaul ......................................................................................................................................... 5
Disassembly/Assembly .................................................................................................................... 5
Note 1: Removal of Solenoid .................................................................................................. .6
Note 2: Removal of Snap Ring ................................................................................................. 6
Note 3: Removal of Snap Ring/Stop Ring ................................................................................ 6
Note 4: Installation of Stop Ring/Snap Ring ........................................................................... .6
Cleaning of Starter Motor Parts ....................................................................................................... 6

Parts Inspection .............................................................................................................................. 6

Commutator ..................................................................................................................................... 6
Brush Holder .................................................................................................................................... 7
Overrunning Clutch ........................................................................................................................ .7
Font and Rear Bracket Bushings ...................................................................................................... 7
Brush and Spring Replacement ........................................................................................................ 7
Brush ................................................................................................................................................ 7
Armature Tests ................................................................................................................................. 8

SM 598, Ott ‘94 Starter Maintenance and Overhaul l 14-3-1

 Main Table of Contents

Group 14, Electrical ClRRK

NOTE External Inspection
This Section covers installation, overhaul,
1. Inspect the terminals for corrosion and loose connec-
and mounting of the starter for both the
tions.
466 gasoline engine and the S4S diesel en-
gine. 2. Inspect wiring for damaged or worn insulation.
Diesel starter overhaul is covered in the 3. Check mounting bolts for tightness.
Diesel Engine service manual found in
Group 00.
Installation and Removal
A CAUTION
Use the following illustration for removal and replacement
SAFE PARKING. Before working on truck:
of the starter
Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
Put upright in vertical position and fully
lower the forks or attachment.
Put all controls in neutral. Turn key switch
OFT and remove key.
Apply the parking brake and block the
wheels.

Torque to 26 N*m (19.2

ft-lb)

14-3-2 l Starter Maintenance and Overhaul SM 598, Ott ‘94

 Main Table of Contents

CIRRK Group 14, Electrical

Bench Tests and Adjustments Pull-h Test of Solenoid

The pull-in coil is in good condition if the plunger is
pulled in to cause the pinion to move out when a battery is
Pinion Gap Adjustment
connected between the terminals S and M of the solenoid.
1. Disconnect the field coil wire from terminal M of the If the pinion does not move out, replace the solenoid.
solenoid.
2. Connect a 12 V battery between terminal S and starter A CAUTION
motor body (positive terminal to terminal S). The connector must be disconnected from
terminal M for this test. The test must be
Switch finished within ten seconds.

0 0
12v
I

\
Field coil wire Field coil wire

A CAUTION
Hold-in Test of Solenoid
This test must be performed quickly (in
less than ten seconds) to prevent the coil With a battery connected between terminals S and the
from burning out, body of the solenoid, manually pull the pinion up to the
pinion stopper. The hold-in coil is in good condition if the
3. Push the pinion back with a finger and measure the
pinion rer&ins out when it is released.
pinion stroke (the travel along which the pinion is
pushed back). This is the pinion gap.

PPinion
Stopper
Pinion gap

4. If the pinion gap is not up to specification, adjust by

adding or removing fiber washers between the sole-
noid and the front bracket. Using more washers makes
,)__I Field coil wire

the gap smaller.

SM 598, Ott ‘94 Starter Maintenance and Overhaul l 14-3-3

 Main Table of Contents

Group 14, Electrical CIRRK

ReturnTest of Solenoid
With a battery connected between terminals M and the
body of the solenoid, manually pull the pinion up to the
pinion stopper. Both coils are fully operational if the pinion
retums immediately after it is released.

n
! CAUTION
This test must be completed within ten sec-
Ollds.

No-load Test
The starter motor is probably in good condition if it turns
smoothly and steadily when commected to a voltage of
11.5 volts.

144-4 l Starter Maintenance and Overhaul SM 598, Apr ‘96

 Main Table of Contents

CUWK Group 14, Electrical

Overhaul

Disassembly/Assembly
To disassemble the starter, follow the steps below. Reas-
sembly is the opposite of disassembly. Service notes and
inspection are on the following pages.

1. Screw 8. Rear bearing 15. Lever

2. Solenoid (See Note 1) 9. Armature 16. Snap ring (See Notes 2,3,4)
3. Screw 10. Yoke assembly 17. Stop ring (See Notes 3,4)
4. Screw 11. Packing A 18. Overrunning clutch
5. Rear bracket 12. Packing B 19. Internal gear
6. Brush holder 13. Plate 20. Planetary gear holder
7. Brush 14. Planetary gears 2 1. Front bracket

SM 598, Ott ‘94 Starter Maintenance and Overhaul l 14-3-5

 Main Table of Contents

Group 14, Electrical ClmK

Note 4: Installation of Stop Ring/Snap Ring

Note 1: Removal of Solenoid
Using and appropriate tool, pull the stop ring over the snap
Disconnect the field coil wire from terminal M of the
ring.
magnetic switch.

ring
Field coil wire

Note 2: Removal of Snap Ring

Using a thickness gauge, measure the end play in the pinion
shaft for the purpose of reassembly.
Note 3: Removal of Snap RinglStop Ring
1. Using an appropriate size socket, push the stop ring
toward the snap ring.
Stop ring
Cleaning of Starter Motor Parts
. Do not immerse the parts in cleaning solvent. Immer-
sion of the yoke, field coil assembly, or armature in
solvent will cause damage to the insulation. Wipe clean
with a cloth if these parts are dirty.
l Do not immerse the drive unit is cleaning solvent. The
overrunning clutch has been lubricated at the factory
and cleaning with a solvent will remove the lubricant.
. Clean the drive unit using a brush wetted with cleaning
solvent and then wipe dry with a cloth.

Parts Inspection

Commutator
1. Place the armature on a pair of V-blocks and check the
2. Remove the snap ring and then remove the stop ring.
runout using a dial gauge.
Standard value: 0.5 mm (0.02 in)
Limit: 0.1 mm (0.004 in)

14-3-6 l Starter Maintenance and Overhaul SM 598,Oct ‘94

 Main Table of Contents
ClClRK
2. Check the O.D. of the commutator.
Standard value: 32.0 mm (1.28 in)
Limit: 3 1.O mm (1.24 in)
3. Check the depth of the undercut between segments
Standard value: 0.5 mm (0.20 in)
Brush Holder
Check for continuity between the brush holder plate and the
brush holder. There must be no continuity.
SM 598, Ott ‘94
Group 14, Electrical
Overrunning Clutch
1. While holding clutch housing, rotate the pinion. Drive
pinion should rotate smoothly in one direction, but
should not rotate in the opposite direction. If clutch
does not operate correctly, replace the overrunning
clutch assembly.
2. Inspect pinion for wear or burrs. If pinion is worn or
burred, replace overrunning clutch assembly. If pinion
is damaged, also inspect the ring gear for wear or burrs.
Front and Rear Bracket Bushings
Inspect bushings for wear or burrs. If bushings are worn or
burred, replace front bracket assembly or rear bracket as-
sembly.
Brush and Spring Replacement
Brushes that are worn beyond the wear limit line or
soaked with oil should be replaced.
pl El-
I
Wear limitline
When replacing field coil brushes, crush worn brush
with pliers, taking care not to damage the pigtail.
Polish the pigtail end with sandpaper for secure solder-
ing.
Insert the pigtail into the hole of a new brush and
solder. Make sure that there is no excess solder on the
brush surface.
Starter Maintenance and Overhaul l 14-3-7
 Main Table of Contents

Group 14, Electrical CUiRK

Armature Coil Ground Test
New brush
Check insulation between the commutator segments and
Soldered the armature coil core. There should be no continuity.
(Make sure that
there is no excess
solder on brush
surface)

Surface marked A
5. When replacing ground brush, slide the brush from the
brush holder by prying the retaining spring back.

Armature Tests

Armature Coil Short Circuit lest Armature Coil Open-Circuit Check

Set the armature on a growler. Check continuity between segments. There should be con-
tinuity .
IMPORTANT
Clean the armature surface thoroughly be-
fore checking.

Hold a thin steel blade parallel and just above the

armature while rotating it in the growler.

Growler

14-3-8 l Starter Maintenance and Overhaul SM 598,Oct ‘94

 Main Table of Contents

CMRK Group 14, Electrical

Section 4.

Alternator Maintenance and

Overhaul

1
External Inspection ........................................................................................................................

2
Installation and Removal ..............................................................................................................

Overhaul ......................................................................................................................................... 3
Disassembly/Assembly .................................................................................................................... 3
Note 1: Removal of Alternator Pulley ..................................................................................... .4
Note 2: Separation of the Stator and front Bracket.. ................................................................. 4
Note 3: Removal of Stator Assembly/Regulator and Brush Holder.. ....................................... 4
Note 4: Installation of Rotor ..................................................................................................... 4
Inspection ......................................................................................................................................... 5
Rotor ......................................................................................................................................... 5
Stator ......................................................................................................................................... 5
Rectifier .................................................................................................................................... 5

NOTE External Inspection

This section covers installation, overhaul, Inspect the terminals for corrosion and loose connec-
and mounting of the Mitsubishi alternator tions.
for the 4664 gasoline engine. Mounting the
diesel engine alternator is also covered in Inspect wiring for damaged or worn insulation.
thii Section. Check mounting bolts for tightness.

DIESEL ALTERNATOR OVERHAUL is Check the alternator drive belt for wear, correct align-
covered in the Diesel Engine service manual ment and correct tension. For information on tensioning
found in Group 00. belts, refer to “Cooling System and Alternator Belt
Service” in Group 1.
n! CAUTION
SAFE PARKING. Before working on truck: Note
1. Park truck on a hard, level, and solid When servicing the charging system, never
surface, such as a concrete floor with no remove a unit until tests have shown it to
gaps or breaks. be defective.
2. Put upright in vertical position and fully
lower the forks or attachment.
3. Put all controls in neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the
wheels.

SM 598,Oct ‘94 Alternator Maintenance and Overhaul l 14-4-l

 Main Table of Contents

Group 14, Electrical CIRRK

Installation and Removal

LTorque to 20-25
N-m (14.8-l 8.5 ft-
lb).
Typical Installation of Alternator

For information on tensioning belts, refer to “Cooling Sys-

tem and Alternator Belt Service” in Group 1.

14-4-2 l Alternator Maintenance and Overhaul SM 598,Oct ‘94

 Main Table of Contents

CWtK Group 14, Electrical

Overhaul
Disassembly/Assembly

16

I
8

To disassemble the alternator, follow the steps below. Re-

assembly is the opposite of disassembly. Service notes and
inspection procedures begin on the following page.

1. Pulley nut 9. Terminal

2. Alternator Pulley (See Note 1) 10. Plate

3. Rotor Assembly 11. Regulator and Brush Holder

4. Rear Bearing 12. Brush

5. Bearing Retainer 13. Brush Spring

6. Front Bearing 14. Slinger

7. Front Bracket (See Note 2) 15. Rectifier Assembly

8. Stator Assembly (See Note 3) 16. Rear Bracket (See Note 4)

SM 598, Ott ‘94 Alternator Maintenance and Overhaul l 14-4-3

 Main Table of Contents

Group 14, Electrical ClRRK

Note 1: Removal of Alternator Pulley Be careful not to exert excessive force on
With the pulley side facing up, hold the rotor in a vise and the diode leads.
remove the pulley. Solder

A ! CAUTION
Use care not to damage the rotor.

Note 4: Installation of Rotor

Note 2: Separation of the Stator and front Bracket
With screwdriver blade inserted between the front bracket
and stator core, pry to separate the stator from the front
bracket.
Before installing the rotor on the rear bracket, thread a steel
wire through the small hole provided in the rear bracket to
hold back the brush. After rotor installation, remove the
steel wire.

n ! CAUTION
Do not insert the screwdriver too deep as
the stator core could be damaged.

Rear Bracket

Note 3: Removal of Stator Assembly/Regulator and

Brush Holder

1. Remove the solder connecting the stator lead wire to

the main diode of the rectifier when removing the
stator.

2. Remove the solder from soldered connections with the

rectifier when removing the rectifier from the brush
holder.

n ! CAUTION
When soldering connections or when re-
moving solder be careful not to let heat
transfer to the diode for long periods of
time. Finish soldering and removing solder
in as short a time as possible.

14-4-4 ’ Alternator Maintenance and Overhaul SM 598, Ott ‘94

 Main Table of Contents

ClllRK Group 14, Electrical

Inspection 2. Check for coil grounding. Make sure that there is no

continuity between the coil and the core. Replace the
stator assembly if there is continuity.
Rotor
1. Check the rotor coil continuity. Make sure that there is
continuity between the slip rings.
Measure the motor resistance. If it is excessively small,
it indicates a shorted rotor. If there is no continuity or
if it is shorted, replace the rotor assembly.
Standard value: 3-5 0.

Rectifier

Inspection of (+) Heat Sink Assembly. Using a circuit

tester, check continuity between the (+) heat sink and
the stator coil lead connection terminals. If there is
continuity in both directions, the diode is shorted and
the rectifier assembly must be replaced.

2. Check for rotor coil grounding. Make sure that there is

no continuity between the slip ring and the core.
Replace the rotor assembly if there is continuity.

Inspection of (-) Heat Sink Assembly. Using a circuit

tester, check continuity between the (-) heat sink and
the stator coil lead connection terminals. If there is
continuity in both directions, the diode is shorted and
the rectifier assembly must be replaced.
Stator
1. Check the stator continuity. Make sure that there is
continuity between the coil leads. Replace the stator
assembly if there is no continuity.

SM 598,Oct ‘94 Alternator Maintenance and Overhaul l 14-4-5

Main Table of Contents
 Main Table of Contents

GROUP 22

GROUP 22

WHEELS AND TIRES

Wheels and Tires Specifications and Description ........ Section 1

Cushion Wheels and Tires .............................................. Section 2

Pneumatic Wheels and Tires .......................................... Section 3

SM 598,Oct ‘94 Wheels and Tires

 Main Table of Contents
EmK
Section 1 m
Wheels and Tires
Specifications and Description
Specifications
Steer Tire Types: Pneumatic rubber/Cushion rubber, non-
marking, and urethane.
Drive Tire Types: Pneumatic rubber/Cushion rubber, non-
marking, and urethane.
Pneumatic Drive and Steer Tire Inflation Pressure: 861 kPa
(125 psi).
Fastener Torques
Steer Tire Mounting Nut Torques: Check mounting proce-
dure in Sections 2 and 3 for cushion and pneumatic tires
and wheels.
Drive Wheel Mounting Nut Torques:
2 Piece (yellow zinc dichromate) 300-370 Nom (225-275 ft-lb)
1 Piece (black) 640-720 Nom (470-530 ft-lb)
Service Intervals,
Wheel Mounting Bolts Check and Tightening: Every 50-
250 hours of operation and each PM.
Tire Condition: Daily inspection.
Tire Pressure Check: Daily inspection.
SM 598, Feb ‘95 Wheels and Tires Specifications and Description
Group 22, Wheels and Tires
Description
The wheels and tires used on the truck come in pneumatic
or cushion types in a variety of sizes depending on truck
model and application. Pneumatic tires are mounted on
multi-piece rims with locking rings.
A WARNING
For your safety and the safety of others,
before you do tire or rim maintenance or
service, read the OSHA rules regarding
owner responsibility. Do not work on tires
or rims unless you have been trained in the
correct procedures. Read and understand
all maintenance and repair procedures on
tires and rims. Serious injury or death can
result if safety messages are ignored.
The Occupational Safety and Health Act (OSHA) specifies
required procedures for servicing multi-piece rim wheels in
29 CFR Section 1910.177. It is the owner’s responsibility
to comply with OSHA.
In accordance with OSHA, the owner must provide a train-
ing program to train and instruct all employees who service
multi-piece rim wheels in the hazards involved and the
safety procedures to be followed. Do not let anyone mount,
demount, or service multi-piece rim wheels without correct
training.
The owner should obtain and maintain in the service area
current copies of the United States Department of Trans-
portation, National Highway Traffic Safety Administration
publications entitled “Safety Precautions for Mounting and
Demounting Tube-Type Truck/Bus Tires,” and Multi-Piece
Rim/Wheel Matching Chart” or other similar publications
applicable to the types of multi-piece rim wheels being
serviced.
l 22-l-l
 Main Table of Contents

ElaRK Group 22, Wheels and Tires

Section 2.

Cushion Wheels and Tires

General Tire Maintenance and Inspection ... . . . . . . .. . . ....._..__m”“U”U”“__UU__..--. 1

Drive Wheel Removal/Installation “U._..“_“.~_~m”__“I.“~..“~.~~~~~~~””~~~~.”~.” ..- 1

Steer Wheel Removal/Installation _~_____I._~_..._.___.._~..__ -. ... . . .. ... . . . . . . . .... . . 2

Cushion Tire Replacement ..“...~“m.._“.....““.....~...“....”...........~..~...~~........~~“~“...“.......~ .3

n
! CAUTION
SAFE PARKING. Before working on truck:
1. Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
2. Put upright in vertical position and fully
lower the forks or attachment.
3. PutallcontrolsiuneutraLTumkeyswitch
OFF and remove key.
4. Apply the parking brake and block the
wheels.
General Cushion Tire Maintenance and
Inspection
3. Check tire for damage from chunking or heat damage.
This is a judgment requirement for replacement. In
general, if the damage is greater than 12 mm (0.5 in)
deep and involves more than a 50 x 50 mm (2 x 2 in)
area, it will usually affect the tire performance and the
tire should be replaced.
Drive Wheel Removal/Installation
Removal
1. Loosen lug nuts then use a portable jack of correct
capacity placed under tbe frame of truck to raise drive
wheel off floor. See “Lifting, Jacking, and Blocking”
in Group SA for correct, safe procedures for jacking
the truck.

1. Inspect cushion tires and remove objects (nails, metal 2. Remove lug nuts and lift the tire and wheel assembly
fragments, etc.) embedded in the tread of the tire. Be from drive axle hub.
careful notto cause further damage to tire whenremov- Drive
ing these objects. , - \

2. Check tire for separation from the base band. If a thin

steel rule or similar tool can be inserted more than 12
mm (S in) into the separation area from the side of the
tire, the tire should be replaced.

The and Wheel

j- Assembly

SM 594, Feb ‘95 Cushion Wheels and Tires l 22-2-l

 Main Table of Contents

Group 22, Wheels and Tires CIRRIC

3. Clean the excess grease from around wheel nut. Re-
Installation move cotter pin from wheel nut.
1i Install wheel and tire assembly on drive axle hub. 4. Loosen and remove O-ring, wheel nut, and washer.
Begin tightening the lug nuts to seat the nuts in the
beveled wheel openings. 5. Pull out on wheel hub slightly to loosen bearing, then
2. Use a crisscrossing nut-tightening sequence to remove outer bearing. Store in clean place.
torque the lug nuts to a prefinal torque of 54-8 1 6. Carefully remove wheel assembly from axle spindle.
Nom (40-60 R-lb). Support the wheel hub to avoid dragging the grease
seal at the back side across the thread on spindle end.

Inner
Grease
Seal

3. Beginthecrisscrossingsequenceagainandtorque
the black lug nuts to 640-729 Nom (470-530 ft-lb).
4. If your truck is equipped with yellow zinc dichro-
mate 2 piece lug nuts the crisscrossing torque
sequenceshouldbe300-370N.m (225-275 ft-lb).
7. If no other maintenance is to be done on wheel bear-
IMPORTANT ings, cover the wheel hub to protect the grease seal and
Do not overtorque the lug nuts. Damage to inner bearing from contamination during tire replace-
the lug nuts, wheel, or drive-axle hub may ment.
result.

5. Lower truck to floor and remove jack. Installation

1. Make sure the truck is safely supported on a suitable
Steer Wheel Removal/Installation jack or blocking.

Removal
1. Parkthetrucksafelyanduseajackofsuitablecapacity
placed under the frame of truck to lift steer wheel off
the floor as described in “Lifting, Jacking, and Block-
ing” in Group SA.
2. Remove hub cap by prying it from wheel hub.
2. Be sure axle spindle is clean and that wheel hub inside
and bearings are clean and have been serviced and
lubricated (packed correctly) before installation.
NOTE
Refer to‘ Group 26,. “Steer Axle”, for addi-
tional information on removing and servic-
ing steer wheels and bearings.

Wheel Nut 3. Install wheel on spindle. Be careful not to damage seal

and Cotter lip when moving the hub over the end of spindle and
Pin threads.
O-Ring
Seal
7

Washer Hub Cap

22-2-2 l Cushion Wheels and Tires SM 598, Feb ‘95

 Main Table of Contents

CIRRU Group 22, Wheels and Tires

4. Install outer bearing after packing bearing cavity one- CushionTire Replacement
half full with proper grease.

n! CAUTION
Replacement of the original equipment tires
with tires other than those recommended
by CLARK may result in decreased oper-
ating performance and stability.

The correct procedure for tire removal and replace-

ment requires a suitable press for pressing old tire off
wheel and pressing new tire onto wheel.
5. Install bearing washer and wheel nut and hand tighten
IMPORTANT
wheel nut.
Cushion tires cannot be reused after once
being pressed on and removed from the
wheel. The correct press fit is destroyed
after one installation and removal. Replace
with new tire.

Position tire on press, making sure there is adequate

clearance for the tire to be pressed off of wheel.

Use suitable tooling with the hydraulic press to cor-

6. While rotating wheel (hub) counter clockwise, torque
the wheel nut to 27-31 Nom (20-23 &lb).
7. Back the wheel nut up until it is loose.
8. While turning the wheel counter clockwise, torque the
wheel nut to 2.3-2.8 Nom (20-24 in-lb; 1.7-2 ft-lb).
rectly contact the base band of tire to press it off the
wheel.
Install new tire. Mount all tires with identification and
type markings toward outside of wheel. Tire is to be
pressed on wheel with the outer edges flush.

9. Back wheel nut off to nearest slot in nut and lock with
new cotter pin. Bend tabs on cotter pin.

10. Recheck for correct bearing adjustment by rotating the

wheel by hand. Wheel should rotate freely or with only
slight “drag.” Readjust bearings, as necessary. Adjust
torque on wheel nut as necessary to avoid binding in
bearings.

12. Pack the area around wheel nut with grease.

13. Replace the O-ring and install hubcap by tapping into

place with a tubber or plastic-faced hammer.

14. Lower truck to floor and remove jack.

SM 594,Oct ‘94 Cushion Wheels and Tires l 22-2-3

 Main Table of Contents

GIlMU Group 22, Wheels and Tires

Section 3.

Pneumatic Wheels and Tires

Pneumatic Tire Maintenance Precautions ..........................“....................................................... 2

General Tire Maintenance, Inspection, and Repair ................................................................... 3

Inspection and Minor Repair ........................................................................................................... 3

Wheel Dismounting and Remounting .......................................................................................... 4

Drive and Steer Wheel Dismounting ............................................................................................... 4
Drive and Steer Wheel Remounting ................................................................................................ 4
Dual Drive Wheel Dismounting ...................................................................................................... 5
Dual Drive Wheel Remounting ....................................................................................................... 5

Wheel Disassembly and Tire Removal ....................~....~............................................................. 6

Tire Replacement and Wheel Reassembly .......................................... ..” .................................... 8

Tire-to-Wheel Mounting .................................................................................................................. 9
Filling Tires with Air ..................................................................................................................... 10
Filling Tires with Nitrogen ............................................................................................................ 10
Checking and Adjusting Tire Pressure .......................................................................................... 11

SM 598,Oct ‘94 Pneumatic Wheels and Tires l 22-3-l

 Main Table of Contents
Group 22, Wheels and Tires
A CAUTION
SAFE PARKING. Before working on truck:
Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
Put upright in vertical position and fully
lower the forks or attachment.
Put all controls in neutral. Turn key switch
OFF and remove key.
Apply the parking brake and block the
wheels.
PneumaticTire Maintenance
Precaution
The following instructions supplement the OSHA require-
ments. In the event of any conflict or inconsistency be-
tween these instructions and the OSHA requirements, the
OSHA requirements shall be controlling.
A
WARNING
Before you do tire or rim maintenance,
read the OSHA rules regarding owner re-
sponsibility. Read and understand all main-
tenance and repair procedures on tires and
rims. Do not work on tires or rims unless
you have been trained in the correct proce-
dures. Serious injury or death can result if
the safety messages are ignored.
1. Do not let anyone mount or demount tires without
proper training.
2. Never sit on or stand in front of a tire and rim assembly
that is being filled with air. Use a clipon chuck and
make sure the hose is long enough to permit the person
filling the tire with airto stand to the side of the tire, not
in front or in back of the tire assembly.
3. Never operate a vehicle on only one tire of a dual
assembly. The carrying capacity of the single tire and
rim is dangerously exceeded, and operating a vehicle
in this manner can result in damage to the rim and truck
tip-over and driver injury.
4. Do not fill a tire with air that has been run flat without
first inspecting the tire, rim, and wheel assembly.
Double check the lock ring for damage. Make sure that
it is secure in the gutter before filling the tire with air.
5. Always remove all air from a single tire and from both
tires of a dual assembly prior to removing any rim
components, or any wheel components, such as nuts
and rim clamps. Always remove the valve core to
remove air from tire. Be sure all air is removed.
22-3-2 l Pneumatic Wheels and Tires
CUIRK
6. Check rim components periodically for fatigue cracks.
Replace all cracked, badly worn, damaged, and se-
verely rusted components.
7. Do not, under any circumstances, attempt to rework,
weld, heat, or braze any rim components that are
cracked, broken, or damaged. Replace with new parts
or parts that are not damaged, which are of the same
size, type, and make.
8. Never attempt to weld on an inflated tire/rim assembly.
9. Clean rims and repaint to stop detrimental effects of
corrosion. Be very careful to clean all dirt and rust
from the lock ring gutter. This is important to secure
the lock ring in its proper position.
A filter on the air filling equipment to remove the
moisture from the air line prevents a lot of corrosion.
The filter should be checked periodically to make sure
it is working properly.
10. Make sure correct parts are being assembled. Ask your
distributor or the manufacturer if you have any doubts.
11. Do not be careless or take chances. If you are not sure
about thepropermating of rim and wheel parts, consult
a wheel and rim expert This may be the tire man who
is servicing your fleet, the rim and wheel distributor in
your area, or the CLARK dealer.
12. Mixing parts of one manufacturer’s rims with those of
another is potentially dangerous. Always ask manu-
facturer for approval.
13. Do not use undersized rims. Use the right rims for the
job.
14. Do not overload rims. Ask your rim manufacturer if
special operating conditions are required.
15. Do not seat rings by hitting with a hammer while the
tire is filled with air pressure. Do not hit a filled or
partially-filled tire/rim assembly with a hammer.
16. Double check to make sure all the components are
properly seated prior to filling tire with air.
17. Have the tire in a safety cage when filling with air.
18. When removing wheels, regardless of how hard or
firm the ground appears, put hardwood blocks under
the jack.
19. Block the tire and wheel on the other side of the
vehicle, before you place the jack in position. Place
blocks under the truck frame as near as possible to the
jack to prevent the truck from falling if the jack should
fail.
20. Remove the bead seat band slowly to prevent it from
dropping off and crushing your toes. Support the band
on your thigh and roll it slowly to the ground. This will
protect your back and feet.
SM 598,Oct ‘94
 Main Table of Contents

elfIRK Group 22, Wheels and Tires

21. Beadbreakersandramsapplypressuretobeadflanges.
Keep your fingers away from the bead flanges. Slant
bead breaker about IO0to keep it firmly in place. If it
slips off, it can fly with enough force to kill. Always
stand to one side when you apply hydraulic pressure.
2. Check the condition of the drive and steer wheels and
tires. Remove objects that are imbedded in the tread.
Inspect the tires for excessive wear, cutsand breaks.

General Tire Maintenance, Inspection,

and Repair
1. Park the truck as described in “Safe Parking” and
check for correct tire inflation air pressure.
l Drive 861 kPa (125 psi)
l Steer 861 kPa (125 psi all models).

n ! CAUTION
Check tire pressure from a position facing the
tread of the tire, not the side. Use a long-
handled gauge to keep your body away from
the side.
Check all wheel lug nuts or bolts to be sure none are
loose or missing. Have missing bolts replaced and
loose bolts tightened to the correct torque before oper-
ating the truck.
Torque pneumatic steer tires to 221-252 Nom (163.7-
186.6 ft-lb).
Torque 1 piece black lug nuts for pneumatic drive tires
to 640-720 Nom (470-530, f&lb&
Torque 2 piece yellow zinc dichromate lug nuts for
pneumatic drive tires to 300-370 Nom (225-275 f&lb).
Torque 1 piece black lug nuq for pneumatic dual-drive
tires to 640-720 N*m (470-530 ft-lb).

L Torque 2 piece yellow zinc dichromate lug nuts for

pneumatic dual-drive tires to 300-370 Nom (225-275
ft-lb).

l If tires are low, do not add air. Have the tire and Inspection and Minor Repair
wheel inspected by a person trained and autho-
Inspect pneumatic tires and wheels carefully for:
rized to do tire and wheel maintenance. The tire
may require removal and repair. 1. Low inflation pressure.
l Incorrect (low) tire pressure can reduce the
2. Damaged tires. Check tires for cuts and breaks.
stability of a lift truck and cause it to tip over.
3. Damaged wheels or loosening of the lock ring on
IMPORTANT
multi-piece rims.
Check wheels ahd tires for damage every
time you check tire pressure. Make re-
pairs when needed. Dirt can get into cuts
and cause damage to the tire cord and tread.
Remove debris from all cuts.

Wheel
Wedge

Lock
Ring

SM 598, Feb ‘95 Pneumatic Wheelsand Tires l 22-3-3

 Main Table of Contents
Group 22, Wheels and Tires.
4. Check for loose nuts or bolts not in position.
5. Check the nuts or bolts for damage.
6. Check the surface of the wheels for bent flanges.
7. Check all parts for rust or corrosion.
8. Markthedamagedareaswithchalksothattheparts
can be removed from operation.
9. Remove all parts that are damaged and install new
parts in the same p&ition.
10. Replace parts with the correct sizes and types. See
your parts manual.
11. Include your truck serial number when ordering re-
placement parts.
Wheel Dismounting and Remounting
Refer to “Lifting, Jacking, and Blocking” in Group SA for
information on jacking up or raising the truck for wheel
removal. Always start with the truck parked safely.
Drive and Steer Wheel Dismounting
1. Remove the valve core from the valve stem to be sure
all air is removed from the tire.
2. Loos,en the five lug nuts on the wheel.
Steer Axle Hub
22-3-4 9 Pneumatic Wheels and Tires
CmK
L Drhre
Axle
Hub
3. Use a portable jack of adequate capacity placed under
the frame of truck to raise drive or steer wheels off
floor.
4. Once tire is off the g-round enough to rotate freely,
remove the lug nuts and lift the wheel from the hub.
Use caution when lifting tire and wheel.
Drive and Steer Wheel Remounting
IMPORTANT
See “Tire Installation” in this Section to
make sure the wheel and tire mounting
orientation is correct. Check the informa-
tion for correct tire-to-wheel mounting and
wheel-to-hub mounting.
1. Makesuretheauckisparkedonaflat,hardsurfaceand
the jacking and blocking devices are secure to hold the
truck in a safe position.
2. Inspecttheremovedlugnutsfordamagetothethreads.
Also inspect all hub studs for thread damage. Replace
any lug nuts or studs that have damaged threads. Make
sure studs are secure in the axle hub.
Steer
Axle
Hub
Lug
Nuts
SM 598, Feb ‘95
 Main Table of Contents
clfllw
3. Set the wheel on the hub and start the lug nuts on the
hub studs. Tighten the nuts only enough to seat the nuts
into the beveled openings on the wheel and to secure
the wheel on the axle hub.
4. Use a crisscrossing nut tightening sequence to torque
the nuts to a pre-final torque of 54-81 Nom (40-60 ft-
lb). Make sure all nuts seat into beveled spacer holes
correctly.
L 2 Piece-
5. Begin the crisscrossing sequence again and tighten the
lug nuts to final torque.
l Torque drive wheel 1 piece lug nuts to 640-720
Nom (470-530 ft-lb).
l Torque drive wheel 2 piece lug nuts to 300-370
Nom (225-275 ft-lb).
l Torquesteerwheellugnutsto221-252N*m(163-
186 f&lb).
6. Carefully lower the truck and remove the jack.
7. Check tire pressure for correct inflation pressure.
l Drive wheel pressure is 861 kPa (125 psi).
l Steer wheel pressure is 861 kPa (125 psi).
Dual-Drive Wheel Remounting
A WARNING
If tires are not fully inflated, see “Adding
Air Pressure To Mounted Wheel/Tire As-
semblies” and follow the procedures for
adding air to the mounted tires.
Before you add air pressure to the tire,
make sure the lock ring is correctly posi-
tioned in the rim and side ring. The lock
ring can separate from the rim with enough
force to cause injury or death.
Dual-Drive Wheel Dismounting
1. Remove the valve core from the valve stem of the outer
wheel to be sure all air is removed from the tire.
SM 598, Feb ‘95
Group 22, Wheels and Tires
2. Loosen the five lug nuts on the wheel.
Shoulder 7
Wheel
Lug Nut
3. Useaportablejackofcorxctcapacityplacedunderthe
frame of truck to raise drive wheels off floor..
4. Remove the five outer-wheel lug nuts and remove the
outer wheel and tire from the dual-wheel spacer studs.
5. Removethevalvecorefromthevalvestem oftheinner
wheel to be sure all air is removed from the tire.
6. Remove the five lug nuts securing the inner wheel to
the dual-wheel spacer.
7. Remove the dual-wheel spacer and retain the wheel-
mounting washers on the dual-wheel shoulder studs
installed on the drive-axle hub.
8. Remove the tire and wheel from the drive-axle hub.
Use caution when lifting wheel and tire assembly
IMPORTANT
See ‘Tire Installation” in this Section to
make sure the wheel and tire mounting
orientation is correct. Check the informa-
tion for correct tire-to-wheel mounting and
wheel-to-hub mounting.
1. Makesurethetruckisparkedonaflat,hardsurfaceand
the jacking and blocking devices are secure to hold the
truck in a safe position.
2. Inspect the lug nuts for damage to the threads. Also
inspect all studs for thread damage. Replace any lug
nuts or studs that have damaged threads. Make sure
studs are secure in the drive-axle hub and the dual-
wheel spacer.
PneumaticWheels and Tires l 22-3-5
 Main Table of Contents

Group 22, Wheels and Tires ClRRK

3. Install inner wheel and tire assembly on drive-axle hub 12. Check tire pressure for correct inflation pressure:
shoulder studs. l Drive wheel pressure is 861 kPa (125 psi).
4. Install five wheel-mounting washers on the shoulder
Studs.
A WARNING
If tire are not fully inflated, see ‘Adding
5. Mount the dual-wheel spacer on the shoulder studs.
Air Pressure To Mounted Wheel/Tire As-
6. Set the lug nuts on the shoulder studs and tighten the
semblies” and follow the procedures for
nuts only enough to seat the nuts into the beveled
adding air to the mounted tires.
openings on the spacer and to secure the wheel on the
spacer and drive-axle hub. Before you add air pressure to the tire,
make sure the lock ring is correctly posi-
7. Use a crisscrossing nut tightening sequence to torque
tioned in the rim and side ring. The lock
the nuts to a pre-fina torque of 54-8 1 N*m (40-60 ft-
ring can separate from the rim with enough
lb). Make sum all nuts are seating into beveled spacer
force to cause injury or death.
holes correctly.

Wheel Disassembly and Tire Removal

1. Remove valve core from the valve stem to be sure all
air is removed.

A WARNING
Before starting disassembly, remove the air
from the tire. Failure to remove the air
from the tire can result in serious injury.

2. Remove lock ring.

8. Begin the crisscrossing sequence again and torque the Wheel

black lug nuts to 640-720 Nom (470-530 ft-lb). Wedge
9. If your truck is equipped with yellow zinc dichromate
2 piece lug nuts the crisscrossing torque sequence
should be 300-370 Nom (225-275 ft-lb).
10. Mount the outer wheel on the studs of the dual-wheel
spacer and tighten the nuts only enough to seat the nuts
into the beveled openings on the spacer and to secure
the wheel on the spacer and drive-axle hub.
3. Remove wheel wedge.
11. Use a crisscrossing nut tightening sequence to torque
the nuts to a pm-final torque of 54-8 1 Nom (40-60 ft- 4. Remove tire from wheel.
lb). Make sure all nuts are seating into beveled spacer
holes correctly. See illustration above.
12. Begin the crisscrossing sequence again and torque the
lug nuts as described in step 8 and 9
NOTICE
The outside diameter of the left or right
wheel or set of wheels must not differ more
than 6 mm (25 in) per side.

22-3-6 . Pneumatic Wheels and Tires SM 598, Feb ‘95

 Main Table of Contents

EIRRK Group 22, Wheels and Tires

5. Remove the rubber inner tube protector (flap). 11. Clean the wheels. Remove rust and dirt.
12. Clean the tire bead seat area. Remove all rust and
rubber with a wire brush or wheel.

6. Repair tire and/or tube, as needed.

7. Check for cracks in the wheel.

13. Clean wedge and lock rings. Make sure the seating
surface and bead seat areas are clean.

Cracks in the wheel are caused by:

l Deep rim tool marks.
l Overload on wheels. 14. Apply paint to the tire rim with a brush. Or, use an
l Too much air pressure in the tires. aerosol can of metal primer.
l Using the wrong size tires. The parts must be clean and dry before you apply the
paint. Make sure to apply paint to the outside or tire
8. Check for cracks in the lock ring.
side of the rim. This is important because air is on the
9. Check for cracks between the stud holes in the wheel. metal surface of the tire side of the rim.
Cracks are caused by:
15. Apply lubricant on the tire side of the rim base. Do not
l Loose wheel nuts.
use a lubricant that has water or solvent which will
l Wheel not installed correctly. cause damage to the rubber.
l Wrong size or type of parts used.
NOTE
l Too much torque on the wheel fasteners. If the Clark dealers can supply the correct lubri-
wheel mounting parts are too tight, the studs or cant, which contains a rust inhibitor.
bolts can break, causing cracks in the wheel be-
tween the stud holes.
l Too little torque on the wheel fasteners. If the
wheel mounting parts are too loose, damage to
parts and tire wear will result.
10. Check wedge ring for wear or damage. Corrosion
buildup will cause wear and damage to the wheel
wedge ring.

SM 598,Oct ‘94 Pneumatic Wheels and Tires l 22-3-7

 Main Table of Contents

Group 22, Wheels and Tires emu

Tire Replacement and Wheel 5. Install the wheel wedge.

Reassembly
1. Put the tube into the tire.

6. Put the side ring over the rim and install the lock ring
as shown.
IMPORTANT
Install washer 22.123 on tube over valve
stem before flap is installed, when speci-
fied. See sketch. Refer to Service Parts
List.

2. Put the rubber tube protector (flap) over the tube.

3. Install the tire onto the wheel rim, against the bead seat 7. Connect air chuck and turn the tire over with the valve
area. stem down. Put 21 kPa (3 psi) of air into the tire.

8. Turn wheel to the other side. Check to make sure lock

ring is in correct location.
4. Put the wheel wedge over the rim.

22-3-8 l Pneumatic Wheels and Tires SM 598,Oct ‘94

 Main Table of Contents

CIRRK Group 22, Wheels and Tires

9. Disconnect the air chuck. Use a mallet and hit the ring Directional-Tread Single Drive Tires
to make sure the ring is fully installed. . Tire arrow to point in the direction of forward rotation.
Rotate wheel to bring arrow on tire above the wheel
center. Arrow must point toward front of truck.

10. Put the tire in an OSHA-approved safety cage.

FRONT OF TRUCK

Directional- Tread Dual Tires

1. Inside dual tire arrow to point in the direction of
forward rotation. Rotate wheel to bring arrow on tire
above the wheel center. Arrow must point toward front
of truck.

Tire-to-WheelMounting

Directional-TreadTires
All directional-tread tires are to be mounted in the correct
position with respect to the arrow cast on the side of the tire
as explained below.
FRONT OF TRUCK
2. Outside dual tire arrow to point in the direction of
rearward rotation. Rotate wheel to bring arrow on tire
above the wheel center. Arrow should point toward
rear of truck.

SM 598,Oct ‘94 Pneumatic Wheels and Tires . 22-3-9

 Main Table of Contents

Group 22, Wheels and Tires ClflRK

FillingTires with Air 2. Turn the regulator valve counterclockwise (CCW)
until you can feel no resistance from the regulator.
Follow these procedures when putting air into tires. All This will adjust the regulator pressure to a low pressure
wheel and tire assemblies must be filled in a safety cage. near zero.
The hose must have an adapter that can be connected to the
valve stem.
Attach an air hose to valve stem.
Open the control valve which will let compressed air
into the tire.
At intervals, close the control valve and check the
pressure in the tire by reading the gauge. Do not put too
much pressure into the tire.
Continue to fill the tire to the correct air pressure
reading of 861 kPa (125 psi).
3. Slowlyturnthecylindervalvecounterclockwise(CCW)
IMPORTANT
to open position.
Put equal pressure in both tires of a dual
assembly. Do not put air into a tire that is
flat without first inspecting it and the wheel
for damage.

FillingTires with Nitrogen

If your air supply does not have enough pressure to fill the
tire, you can use a pressurized cylinder of commercial
nitrogen gas to get the correct tire pressure. With the tire in
a safety cage, connect the nitrogen cylinder to the valve
stem with the use of an air chuck. 4. The tank gauge will now show tank pressure.

A WARNING
Use nitrogen only. Do not use oxygen or
any other gas to fill tires. Make sure alI
items of equipment used (nitrogen cylin-
der, regulator, gauges, hoses) are UL ap-
proved and in good condition. Use the
correct regulator and hose for the pres-
sures that are necessary.

1. Be sure tank valve is closed to connect hose to valve

stem. Tank valve is closed by turning handle on top of 5. Turn the regulator valve clockwise (CW) until the
tank clockwise to a stop. regulator gauge reads the correct tire pressure. Fill the
tire with nitrogen.

22-3-l 0 l Pneumatic Wheels and Tires SM 599,Oct ‘94

 Main Table of Contents

CIRRK Group 22, Wheels and Tires

6. Turn the tank valve clockwise (CW) and close the Checking and Adjusting Tire Pressure
valve.

A WARNING
Before you add air pressure to the tire,
make sure the lock ring is correctly posi-
tioned in the rim and wheel wedge. The
lock ring can separate from the rim with
enough force to cause injury or death.

7. Disconnect the air chuck from the valve stem.

1. Attach a clip-on air chuck to valve stem. Stand by the

side of the wheel and put the correct air pressure in the
tire.

8. Turn the regulator valve counterclockwise (CCW) to

the off position.

2. If your air supply does not have enough pressure to fill

the tire, you can use a nitrogen cylinder to get the
correct pressure.

9. Use a tire pressure gauge to check the tire pressure. If

necessary, put more air into the tire. Do this as many
times as necessary to reach the correct tire pressure.

n ! CAUTION 3. Put a clip-on type air chuck on the nitrogen cylinder

Use a long-handled gauge so that your hand
hose and attach it to the valve stem. Follow the
does not go inside the cage, or in front of
procedures described previously for adjustment of the
any component of a multi-piece wheel.
nitrogen cylinder valves.

A WARNING
Use nitrogen only. Do not use oxygen or
any other gas to fill tires.

SM 598,Oct ‘94 Pneumatic Wheels and Tires l 22-3-l 1

 Main Table of Contents

GROUP 23(H)

GROUP 23(H)

BRAKE/INCHING SYSTEM

(FOR HYDROSTATIC TRANSMISSION)

NOTE
On the hydrostatic truck, braking and inching are accomplished prima-
rily by the hydrostatic drive pump and control system. The hydrostatic
system is covered in Group 06(H), “Hydrostatic Transmission.” Hydro-
static trucks also have a conventional friction brake that can be used for
stopping on inclines or for inching. This Group, 23(H), covers the fric-
tion brake service procedures.

Brake/Inching System
Specifications and Description ................................. Section 1

Service Brake Troubleshooting ......................... ............. Section 2

Brake/Inching Pedals, Linkages, and Adjustments ..... Section 3

Brake Bleeding ................................................... ........... .. Section 4

Master Cylinder Overhaul .............. ............................... Section 5

Service Brake Adjustment and Overhaul ..................... Section 6

Parking Brake Service .................................................... Section 7

SM598, Dee ‘94 Brake/InchingSystem (HydrostaticTransmission)

 Main Table of Contents

cmm Group 23(H), Brake/Inching System (Hydrostatic Transmission)

Section 1.

Brake/Inching System
Specifications and Description

NOTE
On the hydrostatic truck, braking and inching are accomplished prima-
rily through the hydrostatic drive pump and control system. The hydro-
static system is covered in Group 06(H), “Hydrostatic Transmission.”
Hydrostatic trucks also have a conventional friction brake that can be
used for stopping the truck on an incline or for inching. This Group,
23(H), covers the friction brake service procedures.

NOTE
STANDARD TRANSAXLE TRUCK. The brake system for the stan-
dard transaxle truck is covered in Group 23(S).

Specifications

Service Brake: Parking Brake:

Type: Drum and shoe. Manual brake. Self-adjusting.
Fluid: Fluid provided by main hydraulic pump.
Shoe-to-Drum Gap: 0.45-0.60 mm (.017-.024 in)
Shoe Lining Thickness: 1.0 mm ( 0.039 in) minimum.
Drum Thickness: 20.6 mm (0.787 inch) minimum.
Maximum Rebore Diameter: 303 mm (11.92 in).
Pedal Freeplay: 25 .Omm ( 1.OOin)
Star Wheel Adjustment Gap: OS-O.6 mm (0.020-0.023 in)
Type: Ratchet linked to service brake shoe at each wheel.
Holding Test: Rated load on 15% grade.
Inching:
Brake/inching pedals can be used to “inch” the truck, but
the preferred procedure is to use the hydrostatic control.
Inching Pedal Overlap Adjustment (Trucks with Inching
and Braking Pedals): No overlap allowed.

SM 598, Dee ‘94 Brake/InchingSystem Specifications& Description l 23(H)-1-l

 Main Table of Contents

Group 23(H), Brake/Inching System (Hydrostatic Transmission) cmw

General Description Brake/Inching Operation

Thebrakinglimhing qvem consists of the:
Service brake assembly-The chums.shoes, and wheel cylin-
ders.
Brake Master Cylinder-This is a conventional master cyl-
inder with no reservoir. Hydraulic fluid is fed to the master
cylinder from the steering system return line.
Service brake pedal and linkage-A mechanical linkage
operates the brake master cylinder. The service brake also
operates a sensor that sends a signal to the hydrostatic control
system computer.
“Inching” Pedal-This pedal simply operates the service brake
pedal and is not present on “two-pedal*” trucks.
When the operator releases the accelerator or applies the
brake pedal, sensors signal these actions to the computer.
The computer responds by “destroking” the hydrostatic
drive pump (reducing pump output). which hydrostatically
slows the truck. [See Group 06(H) for details about the
hydrostatic system.]
Also, when the operator depresses the brake pedal past the
freeplay zone, the brake link operates the master cylinder.
which forces hydraulic fluid into the wheel cylinders. ex-
tending pistons that apply the brake shoes against the drums.
Upon release of the brake pedal, springs return the wheel
cylinder pistons to their normal positions and fluid is forced
back into the master cylinder.

Parking brake pedal-Operates the servicebrake shoes via To inch the truck, in the preferred manner, the operator
cables. See “Parking Brake Adjustment,” in this Group, for operates the lift. tilt. or aux lever. A sensor signals the
details. position of the operated lever to the computer, and the
“Inching” Pedal Service computer responds by increasing engine rpm and lift pump
(not on two-pedal Brake Pedal output. Meanwhile. the computer varies hydrostatic drive
truck) and Sensor pump output to maintain the travel speed the operator
Parking selects with the accelerator pedal.

q____ ______q To inch the truck with the brake or inching pedal. the
operator depresses the brake pedal, which operates a sen-
I
: I sor that signals the computer to “destroke” the drive pump
I

I- -
L -l Brake (reduce pump output). Meanwhile, the operator depresses
I
I Master the accelerator to increase engine rpm and lift pump out-
I
I Steering Cylinder put.
I
Valve
r-l Service Requirements
Operational checks and inspection of linkages, brake shoes.
and brake lines are specified in the Periodic Service Chart
in Group PS.
Service brake linkage adjustment and lube are not nor-
mally required.
Sump
Brake shoes are self-adjusting and normally require ad-
justment only at initial installation.
A leaking brake cylinder should be overhauled or replaced.
The parking brake should be adjusted if indicated by the
operational check.

Brake
Assemblies
-i-:
:
I
I
I
I
1
:.
I._
.-____--____________~__~~~__________~~____~~_-__________ i *“Two-pedal” trucks have a left-foot pedal for con-
trolling reverse speed, and a right-foot pedal for
________________. Mechanical Linkage controlling forward speed. Two-pedal trucks also
Hydraulic Line have a service brake pedal.

23(H)-1 -2 . Brake/Inching System Specifications & Description SM 598, Dee ‘94

 Main Table of Contents

Cmm Group23(H), Brake/Inching System (Hydrostatic Transmission)

Section 2.

Service Brake
Troubleshooting

Causes/Corrective
Condition Actions*
Brake pedal drops to floor .................................................................................................... BDF

Brake pedal spongy .............................................................................................................. BC

Brake pedal drifts ................................................................................................................. E

Brakes stick. drag excessively, make noise, or overheat ..................................................... FI

Insufficient stopping power: excessive effort required ....................................................... FBCEHG

“Inching” pedal does not apply brake at right time ............................................................. A D

Applying brake or “inching” pedal does not “destroke” pump ........................................... G

*Causes/Corrective Actions

A. Overlap adjustment incorrect... Adjust.

B. External leak in wheel cylinder or other component of braking system... Inspect/replace/repair.

C. Air in braking system... Bleed and recheck.
D. Linkage mis-adjusted or broken. Return spring damaged... Inspect/repair.

E. Internal leak in master cylinder or wheel cylinder.

F. Shoe linings worn or brakes mis-adjusted... Inspect/repair/adjust.

G. Control system failure... See Group 06(H) troubleshooting.

H. Shoe linings glazed, oily, or contaminated with other substance... Replace or clean.

I. Parking brake mis-adjusted... Adjust.

SM 598, Dee ‘94 Service Brake Troubleshooting l 23(H)-2-l

 Main Table of Contents

Ewm Group 23(H), Brake/Inching System (Hydrostatic Transmission)

Section 3.

Brake/Inching Pedals, Linkages,

and Adjustments

Pedal Height Adjustment ............ ..“.....................................................” ....................................... 2

Overlap Adjustment ......... .._.“.....“...“......................”........................~.........................” ............. 2

Freepiay Adjustment ......... ..W....“........_“.~.................................................“............~.....~....._ ... 3.

Linkage and Sensor Installation “~U.~..m..............~.~..~......~~.~.......~.-....~...-....-....“.......~ .... 4

Hydrostatic trucks have a single accelerator pedal design, a
Unitrol pedal design, or a “two-pedal*” design.
Trucks with the single accelerator or Unitrol have two
brake pedals, one of which can be considered the “inching”
pedal, although both pedals have exactly the same function.
The “inching” pedal simply operates the brake pedal. Ei-
ther pedal can be used to inch or stop the truck, but the
preferred method is to simply operate the lift, tilt, or aux
lever and the accelerator pedal, letting the computer control
engine ‘pm, travel speed, and lift pump output.
Trucks with the two-pedal design have a single brake pedal.
Figures 1,2, and 3 on the following pages show:
l The service brake linkage (all Figures), which links the
brake pedal to the brake master cylinder.
l The service brake sensor (Figure 3), which signals the
position of the pedal to the computer.
l The “inching” pedal (Figure l), which simply operates
the brake pedal.
The illustrations and accompanying text serve as a guide to
disassembly/assembly and adjustment.

*“Two-pedal” trucks have a left-foot pedal for controlling re-

verse speed, and a right-foot pedal for controlling forward speed.
Two-pedal trucks also have a service brake pedal.

SM 598, Dee ‘94 Brake/Inching Pedals, Linkages, and Adjustments l 23(H)-3-1

 Main Table of Contents

Group 23(H), Brake/Inching System (Hydrostatic Transmission) Cmm

Brake Pedal Height Adjustment Overlap Adjustment

See Figure 1 or 2. On trucks with braking and inching
pedals, the brake pedal must be at the same height as the
“inching” pedal.
To adjust brake pedal height:
1. Loosen the eccentric stop mounting bolt and nut until
the stop can be withdrawn from the hex hole in the
brake pedal bracket.
2. Rotate the eccentric stop in the hex hole until it stops
the brake pedal at the desired height.
3. Torque the stop mounting bolt and nut 20-25 Nom (14-
18 ft-lb).
The overlap adjustment pertains only to trucks that have
both the “inching” and braking pedals. (Figure 1.) When the
“inching” pedal is depressed, the strike bolt threaded into
the “inching” pedal pushes against the strike lever on the
brake pedal, applying the brake.
There should be no clearance between the top of the strike
bolt and the strike lever on hydrostatic trucks. To adjust:
1. Loosen jam nut.
2. Turn strike bolt to obtain zero clearance.
3. Tighten jam nut.

Return Spring

Rod Coupling

I!_ Brake

Figure 1. Brakellnching Pedal Linkage for Single-Accelerator Pedal and Unitrol Trucks

23( H)-3-2 . Brake/Inching Pedals, Linkages, and Adjustments SM 598, Dee ‘94
 Main Table of Contents

Cmw Group 23(H), B ra ke/I nc h ing System (Hydrostatic Transmission)

Freeplay Adjustment
When rhc hmke pedal linkage is properly adjusted, braking
should begin only after the pedal is depressed a certain
distance. This “freeplay” is adjusted as follows:
1. Loosen the jam nut on the rod coupling (Figure 1or 2).

2. Depress the brake pedal 25 mm (1 .Oin).

3. Adjust the rod coupling until you feel the push rod
(Figure 3) just make contact with the cylinder piston.

Return Spring

Brake
Pedal

Figure 2. Brake Pedal Linkage for Two-Pedal Trucks

SM 598, Dee ‘94 Brake/inching Pedals, Linkages, and Adjustments l 23(H)-3-3

 Main Table of Contents

Group 23(H), Brake/Inching System (Hydrostatic Transmission) Eww

Linkageand Sensor Installation

Orient keeper as shown.

See Figure 1 or 2
for installation at
pedal end.

Push Rod Master Cylinder

Figure 3. Linkage and Sensor at Master Cylinder for All Hydrostatic Trucks.

23(H)-3-4 l Brake/Inching Pedals, Linkages, and Adjustments SM 599, Dee ‘94

 Main Table of Contents

Cmm Group 23(H), Brake/Inching System (Hydrostatic Transmission)

Section 4.

Brake System
Bleeding

Bleed brakes when: 3. Attach aclear hose to ableedscrew on one of the wheel
cylinders. Place the other end of the hose in a jar
l The brake pedal feels spongy.
containing hydraulic fluid, Clark part#180215.5.
l The master cylinder or wheel cylinders--or lines
between-have been leaking and/or have been re-

/‘h
paired or replaced.
l Troubleshooting otherwise indicates that air has been
introduced into the system.
.5.
i
I

Because the friction brake system is supplied with hydrau-

lic fluid from the steering valve, brake bleeding is simpli-
fied. Before bleeding, make sure brake linkage is properly
adjusted as described in Section 3. Then, proceed as fol-
lows:
1. Park truck on level floor. Put direction control in
neutral. Lower forks to floor, tilt forward, and apply
parking brake.
2. Gently clamp the return line from the steering valve as
shwon below so that flow back to the sump is partially
4. Start the truck and leave it in neutral.
blocked. This will cause pressure to build in the line
that feeds the master cylinder, when the engine is 5. Gpen the bleed screw and watch fluid flow into the jar.
started. Do not block all of the flow. When the fluid appears to be free of bubbles, tighten
the bleed screw.
6. Repeat the procedure at the other wheel cylinder.
7. Operate the brake pedal at various rates. If the pedal
feels spongy, bleed the system again.

To Master
Cylinder

Partially block flow by gently

clamping line here.

SM 598, Dee ‘94 Brake Bleeding l 23(H)-4-l

 Main Table of Contents

cmm Group 23(H), Bra ke/I nc h ing System (Hydrostatic Transmission)

Section 5.

Master Cylinder Overhaul

Master Cylinder Removal and

Replacement
1. Remove the spring clip and pin from the yoke on the
push rod.
2. Remove and plug the feed line.
3. Loosen the two mounting bolts.
4. Replacement is reverse of removal. Bleed system and
test brakes as described in Section 4.

L Torque to 20-25 Nom(177-221 in-lb)

SM 598, Dee ‘94 Master Cylinder Overhaul l 23(H)-5-l

 Main Table of Contents

Group 23(H), Brake/Inching System (Hydrostatic Transmission) Emm

Master Cylinder Overhaul

USC the Clark overhaul kit to overhaul the master

IMPORTANT
cylinder.
CLEANLINESS. Perform overhaul pro-
Clean all parts with a safety-approved commercial cedure in a clean environment. Make sure
solvent before inspection. all parts are cleaned before, and kept clean
Inspect all parts. Inspection includes: during, reassembly.
- Checking bores and pistons for scratches, nicks,
burrs, and wear.
- Making sure boot is not tom or loose.
- Making sure push rod is not bent.
- Making sure spring is not bent or cracked.
- Making sure all orifices are free of blockage.
Replace all seals. Do not reassemble with old seals.
Coat all components with hydraulic fluid, Clark part
#1802155. before reassembly. Lubricate and wrap
parts if reassembly will not be done immediately.

23(H)-5-2 l Master Cylinder Overhaul SM 598, Dee ‘94

 Main Table of Contents

Cwm Group 23(H), Brake/Inching System (Hydrostatic Transmission)

Section 6.
Service Brake Adjustment and Overhaul
External Inspection ........................................................................................................................ 1

Shoe-to-Drum Gap Adjustment ..U................................................................................................ 1

Internal Inspection and Repair ......U...._.................~...................~...~.......................................... 2
Brake Drum Removal and Replacement.. ........................................................................................ 2
Inspection ......................................................................................................................................... 2
Brake Shoe Removal ........................................................................................................................ 2
Brake Shoe Replacement ................................................................................................................ .2
Shimming Adjuster Gaps ................................................................................................................. 2
Cylinder Removal and Replacement ............................................................................................... 3
Adjuster Removal and Replacement ................................................................................................ 3
Wheel Cylinder Overhaul “.................................~......................................................................... 4
Brake Assembly Removal, and Installation ................................................................................. 4

External Inspection
The brake linings. drum, and adjustment setting can be 5. Through the adjuster notch. measure the gap between
inspected without removing the drum or hub as follows: each tab and adjacent star wheel with a feeler gauge.
The gap should be 0.5-0.6 mm (0.020-0.024 in). If
Safely jack up and block the front of the truck as
either gap is out of range. shim star wheel shaft as
described in Group SA to avoid personal injury or
described in “Shimming Adjuster Gaps” on page 2.
truck damage.
Remove the wheel and examine the linings through
the shoe inspection notch in the drum.
If the linings appear to be worn to a thickness of 1 mm
(0.04 in) or less at any point, replacement of both
shoes is required.
If the linings are OK. measure each shoe-to-drum gap
through the shoe inspection notch. first rotating the
notch into alignment with the lower end of each shoe.
Ifthc gapisnot 0.45-0.60mm (.017-.024in),adjustas in)
described in “Shoe-to-Drum Gap Adjustment.”
/Shoe
Figure 2. Adjuster Gap Setting (I of 2 Star Wheels)

Shoe-to-Drum Gap Adjustment

The brake shoes are self-adjusting. However. manual ad-
justment is required when shoes are replaced or if brake
shoes are binding against drums.
To decrease gap (for each shoe):
1. Measure the shoe-to-drum gap as described in “Exter-
Measure djuster nal Inspection.”
shoe-to-drum etch
gaps here. 2. Through the adjuster notch. rotate the star wheel one
click with screwdriver or adjusting tool .
Figure 1. Inspection and Adjustment Notches 3. Repeat steps 1 and 2 until proper gap is achieved.
4. Rotate theadjusternotch over the adjuster (at 7 o’clock To increase gap, remove drum. pry shoe from adjuster, and
position). turn adjusting screw (see Figure 2.)

SM 598, Dee ‘94 Service Brake Adjustment and Overhaul l 23(H)-6-l

 Main Table of Contents
Group 23(H), Brake/Inching System (Hydrostatic Transmission)
Internal Inspection and Repair
Safely jack up and block the front of the truck as described
in Group SA to avoid personal injury or truck damage.
Remove the wheel. The hub does not have to be removed.
Brake Drum Removal and Replacement
The drum fits tightly on the hub. To remove drum, install
Ml2 screws into the jackscrew holes to push the drum
away from the hub. To install the drum, align the adjuster
notch with the notch in the hub and drive the drum against
the hub with a soft mallet.
Jackscrew-
Hole
Figure 3. Jackscrew and Adjuster Notch Locations
inspection
Brake Shoes: If the linings are cracked or scored or the
linings are worn to 1 mm (04 in) or less. the shoes must be
replaced. Both sets of shoes (left and right) must be re-
placed when one is replaced.
Brake Drum: The maximum allowed internal diameter for
the brake drum is 303 mm (11.93 in). Brake drum walls
should be free from scoring. Brake drums should be ma-
chined each time brake shoes are replaced, to provide a
smooth and uniformly round braking surface.
Wheel Cylinder: Check for leakage under the boots at
each end of cylinder. If the cylinder leaks. or troubleshoot-
ing otherwise indicates a bad cylinder. disassemble and
inspect the wheel cylinder. If the cylinder surface is
scratched or pitted. replace the cylinder. Always replace
the cups.
General: Check for worn-out springs. warped backplate.
and loose or corroded fasteners. Check adjuster for proper
operation and replace if faulty.
23(H)-6-2 l Service Brake Adjustment and Overhaul
Emm
Shimming Adjuster Gaps
1. With brake shoes mounted, use a feeler gauge to
determine the amount of clearance that must be added
or subtracted from the gap described in “External
Inspection.” The gap should be O-5-0.6 mm (0.020-
0.024 in).
2. Remove the brake shoes as described in “Brake Shoe
Removal.”
3. From the adjuster, pull each star wheel shaft that is out
of adjustment. Clean star wheel shafts and lubricate
with anti-seize compound, Clark part # 1802307.
4. Measure and install the needed shims (Clark part) as
determined in step 1. Insert shafts as far into adjuster
as possible.
5. Check gap again after brake shoe installation.
L Shim here.
Figure 4. Star Wheel Gap Shim Installation
Brake Shoe Removal
Remove the guide springs. lower return springs. upper
return springs. and shoes (Figure 6).
Brake Shoe Replacement
1. Place the forward shoe-the shoe with the parking
brake lever-into position on the adjustets and cylin-
der rods (Figure 6).
2. Install the parking brake cable. making sure it is
hooked on the lever and clipped to the backing plate,
3. Install guide spring and upper return spring.
4. Install cross-strut (with spring and spring retainer).
making sure notch in cross-strut end engages slot in
parking brake lever on forward shoe.
5. Place the rearward shoe into position on the adjuster
and cylinder rods. making sure the spring-end of the
cross-strut engage the upper notch on the shoe.
SM 598, Dee ‘94
 Main Table of Contents

Emm Group 23(H), Brake/inching System (Hydrostatic Transmission)

6. Install the guide spring and upper return spring.
7. Install lower return spring. making sure spring offset is
downward to avoid interference with hub.
8. Make sure that the parking brake lever is in its shoe
notch and that cylinder push rods are in their shoe
sockets (Figure 5).
Push Rod
/ with silicon caulk. Tighten cylinder mounting bolts
Cylinder Removal and Replacement
1. Remove the brake shoes as described previously.
2. Remove the spring anchor. brake cylinder push rods.
and brake cylinder mounting bolts and washers.
Tap cylinder from backing plate with soft mallet.
When reinstalling: Seal the gap where the brake
cylinder fitting extends through the backing plate
and spring anchor plate mounting bolts to 15 Nom
(133 in-lb).

Adjuster Removal and Replacement

1. Remove the brake shoes as described above.
2. Remove the adjuster mounting bolt from backside of
L
mounting plate, and remove the adjuster.
L Notch in
Notch in
Brake Shoe 3. When reinstalling: Adjuster springs should be re-
Parking
Brake Lever placed with new ones if weak or damaged. Torque
adjuster mounting bolt to 10 Nom (89 in-lb).
Figure 5. Placement of Cross-Strut

Wheel Cylinder:
Spring Anchor
\
I

Lower Return

Figure 6. Brake Assembly

SM 596, Dee ‘94 Service Brake Adjustment and Overhaul l 23(H)-6-3

 Main Table of Contents

Group 23(H), Brake/Inching System (Hydrostatic Transmission) EMw

Wheel Cylinder Overhaul

1. Pull off rubber boots.
2. Rush out internal parts (loosen with wooden dowel if
necessary).
3. Replace cylinder if scored or pitted.
4. Clean pistons. spring, and casing in Stoddard-type
solvent or hydraulic fluid, Clark part #1802155.
Dip parts in hydraulic fluid.
Install spring and pistons.
Install each cup from its respective end of cylinder.
Replace boots.

Figure 7. Wheel Cylinder-Disassembled

Brake Assembly Removal & Installation

To access the service brake assembly, remove the brake 5. On the left-hand brake assembly only. remove the bolt
drum and axle hub as described in the “Drive Axle Ends that secures the axle mounting bracket to the brake
Overhaul” Section of Group 06. Inspect the drum as de- backing plate. When reinstalling. torque bolt to 20-25
scribed earlier. Nom (177-221 in-lb).

To remove the service brake assembly:

1. Remove the brake shoes as explained on page 2.
2. Pull the C-clip that holds the parking brake cable to the
backing plate.
3. Unhook the parking brake cable end from the lever and
pull the cable from the assembly.

Figure 9. Axle Mounting Bracket-to-Brake Backing Plate

6. Unbolt the brake backing plate from the drive axle by

removing 8 mounting bolts shown in Figure 6.
7. Installation is the reverse of removal. When reinstall-
ing the brake assembly, torque the mounting bolts to
307-376 Nom (226-277 ft-lb) in a staggered sequence.
Torque fitting 15-19 Nom (133-168 ft-lb).
Figure 8. Parking Brake Cable
8. After installation, bleed the brake system as described
in the brake bleeding Section of this Group (23).
4. Disconnect the brake line from the fitting. Cap or plug
fittings.

23(H)-6-4 . Service Brake Adjustment and Overhaul SM 598, Dee ‘94

 Main Table of Contents
Cmm Group 23(H), Brake/Inching System (Hydrostatic Transmission)
Section 7. Parking Brake Service
Operation
The operator applies the parking brake by depressing a foot Refer to the illustration below, and note the following:
pedal, which is then held down by a ratchet. The depressed
pedal tensions cables connected to a brake shoe at each
brake assembly. thereby applying the brakes.
The operator releases the parking brake by pulling up on a
release handle. This handle releases the ratchet, and a
return spring returns the pedal and cable to the off posi-
tion. The ratchet also operates tire parking brake interlock
switch and the parking brake indicator light switch.
Adjustment
With the pedal fully raised, upstop against tab on
bracket, adjust slack out of brake cables and tighten
adjusting/locking nuts.
Actuate and release pedal six to eight times.
Readjust and tighten nuts.
SM 598, Dee ‘94
Removal and Replacement
Remove return spring for better access to bracket
mounting nuts.
Adjust position of interlock and indicator switches
with pedal upstop against tab on bracket. Switch con-
tacts should snap from their operated contact position
to their normal position when pedal is depressed one
ratchet click.
Torque switch mounting nuts 0.8-1.0 Nom (7-9 in-
lb). Torque bracket mounting nuts 20-23 Nom (177-
210 in-lb).
Apply a thin coat of Clark lubricant, part #1802155,
to ratchet teeth and ball end of wire rope prior to
assembly.
Release Handle
f
Parking Brake l 23(H)-7-1
 Main Table of Contents

Group 23(H), Brake/Inching System (Hydrostatic Transmission) Emm

Parking Brake Cable Removal and

Installation

1. Disconnect each parking brake cable from the ratchet
assembly as shown in the illustration below.
2. Remove the parking cable from the service brake
assembly by first removing the brake shoes as de-
scribed in the “Brake Overhaul and Adjustment” Sec-
tion of this Group.
3. Pull out the C-clip that holds the parking brake cable to
the backing plate.
4. Unhook the parking brake cable end from the lever on
the shoe and pull the cable from the assembly.

C-Clip

5. Installation is the reverse of removal.

23(H)-7-2 l Parking Brake SM 590, Dee ‘94

 Main Table of Contents

GROUP 23(S)

GROUP 23

BRAKE SYSTEM

(STANDARD TRANSAXLE)

NOTE
The HYDROSTATIC TRANSMIWON truck does not use the
power brake system covered in this Group. Refer to Group
23(H) for information about the brake system used on hydro-
static transmission trucks.

Braking/Inching System
Specifications and Description ............................... Section 1

Service Brake Troubleshooting ......... ............................. Section 2

Brake/Inching Pedals and Linkages

Adjustments ...................................... ....................... Section 3

Brake Bleeding ................................................................ Section 4

Brake Valve Service ........................................................ Section 5

Service Brake Adjustment and Overhaul ..................... Section 6

Parking Brake Service ......................... .. ...........*.............Section 7

SM 598,Oct ‘94 Brake System (Standard Transaxle)

 Main Table of Contents

EIRRK Group 23(S), Brake System (Standard Transaxle)

Section 1.

Braking/Inching System
Specifications and Description

Specifications .................................... ..~.“...........................................~.............~ ........................... 1

General Description ....“.............U.....................................................................~ ........................... 2

Inching Operation .........“.........................................”.........................~ ......................................... 2

Braking Operation ......... .._..........“.~..........................~ ................................................................. 3

Brake Hydraulic Schematic .......................... ..~........................~.............................._ .................. 3

Service Needs ................ ..I....................“...............~.............~.....................~.~..............~ .............. 3

NOTE
INCHING. This Section only covers inching in regard to the linkage
between the brake and inching pedals. The inching system is more fuUy
covered in Group 06(S), “Transaxle.(Standard)”

HYDROSTATIC TRUCK. The brake system for the Hydrostatic trans-

mission truck is covered in Group 23(H) and Group 06(H).

Specifications

Service Brake: Parking Brake:

Type: Drum and shoe. Power boost provided by main hy- Type: Ratchet linked to service brake shoe at each wheel.
draulic pump. Self-adjusting.
Holding Test: Rated load on 15% grade.
Fluid: Fluid provided by main hydraulic pump.
Brake System Relief Pressure: 897 kPa (1300 psi).
Inching: (also see standard transaxle specs in Group 06s)
Shoe-to-Drum Gap: 0.45-0.60 mm (.017-.024 in)
Type: Inching pedal mechanically linked to brake pedal
Shoe Lining Thickness: 1.0 mm ( 0.039 in) minimum. aud to inching spool on transaxle.
Drum Thickness: 20.6 mm (0.787 inch) minimum. Pedal Freeplay: None
Maximum Rebore Diameter: 303 mm (11.92 in). Overlap Adjustment: 3.5-5.5 mm (0.13-0.22 in)
Pedal Freeplay: None
Star Wheel Adjustment Gap: OS-O.6 mm (0.020-0.023 in)

SM 598,Oct ‘94 Braking/ Inching Specifications & Description l 23(S)-l-l

 Main Table of Contents

Group 23(S), Brake System (Standard Transaxle) CIRRK

General Description pedal operates the brake valve. The inching pedal is me-
chanically linked to the brake pedal so that the inching
The service brake and inching system (diagrammed below) pedal, near the end of its stroke, also operates the service
consists of: brakes.
Service brake assembly-The drums, shoes, and wheel Inching control valve-A hydraulic valve in the transaxle
cylinders. control valve assembly that hydraulicly varies clutch pack
Brake valve-A hydraulic valve that directs hydraulic flow pressure so the operator can “inch” the truck.
from the main hydraulic system to the brake cylinders on a Parking brake pedal-Operates the service brake shoes
“priority” basis. via cables. See “Parking Brake Adjustment,” in this Group,
Service brake and inching pedals and linkage+A me- for details.
chanical system through which the brake pedal or inching

Service Brake and Inching System Arrangement

Brake Cylinder ‘Oft

/
sumpPort .+o,

Steering
Pressure Port
Sensing
Port

Brake
Valve

Priority
Sensing
Port

________________. Mechanical Linkage

Hydraulic Line

23(S)-1-2 . Braking/inching Specifications & Description SM 598,Oct ‘94

 Main Table of Contents

clmw Group 23(S), Brake System (Standard Transaxle)

Inching Operation
The inching pedal allows the operator to vary transmission
slippage through the clutch pack so that travel speed and
lifting speed can be independent.
The inching pedal also applies the service brakes. When the
inching pedal is depressed to a certain point, a mechanical
linkage between the inching pedal and the brake pedal
begins to apply the service brake. When the inching pedal
is fully depressed, the clutch pack fully disengages and the
service brake fully applies.
Inching is more fully described in Section 1 of Group 6,
“Transaxle.”
Braking Operation
The following is depicted by the brake hydraulic schematic
below.
When the operator depresses the brake pedal, or depresses
the inching pedal far enough to operate the brake pedal, the
brake link operates a spool in the brake valve.
The brake valve receives flow from the main hydraulic
pump. In general, the brake valve allows pressure to build
in the wheel cylinder in proportion to the extent the brake
pedal is depressed.
Brake Hydraulic Schema tic
___-----__---~-_
LiftXiWAux and Filtration Systems
The brake valve assembly contains a valve for power
braking and two cylinders for manual braking.
When the hydraulic system is functioning normally and the
operator applies the brakes, the brake valve spool shifts to
provide pressure to the wheel cylinders for power braking.
The amount of pressure is modulated by the position of the
spool. When the pedal is released, pressure in the wheel
cylinders vents to the sump and the return springs on the
shoes retract the wheel cylinders.
If the hydraulic system is not functioning and the operator
applies the brakes, fluid displaced from the internal cylin-
ders operates the wheel cylinders to provide manual (emer-
gency) braking. Fluid displaced from the large internal
cylinder operates the wheel cylinders to close the gap be-
tween the shoes and drums. Fluid displaced from the small
internal cylinder operates the wheel cylinders to provide
final manual braking force.
When the brakes are applied normally, the load sensing
line contributes braking load to the total braking/steering
load signal. This signal tells the priority valve in the hy-
draulic pump whether to divert some flow from the main
hydraulic system to the steering and braking systems.
1

Service Brakes

,- Brake Valve

I
Load Sensing ____~___________1
_____T~~~___

SM 598,Oct ‘94 Braking/ inching Specifications & Description l 23(S)-1-3

 Main Table of Contents

Group 23(S), Brake System (Standard Transaxle) CMRK

Service Requirements
Operational checks and inspection of linkages, brake
shoes, and brake lines are specified in the Periodic Ser-
vice Chart in Group PS.
Service brake linkage adjustment and lube are not nor-
mally required.
Brake shoes are self-adjusting and normally require ad-
justment only after initial installation.
A leaking brake cylinder should be overhauled or re-
placed.
Parking brake should be adjusted if indicated by opera-
tional check.

23(S)-1-4 . Braking/Inching Specifications & Description SM 598,Oct ‘94

 Main Table of Contents

CMRK Group 23(S), Brake System (Standard Transaxle)

Section 2.

Service Brake
Troubleshooting

SM 598,Oct ‘94 Service Brake Troubleshooting l 23(S)-2-l

 Main Table of Contents

Group 23(S), Brake System (Standard Transaxle) ElRRK

Service Brake Troubleshooting

Causes/Corrective
Condition Actions
Brake pedal drops to floor (engine running) ........................................................................ BD

Brake pedal drops to floor (engine not running) ................................................................. B D F

Brake pedal spongy .............................................................................................................. BC

Brake pedal kicks back when applied.. ................................................................................ C E

Brakes stick, drag excessively, make noise, or overheat.. ................................................... E F I

Insufficient stopping power; excessive effort required ....................................................... FGBEH

Excessive effort required to apply brake ............................................................................. FGB

Inching pedal does not apply brake at right time ................................................................. AD

Causes/Corrective Actions

A. Overlap adjustment incorrect... Adjust.

B. External leak in wheel cylinder or other component of braking system... Inspect/replace/repair.

C. Air in braking system... Bleed and recheck.
D. Linkage misadjusted or broken. Return spring damaged... Inspect/repair.
E. Brake valve defective... Inspect/overhaul or replace.
F. Shoe linings worn or brakes misadjusted... Inspect/repair/adjust.
G. Insufficient pressure from main pump... Check brake relief pressure at pump gauge port.
H. Shoe linings glazed, oily, or contaminated with other substance... Replace or clean.

I. Parking brake misadjusted... Adjust.

23(S)-2-2 . Senrice Brake Troubleshooting SM 590,Oct ‘94

 Main Table of Contents

Group 23(S), Brake System (Standard Transaxle)

ElmK

Section 3.

Brake/Inching Pedals and

Linkages Adjustments

Introduction ..““..........W.............“....................” ............................................................................. 2

Pedal Height Adjustment .......... ..“.......................................................”..................................” ... 2

Overlap Adjustment ........................................... ..“...“..” .............................................................. 2

Brake Yoke Adjustment ......... ..“...............“.“...............”............“..“......”..........“.......” ............... 2

Inching Cable Adjustment .... ..“.“.......“.“...........................................”..........” ............................ 4

SM 598,Oct ‘94 Brake/Inching Pedals and Linkages Adjustments . 23(S)-3-1

 Main Table of Contents

Group 23(S), Brake System (Standard Transaxle) CUIRK

Introduction
Figures 1 and 2 show:
l The service brake linkage, which links the brake pedal
to the brake valve.
l The inching pedal linkage, which links the inching
pedal to the inching valve.
l The inching pedal overlap, which allows the inching
pedal to operate the brake pedal.
The illustrations and accompanying text serve as guide to
disassembly/assembly and adjustment.
NOTE
FREEPLAY: There should be no freeplay
at the brake or inching pedals.
Pedal Height Adjustment
See Figure 1. The brake pedal must be at the same height as
the inching pedal. To adjust brake pedal height:
Loosen the eccentric stop’s mounting bolt and nut
until the stop can be withdrawn from the hex hole in the
brake pedal bracket.
Rotate the eccentric stop in the hex hole until it stops
the brake pedal at the same height as the inching
pedal.
Torque the stop’s mounting bolt and nut 20-25 Nom
(14-18 ft-lb).
Overlap Adjustment
See Figure 1. When the inching pedal is depressed, the
strike bolt threaded into the inching pedal pushes against
the strike lever on the brake pedal, applying the brake.
The clearance between the top of the strike bolt and the
strike lever should be 3.5 to 5.5 mm (0.13-0.22 in), de-
pending on operator preference.
1. Measure clearance.
If necessary, adjust as follows:
2. Loosen jam nut.
3. Turn strike bolt to obtain desired clearance.
4. Tighten jam nut.
Brake Yoke Adjustment
See Figure 1. The brake yoke and link should float freely
when the brake pedal is fully up against its stop (brakes not
applied).
To adjust:
1. Make sure the brake valve is fully up against the lip of
the lower cowl.
2. Remove the spring clip and pin from the yoke.
3. Loosen the jam nut and turn the yoke until the holes
in the yoke line up with the hole in the brake link.
Tighten the jam nut.
4. Reinstall the spring clip and pin into the yoke and
link.

Inching Cable Adjustment

See page 4.

23(S)-32 l Brake/Inching Pedals and Linkages Adjustments SM 598,Oct ‘94

 Main Table of Contents

Emu Group 23(S), Brake System (Standard Transaxle)

Inching Pedal

I
3

\
5
/
I

Pedal 0

Figure 1. Brakellnching Pea!& and Linkage

SM 598,Oct ‘94 Brake/Inching Pedals and Linkages Adjustments l 23(S)-3-3

 Main Table of Contents

Group 23(S), Brake System (Standard Transaxle) ClRRK

Inching Cable Adjustment

With the inching pedal fully up, the inching rod should be
just barely off its seat, so that there is no freeplay in the
inching cable.
With the pedal released, adjust the cable as follows:
1. Use the cable adjusting nuts to loosen the cable until
the inching rod withdraws into the tram&e control
valve as far as it will go.
2. Turn the cable adjusting nuts until the cable tightens
enough to just barely move the rod off its seat.
Tighten the cable adjusting nuts against the mount-
ing bracket.

IMPORTANT
INCHING ROD POSITION. Do not over-
adjust. Adjustment should extend the rod
no more than 1.0 mm (0.04 in) from its
fully seated position.

Cable Adjusting Nuts a //

Figure 2. Inching Valve Linkage

23(S)-3-4 l Brake/InchingPedals and LinkagesAdjustments SM 598,Oct ‘94

 Main Table of Contents

ClClRK Group 23(S), Brake System (Standard Transaxle)

Section 4.

Brake System
Bleeding

Bleed brakes when: 3. Start the truck and leave it in neutral.

l Thebrakepedalkicksbackduringbrakingorthepedal
feels spongy.
l The brake valve or wheel cylinders-or lines be-
tween-have been leaking and/or have been repaired
or replaced.
l Troubleshooting otherwise indicates that air has been
introduced into the system.
4. Open the bleed screw.
5. Depress the brake pedal and watch fluid flow into the
jar. When the fluid appears to be free of bubbles,
tighten the bleed screw, then release the pedal.
6. Operate the brake pedal at various rates. If you feel the
pedal kick back, bleed the system again.

Because the brake system is supplied with hydraulic fluid

from the main hydraulic pump, brake bleeding is simpli-
fied. Proceed as follows:
1. Park truck on level floor. Put direction control in
neutral. Lower forks to floor, tilt forward, and apply
parking brake.
2. Attach aclear hose to ableedscrew on one of the brake
cylinders. Place the other end of the hose in a jar
containing hydraulic fluid, Clark part #1802155.

SM 598,Oct ‘94 Brake Bleeding l 23(S)-4-l

 Main Table of Contents

ClclRK Group 23(S), Brake System (Standard Transaxle)

Section 5.

Brake Valve Service

Brake Valve Removal ..“............“.....“........~......~..~............................................“...“.......~.....~ .. 2

Brake Valve Replacement “..........“........._.........................................~................_......._........“~ .. 3

Brake Valve Overhaul “....“....U...._..................................“.~........................................................ 3

SM 598,Oct‘94 Brake Valve Service l 23(S)-5-l

 Main Table of Contents

Group 23(S), Brake System (Standard Transaxle) EWRK

Brake Valve Removal

1. Remove the spring clip and pin from the yoke on the
brake valve rod. (See box below.)
2. Place a pan directly under the brake valve to catch
drippings. Note the location of the lines on the valve
and label the lines. Loosen the five hydraulic fittings
on the brake valve and remove the lines. Cap or plug
the fittings.
3. Loosen the two mounting bolts that go through the
mounting plate. Slide valve downward and remove.

Brake Valve

23(S)-5-2 l Brake Valve Service SM 598,Oct ‘94

 Main Table of Contents
ElRRlC Group 23(S), Brake System (Standard Transaxle)
Brake Valve Replacement
1. Insert mounting bolts and washers through brake valve
and slots in mounting plate. Loosely tighten nuts.
2. Slide the brake valve upward until it strikes lower edge
of cowl plate.
3. Tighten the mounting bolt nuts 4045 Nom (30-33 ft-
lb).
4. Check to see if the holes in the yoke line up with the
hole in the brake link. If not, loosen the jam nut and
turn the yoke to obtain alignment. Tighten the jam nut.
5. Reinstall the spring clip and pin into the yoke.
6. Reinstall the hydraulic lines as labeled or use sche-
matic in Section 1 to identify location. Lightly snug
fittings until they bottom out on seat or port.
7. Bleed brakes as described in the brake bleeding Sec-
tion of this Group.
SM 598,Oct ‘94
Brake Valve Overhaul
. Use the Clark overhaul kit to overhaul the brake valve.
.
Clean all parts with a safety-approved commercial
solvent before inspection.
.
Inspect all parts. Inspection includes:
- Checking bores, spools, and pistons for scratches,
nicks, burrs, and wear.
- Making sure control rod is not bent.
- Making sure springs are not bent or cracked.
- Making sure all orifices are free of blockage.
l
Replace all seals. Do not reassemble with old seal.
. Coat all components with hydraulic fluid, Clark part
#1802155, before reassembly. Lubricate and wrap
parts if reassembly will not be done immediately.
IMPORTANT
CLEANLINESS. Perform overhaul pro-
cedure in a clean environment. Make sure
all parts are cleaned before, and kept clean
during, reassembly.
Brake Valve Service l 23(S)-5-3
 Main Table of Contents

EmK Group 23(S), Brake System (Standard Transaxle)

Section 6.
Service Brake Adjustment and Overhaul
External Inspection ........................................................................................................................ 1
Shoe-m-Drum Gap Adjustment .._........................_..........~............~..................“~ ...................... 1
Internal Inspection and Repair ............_........................................”...~.~.._...............~ ................ 2
Brake Drum Removal and Replacement .......................................................................................... 2
Inspection ......................................................................................................................................... 2
Brake Shoe Removal.. ...................................................................................................................... 2
Brake Shoe Replacement ................................................................................................................. 2
Shimming Adjuster Gaps ................................................................................................................. 2
Cylinder Removal and Replacement ............................................................................................... 3
Adjuster Removal and Replacement ................................................................................................ 3

Wheel Cylinder Overhaul ................_...“.............................................................~ ....................... 4

Brake Assembly Removal, and Installation .........U.....__....“....~..................................~............. 4

External Inspection 5. Through the adjuster notch, measure the gap between
The brake linings, drum, and adjustment setting can be each tab and adjacent star wheel with a feeler gauge.
inspected without removing the drum or hub. The gap should be 0.5-0.6 mm (0.020-0.023 in). If
either gap is out of range, shim star wheel shaft as
1. Jackupaudblockthefrontoftheuuckasdescribedin
described in “Shimming Adjuster Gaps.”
Group SA.
2. Remove the wheel and examine the linings through
the shoe inspection notch in the dnnn.
If the linings appear to be worn to a thickness of 1 mm
(0.04 in) or less at any point, replacement of both
shoes is required.
3. If the linings are OK, measure each shoe-to-drum gap
through the shoe inspection notch, first rotating the
notch into alignment with the lower end of each shoe.
Ifthegapisnot0.450.60mm (.017-.024in),adjustas in)
described in “Shoe-to-Drum Gap Adjustment.”
Y Shoe
X Inspection Figure 2. Adjuster Gap Setting (I of 2 Star Wheels)

Shoe-to-Drum Gap Adjustment

The brake shoes are self-adjusting. However, manual ad-
justment is required when shoes are replaced or if brake
shoes are binding against drums.
To decrease gap (for each shoe):
1. Measure the shoe-to-drum gap as described in “Exter-
Measure nal Inspection.”
shoe-to-drum
gaps here. 2. Through the adjuster notch, rotate the star wheel one
click with screwdriver or adjusting tool.
Figure 1. Inspection and Adjustment Notches 3. Repeat steps 1 and 2 until proper gap is achieved.
4. Rotate theadjusternotchovertheadjuster(at7 o’clock To increase gap, remove drum, pry shoe from adjuster, and
position). turn adjusting screw (see Figure 2.)

SM 598,Oct ‘94 Service Brake Adjustment and Overhaul l 23(S)-6-1

 Main Table of Contents
Group 23(S), Brake System (Standard Transaxle)
Internal Inspection and Repair
Jack up and block the front of the truck as described in
Group SA. Remove the wheel. The hub does not have to be
removed.
Brake Drum Removal and Replacement
The drum fits tightly on the hub. To remove drum, install
Ml2 screws into the jackscrew holes to push the drum
away from the hub. To install the hub, align the adjuster
notch with the notch in the hub and drive the drum against
the hub with a soft mallet.
Jackscrew-
Jackscrew
Hole Hole
Figure 3. Jackscrew and Adjuster Notch Locations
Inspect ion
Brake Shoes: If the linings are cracked or scored or the
linings are worn to 1 mm (.04 in) or less, the shoes must be
replaced. Both sets of shoes should be replaced when one is
replaced.
Brake Drum: The maximum allowed internal diameter for
the brake drum is 303 mm (11.93 in). Brake drum walls
should be free from scoring. Brake drums should be ma-
chined each time brake shoes are replaced, to provide a
smooth and uniformly round braking surface.
Wheel Cylinder: Check for leakage under the boots at
each end of cylinder. If the cylinder leaks, or troubleshoot-
ing otherwise indicates a bad cylinder, disassemble and
inspect the wheel cylinder. If the cylinder surface is
scratched or pitted, replace the cylinder. Always replace
the cups.
General: Check for worn-out springs, warped backplate,
and loose or corroded fasteners. Check adjuster for proper
operation and replace if faulty.
23(S)-6-2 l Service Brake Adjustment and Overhaul
ElRRK
Shimming Adjuster Gaps
1. With brake shoes mounted, use a feeler gauge to
determine the amount of clearance that must be added
or subtracted from the gap described in “External
Inspection.” The gap should be 0.5-O-6 mm (0.020-
0.023 in).
2. Remove the brake shoes as described in “Brake Shoe
Removal.”
3. From the adjuster, pull each star wheel shaft that is out
of adjustment. Clean star wheel shafts and lubricate
with anti-seize compound, Clark part #1802307.
4. Measure and install the needed shims (Clark part) as
determined in step 1. Insert shafts as far into adjuster
as possible.
5. Check gap again after brake shoe installation.
here.
L Shim here.
Figure 4. Star Wheel Gap Shim Installation
Brake Shoe Removal
Remove the guide springs, lower return springs, upper
return springs, and shoes (Figure 6).
Brake Shoe Replacement
1. Place the forward shoe-the shoe with the parking
brake lever-into position on the adjusters and cylin-
der rods (Figure 6).
2. Install the parking brake cable, making sure it is
hooked on the lever and clipped to the backing plate,
3. Install guide spriug and upper return spring.
4. Install cross-strut (with spring and spring retainer),
making sure notch in cross-strnt end engages slot in
parking brake lever on forward shoe.
5. Place the rearward shoe into position on the adjuster
and cylinder rods, making sure the spring-end of the
cross-strut engage the upper notch on the shoe.
SM 598,Oct ‘94
 Main Table of Contents

CIMK Group 23(S), Brake System (Standard Transaxle)

6. Install the guide spring and upper return spring.
7. Install lowerretum spring, making sure spring offset is
downward to avoid interference with hub.
8. Make sure that the parking brake lever is in its shoe
notch and that cylinder push rods are in their shoe
sockets (Figure 5).
Push Rod
Cylinder Removal and Replacement
1. Remove the brake shoes as described previously.
2. Remove the spring anchor, brake cylinder push rods,
and brake cylinder mounting bolts and washers.
3. Tap cylinder from backing plate with soft mallet.
When reinstalling: Seal the gap where the brake

/
7 4. cylinder fitting extends through the backing plate
with silicon caulk. Tighten cylinder mounting bolts
and spring anchor plate mounting bolts to 15 N-m
(133 in-lb).

Adjuster Removal and Replacement

1. Remove the brake shoes as described above.
2. Remove the adjuster mounting bolt from backside of
mounting plate, and remove the adjuster.
L Notch in L_
Notch in
Brake Shoe 3. When reinstalling: Adjuster springs should be re-
Parking
Brake Lever placed with new ones if weak or damaged. Torque
Figure 5. Placement of Cross-Strut adjuster mounting bolt to 10 Nom (89 in-lb).

Wheel Cylinder
Spring Anchor
\
I

per Return
fing

Brake Shoe

Backing Plate ’
\\\ws

Figure 6. Brake Assembly

SM 598,Oct ‘94 Service Brake Adjustment and Overhaul l 23(S)-6-3

 Main Table of Contents

Group 23(S), Brake System (Standard Transaxle) ClHRK

Wheel Cylinder Overhaul
1. Pulloff rubber boots.
2. Rush out internal parts (loosen with wooden dowel if
necessary).
3. Replace cylinder if scored or pitted.
4. Clean pistons, spring, and casing in Stoddard-type
solvent or hydraulic fluid, Clark part #1802155.
Dip parts in hydraulic fluid.
Install spring and pistons.
Install each cup from its respective end of cylinder.
Replace boots.

Figure 7. Wheel Cylinder-Disassembled

Brake Assembly Removal, and

Installation
To access the service brake assembly, remove the axle hub
and brake drum as described in Group 6, in the “Drive Axle
Ends Overhaul” Section. Inspect the drum as described
earlier.
To remove the service brake assembly:
1. Remove the brake shoes as explained below.
2. Pull the C-clip that holds the parking brake cable to the
backing plate.
3. Unhook the parking brake cable end from the lever and
pull the cable from the assembly.
4. Disconnect the brake line from the fitting. Cap or plug
fittings.
5
Unbolt the brake assembly from the axle.
6. Whenreinstalling thebrake assembly, torque the mount-
ing bolts to 307-376N*m (226-277 ft-lb) in a staggered
sequence. Torque fitting 15-19 Nom (133-168 ft-lb).
7. Bleed the brake system as described in the brake
bleeding Section of thii Group (23).

Figure 8. Parking Brake Cable

23(S)-6-4 l Senrice Brake Adjustmentand Overhaul SM 598,Oct ‘94

 Main Table of Contents

CUIRK Group 23(S), Brake System (Standard Transaxle)

Section 7. Parking Brake Service

Operation Removal and Replacement

The operator applies the parking brake by depressing a foot
pedal, which is then held down by a ratchet. The depressed
pedal tensions cables connected to a brake shoe at each
brake assembly, thereby applying the brakes.
The operator releases the parking brake by pulling up on a
release handle. This handle releases the ratchet, and a
return spring returns the pedal and cable to the off posi-
tion. The ratchet also operates the parking brake interlock
switch and the parking brake indicator light switch.
Adjustment
With the pedal fully raised, upstop against tab on
bracket, adjust slack out of brake cables and tighten
adjusting/locking nuts.
Actuate and release pedal six to eight times.
Readjust and tighten nuts. K Ratchet f-
As shown in illustration below, with these notes:
Remove return spring for better access to bracket
mounting nuts.
Adjust position of interlock aud indicator switches
with pedal upstop against tab on bracket. Switch con-
tacts should snap from their operated contact position
to their normal position when pedal is depressed one
ratchet click.
Torque switch mounting nuts 0.8-1.0 Nom (7-9 in-
lb). Torque bracket mounting nuts 20-23 Nom (177-
210 in-lb).
Apply a thin coat of Clark lubricant, part #1802155,
to ratchet teeth and ball end of wire rope prior to
assembly.
Release Handle

f
Wire Rope Switch
Mounting
Nuts

Switches -/
t3

SM 598,Oct ‘94 Parking Brake l 23(S)-7-1

 Main Table of Contents

Group 23(S), Brake System (Standard Transaxle) CUlRK

Parking Brake Cable Removal and
installation

1. Disconnect each parking brake cable from the ratchet
assembly as shown in the illustration below.
Remove the parking cable from the service brake
assembly by first removing the brake shoes as de-
scribed in the “Brake Overhaul and Adjustment” Sec-
tion of thii Group.
Pull out the C-clip that holds the parking brake cable to
the backing plate.
Unhook the parking brake cable end from the lever on
the shoe and pull the cable from the assembly.

C-Clip -/

5. Installation is the reverse of removal.

23(S)-7-2 l Parking Brake SM 598,Oct ‘94

 Main Table of Contents

GROUP 25

GROUP 25

STEERING COLUMN AND GEAR

Steering System Specifications

and Description ...... .. ........ .... .... .... .. . .. ... ..... ......... .. .. .. Section 1

Steering System Troubleshooting ... ... . .. .. ... ..... ............. .. Section 2

Steering Column and Component

Removal and Replacement . ...... .. ... . .. ... ............... .. .. Section 3

Steering System Relief Pressure Check

and Adjustment .. .. ... ..... .. .... .. ... .. .. .. .. . .. ................ .... Section 4

Steering Gear Overhaul . .... .. ...... .. ..... .. .. .. ... ... ................ . Section 5

SM 598,Oct ‘94 Steering Column and Gear

 Main Table of Contents

Section 1.

Steering System Specifications and

Description

Specifications
Steering System Type: Hydrostatic power steering with
load sensing, dynamic signal neutral circuit.
Steering System Relief Pressure Setting: 8270-8960 kPa
(1200-1300 psi)
Nominal Plow Rating: 23 L/min (6 gahmin)
Inlet Pressure Rating: 12400 kPa (1800 psi)
Return Pressure Rating: 1000 kPa (150 psi) maximum
Service Intervals
Check the steering system relief pressure annually or
after every 2000 hours of operation. Make a visual in-
spection of steering control unit hydraulic fittings peri-
odically to ensure that the fittings are tight with no leakage.
Fastener Torques
Steering Handwheel Nut: 35-40 N*m (25.5-29.5 ft-lb)
Description
All truck models have a hydrostatic power steering sys-
tem, which is supplied with oil pressure from the main
hydraulic system pump. The steering hand wheel oper-
ates the steering gear (steering control unit), which di-
rects oil flow to the steering cylinder on the steer axle. A
steering system pressure relief valve is built in the hy-
draulic pump to prevent over-pressurization of the steer-
ing system. The pressure relief setting can be tested using
the gauge port of the hydraulic pump. A steering priority
valve, also in the pump, diverts flow from the main
hydraulic system to the steering system when it senses
the pressure increase caused by turning the steering hand
wheel.
The power steering gear is a remote positioning control
valve that senses the input signal from the steering hand
wheel, multiplies this signal to assist in reducing the
steering effort, and causes the steering axle to turn the
wheels to the desired position by supplying hydraulic
flow to the steering cylinder.

Steering Column Cover Hex Bolts: 2-3 N*m (18-27 in- The steering gear is connected to the bottom of the
lb; 1.5-2.25 ft-lb) steering column. When the steering hand wheel is turned,
it is linked mechanically to the steering gear spool and
Directional Control Base Lock Nut: 0.8-l Nom (7-9 in-
causes this spool valve to shift from its closed neutral
lb; 0.6-0.75 ft-lb)
position to a “turn” position that allows oil under pres-
Directional Control Base Flange Capscrew: 3.5-4.0 Nom sure to flow to the steering cylinder.
(2.5-2.9 ft-lb)
When the steering hand wheel stops turning, centering
Ignition Switch Ring Nut: lo-14 Nom (7.3-10.3 ft-lb) springs in the valve automatically center the spool, stop-
ping the flow of oil to the cylinder.
Tilt Lock Assembly Base-to-Cowl Bolts: 20-25 N*m
(14.8-18.5 ft-lb) The low pressure oil from the opposite side of the steer-
ing cylinder is returned through the opposite port in the
Orbitrol Bracket Bolts: 34-38 N=m (25-28 ft-lb)
gear. It is controlled by the same spool as the high
Lower Column Assembly Base-to-Steering Gear Bolts: pressure port.
34-38 N*m (25-28 ft-lb)
In the event of a pump failure, the steering gear can
Universal Joint Pinch Bolt: 25-30 Nom (18.5-22 ft-lb) generate sufficient hydraulic power by movement of the
Wiring Harness Bracket Bolts: 11-13 Nom (8-9.5 ft-lb) steering handwheel to serve as a limited steering method.
An internal check valve automatically closes to divert
this generated oil flow to the proper port of the steering

SM 598, Ott ‘94 Steering System Specifications and Description l 25-l-l

 Main Table of Contents

Group 25, Steering Column and Gear 61cIRK

cylinder. The handwheel turning effort is considerably
higher, however, than with power steering.
The column tilt lock mechanism allows the operator to
adjust the steering column. The column tilt lever knob
releases the adjustment setting and the column returns to
the up position by the use of springs. The tilt lock mecha-
nism, the directional control lever, and the ignition switch
are protected by the steering column cover. The cover
can be removed for service to steering column compo-
nents. The entire column can be removed for service or
replacement. The steering gear, attached to the base of
the column, can be removed without disassembling the
other parts of the steering column.

Column

Horn Contact Ring -1 I

i’ Upper
Cover

Tilt Lock
Ignition Switch Assembly
Boot

Lock Ring1 v

v
Directional Control
/ Tilt Lock
Ignition Switch Switch Wiring
Assembly
Wiring Harness Harness
Directional Control
Lever Assembly

25-l-2 l Steering System Specifications and Description SM 598,Oct ‘94

 Main Table of Contents

clmu Group 25, Steerinq Column and Gear

Section 2.

Steering System Troubleshooting

No steering Truck turns in wrong direction

l Hydraulic fluid level very low. l Hydraulic lines not installed correctly.
l Air in hydraulic oil.
Handwheel kickback
l Steering column sections not connected properly.
l Check valve faulty (or not in system).
l Hose broken.
l Hydraulic pump contaminated or defective.
Slow steering response
l Oil viscosity too high.
Hard steering
l Contaminated or defective steering gear.
. Hydraulic fluid level low.
. Air in hydraulic oil. Chatter conditions
. Steering gear contaminated l Loose mountings or linkage. Make certain all mount-
or defective.
ing fasteners and other linkage is tight.
. Relief valve setting too low; adjust or replace.
l Pressure relief valve set too low and is out of adjust-
. System leaking.
ment; adjust or replace the relief valve.
. Incorrect tire pressure.
l Insufficient pump flow. Check pump for leaks and
. Axle load too heavy. see Group 29, Section 2.
. Lack of lubrication. Unsatisfactory steering in either direction
. Air in hydraulic oil.
Air in system due to excessive wear in steering
. Defective steering gear. cylinder. Check for air in system. Excessive noise or
. Malfunctioning, damaged, or worn priority demand foamy condition of hydraulic fluid indicates aera-
tion.Checkthatairisnotenteringthesystemthrough
valve (flow control valve).
poor threads, cracked, split, or worn hoses, bad
High number of handwheel turns pump seals, bad O-rings, bad gaskets, or loose
connections.
l Steering cylinder seal leakage.
Worn cylinders result in leakage past the piston.
l Worn steering gear. .
Overhaul (see Group 26, Section 7) or replace the
Steering handwheel spins freely steer cylinder.

l Air in system (cavitation). Incorrect system pressure due to worn pump. Re-
place the relief valve or repair or replace the pump
l Low oil supply.
(see Group 29).
l Steering column detached from steering gear.
Noise during turns
l Defective steering gear.
l Worn bearing(s) in steering arm; replace bearings.
Jerky steering
l Worn pin in steering knuckle; replace pin.
l Steering gear malfunction because of worn parts or
l Worn bearings in steering knuckle; replace bear-
contamination. Steering gear may require overhaul.
ings.
l Steering knuckle is loose; tighten castle nut.

SM 598, Ott ‘94 Steering System Troubleshooting l 25-2-1

 Main Table of Contents

Group 25, Steering Column and Gear CIRRK

Constant noise from steering axle Low pressure at the pump
l Loose or worn hub bearing cones. Adjust or replace l Refer to the pump troubleshooting and overhaul
hub bearing cones. Replace bearing cones and bear- procedures in Group 29.
ing cups as a set.
Low pressure at the steering gear
Noise when axle pivots
l Refer to Section 5, “Steering Gear Overhaul.”
l Lack of lubricant in steering axle mounting.
l Steering axle mountings worn; replace mountings.
Low pressure at the steer cylinder
l Seals worn out at piston rod end of steer cylinder;
l Steering axle mounting cap(s) loose; tighten mount-
replace seals.
ing cap(s).

Fluctuating pressure Steer cylinder rod binding or sticking

l Binding of linkage. With hydraulic flow shut off
l Faulty operation of relief valve. Fluctuating pres-
from the cylinder and the rod end uncoupled, the rod
sure or loss of pressure in the system is usually
should slide freely in or out by hand. If the piston is
caused by scales, chips, sludge, or filings that have
binding, overhaul or replace the cylinder.
lodged between the relief valve and seat. A damaged
spring or worn valve may also be the cause of the
trouble. Flush and refill the system and replace the
hydraulic return line filter element. If condition still
exists, replace the relief valve.

25-2-2 l Steering System Troubleshooting SM 598,Oct ‘94

 Main Table of Contents

CIRRK Group 25, Steering Column and Gear

Section 3.
Steering Column and Component Removal and Replacement

Steering Column and Component Removal ................................................................................ 2

Ignition Switch Removal ................................................................................................................. 2
Hand Wheel, Horn Contact Ring, and Directional Control Assembly Removal.. .......................... .2
Column Tilt Lock Assembly Removal ........................................................................................... .4
Steering Gear and Lower Steering Column Removal.. ................................................................... .5

Steering Column and Component Replacement ......................................................................... 6

Steering Gear and Lower Steering Column Replacement ............................................................... 6
Column Tilt Lock Assembly Replacement.. .................................................................................... 7
Directional Control Assembly Reassembly ..................................................................................... 7
Directional Control Assembly and Ignition Switch Replacement ................................................... 8
Steering Hand Wheel Replacement ................................................................................................ .9

IMPORTANT
Before removing any component for overhaul, make sure
the correct repair parts, seals, and gasket sets are available.

Column

L
Upper
Cover

Horn Contact Ring

Tilt Lock
-1
Assembly
Ignition Switch 1
Boot

Lock Ring1 -

tL)
Ignition Switch
Directional Control
Switch Wiring
L Tilt Lock
Assembly
Directional Control
Wiring Harness Harness
Lever Assembly

Typical Steering Column Assembly

SM 598,Oct ‘94 Steering Column and Component Removal and Replacement l 25-3-l
 Main Table of Contents

Group 25, Steering Column and Gear ElRRK

3. Remove the lock ring nut securing the ignition switch
A CAUTION to the lower cover. Label all wires and terminals for
SAFE PARKING. Before working on truck: correct reconnection when reassembling.
1. Park truck on a hard, level, and solid ignition Switch
surface, such as a concrete floor with no
gaps or breaks. Ignition Wire #117
2. Put upright in vertical position and fully Ground7 /
lower the forks or attachment.
3. Put alI controls in neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the
wheels.

i- Battery
Wire #8
-Starter
Steering Column and Component Wire #6
Removal
Hand Wheel, Horn Contact Ring, and
Use the following steps to disassemble the steering column Directional Control Assembly Removal
for service to the:
1. Disconnect the negative lead at the battery.
Ignition Switch
Horn 2. Gently pry the horn button from the steering hand
Directional Control Lever Assembly wheel hub using a small, flat-bladed screw driver.

Column Tilt Lock Assembly

Horn
Upper and Lower Steer Column Contact
Steering Gear. Ring
Wire
Determine which component requires service and check
the procedure for removing that component. Read the pro-
cedure completely before beginning disassembly.

Ignition Switch Removal

Hand
1. Disconnect the negative lead at the battery. Wheel

2. Remove the four socket head bolts holding the two

halves of the column cover together. The directional
control assembly and the ignition switch are exposed.
Disconnect the horn wire from the steer column and
unplug the horn contact wire from the terminal on the
bottom of the horn button.

Remove the nut holding the hand wheel to the steering

column.

Use a wheel puller to remove the hand wheel from the

steering column. Hand wheel has two MSX1.25
threaded inserts in the hub for this purpose.

25-3-2 l Steering Column and Component Removal and Replacement SM 598,Oct ‘94
 Main Table of Contents

ElmK Group 25, Steering Column and Gear

6. Unplug the horn contact ring wire from the terminal on 9. Lift the directional control lever and boot off the die-
the bottom of the handwheel. cast base.

Directional
Control Lever

Horn
Wire

Horn Contact

7. Using a 2.5 mm allen wrench, remove the four socket

head bolts holding the two halves of the column cover 10. Unplug wires from directional switches. Label all
together. Remove the top cover. Gently pull the bottom wires and terminals for correct connection when reas-
cover away. sembling. Remove the direction control switches by
removing the mounting screws on the base.

Mounting
Screw

and Terminals

Directional Control Lever Detent Spring Removal

NOTE
1. If not already disassembled, remove the four socket
Use care when removing the bottom cover
bolts holding the two sides of the column cover to-
as the ignition switch wiring is attached.
gether. Remove the top cover.
8. Remove the horn contact ring. Unplug the wire from 2. Pry the two retainer clips from the posts on the direc-
the terminal on the bottom of the ring. tional control base securing the detent spring. Lift
spring off posts.
Horn
Contact Retainer Clips , , m
Ring

SM 598, Ott ‘94 Steering Column and Component Removal and Replacement l 25-3-3
 Main Table of Contents

Group 25, Steering Column and Gear CUIRK

Column Tilt Lock Assembly Removal a. Remove the three screws securing the instrument
pod to the dash.
NOTE
The tilt lock assembly is not serviceable;
only the return springs are serviceable. The
tilt lock assembly should be removed only
for replacement as a complete assembly.

1. Raise the operator’s seat deck and lift out the floor
plate.

2. Remove the left, right, and center cowl covers from

under the dash. See removal and replacement proce-
dures in Group 38.

3. See “Hand Wheel, Horn Contact Ring, and Directional

Control Assembly Removal” to remove the steering
hand wheel, horn ring, and directional control assem-
bly.

4. Unplug the ignition switch and directional control

switches. Label all wires for correct reassembly. Dis-
connect the ignition and directional control wiring Remove screws
harness from the main harness at lower right of cowl. from under dash.

5. Loosen the pinch bolt of the lower universal joint

connection.
b. Gently lift the instrument pod up exposing the
harness connector. Unscrew jack screw in con-
nector and unplug the connector from the instm-
ment pod.
c. Remove the screws securing the dash panel to the
cowl.

Pinch Bolt

6. Slip the boot off the tilt lock assembly.

7. Remove the dash panel and instrument pod:

d. Remove the hydraulic control lever cover panel

and dash.

25-3-4 l Steering Column and Component Removal and Replacement SM 598,Oct ‘94
 Main Table of Contents

CHIC Group 25, Steering Column and Gear

e. Remove the two bolts from the wiring harness

bracket located under the cowl.

2. If upper portion of the steering column has not been

removed, loosen the pinch bolt of the lower universal
joint connection.

f. Remove the four bolts holding the base of the tilt 3. Remove the two bolts and spacers securing the lower
lock assembly to the cowl. column shaft and steering gear to the bracket on the
lower cowl.
Lower Column U-Joint
/f and Pinch Bolt
Tilt Lock
Assembly

Remove bolts
from under cowl.

Steering Gear and Lower Steering Column

Removal
Lower Column Shaft and
NOTE Steering Gear
Lower steer column is not serviceable. It
should be removed only for replacement as
a new assembly.

1. Put a pan under the truck to catch hydraulic fluid which

will drip when fittings are loosened. Label the four
hose fittings of the steering gear to make sure they are
reassembled correctly. Loosen and remove the hy-
draulic fittings at the steering gear. Cap the ends to
prevent fluid leaks. Cap the steering gear ports to
prevent dust and debris from getting into the steering
gear. Keep hydraulic ports and hoses clean.

SM 598, Ott ‘94 Steering Column and Component Removal and Replacement l 25-3-5
 Main Table of Contents
Group 25, Steering Column and Gear ClRRK
4. Remove the bolts to detach the steering gear from the 1. Attach the steering gear to the lower column base.
lower steering column. Torque the two bolts to 34-38 Nom (25-28 ft-lb).

2. Set the column into position with the lower column

assembly aligned through the bracket mounted on the
lower frame cowl.

Lower
Steering
Column

Steering
Control
Valve

5. Remove the lower shaft and steering gear assembly

from the truck. Lower Column Shaft and -
Steering Control Valve

Steer Column and Component 3. Coat the splines of the lower assembly with a light coat
Replacement of anti-seize lubricant and insert into the universaljoint
pinch connector of the upper assembly. Match the skip
These steps cover the procedures for reinstallation of the tooth on the spline with spline on universal joint.
steering column including the steering gear, the tilt lock Torque the pinch bolt to 25-30 N*m (18.5-22.25 ft-lb).
assembly, directional control assembly, ignition switch,
4. Reconnect the clean hydraulic fluid lines to the clean
and steering hand wheel and horn.
steering gear. Make sure the hoses are reconnected to
IMPORTANT the correct ports. Torque the fittings per Group 40,
Make sure all parts are clean and dry be- “Hydraulic Fitting Tightening Procedure.”
fore reassembling.
It may be necessary to assemble the steer-
ing column in place and hand tighten fit-
tings so that the correct alignment of the
entire column and parts can be checked.
Once you have the correct alignment,
torque all fittings to their correct specifica-
tions.

Steering Gear and Lower Steering Column

Replacement
NOTE
If the upper steering column has not been
removed, the lower steering column must
be left loose at the universal ‘joint pinch
connection to allow some play in the col-
umn for positioning the steering gear.

25-3-6 l Steering Column and Component Removal and Replacement SM 598,Oct ‘94
 Main Table of Contents

Group 25, Steering Column and Gear

ElmK
Column Tilt Lock Assembly Replacement
1. Set the tilt lock assembly onto the cowl. Replace the
four bolts and torque to 20-25 Nom (14.8-18.5 ft-lb).
Directional Control Assembly Reassembly
1. Slip the lever boot onto the lever if it has been removed.
2. Make sure the flange capscrew and clamp are on the
directional control base.

pinch connector
with lower
P Capscrew
column spline.

Clamp 0
W
under cowl.
3. Install the detent spring on the posts of the base and
secure with the retainer clips.
2. Coat the splines of the lower assembly with alight coat
of anti-seize lubricant and insert into the universal joint
pinch connector of the upper assembly. Match the skip
tooth of the lower column spline shaft to that on the
universal joint. Torque the pinch bolt to 25-30 Nom
(18.5-22.25 e-lb).

3. Set the harness bracket into place and secure with the
two bolts. Torque the bolts to 1 l-13 N*m (8.1-9.6 ft-
lb).

4. Reset the forward or reverse switch onto the base and

secure with screws.
Mounting
Screw \/(Gi---=v =DTY

Bracket

4. If the wiring harnesses have been removed, reroute

them through the tilt lock assembly with the ignition
wiring harness in the left hole and the directional
switch wiring harness in the right hole. Harnesses must
exit lower part of the steer column behind the steer
shaft (towards rear of truck). Reclamp to cowl if
and Terminals
necessary. Reconnect the assembly wiring harnesses
to the truck wiring harnesses.

5. Slip the boot over the tilt lock assembly.

SM 598,Oct ‘94 Steering Column and Component Removal and Replacement l 25-3-7
 Main Table of Contents

Group 25, Steering Column and Gear CUIRK

5. Apply a thin coat of grease in the bore of the directional direction (push lever up) until a #8 (or 4 mm)
control lever. Slip the lever onto the directional control screw can be inserted into the middle detent on the
base. lever.
d. Loosen the mounting screw on the forward switch
and adjust the switch box to achieve continuity
Directional
through the switch.
Control Lever
and Boot e. Remove #8 (4 mm) screw and return lever to
neutral detent. Switch must break continuity, If
switch does not break continuity, it must be read-
justed using the above steps.
f. When adjustment is correct, torque switch box
mounting screws to 0.8-1.0 Nom (7-9 in-lb; 0.6-
0.73 f&lb).

g* Repeat procedure for Reverse switch.

6. Tighten the capscrew/clamp of the directional control Directional Control Assembly and Ignition
lever assembly to 3.5-4 Nom (2.5-2.9 ft-lb). Switch Replacement
l Clean the capscrew and apply Loctite 262 before
1. Disconnect the negative lead at the battery.
applying torque.
2. Slip the directional control assembly onto the steering
7. Adjust the directional control using the following
column shaft.
illustration:

Directional
Control
Assembly

3. Clean the capscrew, apply Loctite 262, and tighten the

I / \ clamp bolt of the assembly to 3.5-4 Nom (2.5-2.9 ft-
Wire #78 -J Wire #73 J Wire #82 1 lb).
Normally Normally Open Common
Open 4. Check the assembly for smooth operation and make
necessary adjustments before proceeding.
a. Loosen mounting screws and set the directional
switch boxes to approximately the middle of the 5. Connect the wiring to the directional control switches
mounting slot on the assembly base. according to the labels you made during disassembly.

b. Connect a continuity meter on the forward switch 6. Connect the ignition wiring harness ends to the igni-
from the Common terminal to the Normally Open tion switch terminals according to the labels you made
terminal. If the adjustment procedure is being during disassembly.
performed with the directional control assembly
mounted on the steering column, connect the
continuity meter from the Normally Open termi-
nal to vehicle ground.
c. Rotate the directional control lever in the forward

25-3-8 l Steering Column and Component Removal and Replacement SM 598,Oct ‘94
 Main Table of Contents

CIRRK Group 25, Steering Column and Gear

7. Set the ignition switch into the mounting hole on the Steering Hand Wheel Replacement
lower half of the column cover. Tighten the lock ring
nut to IO-14 Nom (7.5-10.3 ft-lb). 1. Reconnect the horn contact ring wire from the base of
the handwheel to the bottom of the horn button.

Lock
Ring

Horn
Contact Horn
Ring Wire
Wire

Wire #6

8. Reconnect the horn contact ring wire to the horn 2. Apply a coat of insulating paste (Clark part no. 2802205)
contact ring. to horn contact ring, then set the handwheel into
position and tap with a rubber or plastic mallet to seat
it on the column.
Horn
Contact 3. Tighten the nut onto the colunm to a torque of 35-40
Ring N*m (25.5-29.5 ft-lb).

4. Screw the horn wire into the column and plug it into its
connection on the bottom of the horn button.

Horn

Ring
Wire

9. Slip the horn contact ring onto the steering column.

The groove in the ring should be on the lower portion
of the ring when it is replaced on the column. The
terminal should be on the right-hand side of the truck.

10. Join both halves of the cover over the upper column.
The parting line of the boot must be aligned with the
parting line of the two cover halves. Set the directional
control lever boot into the correct position. The horn 5. Set the horn button into place and pop it into position
ring contact should be positioned so that the two cover carefully. The horn symbol should be parallel to the
halves fit the groove in the ring. Tighten the four socket CLARK lettering on the hand wheel.
bolts to 2-3 Nom (1.5-2.25 ft-lb).
6. Reconnect the leads at the battery.

7. Replace the center cowl cover over the steering col-

umn. See Group 38 for instructions to replace the cowl
covers. Torque the screws to 8-10 Nom (5.5-7.5 ft-lb).

SM 598, Ott ‘94 Steering Column and Component Removal and Replacement l 25-3-9
 Main Table of Contents

Group 25, Steering Column and Gear CIRRU

IMPORTANT 9. Set the floorplate back into the driver’s compartment

If you set the column loosely into place to
assure correct alignment, recheck that all
mounting brackets, the universal pinch
joint, and all fasteners are torqued to their
correct limits. See the individual steps in
the reassembly procedures to find torque
limits.
and lower the operator’s seat deck.
Start the truck to check the function of the ignition switch.
Make sure no fluid leaks are evident in the steering control
valve hydraulic fittings. Remove the wheel chocks to check
all functions of the steering column, including ignition,
directional controls, tilt lock mechanism, and steering gear
for correct operation before returning the truck to service.

8. Replace the right and left cowl covers. The top lip of
the two covers must be inserted under the edge of the
dash before securing the covers in place. Torque the
cover set screws to X-10 N-m (5.5-7.5 ft-lb).

25-3-10 l Steering Column and Component Removal and Replacement SM 598, Ott ‘94
 Main Table of Contents
ClRRK
Section 4.
Steering System Relief Pressure Check and Adjustment
A CAUTION
SAFE PARKING. Before working on truck:
1. Park truck on a hard, level,-and solid
surface, such as a concrete floor with no
gaps or breaks.
2. Put upright in vertical position and fully
lower the forks or attachment.
3. Put all controls in neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the
wheels.
Description and Operation
Steering system relief pressure settings above the specified
values can cause failure of the hydraulic lines, damage to
seals in the steering gear, and ball joint breakage on the
steer axle.
The steering system’s pressure relief valve is part of the
main hydraulic pump assembly. Steering system relief pres-
sure is adjustable and should be checked if indicated by
troubleshooting. Use the gauge port on the pump to check
steering relief pressure.
Steering system relief pressure setting should be 8270-
8960 kPa (1200-1300 psi).
NOTE
If relief pressure is not correct, the prob-
lem may be caused by dirt in the valve or
worn parts, including steering control valve
and main hydraulic pump. Generally, if
the relief pressure measured when the steer-
ing system is in bypass is not correct, the
priority demand valve should be replaced.
SM 598, Ott ‘94 Steering System Relief Pressure Check and Adjustment
Group 25, Steering Column and Gear
A WARNING
Do not use your hands to check for hydrau-
lic leakage. Use a piece of cardboard or
paper to search for leaks. Escaping fluid
under pressure can penetrate the skin caus-
ing serious injury. Relieve pressure before
disconnecting hydraulic or other lines.
Tighten all connections before applying
pressure. Keep hands and body away from
pinholes and nozzles which eject fluids un-
der high pressure.
If any fluid is injected into the skin, it must
be surgically removed within a few hours
by a doctor familiar with this type of injury
or gangrene may result.
Steering System Relief Pressure Setting
Check and Adjustment
This procedure requires installation of a pressure gauge at
the gauge port on the main hydraulic pump. The pressure is
measured while the steering handwheel is turned fully in
one direction to put the steering system in bypass.
Steering system relief pressure setting may be checked
using a Mica Quadrigage (Clark Part No. 1800106) or with
a conventional pressure gauge, O-20,700 kPa (o-3000 psi).
1. Tilt the steering column fully forward and raise the seat
deck.
l 25-4-l
 Main Table of Contents

Group 25, Steering Column and Gear elMI

2. Clean the port opening and connect the pressure gauge

(also cleaned) to the gauge port on the main pump.
con?
Plug
v
= Relief
Valve
El-
O-Rings x Seat

Poppet A
z Spring
?
I!-
Valve
Body

b. Clockwise adjustment of the relief valve seat

raises the pressure setting at which the valve
relieves pressure; counterclockwise adjustments
lowers the pressure setting at which the valve
3. Starttheengineandletitwarmupuntil itrunssmoothly. relieves pressure.

4. Check steering system relief pressure setting at full 7. Restart engine and repeat steps to read and adjust the
throttle. Accelerate engine to full throttle and hold at relief pressure setting until correct relief pressure is
this speed while taking the pressure readings. set.

IMPORTANT l Once you adjust to the correct relief pressure

Do not operate system over relief any longer
than required to read the pressure gauge.
Prolonged time at relief pressure can result
in a damaged pump and valve.
5. Turn the steering handwheel in one direction until
steering cylinder reaches its stop (relief bypass). Hold
steering handwheel in relief position until pressure
reading is taken, and then release. Turn off engine.
Pressure should read between 8270-8960 kPa (1200-
1300).
setting, reset the core plug in the valve bore.
l If the correct relief pressure cannot be gained,
consider overhauling or replacing both the prior-
ity valve and the pressure relief valve. See Group
29, “Hydraulic Pump Overhaul” for instruction to
remove, overhaul, and replace the valves on the
pump.
8. Disconnect the pressure gauge and close the engine
compartment.

6. To adjust the steering pressure relief to 8270-8960 kPa

(1200-13OOpsi):
a. Carefully remove the core plug of the steering
pressure relief valve on the main pump by prying
the plug out.

25-4-2 l Steering System Relief Pressure Check and Adjustment SM 598,Oct ‘94
 Main Table of Contents

CIRRK Group 25, Steering Column and Gear

Section 5.

Steering Gear Overhaul

Disassembly .................................................................................................................................... 2
Meter (Gerotor) End ........................................................................................................................ 2
Control End ...................................................................................................................................... 2

Parts Inspection ..............................................................................................................................4

Reassembly .................................................................................................................................... 4
Control End ...................................................................................................................................... 4
Meter (Gerotor) End ........................................................................................................................ 6

IMPORTANT
Before removing any component for overhaul, make sure the correct repair
parts, seals, and gasket sets are available.

NOTE
The following material does not show the load sensing port on the steering gear
(steering control unit). The port is located in the center of the other four ports.
The load sensing port requires no special overhaul procedures.

SM 598, Ott ‘94 Steering Gear Overhaul l 25-5-l

 Main Table of Contents

Group 25, Steering Column and Gear CIARK

Remove meter (gerotor). Be careful not to drop star
Disassembly
(rotor).
Cleanliness is extremely important when repairing a steer-
ing gear. Work in a clean area. Before disconnecting lines, Rotor
clean port area of unit thoroughly. Use a wire brush to
remove foreign material and debris from around exterior
joints of the unit.
NOTE
Although not all illustrations show the unit
in a vise, it is recommended to keep the
unit in the vise during disassembly. Follow
the clamping procedures explained
throughout the text.

Meter (Gerotor) End Remove seal from meter.

1. Clamp unit in vise, meter end up. Clamp lightly on Remove drive spacer(s).
edges of mounting area, as shown. Use protective Remove drive.
material on vise jaws. Do not over-tighten jaws.

,e Capscrew

cer
are
.

9. Remove spacer plate.

1
10. Remove seal from housing.

2. Remove capscrews. Control End

11. Remove housing from vise and place on a clean soft
cloth to protect surface finish. Use athin-bladed screw-
driver to pry retaining ring from housing.

Sial Cap Screw

3. Remove end cap.

4. Remove seal from end cap.

25-5-2 l Steering Gear Overhaul SM 598,Oct ‘94

 Main Table of Contents

emK Group 25, Steering Column and Gear

12. Place assembly so shaft is horizontal. Rotate spool and IMPORTANT

sleeve until pin is horizontal. Push spool and sleeve Do not bind spool and sleeve in housing.
assembly forward with your thumbs just far enough to Rotate spool and sleeve assembly slowly
free seal gland bushing from housing. Remove bush- when removing from housing.
ing.
17. Push pin from spool and sleeve assembly.

18. Push spool partially from control end of sleeve, then

remove six centering springs from spool carefully by
hand. Note their position in the unit before they are
Seal removed.
Gland
Bushing

13. Remove quad ring seal from seal gland bushing.

/
Dust Seal
_. -

14. Use a thin-bladed screwdriver to pry dust seal from

seal gland bushing. Do not damage bushing.

15. Remove two bearing races and the needle thrust bear-
ing from spool and sleeve assembly.
19. Push spool back through and out of sleeve. Rotate
spool slowly when removing from sleeve.
Needle Bearing
Thrust
Bearing
20. Remove seal from housing.

Bearing/w
Race

16. Remove spool and sleeve assembly from cap (14-hole)

end of housing. (Not used on ’ C;“;k ‘Check
\
units with t Check Ball
integral column) Seat 7/16” Seal Ball Retainer

21. Remove set screw from housing.

22. Screw a l/8-inch-24 NC machine screw into end of

check ball seat. Then pull on screw with pliers to lift
seat out of housing.

23. Remove two seals from check valve seat.

Pin
24. Tip housing to remove check ball and check ball
retainer.

SM 598,Oct ‘94 Steering Gear Overhaul l 25-5-3

 Main Table of Contents

Group 25, Steering Column and Gear ElRRK

Parts Inspection
Inspect all parts for damage, cracks, broken parts, damaged
threads, corrosion or erosion of surfaces, worn spots, nicks
or scratches.
Check all mating surfaces. Replace any parts that have
scratches or burrs that could cause leakage. Discard all old
seals and replace with new ones.
Clean all metal parts in clean solvent. Blow dry with air. Do
not wipe dry with cloth or paper towel because lint or other
matter can get into the hydraulic system and cause damage.
Do not use a coarse grit or try to file or grind these parts.
If parts are left exposed, cover them with a clean cover to
prevent airborne dust from collecting on them.
4. Lubricate check ball seat and seals thoroughly before
installing seat in housing. When installing seat do not
twist or damage seals. Install check ball seat in hous-
ing; insert open end of seat first. Push check ball seat
to bottom of hole.
5. Install set screw. Use a 5/16-inch Allen wrench to
torque set screw to 11 Nom (100 in-lb; 8.3 ft-lb). To
prevent interference of parts, make sure top of set
screw is slightly below housing mounting surface.
6. Assemble spool and sleeve carefully so that the spring
slots line up at the same end. Rotate spool while sliding
parts together. Some spool and sleeve sets have iden-
tification marks; align these marks. Test for free rota-
tion. Spool should rotate smoothly in sleeve with
finger tip force applied at splined end.

Reassembly
Refer to Service Parts Book when ordering replacement
parts. A good service policy is to replace all old seals with
new seals at overhaul.
NOTE
Lubricate all seals (with exception of new
quad ring seal) with clean petroleum jelly
such as Vaseline.
Do not use excessive lubricant on seals for
meter (gerotor) section. 7. Bring spring slots of both parts in line and stand parts
Make sure all parts are clean and free of on end of bench. Insert spring installation tool (avail-
dust. Before assembly, lightly coat all in- able as Part No. 6000057) through spring slots of both
ternal metal parts with oil. parts. Position three pairs of centering springs (or two
sets of 3 each) on bench so that extended edge is down
and arched center section is together. In this position,
Control End insert one end of entire spring set into spring installa-
tion tool, as shown.
1. Use a needle-nosed pliers to lower check ball retainer
into check valve hole of housing. Make sure retainer is
straight (not tilted on edge) in housing.

. e-- Set Screw ( Not Used on

Units with Integral Column -
See Figure 12A 1
Seal

” Seal 0
0

3.9
Check Ball Seat

Check Ball
On those units which use the low torque centering
0 4 springs, there are two pairs of centering springs (or two
Check Ball sets of each) and one pair (two) spring spacers. The
&!z e 4m Retainer
(Standard Steering
spring spacers are installed together between the two
Figure 12 Control Unit) sets of centering springs. The installation procedure is
the same as that used on the standard (three pairs of
centering springs) units.
2. Install check ball in housing.

3. Lubricate 5/8-inch diameter seal and 7/16-inch diam-

eter seal. Install seals on check ball seat, as above.

25-S-4 l Steering Gear Overhaul SM 598,Oct ‘94

 Main Table of Contents

CWRK Group 25, Steering Column and Gear

8. Compress extended end of centering spring set and 13. Install two bearing races and the needle thrust bearing
push into spool sleeve assembly withdrawing installa- in the order shown.
tion tool at the same time.
Needle
9. Center the spring set in the parts so that they push down
evenly and flush with the upper surface of the spool
and sleeve.

10. Install pin through spool and sleeve assembly until pin
becomes flush at both sides of sleeve.

Pin

14. Install I-l/4-inch diameter dust seal in seal gland

11. Position the spool and sleeve assembly so that the bushing; flat or smooth side of dust seal must face
splined end of the spool enters the 1Chole end of down towards bushing.
housing first.
15. Install dry quad ring seal in seal gland bushing. Smooth
seal in place with your finger. Do not use any seal that
falls freely into pocket of bushing. Seal should not
“fall” into place but should require light force to seat.

Retaining
Ring

Seal
Gland -
Bushing
(with seals)

IMPORTANT
Be extremely careful that the parts do not
tilt out of position while being installed.
Push parts gently into place with slight ro-
tating action; keep pin nearly horizontal.
Push the spool assembly entirely within the
housing bore until the parts are flush at the
meter end or 16hole end of housing. Do
not push the spool assembly beyond this
point to prevent the cross pin from drop-
ping into the discharge groove of the hous-
ing. With the spool assembly in this flush
position, check for free rotation within the
housing by turning with light finger tip
force at the splined end.

12. Place housing on clean, lint free cloth. Install 2-1/8-

inch diameter seal in housing.

SM 598,Oct ‘94 Steering Gear Overhaul l 25-5-5

 Main Table of Contents

Group 25, Steering Column and Gear CUIRK

16. Install seal gland bushing over the spool end with a Meter (Gerotor) End
twisting motion. Tap the bushing in place with arubber
hammer. Make sure the bushing is flush against the 18. Clamp housing in vise, as shown. Clamp lightly on
bearing race. edges of mounting area. Do not overtighten jaws.

On those units which use the Teflon seal, install the

Teflon back-up ring into the recess cut into the seal
gland bushing. Install the Teflon seal over the spool
end, then carefully install the seal gland bushing over
the spool end using a rotary motion.
NOTE
The seal gland bushing which is used with
the Teflon seal is not the same as the seal
gland bushing used with the standard quad-
ring seal. The seal gland bushing with the
Teflon seal has an identification groove cut
into the outer diameter of the bushing. The
grooved bushings can only be used with the
Teflon seals and the non-grooved bushings NOTICE
used only with the quad-ring seals. Check to ensure that the spool and sleeve
are flush or slightly below the surface of
the housing.
Teflon Seat
IMPORTANT
Clean the upper surface of the housing by
wiping with the palm of clean hand. Clean
each of the flat surfaces of the meter sec-
tion parts in a similar way when ready for
reassembly. Do not use cloth or paper to
clean surfaces.

19. Install 3-inch diameter seal in housing.

Spacer Plate

17. Install retaining ring in housing. After installing ring, - Seal

tap on ring or pry with screwdriver around entire
circumference of ring to properly seat ring in groove.

20. Install spacer plate. Align bolt holes in spacer plate

with tapped holes in housing.

21. Rotate spool and sleeve assembly until pin is parallel

with port face. Install drive, making sure you engage
drive with pin.

25-5-6 l Steering Gear Overhaul SM 596,Oct ‘94

 Main Table of Contents

ClClRU Group 25, Steering Column and Gear

24. Install drive spacer(s) when used, in meter.

IMPORTANT
Failure to properly install drive and pin
may cause unit to self steer.

NOTE
To assure proper alignment, mark spline
end of drive shaft with a line parallel to slot
on other end, before installing. cu. m/rev. Displ. Unit
equires 2 Spacers
22. Install 3-inch diameter seal in meter (gerotor).

25. Install 3-inch diameter seal in end cap.

26. Install end cap on gerotor, and align holes.

27. Install 7 &y cap screws in end cap. Pretighten.screws

to initial torque of 17 I+m (150 in-lb), then torque
screws to final torque of 31 N*m (275 in-ib) in the
sequence shown.
23. With seal side of meter toward spacer plate, align star
valleys on drive. Note the parallel relationship of
reference lines A, B, C, and D in figure. Align bolt
holes without disengaging meter from drive. Be sure
star has engaged drive spline in position shown.

Meter (Gerotorl Star VakV

28. Inspect the assembly to be sure all parts have been

installed and fasteners correctly installed and tight-
ened.

(Reprint courtesy of EATON Corporation)

Pin Port Face

SM 598,Oct ‘94 Steering Gear Overhaul l 25-5-7

 Main Table of Contents

GROUP 26

GROUP 26

STEER AXLE

Steer Axle Specifications and Description .... ... . . .. .. .. ..... Section 1

Steer Axle Wheel Bearing Maintenance and Adjustment.. ........

................................................................................... Section 2

Steer Axle Removal and Replacement ....... .. ... .. .. ... .. ..... Section 3

Steer Axle Overhaul .... .. . . .. .. .. .. ..... ... ........ ...... ... ... . .. .. ....... Section 4

Steer Cylinder Removal and Replacement . ... .. .. .. ... .. .... Section 5

Steer Cylinder Overhaul .. .... .. ... .. ....... ......... ... ... . ... ... .. .... Section 6

SM 598,Oct ‘94 Steer Axle

 Main Table of Contents

Group 26, Steer Axle

clmu
Section 1.

Steer Axle Specifications and Description

Specifications Service intervals

Cushion-Tire Steering Linkage Inspection and Lubrication: Every 50-
250 hours and each PM.
Steering System Relief Pressure Setting: 8270-8960 kPa
(1200-1300 psi). Steer Wheel Bearing Inspection and Lubrication: Every
500 hours of operation.
Steer Cylinder Type: Double-acting, piston-type.
Steer Cylinder Seals Leakage Check: Every 50-250 hours
Turning Arc: 83” maximum inside turning angle; 60” maxi-
and each PM.
mum outside turning angle.
Steer Axle Mounting Inspection: Every 50-250 hours and
Pneumatic-Tire
each PM.
Steering System Relief Pressure Setting: 8970 kPa (1300
Power Steering Relief Pressure Check: Every year or 2000
psi) hours of operation.
Steer Cylinder Type: Double-acting, piston-type
Turning Arc: 75”maximum inside turning angle; 54” maxi- Description
mum outside turning angle.
The steer axle has the steer cylinder, steer knuckles, and
Bearing Grease: Grade No. 2 EP multi-purpose grease, steering links mounted on it. All these components can be
Clark Part MS-107C. removed, serviced, and replaced.
The steering gear (steering control unit) at the base of the
Fastener Torques steering column directs hydraulic fluid to one end or the
Steer Axle Mounting Bolts: 170-190 Wm (125-140 ft-lb) other of the steer cylinder to pivot the steer wheels.

Cylinder to Axle Mounting Bolts: 280-320 Wm (205-234.5
ft-lb)
Steering Link to Steering Knuckle Nuts: 135-150 Nom (9%
110 ft-lb)
Steer Knuckle King Pin Castle Nuts: See installation
dures in Section 4, “Steer Axle Overhaul.”
The steer axle is bolted to the truck frame. The steer cylin-
der is connected to the steering knuckles by steer links.
Mounting trunnions allow the axle to tilt independently of
the truck and “silent” mounts cushion the axle on the
trunnions.
proce-
All bearings used in the steer axle linkage have lubrication
fittings and are serviceable. Axle removal, replacement,
and service for all components, including overhaul of the
steer cylinder, is explained in the Sections for this Group.

SM 598, Ott ‘94 Steer Axle Specifications and Description l 26-l-l

 Main Table of Contents
Group 26, Steer Axle CIRRK

Steer Axle 7

Steer -
Cylinder
Axle
Mounting
frunnion Steer
Knuckle

Silent
Mount ‘-ink

Steer Axle and Mounting - Cushion-Tire Axle

Steer

Steer -
Steer
Cylinder
Knuckle

Mounting Steering J
Trunnion Link

Steer Axle and Mounting - Pneumatic-Tire Axle

26-1-2 l Steer Axle Specifications and Description SM 598,Oct ‘94

 Main Table of Contents

CHIC Group 26, Steer Axle

Section 2.

Steer Axle Wheel

Bearing Maintenance and Adjustment
Wheel Bearing Check ...................f..................................................................
.............................. 1

Wheel Bearing Lubrication ........................................................................................................... 1

Bearing Disassembly ....................................................................................................................... 2
Bearing Reassembly ......................................................................................................................... 3

Wheel Bearing Adjustment ........................................................................................................... 4

IMPORTANT
Before removing any component for overhaul, make sure the correct repair
parts, seals, and gasket sets are available.

A CAUTION Wheel Bearing Lubrication

SAFE PARKING. Before working on truck:
These procedures cover bearing lubrication for the two
Park truck on a hard, level, and solid
types of steer wheels used on the truck; pneumatic-tire
surface, such as a concrete floor with no
wheels which are mounted on a hub that contains the bear-
gaps or breaks.
ing components and cushion-tire wheels with the bearings
Put upright in vertical position and fuBy
installed in the wheel. Use the procedures to clean, repack
lower the forks or attachment.
and adjust bearings for both the cushion-wheel and the
Put ah controls in neutral. Turn key switch
pneumatic-tire hub.
OFF and remove key.
Apply the parking brake and block the
,CushiFr ,
wheels. Pneumatic-Tire
Wheel Mounting

Wheel Bearing Check

A wheel bearing check should be performed about every
500 hours of operation or three or four times a year. Wheel
bearings need adjustment only after 2000 hours or as needed.
It is recommended that you clean and repack the bearings
before adjustment. Check hourmeter total hours and refer
to the truck’s PM schedule. See steer wheel bearing
lubrication procedure below.
To check the steer wheel bearings for excessive free play or
looseness:

1. Grasp the wheel with both hands and try to move it by

a rocking motion top-to-bottom. I I
Steer Axle Knuckle 1
2. Try to pull it in and out along the wheel spindle.

Watch for excessive free
steering knuckle bearings.
of free movement. If the
ment, the bearings require
ment.
movement in wheel bearings or
There should be a small amount
wheel has excessive free move-
additional service and/or adjust-
Pneumatic-tire (lef) and cushion-tire (right) wheel-
bearing assemblies.
The bearing components and arrangement are the same for
both the cushion and pneumatic types. Instructions for
repacking/lubricating the bearing components apply to both
types*

SM 588,Oct ‘84 Steer Axle Wheel Bearing Maintenance and Adjustment l 26-2-l
 Main Table of Contents
Group 26, Steer Axle
Bearing Disassembly
Be sure truck is parked and blocked up correctly and
safely to raise steer wheels off the floor. Refer to
“Lifting, Jacking, and Blocking,” in the Group “SA.”
Loosen lug nuts of pneumatic-tire wheels before com-
pletely raising rear wheels off the floor
Lower truck onto blocking. Remove lug nuts and then
wheel assembly.
NOTE
Because of the heavy weight of the pneu-
matic wheel and tire, it is suggested to first
remove the wheel and tire assembly from
hub when servicing the bearings to avoid
damage to the grease seal when the wheel
hub is moved off or on the spindle. It also
makes the work simpler and easier.
CIARK
4. Refer to the exploded view illustration of the cushion-
wheel bearing assembly.. Loosen and remove the
hubcap from wheel or hub. You may have to lightly tap
hub cap with a hammer and chisel and use a pry bar to
loosen. Be careful not to damage mounting surfaces.
Remove O-ring from hubcap.
5. Clean the excess grease from around the wheel nut.
6. Remove cotter pin, loosen and remove wheel nut and
bearing washer.
7. Remove outer bearing by pulling out on the cushion
wheel or pneumatic hub slightly to loosen bearings.

Cushion Wheel Bearing Assembly

26-2-2 l Steer Axle Wheel Bearing Maintenance and Adjustment SM 598,Oct ‘94
 Main Table of Contents

CIRRK Group 26, Steer Axle

8. Pull the wheel or hub off the spindle. Support the wheel 1. Install new inner and outer bearing cups by pressing
or hub to avoid dragging the grease seal at the back side into hub or wheel. Be sure cups are fully seated in bore.
across the thread on spindle end. Spindle guard re-
mains on spindle.

9. Clean the old grease out of center of the wheel or hub.

10. To remove inner bearing and seal, lay wheel or hub

down with outer edge up (support hub on blocking).
Remove the inner bearing cone and grease seal, using
a brass drift pin, rod, or piece of pipe to drive the
bearing and seal out of the hub.

2. Pack the bearings with grease and install the inner

- Bearing
and bearing in the hub or wheel.
Cone

Grease
Seal

11. Clean and inspect the bearing cups and cones for wear
or other damage. Replace, as necessary.

IMPORTANT
Keep serviceable bearing cups and cones
matched together. Always replace bearing
cups and cones as a set.
12. Inspect grease seal for wear and damage. Replace as
necessary. It is recommended to install a new grease
seal whenever old ones are removed.
3. Pack cavity between bearing and grease seal half full
with grease.
4. Install new grease seal in hub or wheel inner bore.
Apply coating of grease to inside diameter of seal lips
prior to assembly, then install seal in hub or wheel
bore.

13. Use a standard puller to remove bearing cups from hub

or wheel if bearings require replacement.

Bearing Reassembly
The procedures for packing and reassembling the bearing
are the same for the cushion wheel or pneumatic wheel hub.
NOTE
Use Grade No. 2 EP multi-purpose grease,
Clark MS-10X.
Carefully press or tap grease seal into place with a soft-
faced mallet until seal is seated in bottom of bore.

Install hub or wheel on spindle. Be careful not to

damage grease seal lip when moving the hub over the
end of spindle and threads.

Pack cavity in hub between bearings one-half full with

grease.

SM 598,Oct ‘94 Steer Axle Wheel Bearing Maintenance and Adjustment l 26-2-3
 Main Table of Contents
Group 26, Steer Axle
8. Install the outer wheel bearing after it has been packed
with grease.
9. Install bearing washer and hand tighten wheel nut.
10. Rotate hub or wheel counter clockwise and torque
wheel nut to 27-31 N*m (20-23 ft-lb).
11. Back wheel nut up until it is loose.
12. While turning the hub or wheel counter clockwise,
torque the wheel nut to 2.3-2.8 N*m (1.7-2 ft-lb).
13. Back up wheel nut to nearest slot and install new cotter
pin. Bend cotter pin tabs.
14. Recheck for correct bearing adjustment by rotating the
wheel by hand. Wheel should rotate freely or with only
slight “drag”. Readjust bearings by adjusting wheel
nut as necessary to avoid binding in bearings.
15. Pack the area around wheel nut with grease.
16. Refit O-ring on hubcap and install hubcap by tapping
into place with a rubber or plastic-faced hammer.
26-2-4 l Steer Axle Wheel Bearing Maintenance
Emu
17. Remount wheel and tire as applicable for pneumatic-
tire assemblies. See Group 22 for mounting procedures
and nut torques.
Wheel Bearing Adjustment
The steer wheel bearings are retained and adjusted by the
wheel nut.
NOTE
You should clean and repack the wheel
bearings before performing a wheel bear-
ing adjustment. See “Wheel Bearing Lu-
brication” in this Section for the complete
procedure.
1. Make sure the truck is parked on a level, hard surface,
the upright is fully lowered, the drive wheels are
chocked, and the steer wheels are jacked and blocked
securely. Refer to “Lifting, Jacking, and Blocking” for
safe procedures.
Remove hubcap.
Remove and discard cotter pin.
Loosen wheel nut.
After wheel nut is loosened, hit the top of wheel to
loosen the bearings. This moves the bearings free of
their seated, running position.
6. Rotate hub or wheel counter clockwise and torque
wheel nut to 27-31 N*m (20-23 ft-lb).
7. Back wheel nut up until it is loose.
8. While turning the hub or wheel counter clockwise,
torque the wheel nut to 2.3-2.8 Nom (1.7-2 ft-lb).
9. Back up wheel nut to nearest castellation slot and
install new cotter pin.
10. Recheck for correct bearing adjustment by rotating the
wheel by hand. Wheel should rotate freely or with only
slight “drag”. Readjust bearings by adjusting wheel
nut as necessary to avoid binding in bearings.
11. Bend cotter pin tabs over.
12. Pack the area around wheel nut with grease.
13. Refit O-ring on hubcap if removed or replaced and
install hubcap by tapping into place with a rubber or
plastic-faced hammer.
and Adjustment SM 598,Oct ‘94
 Main Table of Contents

ElfIRK Group 26, Steer Axle

Section 3.

Steer Axle Removal and Replacement

2
Steer Axle Removal ........................................................................................................................

3
Steer Axle Replacement ........_.......................................................................................................

SM 598, act ‘94 Steer Axle Removal and Replacement l 26-3-l

 Main Table of Contents

Group 26, Steer Axle CUlRK

A CAUTION
SAFE PARKEVG. Before working on truck:
1. Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
2. Put upright in vertical position and fully
lower the forks or attachment.
3. Put all controls in neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the
wheels.

Steer Axle Removal

These procedures describe steer axle removal for both cush-
ion-tire and pneumatic-tire steer axles. The removal proce-
dures are basically the same for both axles even though the
axles are different. Minor differences will be explained in
the text. L Disconnect cylinder lines here.
Remove the counterweight before removing the steer
axle. Refer to Group 38, Section 2, “Counterweight
Removal and Replacement.” A! CAUTION
Axle must be supported before any attach-
A WARNING
Do not remove the counterweight unless
ing fasteners are removed.

5. If another lift truck is used to temporarily support axle

you have training and are familiar with the
while removing, put forks in center of carriage about
correct procedures. Counterweights can
305 mm (12 in) apart. Move forks under axle and raise
fall if not handled correctly and cause se-
itjust to remove its weight frommounting bolts. Or use
vere injury or death.
a portable floor jack to carefully support the axle at its
Loosen lug nuts of steer wheels. center section.

A
Do not raise truck by hoisting on overhead
6. Loosen and remove nuts from axle mounting
front and rear.
bolts,

For cushion-tire axles, remove the mount plates

guard or by jacking or lifting on counter-
l

from the bottom of the trunnion mounts of the

weight.
Block the drive wheels of the truck and raise and block
the rear end. Remove steer wheels. See “Lifting,
Jacking, and Blocking” in Group “SA” for safe proce-
dures to jack the truck.
steer axle (Figure A.).
. For pneumatic-tire axles, remove the washers
behind the nuts also (Figure B.).
7. Remove the mounting bolts.

8. Lower the axle allowing its weight to pull the silent

n ! CAUTION
Make sure truck is correctly raised
safely blocked using hardwood blocks
der the frame. Be sure the blocking
permit installation of the axle without
turbing the blocking.
blocks out of frame recesses. Watch the silent blocks
and to be sure they release freely from frame. You may
un- have to loosen blocks with a pry bar if they bind.
will
dis- 9. Carefully withdraw the axle from beneath the truck
and move to safe storage.

Loosen and remove hydraulic steering lines from steer-

ing cylinder. Plug fittings and cap open ends of lines.
Keep all hydraulic fittings and openings clean.

26-3-2 l Steer Axle Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents
clmu
NOTE
On pneumatic-tire trucks, removal of the
silent blocks after a long period of usage
may be difficult. Routine removal of the
silent blocks from the steer axle trunnions
(pivot pins) is not recommended unless they
have obvious wear, damage, or failure. If
removal by conventional pulling methods
is not successful, they then must be removed
by destruction of the silent block assembly
using a cutting torch and/or hammer and
chisel to separate them from the axle trun-
nions. Be sure that the axle trunnions are
not damaged.
Figure A. Steer Axle Mounting - Cushion
SM 598,Oct ‘94
Group 26, Steer Axle
Steer Axle Replacement
Replacement is the reverse of removal. Refer to Figures A
and B for replacement.
A! CAUTION
Make sure truck is correctly raised and
safely blocked using hardwood blocks un-
der the frame. Be sure the blocking will
permit installation of the axle without dis-
turbing the blocking.
If silent blocks have been removed from axle, install
new silent block assemblies. Use a rubber or plastic
mallet to seat the silent mounts onto the axle trunnions.
Make sure that the silent blocks are positioned cor-
rectly front and rear on the steer axle trunnions at the
start of installation. Align the silent blocks square with
the axle.
Use a fork lift truck or mobile floor jack to temporarily
support and raise the axle into place under the truck. If
another lift truck is used to handle axle, center the forks
with about 305 mm ( 12 in) spread between them. Place
steer axle assembly in secure position on fork tips.
If hydraulic jack is used, be sure axle is securely
supported on jack pad.
Silent
Mount and
Trunnion
Figure B. Steer Axle Mounting - Pneumatic
Steer Axle Removal and Replacement l 26-3-3
 Main Table of Contents
Group 26, Steer Axle
A WARNING
Heavy components can fall and cause se-
vere injury. Keep your body clear at all
times.
4. Install axle assembly into frame by slowly raising it up
while guiding silent block bushings into frame sockets.
5. Install silent blockmounting bolts through frame socket
holes and silent block, front and rear.
For cushion-tire steer axles, reset the two mounting
plates under the silent blocks of the axle.
6. Install nuts on silent block fasteners and tighten to 170-
190 Nom (125140 ft-lb).
8. Remove temporary axle support from under truck.
9. Connect the hydraulic lines to steering cylinder. Tighten
fittings to 12-14 Nom (106-123 in-lb; 8.8-10.3 ft-lb).
IMPORTANT
Make sure all fittings and openings on the
hydraulic lines are clean.
26-3-4 l Steer Axle Removal and Replacement
EmK
10. As applicable, install pneumatic wheel and tire assem-
blies. See Group 22, “Wheels and Tires” for mounting
procedures.
11. Carefully raise the truck off the blocking as described
in “Lifting, Jacking, and Blocking.” Remove the
blocking and lower the truck to the floor.
12. Install counterweight; refer to Group 38, Section 2,
“Counterweight Removal and Replacement.”
13. Check the axle and steering system for proper opera-
tion. Start the engine and operate the steering gear to
move the steer wheels to maximum travel in both
directions. Note any unusual motion or noise.
If the system appears to be operating correctly, drive
the truck slowly. Fully steer the vehicle in each
direction and check response.
14. Check steering cylinder hose line connections and
cylinder rod seals for any evidence of oil leakage
before returning the truck to service.
SM 598,Oct ‘94
 Main Table of Contents
Group 26, Steer Axle
EmIt

Section 4.

Steer Axle Overhaul

2
Preparation for Steer Axle Disassemble and Overhaul ..............................................................

2
Steer Axle Disassembly ..................................................................................................................

..”..............3
Parts Inspection ............................................................................................................

3
Steer Axle Reassembly ...................................................................................................................

IMPORTANT
Before removing any component for overhaul, make sure the correct repair
parts, seals, and gasket sets are available.

! n
CAUTION
SAFE PARKING. Before working on truck:
1. Park truck on a hard, level, and solid surface, such as a concrete floor with
no gaps or breaks.
2. Put upright in vertical position and fully lower the forks or attachment.
3. Put all controls in neutral. Turn key switch OFF and remove key.
4. Apply the parking brake and block the wheels.

SM 598,Oct ‘94 Steer Axle Overhaul l 26-4-l

 Main Table of Contents

Group 26, Steer Axle CUIRK

Preparation For Steer Axle 2. Remove and discard cotter pin from kingpin castel-
lated nut. Remove the nut.
Disassembly and Overhaul
NOTE
Cleanliness is of extreme importance in the
repair and overhaul of this assembly.

Before starting disassembly, thoroughly clean the axle

assembly of all accumulations of dirt, oil, corrosion,
and other substances to prevent contamination of the
parts during disassembly and overhaul.
Work in a clean area.
Keep all parts in order as disassembly progresses.
Take care to properly identify each part and its order Kingpin Retainer Pin
of removal. If necessary, keep notes and put mark-
ings on parts using a non-destructive marker such as a Drive the kingpin down and out of the assembly.
grease pencil or felt-tipped pen. Remove the steering knuckle. Note right and left
knuckle parts.
l See Section 2, “Steer Axle Wheel Bearing Mainte-
nance,” for procedures to remove the pneumatic-tire IMPORTANT
assembly hub from the spindle/knuckle of the steer Do not let the knuckle or pin fall when the
axle. Removal of the hub assembly will make disas- pin is removed.
sembly of the steer axle knuckle easier.
Remove the kingpin retainer pin from the base of the
l If necessary, see Section 3, “Steer Axle Removal and
kingpin.
Replacement,” for the procedures to remove the steer
axle from the truck. Remove the knuckle bearing washers, dust covers,
l See Section 5, “Steer Cylinder Removal and Replace- upper and lower grease seals, bearings, and bearing
ment,” for the procedures to remove the steering cyl- cups from the assembly.
Grease
inder and steering links from the steer axle. Washer --, Seals
l See Section 6, “Steering Cylinder Overhaul,” to disas-
semble the steer cylinder.

Steer Axle Disassembly

To disassemble the steering knuckle, kingpin, and bearing
from the steer axle, it is not necessary to remove the axle
from the truck.

1. Remove the snap ring from the bottom of the steering

link pin and remove the pin. Steering link is free to be
Bearing Cup 1 ’
removed from the cylinder rod and knuckle.

Bearing cups may be removed by hand, by using a bearing

puller, or by tapping out using a brass drift pin.

26-4-2 l Steer Axle Overhaul SM 598,Oct ‘94

 Main Table of Contents

CMRK Group 26, Steer Axle

Parts Inspection 3. Set the retainer pin into the king pin and slide the king
pin into the steer axle/knuckle bore.
Clean all bearings, cups, seals, pins, and other parts in
IMPORTANT
an approved cleaning fluid.
Make sure that retainer pin enters the hole
Inspect all parts for scratches, chips and wear. Check in the underside of the axle
the steering arms of the knuckles to be sure they are not
bent or twisted. Check all threaded parts for damage.

Replace all parts which show damage.

If parts are to be left exposed, coat all mating surfaces

of parts with a light coating of engine oil.

Steer Axle Reassembly

Recommended greasing procedure:
a. Use Grade No. 2 EP multi-purpose grease, Clark
MS- 107 or equivalent. Kingpin Retainer Pin

b. Pack all tapered roller bearings with grease before

assembly. 4. Reset the kingpin castellated nut to the top of the
kingpin. Torque nut to 50-60 Nom (36.5-44 ft-lb).
c. Pack knuckle pin (bearing) seals with grease be-
fore assembly. 5. Rotate the steer knuckle three times through its full
range of movement. Check to be sure that it is free to
d. Fill steer link sockets with grease through grease
rotate in the bearings without binding.
fittings after axle is assembled.
6. Loosen the kingpin nut and retorque the nut to 30-35
1. Install the upper and lower knuckle bearing cups into
the knuckle housing bore. Tap into place with a brass Nom (22.2-25.5 f&lb).
drift pin or equivalent. 7. Advance the nut to the next castellated slot and lock the
nut into position with a new cotter pin. Bend cotter pin
tabs over.

8. Replace steering link pin and snap ring to join the

cylinder rod to the steering link and knuckle.
Cylinder Rod Stem

-===l 7

Bearing Cup -!I LBearing Steering Link J

9. Reinstall grease fitting in knuckle housing and lubri-
IMPORTANT cate with recommended grease.
Make sure that bearing cup is fully seated
against the shoulder in bore. There must
be no gap left between cup and the shoul-
der in the bore at assembly.

2. Apply grease to upper and lower knuckle bearings and

install bearings, grease seals, and washers to bores of
knuckle.

SM 598,Oct ‘94 Steer Axle Overhaul l 25-4-3

 Main Table of Contents

EmK Group 26, Steer Axle

Section 5.

Steer Cylinder Removal and Replacement

A CAUTION
Steer Cylinder Rod
Stem
SAFE PARKING. Before working on truck:
1. Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
2. Put upright in vertical position and fully
lower the forks or attachment.
3. Put all controls in neutral. Turn key switch I

OFF and remove key.

J
---

4. Apply the parking brake aud block the Steering Link
wheels.
Steer Cylinder Removal
The steer cylinder can be removed from the steer axle for
overhaul or replacement without removing the steer axle
from the truck. The cylinder should be overhauled or re-
placed if steering problems or troubleshooting information
indicate the cylinder is malfunctioning. See Group 25,
Section 2, “Steering System Troubleshooting,” for steering
problem diagnoses. See Section 6 in this Group for steer
cylinder overhaul procedures.
1. Place a drain pan under the steer cylinder and remove
the hydraulic lines from the cylinder fittings. Cap
fittings and lines to prevent fluid from leaking and to
protect the components and hydraulic system from
dust and dirt. Label hoses and fittings for correct
reassembly.
1 * Snap Ring
Steer Link Bearing
NOTE
Mark left-side and right-side parts for cor-
rect reassembly.
3. Tap steer link pin upward until it clears the steering
link bearing and remove the pin.
4. Remove steer link bearing from steering link-to-cylin-
der rod end bore.
5. Rotate the steering link away from the cylinder rod
end.
6. Repeat steps 1 through 5 for the opposite side of the
steer cylinder.
7. Remove the four steer cylinder mounting bolts and
washers from the steer axle. Removal torque on these
bolts can be as high as 405 Nom (300 ft-lb).
Cylinder is now ready to be removed from the steer axle
body. Cylinder must be lifted off dowel pins positioning
cylinder to axle body.

Remove fittings.

2. Remove the snap ring from the bottom of the steering

link pin. Steering link pin attaches steer cylinder rod
n ! CAUTION
end to steering link.
Cylinder is somewhat heavy and bulky.
When removing cylinder from mounting
be prepared to lift and move the full weight
of the cylinder.

SM 598,Oct ‘94 Steer Cylinder Removal and Replacement l 26-5-l

 Main Table of Contents

Group 26, Steer Axle ElfIRK

Parts Inspection 2. Position the steering link with the cylinder rod end.
Reuse steer link bearing if still serviceable. Install new
Completely inspect all parts: bearings if scoring or wear marks are evident or if the
1. Clean all bearings, cups, seals, pins, and other parts in bearings do not operate smoothly.
an approved cleaning fluid. Steer Cylinder Rod
2. Inspect all parts for scratches, chips, scoring, and
uneven or heavy wear. Check steering links to be sure
they are not bent or twisted. Check all threaded parts
for damage.
3. Replace all parts showing excessive wear or signs of
damage.
4. If parts are to be left exposed, coat all mating surfaces Snap RingYd\
of parts with a light layer of engine oil. Keep all parts Steer Link Bearing
clean and covered.
3. Rotate steering link into cylinder rod end and align
5. Remove and clean all grease fittings before reassem-
bearing hole with rod end.
bling cylinder components.
4. Tap pin through steer link bearing hole with snap ring
Refer to Section 6, “Steer Cylinder Overhaul”, if pressure groove on lower end.
check or troubleshooting tips indicate a problem with steer
cylinder performance. IMPORTANT
Make sure bearing is properly aligned with
pin in the hole.
Steer Cylinder Replacement
5. Install the snap ring to the steering link pin.
1. Remount the steer cylinder onto the steer axle dowel
6. Repeat steps 1 to 5 for rod end-to-steering link connec-
pins; set bolts and washers in place and torque mount-
tion for opposite side.
Ing bolts to 280-320 N*m (205234.5 ft-lb).
7. Clean and replace hydraulic hoses on correct, clean,
n Mounting Bolt 7 cylinder fittings. See Group 40, Hydraulic Fitting
Tightening Procedure” for replacement procedures.

Mounting Bolt

n ! CAUTION
Cylinder is somewhat heavy and bulky.
When remounting cylinder to steer axle
body, be prepared to lift and maneuver the
full weight of the cylinder as you set it into
Replace fittings.
position.
8. Check to be sure all lube fittings are installed. Fill all
lubrication points with correct lubricant. See recom-
mended greasing procedure above.
9. Test function of steer cylinder before returning the
truck to service.

26-5-2 l Steer Cylinder Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents

CIRRU Group 26, Steer Axle

Section 6.

Steer Cylinder Overhaul

Preparation for Steer Cylinder Disassembly and Overhaul ......................................................

2

Steer Cylinder Disassembly ......................................................

. ...........................
.. .....................
2

Parts Inspection ..............................................................................................................................

2

Steer Cylinder Reassembly ...........................................................................................................

3

Operational Pressure Test ..........................

. .................................................................................
4

IMPORTANT
Before removing any component for overhaul, make sure the correct repair
parts, seals, and gasket sets are available.

Cylinder Rod 7

Steering Cylinder
Cushion-tire truck cylinder with “C” stamped on rod end;
pneumatic-tire truck cylinder with “P” stamped on rod end.

SM 598, June ‘94 Steer Cylinder Overhaul l 28-8-l

 Main Table of Contents

Group 26, Steer Axle CIRRK

Preparation for Steer Cylinder 4. Remove gland from opposite end of steer cylinder.

Disassembly and Overhaul 5. Remove the seal and O-ring set from the piston.
Discard seals. Replace with new seal set at assembly.
Refer to Section 5 for removal of steer cylinder from the
steer axle body.
IMPORTANT
Cleanliness is of extreme importance in the
repair and overhaul of this assembly.

1. Overhaul steer cylinder only in a clean, dust-free

location, using clean tools and equipment. Dirt or grit
will damage the highly-machined surfaces and will
result in leakage or premature failure of components.
Cleanliness of the hydraulic circuit is extremely im-
portant to the proper operation and maintenance of the
system. Be sure the work area is clean.

2. Before disassembly, the exterior of the steer cylinder

should be carefully cleaned to remove all dirt and 6. Remove (inner) gland packing (O-ring) seal. Replace
grease accumulation. with new seals at assembly.

inner Gland
3. Be sure all hydraulic fluid has been removed from the
Packing (O-
cylinder. Stroking the piston rod will help force the
Ring) Seal
fluid out.

4. Before starting disassembly, the steer cylinder should

be carefully examined to determine if there is any
external damage.

Steer Cylinder Disassembly

1. Clamp the steer cylinder assembly in a vise. Wrap the
cylinder in a course cloth to prevent slipping and
scratching. Use extreme caution when tightening vise
and do not overtighten; cylinder can be bent, distorted,
and potentially destroyed.
2. Remove one gland by pulling it from cylinder barrel
and pulling it off the piston rod.
Gland 1 7 Gland
7. Remove the rod (U-cup) seal and rod wiper from gland
and discard. Note direction of seal and wiper seating
for correct reassembly. Replace with new seals and
wipers at assembly.
Parts Inspection
1. Carefully clean all parts in an approved solvent and
place on a clean surface.

2. Check the piston for chips, cracks, and looseness on the

rod. If loose, replace rod and piston assembly.

3. Be sure the piston-seal groove in the piston is smooth,

true, and undamaged.

4. Check the piston rod for damage. Look for scratches,

grooves, gouges, pitting, corrosion or other evidence
of unusual wear. Minor surface damage may be
repaired by use of fine abrasion cloth or stoning.
3. Remove the piston and rod assembly from the cylin-
Deeper damage will require replacement of piston rod
der.
assembly.

26-6-2 l Steer Cylinder Overhaul SM 598, June ‘94

 Main Table of Contents

CIRRK Group 26, Steer Axle

5. Carefully inspect the cylinder internal bore for wear, 2. Install new piston seal over the O-ring seal.
scratches, corrosion or other damage. Check the
outside for damage. Inspect all welds for cracks.

6. Inspect the cylinder ports and threads to be sure they

are free of contamination and that the threads are clean
and not damaged.

7. Check the gland for cracks or damage that could cause

failure.

8. Deep gouges or pitted surfaces require replacement of

parts.

9. Put a light coating of hydraulic fluid on all parts. If

parts are to be left disassembled for a period of time, 3. Install new gland packing (O-ring) seal on inner end of
such as overnight, they should be covered with a clean gland.
cloth. Inner Gland
Packing (O-
Ring) Seal
Steer Cylinder Reassembly
Check to make sure the overhaul kit you have is correct and
that all parts are included.
IMPORTANT
Be sure inside of cylinder and all parts are
clean before starting reassembly.
Assemble cylinder carefully to prevent dam-
age to seaI lips and O-rings. Seak should
be lubricated with hydraulic oil to assist
assembly into cylinder barrel and gland.
Heating seal rings in boiling water before
4. Install new rod wiperand rod (U-cup) seal in outer end
starting assembly will aid in assembly.
of gland.

1. Install new O-ring seal on the piston.

4 Rod Wiper

Rod (U-Cup)
Seal

IMPORTANT
Be sure the rod wiper and rod (U-cup) seal
are installed in the correct directions.

5. Lightly lubricate the cylinder and gland mating sur-

faces with hydraulic oil before assembly.

SM 598, June ‘94 Steer Cylinder Overhaul l 26-6-3

 Main Table of Contents

Group 26, Steer Axle CIRRK

Install the gland onto the cylinder bore rim, making
sure gland is fully seated on cylinder.
Install piston and rod assembly into the cylinder.
NOTE
A special part is included in the parts kit to
allow you to slip the gland over the rod end
without damaging the gland seals.
OperationalPressureTest
Once cylinder is remounted on axle (see Section 5), con-
nect pressure source in turn at each port. Extend piston rod
at each side and test with internal pressure of 13790 kPa
(2000 psi). At this pressure no leakage must occur.

Repeat above procedure for installation of opposite

gland.

26-6-4 l Steer Cylinder Overhaul SM 598, Apr ‘96

 Main Table of Contents

GROUP 29

GROUP 29

HYDRAULIC SUMP, FILTERS, AND PUMP

Hydraulic Sump, Filters, and Pump

Specifications and Description ........... .................... Section 1

Hydraulic Pump Troubleshooting ........... ...................... Section 2

Hydraulic Filters and Fluid Maintenance .................... Section 3

Hydraulic Pump Removal and Replacement ............... Section 4

Hydraulic Pump Overhaul ...................... ...................... Section 5

NOTE
This Group (29) covers the hydraulic pump for the load handling system,
steering system, and standard brake system. it also covers the charging
pump for the standard transaxie, which is contained in the same housing
as the load handling system pump.
This Group does not cover the drive pump and drive pump filter used on
HYDROSTATIC TRANSMISSION trucks. That information is provided in
Group 06(H). The hydrostatic drive system, however, uses the same fluid
from the same sump as described in this Group (29).

NOTE
Other hydraulic-related components and circuits are described and
illustrated in Group 25, “Steering Column and Gear,” Group 26 “Steer
Axle,” Group 30, “Hydraulic Control Valve/Lift Circuit,” Group 32, “Tilt
Cylinders,” and Group 34, “Uprights.” Refer to these other groups for
hydraulic components not covered in this group.

SM 598, Ott ‘94 Hydraulic Sump, Filters, and Pump

 Main Table of Contents
CIRRK Group 29, Hydraulic Sump, Filters, and Pump
Section 1.
Hydraulic Sump, Filters, and Pump
Specifications and Description
Specifications
Hydraulic Pump Type: Transmission-driven, gear-type with
integral load sensing priority flow valve and pressure relief
valve. On the standard transaxle truck, the pump is tandem-
mounted with the transmission charging pump. On the
hydrostatic transmission truck, the transmission charging
section of the pump is omitted
Sump Type and Capacity: Tank is built into truck frame
with capacity of 40.16 L (9.5 gallons) for cushion-tire
trucks and 52.85 L (12.5 gallons) for pneumatic-tire trucks.
Hydraulic Fluid Type: Hydraulic Fluid MS-68, Clark part
#180215and#1800236.
Filter Type: Disposable, glass micro-fiber element. Mounted
in return line within sump.
Suction Screen: 100 mesh stainless steel screen mounted in
sump.
Dirty Filter Element Indicator Pressure Switch Setting:
138%!0 kPa (2W psi).
Service Intervals
Hydraulic Fluid Level Check/Condition Sample: Every 50-
250 hours or each PM.
Hydraulic Fluid Change (Drain and Refill): Every year or
2000 hours of operation.
Hydraulic Fluid Filter Replacement: After the first 50 hours
of operation, then every year or 2000 hours of operation or
when dirty filter element indicator light is illuminated.
Hydraulic Sump Suction Screen Cleaning: Every year or
2000 hours of operation/ with every fluid change.
Lii Speed Test: Every 50-250 hours or each PM.
Fastener Torques
Pump to Transmission Fasteners: 151-183 Nom (111-135
f&lb)
Suction Hose to Pump Coupling: 20-27 Nom (15-20 ft-lb)
Suction Screen to Sump Threading: 411 Nom (303 ft-lb)
Return-Line Filter Socket and Flange Mounting Capscrews
5-6 Nom (45-53 in-lb; 3.75-4.5 f&lb)
Dipstick Fitting: 5-6 N*m (45-53 in-lb; 3.754.5 ft-lb)
SM 596, Apr ‘96 Hydraulic Sump, Filters, and Pump Specifications and Description
Description
NOTE
SeeGroup 30 for a description of the com-
plete hydraulic circuit.
The hydraulic sump is installed in the right-hand side compart-
ment of the truck fiame. The sump is equipped with a return
line f&r, oil level dipstick, and suction screen.
On the standard tmnsaxle truck, the main hydraulic pump is
mounted tothe mmsmission and is gear-driven by the trans-
mission. (On hydrostatic transm&ion trucks, the main hy-
draulic pump is mounted to, and driven by, the hydrostatic
drive pump.)
On the standardtramaxletruck,the main hydraulic pump is
tandem-mounted with the trammission charging pump. The
main hydraulic pump and transmission charging pump are
removed and replaced as a single unit. The tmnsmission charg-
ing pump should be overhauled whenever the main hydraulic
pump is overhauled. (On hydrostatic trucks, the transmission
charging section of the pump assembly is omitted.)
The main hydraulic pump draws fluid from the sump. The
pump includes a load-sensing steering priority valve. The
valve variably divides flow between the steering system and
the main hydraulic system, with priority given to the steering
system. The system also provides fluid to the brake valve (on
standard tramaxle trucks).
The steering system pressure relief valve is in the pump
assembly. This valve limits the fluid pressure to the steering
circuit by rerouting fluid avoiding possibly damaging pres-
sures liom building in the circuit. A gauge port on the pump
allows you to test the hydraulic pressures for both steering
relief and hft/tilt functions. (See Croup 30 for pressure testing
procedures.)
Oil from the load handling, steering, and braking circuits
returns to the sump tank through the full-flow return-line iilter.
Thethrowawayhydraulicfluidfilterfitsinacann&rmounted
in the sump tank opening. A pressure switch gauges flow
conditions and lights a waming on the dash panel to indicate
flow restrictions. On hydrostatic trammission trucks, drive
circuit oil returns to the sump through a separate port after
being filtered in the drive pump assembly.
Serviceable items are the pump, the return line filter, and the
suction screen. Other components, such as hoses, fittings,
clamps, and the return-line filter restriction switch are non-
serviceable and should be replaced iffaulty.
l 29-l-l
 Main Table of Contents

Group 29, Hydraulic Sump, Filters, and Pump CIRRK

Load Sensing Port -, Steering Gear

(Hose to pump not shown.) Brake Valve

Supply Line to Steering Gear

Supply Line to Brake Valve

Hydraulic
i\ Control
i ‘1 Valve

Gauge Port
Sucttion 1.ine

Main Hydraulic
Pump

Supply Line to
Hydraulic
Control
Valve
Sump
pump,
sl‘@qh Suction
Filters, and Screen

Plumbing Sump
Arrangement for
Standard
Transaxle Truck.
Return Line Return Line
from Control from Steering
Valve 1 ,- Gear r Steering

Hydraulic
Control
Valve

Return -/
Line Filter
Assembly

29-l-2 l Hydraulic Sump, Filters, and Pump Specifications and Description SM 598,Oct ‘94
 Main Table of Contents

CmK Group 29, Hydraulic Sump, Filters, and Pump

r Steering Gear
Brake Master
Cylinder

Supply Line to Steering Gear

Hydraulic
Control
Valve

Supply Line to
Hydraulic Control
Valve

Supply to Hydro- Load Sensing

Line

Gauge Port

Main Hydraulic
Pump

Pump, Sump,
Filters, and
Sump
Plumbing
Arrangement for
Hydrostatic
Transmission
Truck Return Line Return Line
from Control from Steering
ValT iGear r Sttf;ing

Line Filter
Assembly

SM 598,Oct ‘94 Hydraulic Sump, Filters, and Pump Specifications and Description l 29-l-3
 Main Table of Contents

Group 29, Hydraulic Sump, Filters, and Pump ClRRK

Hydraulic Sump, Filters, and Pump Schematic

Restic-
tion Light
Switch

1 P- - Suction Screen

Sump
I I

Schematic for Standard Transaxle Truck

Restric-
tion tight
Switch

Hydrostatic
Drive Circuit _

Sump

Schematic for Hydrostatic Transmission Truck

29-l-4 l Hydraulic Sump, Filters, and PumpSpecificationsand Description SM 598,Oct ‘94

 Main Table of Contents

emu Group 29, Hydraulic Sump, Filters, and Pump

Section 2.

Main Hydraulic Pump Troubleshooting

The following is a list of problems and solutions relating to
the main hydraulic pump and associated components. For
other hydraulic system troubleshooting, refer to Groups 30
and 34.
Hydrostatic transmission trucks use fluid from the main
hydraulic system to operator the truck’s drive system. If the
truck has the hydrostatic transmission, rather than the stan-
dard transaxle, overheating or fluid contamination could be
caused by the transmission.
Noisy pump
Hydraulic fluid level low: measure, and correct, fluid
level.
Fluid viscosity too high; change to specified fluid.
Sump suction screen dirty; check and clean.
Air leak at pump inlet line; check plumbing tightness.
Inlet line restriction: check for foreign material or line
kinks, clean sump suction screen.
Air leak at pump shaft packing; replace packing.
Defective hydraulic pump; continue other trouble-
shooting items, then consider rebuilding or replacing
pump.
Pump not delivering hydraulic fluid
Hydraulic fluid level low; check, and correct, fluid
l
level.
l Sump suction screen dirty; check and clean.
l Inlet line restriction: check for foreign material or line
kinks, check and clean suction screen.
l Air leak in suction line; check plumbing tightness.
+ Fluid viscosity too high; check fluid viscosity and
change to specified fluid.
l Defective hydraulic pump: continue other trouble-
shooting items, then consider rebuilding or replacing
pump-
Failure to build pressure
l Hydraulic fluid level low; measure, and correct, fluid
level.
l Defective relief valve or pump; perform pressure check
to test valve and pump.
Pump not developing sufficient pressure
Leak in hydraulic control system; check system for
and correct leaks.
Inlet line restriction; check for foreign material or line
kinks, check and clean suction screen.
Suction screen dirty; clean screen.
Defective hydraulic pump; continue other trouble-
shooting items, then consider rebuilding or replacing
pump.
Pump output low
Cavitating pump; see “Noisy pump” above.
Air in fluid or wrong fluid; drain and refill with cor-
rect fluid.
System relief valve set too low or too high, stuck or
leaking; correct relief valve, pump may be OK
Overheated fluid; see remedies under “Overheated
pump and/or fluid” below.
Contaminated fluid; correct contamination source and
replace fluid.
Gear face, body or cover nicked; repair, rebuild.
Excessive side loading, wear plate tight in body bore,
pinched thrust plate; inspect and rebuild.
Foaming fluid
l Cavitating pump; see “Noisy pump” above.
l Wrong fluid: drain and refill with correct fluid.
Overheated pump and/or fluid
Low viscosity fluid; drain and refill with correct fluid.
Contaminated fluid; drain fluid, clean suction screen,
replace filter, and refill sump.
Cavitating pump: see “Noisy pump” above.
Rump drive shaft misaligned; check mounting and
alignment.
Axial loading on drive shaft; check shaft end clear-
ance and shaft alignment; check for worn key/spline.
Relief valve usually in bypass: check relief setting.
Hydrostatic transmission producing excess heat. (Does
not apply to standard transaxle trucks.) See Group
06(H) troubleshooting.

SM 598,Oct ‘94 Hydraulic Pump Troubleshooting l 29-2-l

 Main Table of Contents

Group 29, Hydraulic Sump, Filters, and Pump CUIRU

External leakage Shaft seal leakage

Excessive system pressure; replace pressure control l Damaged or worn seal; replace.
valve on main hydraulic valve. . Shaft scratched or worn or seal nicked; repair (polish)
Faulty or distorted pump seal gasket; replace seal or replace and add new seal.
gasket. . Front cover bearing out of position; replace front
Damaged surfaces on pump body or cover; correct cover assembly.
and replace as required. . Shaft seal housing bore scratched; replace front cover
assembly.
Improper fit of shaft; replace front cover assembly.
Contamination; inspect and rebuild.
Pump run with wrong rotation; replace shaft and pres-
sure loading seals.
Seal installed backwards; inspect and rebuild.

29-2-2 l Hydraulic Pump Troubleshooting SM 598, Ott ‘94

 Main Table of Contents

CIINRU Group 29, Hydraulic Sump, Filters, and Pump

Section 3.

Hydraulic Filters and Fluid Maintenance and Change

Hydraulic Sump Fluid Level Check ............................................................................................. 2

Hydraulic Filters Change .............................................................................................................. 2

Hydraulic Fluid Change ................................................................................................................ 3

Fluid Draining .................................................................................................................................. 3
Suction Screen Cleaning .................................................................................................................. 3
Fluid Replacement ........................................................................................................................... 3

Check Operations of Hydraulic System ....................................................................................... 4

IMPORTANT IMPORTANT
On HYDROSTATIC TRANSMISSION Before removing any component for ser-
trucks, an additional hydraulic fluid fdter is vice, make sure the correct repair parts,
in the hydrostatic drive pump assembly. seals, and gasket sets are available. Keep
Whenever you change the return line fdter, all parts clean during maintenenace and
you should also change the hydrostatic pump fluid and filter changes. Do not allow any
fdter. Group 06(H) tells when and how to contamination into the hydraulic fluid sump
service the hydrostatic pump fdter. or other components.

Pressure From Main

Switch Hydraulic
Control
Valve

Breather Element

Filter Element

Return Line Filter Suction Line Filter

SM 598,Oct ‘94 Hydraulic Filters and Fluid Maintenance and Change l 29-3-l
 Main Table of Contents

Group 29, Hydraulic Sump, Filters, and Pump CUIRU

Hydraulic Sump Fluid Level Check NOTE
In the event of failure of a major compo-
Check the hydraulic sump tank fluid level with:
nent (e.g., main pump) in the hydraulic
l Truck on a level surface. system or with the possibility of other se-
l Engine stopped. vere contamination of the fluid, samples of
l Upright tilted fully back. hydraulic fluid should be submitted to an
l Fork and carriage fully down. independent commercial laboratory for
l Fluid at room temperature. analysis of the contaminant level.

1. Tilt steering column forward and open the engine

cover. Hydraulic fluid return filter and dipstick assem- Hydraulic Filters Change
bly is on right side of frame.
Replace the in-tank, return-line filter and sump breather
element every 2000 hours. at each fluid change. or when
signalled by the filter indicator light.
Dipstick 1. Open the engine compartment for access to sump
filter.
2. Remove the return filter cap and remove and discard
fiter element. Fit new filter onto cap holder.

Hydraulic Fluid Return Filter and Dipstick Assembly.

2. Pull the dipstick out. wipe it clean, and push it back into
the dipstick tube. Remove the dipstick again andcheck Filter
the fluid level indication. Return Element
Filter
3. The hydraulic system fluid level should be between the
Canister
fluid level markings on the dipstick. These marks
represent an operating range for fluid levels.
NOTE 3. Slip breather cover up off filter canister. Replace the
Approximately 40 L (9.5 gal) of hydraulic breather element and replace breather element cover.
fluid are required to fill the hydraulic sump
to the F (Full) mark on a cushion-tire truck. Breather Element -\ y--
Do not overfill.
Approximately 53 L (12.5 gal) are required
on a pneumatic-tire truck. Do not overfill.

4. Add recommended fluid only. Remove the return filter

cap. set a funnel in the opening. and slowly add
hydraulic fluid.
NOTE
Remove or pull dipstick part way out to Breather y
vent air from sump while filling. Element
Cover
5. Check the time (hours) of usage and condition of the
hydraulic fluid (age, color or clarity, contamination,
etc.). Replace fluid every 2000 hours of operation or as 4. Replace the cap but do not over-tighten.
necessary.
29-3-2 l Hydraulic Filters and Fluid Maintenance and Change SM 598,Oct ‘94
 Main Table of Contents
EmIt Group 29, Hydraulic Sump, Filters, and Pump
HydraulicFluid Change
Fluid Draining
1. Place a suitably-sized drain pan under the sump and
open the drain. Drain pan should be at least 15-gallon
capacity.
2. When the sump is completely drained, loosen the
suction hose clamp at the sump suction screen.
.
Sump Suction Screen
3. Disconnect and cap the pump suction hose.
4. Remove the suction screen by loosening the hex head
cap from the sump threads. Pull the suction screen
from the sump tank.
5. Check condition of O-ring. Replace O-ring if it is
cracked, nicked, scuffed, hardened, or does not seat
properly.
Flush the sump with 2 L (2 quarts) of new hydraulic fluid to
clean away any dirt or other contaminants.
SM 598, Apr ‘96 Hydraulic Filters and Fluid Maintenanceand Change
Suction Screen Cleaning
Clean the suction screen in solvent and let dry completely. If
contaminants remain on the screen, blow screen clean with air
from inside to outside. Replace the suction screen if damaged.
n ! CAUTION
OSHA-approved eye protection rated for
200 kPa (30 psi) is required for air-clean-
ing operation.
Fluid Replacement
Replace sump drain plug.
Check condition of O-ring. Replace O-ring if it is
cracked, nicked scuffed, hardened, or does not seat
properly.
Insert the clean suction screen into the sump opening
and tighten the hex head to 411 Nom (303 f&lb).
3. Replace the suction hose and clamp on the screen
fitting. Torque clamp to 38 Nom (28 ft-lb).
Suction Hose
4. Install a new return filter element and breather element
5. Set a large, clean funnel in place in the retum filter
opening.
6. Refill the cushion-the truck sump with 40 L (9.5 gal)
new, clean hydraulic fluid; refill the pneumatic-tire
truck sump with 53 L (12.5 gal) clean hydraulic fluid
Use only Hydraulic Fluid MS-68, Clark part number
1802155.
NOTE
Remove the dipstick to vent air from sump
while refilling.
7. Clean up any oil spills.
l 29-3-3
 Main Table of Contents

Group 29, Hydraulic Sump, Filters, and Pump ClClRK

Check Operation of Hydraulic System

A
! CAUTION
Be sure there is adequate overhead clear-
ante before raising the upright.

Startthe engine and cycle the hydraulic system several

times:
l Raise the lift carriage to the highest position and
lower fully down.
l Tilt upright fully forward and fully back in both
raised and lowered position.
Check for leaks in the hydraulic system. Clean up any
fluid spills.

A WARNING
Do not use your hands to check for hydrau-
lic leakage. Use a piece of cardboard or
paper to search for leaks. Escaping fluid
under pressure can penetrate the skin caus-
ing serious injury. Relieve pressure before
disconnecting hydraulic or other lines.
Tighten all connections before applying
pressure. Keep hands and body away from
pinholes and nozzles which eject fluids un-
der high pressure.

Turn engine off and check hydraulic sump fluid level.

Add fluid, as necessary, to bring the fluid level to the
correct FULL level as shown on dipstick. Do not
overfill.
Close the engine compartment. Remove blocks from
the wheels, if used.

29-3-4 l Hydraulic Filters and Fluid Maintenance and Change SM 598, act ‘94
 Main Table of Contents

CIRRK Group 29, Hydraulic Sump, Filters, and Pump

Section 4.

Hydraulic Pump Removal and Replacement

A CAUTION Hydraulic Pump Removal

SAFE PARKING. Before working on truck:
1. Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
2. Put upright in vertical position and fully
lower the forks or attachment.
3. Put all controls in neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the
wheels.
The hydraulic _uumu* and the transmission chakng
VYI Dumo A
are a combined unit. The hydraulic pump and transmission
charging pump must be removed, overhauled, and replaced
as a unit.
1. Tilt the steering column fully forward and raise the
engine cover.
2. Remove the floorboard.
3. Remove and label lines f?om pump and cap the ends.
Place the open ends of lines in an out of the way
position that will prevent oil spillage.

To Brake
r Valve

To Hydraulic Load Sensing

Control Line to Steering

/ Va’ve /Oear

Hydraulic
Sump

From Hydraulic 1
Sump

Hydraulic Pump Plumbing for Standard Transaxle Hydraulic Pump Plumbing for Hydrostatic Transanle
Truck. Also, load sensing line to steering gear connects to Truck.
pump on side not shown.

SM 598,Oct ‘94 Hydraulic Pump Removal and Replacement l 29-4-l

 Main Table of Contents

Group 29, Hydraulic Sump, Filters, and Pump 61RRK

IMPORTANT 3. Install the hydraulic lines on pump:

Keep all lines, fittings, and ports covered l Lubricate all O-rings with a light coating of system
and clean. hydraulic fluid or a compatible oil.
4. Remove the fasteners attaching pump to transmission. . Use two wrenches to tighten hose fittings to pre-
vent twisting lines. See Group 40 for hydraulic
5. Remove pump and O-rings. fitting tightening procedures.
6. See Section 5, “Hydraulic Rump Overhaul,” for ser-
NOTE
vice to the pump.
Always replace hydraulic sump return fluid
filter when installing new or rebuilt pump.
Hydraulic Pump Replacement See Section 3, “Hydraulic Filters and Fluid
Maintenance and Change.”
Be sure new or rebuilt pump is well oiled prior to
installation. 4. Replace the floorboard.
IMPORTANT 5. Close engine cover.
Keep ali components clean while replacing.

Install pump on transmission using new O-rings. In-

Pump Operation Check
stall and tighten pump mounting fasteners to torque 1. Start the engine and note if pump is running properly
151-183 Nom (111-135 ft-lb). and not making any unusual noise.
Check pump output. Cycle (raise and then lower) the
upright several times. Tilt the upright fully forward and
back, and again listen for any unusual pump noise.

n ! CAUTION
Make sure there is sufficient headroom to
fully extend the upright.

Transmission Hydrostatic
Case Transmission
7 Pump Case

ling

Hydraulic Pump 1

Hydraulic Pump Mounting on Standard Transaxle Truck Hydraulic Pump Mounting on Hydrostatic Transmission
Truck

29-4-2 l Hydraulic Pump Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents

CMRU Group 29, Hydraulic Sump, Filters, and Pump

Section 5.

Hydraulic Pump Overhaul

Preparation for Pump Disassembly ........................................... .._ .................... __ ...................... 1

Pump Disassembly .................._........-..................-.................................................................- .... 2

Parts Inspection ..........................“............~ .................................................................................... 4

Pump Reassembly ..................U.......................~............................................................................ 6

Preparation for Pump Disassembly

IMPORTANT
NOTE
On the STANDARD TRANSAXLE truck,
Pump disassembly involves separating the
the hydraulic pump and the transmission
lift pump from the transmission charge
charging pump are a combined unit. The
pump. It is recommended that the trans-
hydraulic pump and the transmission
mission charge pump be overhauled when
charging pump must be removed, over-
the lift pump is overhauled. Instructions
hauled, and replaced as a unit.
for overhauling both pumps are included
On the HYDROSTATIC TRANSMISSION in the following procedures.
truck, the transmission charging pump sec-
tion of the pump assembly is omitted. l Overhaul pump only in a clean. dust-free location,
The following pump overhaul procedures using clean tools and equipment. Dirt or grit will
depict the pump assembly for the standard damage the highly-machined surfaces and will result
transaxle truck. If you are overhauling a in leakage or premature failure of the pump. Be sure the
pump for the hydrostatic transmission work area is clean.
truck, disregard the procedures that relate l Plug openings before cleaning and brushing to avoid
to the transmission charging pump section contaminating internal parts. Clean exterior of pump/
of the assembly valve with a good grade solvent, and dry thoroughly.
Use a wire brush if necessary to remove dirt accumu-
lations.
l Before beginning disassembly, scribe match marks on
IMPORTANT the body and cover to ensure that pump will be reas-
Before removing any component for over- sembled in the same manner as it was shipped from
haul, make sure the correct repair parts, factory. If the body or rear cover is replaced during
seals, and gasket sets are available. overhaul, scribe amatch mark on the new part as on the
part it replaced. This ensures that inlet and outlet with
respect to rotation. is kept the same.

SM 598,Oct ‘94 Hydraulic Pump Overhaul l 29-5-l

 Main Table of Contents
Group 29, Hydraulic Sump, Filters, and Pump
Pump Disassembly
IMPORTANT
The transmission charge pump section of
the pump assembly is present only on stan-
dard transaxle trucks. Disregard the items
labeled 12 through 21,23, and 25 through
28 in the illustration on the next page if you
are servicing the hydraulic pump used on
hydrostatic transmission trucks.
IMPORTANT
Keep parts in assembly order as removed
to assure correct reassembly.
Case Disassembly
1. Remove the four bolts and washers (1 & 2).
2. Lightly tap the lift pump to free it from the flange
adapter (14) or the pump flange (22), depending on
pump configuration. Completely separate the units.
3. Remove and discard the body O-ring (4) from the face
of the flange adapter (14) orthepump mounting flange
(22) depending on pump configuration.
4. On the pump used on the hydrostatic transmission
truck, remove and discard shaft seal (24) from the
pump mounting flange (22) by firs removing the
circlip (not shown). Push the shaft seal squarely and
carefully out of the mounting flange seal bore. An
arbor press can be used to remove the seal.
5. Proceed to “Transmission Charge Pump Disassem-
bly” if you are servicing the pump used in the standard
transaxle truck; otherwise proceed to “Lift Pump Dis-
assembly.”
Transmission Charge Pump Disassembly
This procedure does not apply to pumps mounted on hydro-
static transaxle trucks.
1. Remove the lock nut (27), tab washer (26), woodruff
key (25) from the driveshaft (18) or (lo), depending on
pump configuration.
2. Remove the drive gear with a suitable puller.
3. Remove and discard shaft seal (24) from the pump
mounting flange (22). Push the shaft seal squarely and
carefully out of the mounting flange seal bore. An
arbor press can be used to remove the seals.
IMPORTANT
Be careful not to damage the machined seal
bore in pump body when removing the seal
because this will result in seal leakage.
29-5-2 l Hydraulic Pump Overhaul
CIRRK
If seal bore or recess is scored, Loctite hy-
draulic sealant must be applied to the outer
diameter of the seal.
4. Loosen and remove the four allen capscrews and
washers (12,13) securing the flange adapter (14) to the
pump mounting flange (22).
5. Separate the adapter from the flange. Use a rubber
mallet to tap the two components apart if necessary.
6. Remove and discard the charge pump ring-seal (21).
7. Remove and discard the charge pump flange O-ring
(28) and two smaller O-rings (23) from the transmis-
sion fluid inlet and outlet orifices on the flange.
8. Push the drive shaft (18) squarely out of the flange and
remove the driven gear (17).
9. Remove the bushing seal (20) and the thrust plate (19)
from the flange body.
10. Removetheshaftseal(15)andtbecirclip(16)fromthe
flange adapter. Remove anddiscardthe inner shaft seal
(15)l?omunderthecirclip.Pushtheshaftsealsquarely
and carefully out of the flange adapter seal bore. An
arbor press can be used to remove the seals.
IMPORTANT
Be careful not to damage the machined seal
bore.
11. Proceed to “Lift Pump Disassembly.”
Lift Pump Disassembly
1. Carefully pull the pump body (9) and the valve body
(3) apart. Tap the pump body with a rubber mallet to
separate the two units if necessary. Valve disassembly
is explained in the next subsection.
2. Remove the back-up seal (5) andbush seal (6) from the
rear (flange-adapter end) of the pump body.
3. Remove the back-up seal (5) bush seal (6) from the
front (valve-body end) of the pump body.
4. Before removing the other internal components of the
pump body, mark the bushes (7,8) on the front and rear
of the pump body for correct reassembly. Mark the
four bushes to denote:
l Bush on driveshaft flange-adapter end
l Bush on driven gear flange-adapter end
. Bush on driveshaft valve-body end
l Bush on driven gear valve-body end.
5. Withthepumpbodylyingonitsside,pullthedriveshaft
and gear (10) squarely from the pump body bringing
the flange-end bushes (7,8) out at the same time.
6. Remove the driven gear (11) and the remaining two
valve-end bushes (7,8).
SM 598,Oct ‘94
 Main Table of Contents

GIRRK Group 29, Hydraulic Sump, Filters, and Pump

1. Bolt 10. Drive Shaft and Gear (for lift 22. Pump Mounting Flange
2. Washer pump) (design differs on hydro-
3. Valve Body 11. Driven Gear (for lift pump) static truck)
4. Body O-Ring 12. Allen Capscrew 23. O-Ring
5. Back-up Seal 13. Washer 24. Shaft Seal (and circlip on
6. Bush Seal 14. Charge Pump Flange hydrostatic trucks)
7. Bush Adapter 25. Woodruff Key
8. Bush 15. Shaft Seal 26. Tab Washer
9. Pump Body 16. Circlip 27. Lock Nut
17. Driven Gear (for charge 28. Charge Pump Flange O-
pump) Ring
31-- 0
18. Drive Shaft and Gear (for 29. O-Ring
charge pump) 30. Spool Plug
19. Thrust Plate 31. O-Ring
20. Bushing Seal 32. Load Sensing Spring Seat
21. Charge Pump Ring Seal 33. O-Ring
34. Control Spring
36 .-t3 35. Spool
36. Guide Cap
38. Relief Valve Seat
39. Pilot Relief Valve
40. O-Ring
41. O-Ring
42. Pilot Relief Valve Seat
43. Core Plug

P
r-. 30&J
I -.__

. .._.
__ -
‘_ . ._ :
;
‘_ .. .

NOTE: These parts are not present in the

pumps used on hydrostatic transmission
trucks.

SM 598,Oct ‘94 Hydraulic Pump Overhaul l 29-5-3

 Main Table of Contents
Group 29, Hydraulic Sump, Filters, and Pump
Steering Priority and Steering Pressure Relief
Valve Disassembly
NOTE
Before beginning valve disassembly, clean
the exterior of the valve body (3) of all
accumulated grime that could enter the
valve on disassembly.
Steering Priority Valve Disassembly
1. Remove the spool plug and O-ring (30,29) from the
bottom of the valve body. Discard the O-ring.
2. Remove the load sensing spring seat (32) and O-rings
(31,33) and discard the O-rings.
3. Take out the control spring and spool (34,35).
4. Remove the guide cap (36) from the top of the spool to
check and clean spool ports.
Steering Pressure Relief Valve Disassembly
NOTE
Disassembly of the relief valve seat (42) is
not recommended. If steering pressure re-
lief settings cannot be set accurately (see
Group 25, “Steering System Relief Pres-
sure Check and Adjustment”) replace the
valve seat.
1. Gently pry out the core plug (43) from the relief valve
bore.
2. Screw out the threaded pilot relief valve seat (42).
3. Remove and discard the two O-rings (41,40).
4. Remove the pilot relief valve (39).
5. Remove the relief valve spring (38).
29-5-4 l Hydraulic Pump Overhaul
ClRRK
Parts Inspection
General Inspection
Wash all parts with clean solvent and dry thoroughly.
Do not use wiping cloth material that leaves lint when
drying parts. If parts must be left for a long period or
overnight, cover with a clean cover.
Thoroughly inspect all components to determine suit-
ability for reuse. The following subsections provide
advice on what to look for on the different pump
components.
Look for warping, scoring, bearing bums, grooves,
thread damage, and wear steps on all parts. Parts
showing evidence of these conditions should be re-
placed. Parts that are even slightly out of true or
uneven, scratched, or grooved may lead to fluid leak-
age and diminished and shortened pump life.
Bodies
1. Inspect all body bore cut-ins where gears fit into the
parts. Bodies can only be reused if the cut-ins are bright
and polished looking.
2. Bodies should be replaced if:
a. Inner surfaces are scored (scratched grooved, or
notched)
b. The finishes are dull or have a roughened surface
C. They show signs that the tips of gears are digging
in the bores.
3. Inspect end surfaces for smoothness and flatness: no
superficial damage which may adversely effect perfor-
mance or sealing can be evident.
4. Check all threaded ports and O-ring and shaft seal
recesses for marks, scratches, or evidence of unusual
wear that may cause imprecise fits and leakage.
NOTE
Replacement shaft seals can be installed
with Loctite hydraulic sealant to overcome
slight damage in areas where the seals are
fitted.
SM 598, Ott ‘94
 Main Table of Contents

CUlRK Group 29, Hydraulic Sump, Filters, and Pump

Bushes Transmission Charge Pump

1. The flat ends of the bushes (bush side-face) which fit Examine the driveshaft and gear of the transmission
against the ends of the gear teeth (gear side-face) charge pump for excessive wear or damage from
should be perfectly flat with no signs of scoring. coupling with the drive gear in the transmission. Re-
a. The side faces of both the bushes and the gears place the gear if damage is evident.
should bear a bright. polished appearance. NOTE
b. Often there is a shadow (or witness) where the tips If the driveshaft and gear are not service-
of the opposing gears have wiped an overlap able, replace the gears as a matched set.
resembling a half-moon shape. No noticeable
wear step must be evident between the bush and Examine the thrust plate and bushing seal for scoring
gear side-faces; they must fit completely flat to- or uneven wear and replace if damaged or worn. No
gether. wear step should be evident on the plate and it should
be smooth and completely flat.
c. Replace the bushes andgears if they show scoring,
have a dull or roughened finish, or show signs of NOTE
wear steps or tearing of the bush or gear side-face A somewhat heavier wear pattern is nor-
materials. mal on the low pressure (inlet) side of the
wear plate. However, there should be no
2. Bush bearing liners (inner bore) are reusable if they
heavy scoring in this area.
show no signs of damage or scoring. The general
outside areas of the bushes should not show any
prominent signs of wear. Steering Priority and Relief Valve
Valve components should be free of evident damage.
Gears All parts are reusable except for replacement kit items.
NOTE All items should be thoroughly cleaned and dried with
If the driveshaft and gear are not service- a lint-free cloth before reassembly.
able, replace the gears as a matched set. The load sensing valve spring seat (32) has an orifice
in the base of the spring recess that must be clean and
1. Gear side-faces should be examined for scoring or free from contaminants. Clean all threads completely.
other damage.
2. Operation with contaminated fluid will leave scoring
between the driveshaft and the journal (the portion of
the driveshaft that rotates in the bush bearing) which
leaves a wear step.
Check for a wear step by drawing a sharp point across
the surface from the journal to the tip of the gear. If a
wear step is evident, the gear is unserviceable.
2. Examine all gear teeth for signs of pitting or uneven or
unusual wear.
3. Journal surfaces should be completely free from scor-
ing or grooving and should be highly polished and
smooth to the touch.
Replace the gear if journal wear exceeds .OOl inch
(0.025 mm).
4. Examine the areas where shaft seals run on gear
driveshafts. These areas show up as polished rings.
If a noticeable groove can be felt.,or there is scoring on
the shaft, the driveshaft should be replaced.

SM 590,Oct ‘94 Hydraulic Pump Overhaul l 29-5-5

 Main Table of Contents
Group 29, Hydraulic Sump, Filters, and Pump
Pump Reassembly
IMPORTANT
The transmission charge pump section of
the pump assembly is present only on stan-
dard transaxle trucks. Disregard the items
labeled 12 through 21,23, and 25 through
28 in the illustration on the next page if you
are servicing the hydraulic pump used on
hydrostatic transmission trucks.
NOTE
Make sure all parts are completely clean.
Lubricate all bushes and gears with clean
hydraulic fluid. O-ring recesses and end
faces of the valve body, pump body, charge
pump flange adapter, and charge pump
flange must remain dry, however.
Steering Priority and Relief Valve
Reassembly
Steering Priority Valve Reassembly
1. Set the spool plug (30) with a new O-ring (29) in the
plug bore on the bottom of the valve body. Tighten the
spool plug to 55-59 f&lb (75-80 Nom).
2. Replace guide cap (36) on top of spool (35).
3. Set the spool (35) and control spring (34) into the valve
bore.
4. Thread the spring seat (32) with new O-rings (31,33)
into the valve body. Tighten the spring seat to 74-78 ft-
lb (100-105 N-m).
Pressure Relief Valve Reassembly
1. Setthepilotreliefvalve(39)intothespring(38)andset
the two into the valve bore.
2. Replace the O-rings (40.41) on the pilot relief valve
seat (42).
3. Insert the pilot relief valve seat into the body and
tighten the threads enough to take up the spring load.
NOTE
If a new seal kit was necessary for pump
overhaul, see Group 25, “Steering System
Relief Pressure Check and Adjustment” to
test for correct relief pressure in the valve.
Set the relief valve at that time and replace
the core plug (43) after final adjustment of
the valve.
29-6-6 . Hydraulic Pump Overhaul
cu1Ru
Lift Pump Reassembly
1. Lightly clamp the valve body (3) face up into a vise.
2. Fit valve-end bushes (7,8) into the lift pump body (9).
3. Place the pump body on top of the valve body and fit the
driveshaft and gear (10) and the driven gear (11) into
their original positions in the pump body.
4. Fit the flange-end bushes (7,8) into their original bores
on the pump body.
5. Fit the new bush seal (6) and back-up seal (5) in the
flange-end bushes. The bush seal is molded so that the
back-up seal is seated partially in it.
NOTE
Make sure the bush seal and back-up seal are
fitted correctly in the seal grooves of the
bushes.
6. Lift the pump body off the valve body and prop it on the
body-end so it is not resting on the driveshaft.
7. Fit another new bush seal (6) and back-up seal (5) in the
valve-body-end bushes. The bush seal is molded so that
the back-up seal is seated partially in it. Check fit as in
step 5.
8. Set a new body O-ring (4) into place on the valve end of
the pump body.
9. Placetbevalvebodyonthepumpbodyandinsertthefour
bolts andwashers(l&2)throughtbevalveandliftpump
bodies.
NOTE
Component mating surfaces should be clean,
completely dry, and free of any hydraulic or
other fluids for correct fit.
10. Fit a new body O-ring (4) onto the lift pump side of the
flange adapter or pump mounting flange (22). depending
on pump configuration.
11. Set the valve and pump body assembly onto the flange
adapter (14) or pump mounting flange (22), depending
on pump configuration, and tighten the bolts to 65-75 fi-
lb (88-102 N-m).
12. On hydrostatictransmissiontrucks.fit a new shaft seal
(24) over the pump drive shaft (10) and down into the
pumpmountingflangerecess.Useapressifnecessary to
fit the seal. Do not scratch or dent the seal recess. Install
circlip (not illustxxed) over seal and into groove. Pro-
ceed to “Final Check.”
NOTE
If seal recess is scored, Loctite hydraulic seal-
ant must be applied to the outer diameter of
the seal. Apply a coat of high melting grease
to the shaft seal lips. Do not allow Lo&e
onto seal lip.
SM 598,Oct ‘94
 Main Table of Contents

CllflRK Group 29, Hydraulic Sump, Filters, and Pump

1. Bolt 10. Drive Shaft and Gear (for lift 22. Pump Mounting Flange
2. Washer pump) (design differs on hydro-
3. Valve Body 11. Driven Gear (for lift pump) static truck)
4. Body O-Ring 12. Allen Capscrew 23. O-Ring
5. Back-up Seal 13. Washer 24. Shaft Seal (and circlip on
6. Bush Seal 14. Charge Pump Flange hydrostatic trucks)
7. Bush Adapter 25. Woodruff Key
8. Bush 15. Shaft Seal 26. Tab Washer
9. Pump Body 16. Circlip 27. Lock Nut
17. Driven Gear (for charge 28. Charge Pump Flange O-
pump) Ring
31- 0
18. Drive Shaft and Gear (for 29. O-Ring
charge pump) 30. Spool Plug
-443
19. Thrust Plate 31. O-Ring
1 --42 20. Bushing Seal 32. Load Sensing Spring Seat
E
&_ ___-_-41 21. Charge Pump Ring Seal 33. O-Ring
o- -__
34. Control Spring
36 4 f&_--g
35. Spool
-_ 36
36. Guide Cap
35 -
38. Relief Valve Seat
.. Iif
..I 39. Pilot Relief Valve
40. O-Ring
41. O-Ring
42. Pilot Relief Valve Seat
9
43. Core Plug

NOTE:These parts are not present in the

pumps used on hydrostatic transmission
truck.

SM 598,Oct ‘94 Hydraulic Pump Overhaul l 29-5-7

 Main Table of Contents

Group 29, Hydraulic Sump, Filters, and Pump CIRRK

Transmission Charge Pump Reassembly

Thisprocedure does not apply to pumps mounted on hydro-
StZitiC )l transaxle trucks.
1. Set the pump and flange adapter assembly so that
adapter surface faces up.
2. Fitanewshaftseal(15)overthedriveshaft(lO)and
down in the adapter recess. Use a press if necessary to
fit the seal. Do not scratch or dent the seal recess.
NOTE
If seal recessis scored, Lo&e hydraulic
sealant must be applied to the outer diam-
eter of the seaL Apply a coat of high melt-
ing grease to the shaft seal lips. Do not
allow Loctite onto seal lip.
11. Pressthe drivegearonto the drive shaft (18) and set the
woodruff key (24), the tab washer (26), and lock nut
(27) on the shaft
12. Fit new O-rings (23) into the charge pump inlet and
outlet ports on the mounting flange.
13. Proceed to “Final Check.”
Final Check
Pour a small amount of clean hydraulic fluid into a port and
check that the shaft can be rotated without undue force.

3. Fitcirclip(l6)intogroovedrecessoftheflangeadapter.
Follow this with another new shaft seal (15) as in the
previous step.
4. Prop the pump mounting flange (22) on a level, flat
surface with the mounting-side down
5. Set the bushing seal (20) and the thrust plate (19) into
the flange body.
6. Fit driveshal? and gear (18) and driven gear (17) into
their original positions in the charge pump mounting
flange (22).
7. Set the charge pump ring seal (21) on the mounting
flange.
8. With mating surfaces dry and clean set the lift pump
assembly on the charge pump flange and insert the four
allencapscrewsandwashers(12,13)thoughtheflange
adapter (14) into the mounting flange. Tighten the
capscrews in alternating sequence to pull the assembly
down evenly into place. Tighten the capscrews to 28-
32 ft-lb (3843 N*m).
9. Turn the assembly over and prop it so that the mount-
ing end is level and flat.
10. Fit a new shaft seal (24) over the charge pump drive
shaft and down in the flange recess. Use a press if
necessary to fit the seal. Do not scratch or dent the seal
receSS.

NOTE
If seal recess is scored, Loctite hydraulic
sealant must be applied to the outer diam-
eter of the seal. Apply a coat of high melt-
ing grease to the shaft seal lips. Do not
allow Lo&e onto seal lip.

29-5-6 l Hydraulic Pump Overhaul SM 596, Apr ‘96

 Main Table of Contents

GROUP 30

GROUP 30

HYDRAULIC CONTROL VALVE/ I

LIFT CIRCUIT

Hydraulic Control Valve/Lift Circuit

Specifications and Description ..................... .......... Section 1

Section 2
Hydraulic System Schematic .............................*.**....*.*.

Hydraulic System Troubleshooting ............................... Section 3

Hydraulic System Pressure Checks and

Adjustments ............................................................. Section 4

Hydraulic Control Valve Removal

and Replacement .................................................... Section 5

Hydraulic Control Valve Overhaul ............................... Section 6

IMPORTANT
Other hydraulic-related components and circuits are described and illus-
trated in Group 25, “Steering Column and Gear,” Group 26 “Steer Axle,”
Group 29, “Hydraulic Sump, Filters, and Pump,” Group 32, “Tilt Cylinders,”
and Group 34, “Uprights.” Refer to these other groups for hydraulic compo-
nents not covered in this group.

SM 598, Apr ‘96 Hydraulic Control Valve/Lift Circuit

 Main Table of Contents

CIRRK Group 30, Hydraulic Control Valve/Lift Circuit

Section 1.

Hydraulic Control Valve/Lift Circuit

Specifications and Description

Specifications Service Intervals

Hydraulic Fluid Type: Clark specification MS-68 (Clark Hydraulic System Relief Pressure Check: Every year or
part#1802155and#1800236) every 2000 hours of operation.
Main Relief Valve Setting: 21,400 to 22,100 kPa (3100 to
3200 psi) at rated flow. FastenerTorques
Auxiliary Relief Valve Setting: 13,300 to 14,300 kPa (1925 Lever to Spool Rod Turnbuckle Adjustment Jam Nuts:
to 2075 psi) at rated flow. 28.5-32.5 ft-lb (39-44 Nom).
Rated Blow: Pivot Pin Keeper Hexnut: 14.5-18.5 ft-lb (20-25 Nom).
Lift spool (spool #l): 76 L/mm (20 gpm). Lever Pivot-Bracket Mounting Nuts: 14.5-17 ft-lb (20-23
Tilt spool (spool #2): 38 L/min (10 gpm). Nom).
Auxiliary spool (spool #3): 38 L/min (10 gpm).
Integral Pressure Compensated Flow Control Settings:
Tilt spool (spool #IQ):15 L/mm (4 gpm).
Auxiliary spool (spool #3): 9 L/min (2.5 gpm).
Maximum Pressure Drop at Rated Blow:
Inlet to outlet: 689 kPa (100 psi).
Lift spool (spool #l):
- Inlet to cylinder port: 689 kPa (100 psi)
- Cylinder port to outlet: 550 kPa (80 psi).
Tilt spool (spool Wz):
- Inlet to cylinder port: 689 kPa (100 psi)
- Cylinder port to outlet: 550 kPa (80 psi).
Auxiliary spools (spools #3 and #4):
- Inlet to cylinder port: 345 kPa (50 psi)
- Cylinder port to outlet: 207 kPa (30 psi).
Tilt Flow Settings:
Tilt I&!
(“/set) LPm (gpm)
5715mm(225in) MFH& above 3 9 (2.5)
Below5715mm(225in)MFB 5 15 (4)
EuropeanUprightOption 8 26 (7)
Flow Control Adjustments: Adjustable from 4 to 38 L/min
(1 to 10 gpm). Before adjusting, turn fully CCW to stop.
Bach CW half turn increases flow by 4 L/min (&pm).

SM 598, Apr ‘96 Hydraulic Control Valve/Lift Circuit Specifications and Description l 30-l-l
 Main Table of Contents
Group 30, Hydraulic Control Valve/Lift Circuit
Description
The following description focuses primarily on hydraulic
circuitry controlled by the main hydraulic control valve,
that is, the lift/tilt/aux circuit. Various other hydraulic sys-
tems come into play, however, and are mentioned. The
entire hydraulic system is depicted in the schematics in
Section 2 (next page).
Descriptions of the braking and steering circuits are given
in Groups 23 and 25. The drive circuit for hydrostatic
transmission trucks is covered in Group 06(H)
The main hydraulic pump (described in Group 29) is me-
chanically driven by the transmission (transaxle or hydro-
static pump) and draws fluid from the sump through a
particle-blocking suction screen. A priority valve, con-
tained in the pump assembly, senses the demand for flow to
the steerir&braking circuit and divides pump flow between
the lift/tilt/aux circuit and the steering/braking circuit ac-
cordingly, with priority given to steering and braking.
Fluid from the priority valve goes to the main hydraulic
control valve. The lift truck operator moves the main hy-
draulic control valve spool by hand, directing fluid to the
lift and tilt cylinders and auxiliary actuators as needed for
manipulating the load-handling mechanism.
The main hydraulic control valve features an open-center,
parallel-circuit type modular design. It has the main (lift/
tilt) pressure relief valve (steering pressure relief valve is
on main hydraulic pump), a secondary pressure relief valve
for optional auxiliary components, a lift spool, a tilt spool
with an integral counterbalance valve, optional auxiliary
spools, and adjustable pressure-compensated flow controls.
All spools are low-leakage design.
The main hydraulic valve has from two to four valve sec-
tions. Each section performs a separate function; standard
two spool assemblies have a inlet/lift section (with fluid
inlet port), a tilt section, and an outlet section. A third and
fourth section may be added to control auxiliary compo-
nents.
When lift attachments are used, an auxiliary section may be
added to the outer (RH) side of the standard (lift/tilt only)
main valve. The optional auxiliary sections also have an
adjustable relief valve and can be assembled with optional
flow control levels.
The valve spools are arranged in standard sequence (from
the operator’s position) to first provide lift control, then tilt,
and finally auxiliary control. The control levers are spring-
NOTE
Hydraulic plumbing arrangement is illustrated in
Group 29.
30-l-2 . Hydraulic Control Valve/Lift Circuit Specifications and Description
EmK
loaded (by the valve spool centering springs) to return them
to neutral when released. Oil flow is controlled by the
amount or distance the control handles are moved. Excess
oil flow is returned to the sump. A check valve prevents
reverse flow.
When all the control valve spools are in neutral, fluid flows
through the open-centers of the valve spools to the sump
return line. When a spool is partially shifted and the associ-
ated cylinder or other actuator has not reached its end-of-
travel, some of the fluid flows to the cylinder (actuator) and
the rest flows to the sump line. In both cases, the pressure in
the system should be less than the amount required to open
the relief valves.
The main relief valve vents flow to the sump when one of
the following conditions is present:
. The operator continues to hold the lift control in the
lift position after the lift mechanism reaches its end-
of-travel.
. Too heavy a load is being lifted
. The operator continues to hold the tilt control in the
tilt position after the tilt mechanism has reached its
end-of-travel (This is called “tilt bypass.“)
. Auxiliary relief fails to operate.
The : auxiliary
relief valve vents flow to the sump when the
operator continues to hold the attachment control in the
operated position after the attachment reaches its end-of-
travel.
Main and auxiliary relief pressure settings can be checked
through a gauge port on the pump.
Flow from the sump return line is filtered before entering
the sump. If the filter is clogged, a by-pass valve routes the
flow around the filter. On hydrostatic trucks, fluid in the
return line serves as a source for the hydrostatic pump.
Fluid from the hydrostatic pump is filtered within the pump
assembly and returned through a separate port in the sump.
A tilt-lock valve built into the main control valve assembly
locks the upright into its current tilt position when the truck
is turned off. A load lowering flow valve mounted on the
upright limits the speed at which the operator can lower a
load, decreasing the speed for heavier loads. A velocity
fuse built into one of the lift cylinder ports prevents the
upright from falling rapidly should a hydraulic line rupture
or be disconnected.
SM 598, Apr ‘96
 Main Table of Contents

ClRlW Group 30, Hydraulic Control Valve/ Lift Circuit

Section 2. Hydraulic System Schematics

Schematic for Standard Transaxle Truck

TILT
CYLINDERS CYLINDERS
OPTIONAL
SIDESHIFTER

UPi
VEN
AS RI

LIFT AUX I AUX 2

El

r
P T

/E(
i
T P j LS
:
I
l
.___--___----__-- ____---___-J

.______ ----

--l
El

Hydraulic Sump q Main Hydraulic Valve: Main Pressure RelieE Lift Spool; Tilt Spool
Suction Strainer &T&Lock Valve; Aux Spools with Secondary PressureRelief Valve;
Hydraulic pump; priority valve; steering relief valve Adjustable Pressure-Compensated Flow Controls
Power Steering Valve q Load-Lowering Valve
q Power Brake Valve q Filter; Bypass; Breather
q Filter By-Pass Indicator

SWl598,Oct ‘94 Hydraulic System Schematic . 30-2-l

 Main Table of Contents

Group 30, Hydraulic Control Valve/Lift Circuit ClRRK

UPRIuiT
Schematic for Hydrostatic I
______________~____________-________------__ VENTLIE
AS RMUIRED
--. -7

TILT
Transmission Truck CYLINDERS
oPTIoNAL
SIDESHIF~ “R’o’r:k

i]

q Hydraulic Sump q Load-Lowering Valve

El Suction Strainer q Filter; Bypass; Breather
q Hydraulic pump; priority valve; steering relief valve q Return Line Filter, Breather, and By-Pass Valve
q Power Steering Valve q Filter By-Pass Indicator
q Steer Cylinder q Hydrostatic Pump
q Brake Master Cylinder q Hydrostatic Drive Axle with Integral Loop-Flushing Valve
q Brake Wheel Cylinders q Cooler Bypass Valve
q Main Hydraulic Valve: Main Pressure Relief; Lift Spool; Tilt Spool q Charge Circuit Pressure Filter
& TiIt-Lock Valve; Aux Spools with Secondary Pressure Relief Valve; iiJ Oil Cooler
Adjustable Pressure-Compensated Plow Controls

30-2-2 l Hydraulic System Schematic SM 598,Oct ‘94

Main Table of Contents
 Main Table of Contents
CUlRK Group 30, Hydraulic Control Valve/Lift Circuit
Section 3.
Hydraulic System Troubleshooting
The following is a list of problems and solutions relating to
the main hydraulic control valve and associated compo-
nents. For other hydraulic system troubleshooting, refer to
Groups 29 and 34.
Hydrostatic transmission trucks use fluid from the main
hydraulic system to operator the truck’s drive system. If the
truck has the hydrostatic transmission, rather than the stan-
dard transaxle, overheating or fluid contamination could be
caused by the transmission.
NO lift, tilt, or auxiliary function
. Hydraulic fluid very low; check and fill to correct
level.
. Hose or fittings broken; replace component.
. Defective main lift valve; check other Troubleshoot-
ing items for possible cause, then consider rebuilding
or replacing main lift valve.
. Hydraulic pump defective; check other Troubleshoot-
ing items for possible cause, then consider rebuilding
or replacing pump.
No motion, slow or jerky action of hydraulic
system
l Spool not moved to full stroke; check travel and link-
age adjustment.
l Relief valve not properly set, stuck in place, and/or
worn; check and clean valve, replace if necessary.
l Dii or foreign particles lodged between relief valve
control poppet and seat; check valve and clean.
l Valve body cracked inside; check and replace entire
valve.
Foaming hydraulic fluid
Low oil level; check and fill to correct level.
Wrong fluid; drain and refill with correct oil.
Oil too heavy; change to correct viscosity.
Pump inlet line restriction or line kinked; clean line
and suction screen or repair kinked hose.
Hydraulic pump (or hydrostatic pump) cavitating
(pumping air with fluid); check hydraulic plumbing
for airtight hoses and connections.
SM 598,Oct ‘94
Overheated hydraulic fluid
Thin fluid; drain and fill with correct fluid
Fluid contaminated; drain sump, clean suction screen,
replace filter, and refill.
Cavitating pump: check hydraulic plumbing for air-
tight hoses and connections.
Pump driveshaft misaligned; check mounting and
alignment.
Axial loading on drive shaft, check shaft end clear-
ance and shaft alignment; check for worn key/spline.
Relief valve in bypass: check relief setting.
Hydrostatic transmission producing excess heat_(Does
not apply to standard transaxle trucks.) See Group
06(H) troubleshooting.
Load cannot be lifted to maximum height
l Hydraulic fluid low; check and fdl to correct level.
l Hydraulic pump defective: check other Troubleshoot-
ing items for possible cause, then consider rebuilding
or replacing pump.
Oil leaks at top of lift (secondary) cylinder(s)
l Plugged vent line; check and clear line.
l Worn or damaged piston seal, rebuild cylinder.
l Scored cylinder wall; replace cylinder.
See Group 34, “Cylinder Removal, Overhaul, and Replace-
ment.”
Oil leak at tilt or auxiliary function cylinder
l Worn or damaged seal; rebuild cylinder.
. Scored piston rod; repair or replace rod.
See Group 34, “Cylinder Removal, Overhaul, and Replace-
ment.”
Load will not hold
l Oil bypassing between lift spool and valve body;
overhaul valve and spool.
l Spool not centered; see spool remedies for correcting
problems when spools do not return to neutral.
l Oil bypassing piston in cylinder: repair or replace
cylinder.
Hydraulic System Troubleshooting l 30-3-l
 Main Table of Contents

Group 30, Hydraulic Control Valve/Lift Circuit emI&

Oil leaks at either end of main hydraulic valve
spool
l Defective O-ring seals; rebuild valve.
Spring-centered spools do not return to
neutral
Broken springs; rebuild valve.
Entrapped foreign particles; check and clean system
and valve.
Bent spool; replace with new valve section.
No relief valve action (high pressure)
l Small particles of dirt in relief valve subassembly;
check, clean, and/or replace relief valve, clean hole.
l Relief valve subassembly installed backwards; rein-
stall correctly.
Load drops when spool is moved from
neutral to a power position
l Dirt or foreign particles lodged between check valve
ball and seat; check and clean.

Misalignment or binding of linkage; check and align/ l Sticking or scored check valve; clean if sticking, re-
adjust linkage. place if scored, replace poppet.

30-3-2 l Hydraulic System Troubleshooting SM 598, Ott ‘94

 Main Table of Contents

Section 4.

Hydraulic System Pressure Checks and Adjustments

n! CAUTION
SAFE PARKING. Before working on 2. Remove the cap from the gauge port on the pump
&II&Z and connect pressure gauge to the fitting.
l. Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
2. Put upright in vertical position and fully
lower the forks or attachment.
3. Put all controls in neutrak Turn key
switch OFF and remove key.
4. Apply the parking brake and block the
wheels.

Relief PressureChecks
Following is the procedure for checking main hydraulic
valve lift pressure and auxiliary relief pressure (if the
truck is equipped with an auxiliary component).
Hydraulic system relief pressure setting may be checked
Checking Relief Pressure. Gauge port location varies.
using a Mica Quadrigage (Clark Part No. 1800106) or
with a conventional pressure gauge with suitable pres- NOTE
sure range calibration. To cover all models of the truck, a Use quick-disconnect adapter fitting,
gauge with capacity range of 0 to 27,580 kPa minimum Clark Part Ml3125
(0 to 4000 psi) is recommended.
3. Start the engine and let it warm up until it runs

A WARNING
HYDRAULIC FLUID SAFETY. Keep all
hydraulic ports and components clean.
Wipe the area on the pump around the
diagnostic check port completely clean
to prevent any contamination from en-
tering the hydraulic system.
When checking the hydraulic system, do
not use your hands to check for leakage.
Use a piece of cardboard or paper to
search for leaks. Escaping fluid under
pressure can penetrate the skin causing
serious injury. Relieve pressure before
disconnecting hydraulic or other lines.
Tighten all connections before applying
pressure. Keep hands and body away
from pinholes and nozzles which eject
fluids under high pressure.
1. Tilt the steering column fully forward and raise the
engine cover.
smoothly. Continue with step 4.
4. Accelerate the engine to no-load governed speed
(full throttle), and hold at this speed. Gauge should
read between 897.5 to 1132 kPa (130-W psi).
5. Check main relief pressure: Move the tilt control
lever to full back (or forward) tilt relief position.
Hold tilt control in relief position until pressure
reading is obtained, and then release. Gauge should
read 21,400 to 22,100 kPa (3100 to 3200 psi).
IMPORTANT
Do not operate system in relief any longer
than required to read the pressure gauge.
6. Check auxiliary relief pressure: (Truckmust have
auxiliary component and auxiliary section added to
main hydraulic valve.) Move the auxiliary control
lever to full back or forward relief position. Hold
auxiliary control in relief position until pressure
reading is obtained, and then release. Gauge should
read 13,300 to 14,300 kPa (1925 to 2075 psi).

SM 596, Apr ‘96 Hydraulic System Pressure Check and Adjustments l 3041
 Main Table of Contents

Group 30, Hydraulic Control Valve/Lift Circuit ElRRK

Main PressureRelief Adjustment Auxiliary PressureRelief Adjustment
IMPORTANT IMPORTANT
Main pressure relief setting is set at the The auxilkwy relief setting only applies
factory and should not be adjusted. If the to a hydraulic valve that has auxilkuy
relief pressure does not measure within sections added.
tbe setting range, a hydrostat in the pres-
sure relief valve must be replaced. If you To adjust the hydraulic system auxiliary pressure relief
attempt to adjust the hydrostat in the valve:
relief valve, your warranty on the equip 1. Loosen the jam nut on the auxiliary relief valve
ment may be voided. adjustment screw.
Jam Nut and
To reset the hydraulic system main pressure relief valve:
1. Remove the plug, O-ring, and spring from hydraulic
valve port shown in the following illustration.
Adjustment Screw
71

Spring

LJLU

\ Auxiliary Pressure Relief Valve

Relief
Valve
2. Turn the adjustment screw to set the auxiliary pres-
sure relief setting to the normal range.
3. Reset the jam nut on the auxiliary relief valve adjust-
ment screw.

Flow ControlAdjustment
1. Remove the nut from the main hydraulic valve tie-
bolt stud
&

2. Remove the main pressure relief valve.

n
3. Screw open the main pressure relief valve and re-
move the hydrostat in the valve. Remove nut
4. Replace the hydrostat in the same position with the and tie-bolt.
new unit.
5. Recap the pressure relief valve and replace in the
-Adjust flow here.
valve body.
6. Replace the spring, O-ring, and plug. Bottom View of Tjpicd Valve (no auxikny attachments).

2. Remove the stud from the valve.

3. TurntheflowcontroladjusterfullyCCWtothestop.
Turn CW per specifkations (in Section 1) to adjust.
4. Reinstall the tie bolt stud in the valve. Torque the
stud to 38-43 N*m (28-32 f&lb). Reinstall the nut on
the tie bolt and torque to 38-43 N*m (28-32 ft-lb).

30-4-2 l Hydraulic System Pressure Check and Adjustments SM 598, Apr ‘96
 Main Table of Contents

ElRRK Group 30, Hydraulic Control Valve/Lift Circuit

Section 5.

Hydraulic Control Valve Removal

and Replacement

Hydraulic Control Valve Removal ............................................................................................... 2

Preparation for Valve Removal ....................................................................................................... 2
Control Valve Linkage Disassembly .............................................................................................. -2
Valve Removal ................................................................................................................................. 2

Hydraulic Control Valve Replacement ........................................................................................ 3

Valve Replacement .......................................................................................................................... 3
Control Valve Linkage Reassembly ................................................................................................ 3

Operational Checks ................................................................................................................. ...... 4

! CAUTlON n
SAFE PARKING. Before working on truck:
1. Park truck on a hard, level, and solid surface, such as
a concrete floor with no gaps or breaks.
2. Put upright in vertical position and fully lower the
forks or attachment.
3. Put all controls in neutral. Turn key switch OFF and
remove key.
4. Apply the parking brake and block the wheels.

NOTE
HYDROSTATIC TRANSMISSION TRUCK. The con-
trols and linkages on the following pages do not show
the associated sensors and switches that are part of the
hydrostatic control system. If you are servicing a hy-
drostatic transmission truck rather than the standard
transaxle truck, refer to Group 06(H) for information
on those devices.

SM 598, Ott ‘94 Hydraulic Control Valve Removal and Replacement l 30-5-l
 Main Table of Contents

Group 30, Hydraulic Control Valve/Lift Circuit CICIRK

HydraulicControl Valve Removal Control Valve Linkage Disassembly

IMPORTANT
Keep all hydraulic ports, components, and
fittings completely clean during valve re-
moval and replacement to prevent any con-
tamination from entering the hydraulic sys-
tem.
Remove the cotter rings and clevis pins connecting the lift
and tilt (and auxiliary, as applicable) lever rods from the
hydraulic valve spools. Back off the lower jam nut at the
turn buckle to allow the valve spool to be rotated before
removing the clevis pins.

Preparation for Valve Removal

1. Park truck in a safe position and fully lower the upright.
2. Return all controls to neutral, apply the parking brake,
stop the engine and turn key switch OFF.
3. Move all hydraulic control levers to all working posi-
tions and return them to neutral. Be sure there is no
hydraulic pressure applied to the system by attach-
ments.
4. Open the engine compartment and remove floorboard.
5. Remove the right cowl cover from under the dash in the
operator’s compartment. See removal and replace-
ment procedures in Croup 38.
6. Air clean the hydraulic valve and fittings.
7. Place a drain pan under the truck and loosen and
remove all hydraulic lines from the valve. Plug the
valve ports. Mark or tag each line as removed to assure
correct position of line at assembly. Valve Removal
1. Remove the three hex capscrews mounting the hy-
draulic valve to the hydraulic assembly bracket (lower
cowl). Two of the capscrews thread into the valve
itself; the third is secured with a flange nut.

Hydraulic Assembly
Bracket (Lower Cowl)
qq
..-

Feed Line1
from Pump Tilt Cylinder
Lines
2. Remove valve assembly from truck. See Section 6 for
8. Cap ends of lines to keep them clean. Tie ends of lines valve overhaul instructions.
to truck to prevent loose ends dropping and leaking oil
onto floor. NOTE
Be sure to clean up any oil spills and dry
the floor to prevent accidents.

30-5-2 l Hydraulic Control Valve Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents

ClmK Group 30, Hydraulic Control Valve/Lift Circuit

HydraulicControlValve Replacement Control Valve Linkage Reassembly

1. Insert the clevis pins through the rod-end clevises and
Valve Replacement valve spools of the lift and tilt spools (and auxiliaty-
lever rods and spools where applicable) and secure
1. Position the main valve on the hydraulic assembly
with the cotter rings. Rotation of the valve spools is
bracket (lower cowl). Install valve mounting fasteners
required to allow insertion of the clevis pins. Rotate
and tighten hand tight so that valve mounting can be
spools back so all pins are in line.
adjusted for alignment with the lever connecting rods.

Hydraulic Assembly
Bracket (Lower Cowl)

2. Install the hydraulic lines on the proper ports. Make

sure all lines are clean, are routed correctly in the truck,
and are not kinked. Torque fittings according to “Hy-
draulic Fitting Tightening Procedure” in Group 40.

NOTE
The illustration above and system specifi-
cation torques also apply for auxiliary hy-
draulic functions, such as a side-shifter or
rotator.

2. When alignment between the lever rods and the valve

is set and levers are inline and level with one another,
tighten the valve mounting capscrews and flange nuts
to 40-50 Nom (30-33 ft-lb).

Feed Line1 ‘LTilt Cylinder

from Pump Lines

3. Adjust the valve to align with the lever connecting

rods.

SM 598,Oct ‘94 Hydraulic Control Valve Removal and Replacement l 30-5-3

 Main Table of Contents

Group 30, Hydraulic Control Valve/Lift Circuit emu

Operational Checks a. Loosen jam nuts on adjustment turnbuckles of

lever rods.
Start and operate the truck and hydraulic system.
Check the system for leaks.

A WARNING
Do not use your hands to check for hydrau-
lic leakage. Use a piece of cardboard or
paper to search for leaks. Escaping fluid
under pressure can penetrate the skin caus-
ing serious injury. Relieve pressure before
disconnecting hydraulic or other lines.
Tighten all connections before applying
pressure. Keep hands and body away from
pinholes and nozzles which eject fluids un-
der high pressure.
If any fluid is injected into the skin, it must
be surgically removed within a few hours
by a doctor familiar with this type injury
or gangrene may result

Check the operation of the valve and hydraulic system

by moving the valve control levers to the various
b. Adjust turnbuckle to increase or decrease spool
positions. The levers must operate smoothly with no
movement to correct measure.
binding. When released from any working position,
the levers must return sharply to their neutral positions. c. Retighten tumbucklejam nuts to 39-4-4N.m (28.5
32.5 ft-lb).
If valve spools do not moved or return to correct
position for full function of lift, tilt, or auxiliary cylin- 3. Refer to Section 4, “Hydraulic System Pressure Check”
ders: if valve was disassembled or overhauled.
4. Replace the cowl cover under the operator’s compart-
ment dash. See removal and replacement procedures in
Group 38.

30-5-4 l Hydraulic Control Valve Removal and Replacement SM 599,Oct ‘94

 Main Table of Contents

ClRRK Group 30, Hydraulic Control Valve/Lift Cirouit

Section 6.

Hydraulic Control Valve Overhaul

Preparation for Disassembly ........“......................~....“....”..........__......_............“...._...“...._ ..... 1

Disassembly ..“....U...._....“....~..........”....~....~.~..................~..........~.....~...~....~....”....“....~.~.~ . 2

Cleaning, Inspection, and Repair .._....“....“..........~....~....””..~......................~....~~..~....~...~ ... 3

Reassembly ........““..“.~.“_..~..........~..........~..~........................~....~....~“..“....“..“......~~........~ .- 4

Relief Valve Settings ...... ..U....“....“......_..“......_..~..........~....“....“....~...._...._.........._....~..._ ....- 4

IMPORTANT
Before removing any component for overhaul, make sure the correct repair
parts, seals, and gasket sets are available.

The following overhaul instructions describe a two spool
assembly with the inlet/lift section, a tilt (or auxiliary)
section, and outlet section (outlet section contains no spool).
Preparationfor Disassembly
Overhaul valve only in a clean, dust-free location, using
clean tools and equipment. Dii or grit will damage the
highly-machined surfaces and will result in leakage or
premature failure of components. Cleanliness of the hy-
draulic circuit is extremely important to the proper opera-
tion and maintenance of the system. Be sure the work area
is clean.
Clean outside of valve with a good grade of solvent
and dry thoroughly.
Before starting disassembly, the valve should be care-
fully examined to determine if there is any evidence
of external damage.

SM 598, Apr ‘96 Hydraulic Control Valve Overhaul l 30-6-l

 Main Table of Contents

Group 30, Hydraulic Control Valve/Lift Circuit ClRRK

Disassembly 2. Remove and label all parts between the sections for
correct reassembly. These include:
During disassembly, pay particular attention to identifica- a. Retainers and seals which are included in the
tion of parts for reassembly. Spools are selectively fitted to replacement seal kit.
valve bodies and you must return each spool to the same
b. O-rings, springs, and ball which are replaced
body from which it was removed. You must also be sure to
separately.
reassemble the valve sections in the original order.
NOTE
NOTE
Keep parts in order as removed and avoid
Valvesectionsmay or may not require sepa-
ration for overhaul. mixing the sections and parts.

3. Disassemble each valve spool, one at a time, from

If only valve spools are being overhauled, you do not have
to separate the sections. For a complete overhaul, including
replacement of the seals, retainers, O-rings, springs, and
balls used between the sections, follow steps 1 and 2. To
overhaul only the valve spools, begin with step 3.
1. Remove the nuts and studs connecting the valve sec-
tiOIlS.
bottom of valve as shown in the illustration.
4. Remove the valve spools by tapping lightly on the top
end with a soft-faced hammer to drive them out of the
valve body.
5. Arrange the parts in the sequence of removal.

AUXILIARY PRESSURE MAIN PRESSURE

RELIEF VALVE (adjustable) RELIEF VALVE

O-ring (4 required)

I/- Retainer
Lift Spool Assembly
(Construction shown in

m O-ring

Figure 1. InletlLifi:Body, Main Pressure Relief Valve, and Auxiliary Pressure Relief Valve.
Contents of spool assembly are shown in Figure 2.

30-6-2 . Hydraulic Control Valve Overhaul SM 598, Apr ‘96

 Main Table of Contents

ElfIRK Group 30, Hydraulic Control Valve/Lift Circuit

NOTE
Remove the outlet port section only if there
is need for further inspection and cleaning
of contaminants in the valve. To remove,
loosen and remove the nuts and studs and
separate the outlet port section from the
valve body. Label and keep all parts for
correct reassembly.
Cleaning, Inspection, and Repair
1. Discard all old seals. Wash all parts in a clean mineral
oil solvent and place them on a clean surface for
inspection.
2. Carefully remove any burrs by light stoning or lapping.
Be sure there is no paint or burrs on mating surfaces of
valve bodies.
Inspect valve spools and bores for burrs and scoring. If
scoring is not deep enough to cause leakage, the
surfaces can be stoned or polished with crocus cloth. If
scoring is excessive, valve body and spool must be
replaced. Check each valve spool for free movement in
its bore.
Inspect the main pressure relief valve for damage.
Relief valve must be free from contamination, burrs,
and scoring. Plug, spring, and O-ring should be cleaned
and inspected for damage.
NOTE
Entire relief valve assembly must be re-
placed if damaged. Relief valve pressure is
controlled by a hydrostat in the valve relief
valve assembly and is set at the factory. No
adjustments are recommended; if pressure
relief setting is not in recommended range,
hydrostat must be replaced.

Tiltor Auxiliary
Spring
Body
Quad Ring

Ball (Used only in lift section.)

Flow Control Poppet (Used only

in tilt and auxiliary sections.)

sections only.)

FLOW CONTROL

Figure 2. Valve Spool and Tilt (or Auxiliary) Body . Differences in lip (or tilt) and auxiliary components noted.

SM 598, Apr ‘96 Hydraulic Control Valve Overhaul l 30-6-3

 Main Table of Contents
Group 30, Hydraulic Control Valve/Lift Circuit
Inspect the lift and tilt relief valves for damage. Check
the relief valve for smooth free movement in its bore.
The valve poppet should move easily from only the
force of its own weight.
Inspect the valve body to make sure it has not been
physically damaged. Examine all threads to be sure
they are clean and not damaged or burred. Inspect all
bores and poppet seats. Poppet seat must be even all
around its circumference with no nicks, burrs, or
indentations in any of the seat face.
AU springs should be free of corrosion and not broken
or bent.
If parts must be left unassembled for a period of time
or overnight, cover with a lint-free clean material.
Outlet Body
Figure 3. Outlet Body
30-6-4 l Hydraulic Control Valve Overhaul
Reassembly
Use the exploded view illustration of the valve section,
spools, and relief valves for reassembly.
1. Assemble valve in reverse order of disassembly.
2. Coat all parts with clean hydraulic oil to facilitate
assembly and provide initial lubrication. Petroleum
jelly can be used to hold seal rings in place during
assembly.
3. Use new O-rings and seals for all parts.
4. Install seal rings and the seal ring retainer in the
grooves in body of each inlet and center section. Use
petroleum jelly to hold the seals in place. Carefully
place the sections together in the same order in which
they were removed.
5. Torque dust-cover screws to 10.8-13.5 Nom (8-10 ft-
lb).
6. Reinsert studs between valve sections and torque nuts
to 27-34 Nom (20-25 &lb).
ReliefValve Settings
After overhaul and reisintallation of the main hydraulic
valve, the hydraulic system relief pressure and auxiliary
valve relief pressure settings (iftruck and valve are equipped
with an auxiliary component and section) must be checked.
See the hydraulic system checks and adjustments Section
of this Croup (30) for procedures.
If the truck is not equipped with any auxiliary equipment,
no adjustments are necessary. If an auxiliary section has
been added to the hydraulic valve and auxiliary compo-
nents have been installed on the truck, check the relief
pressure. See the hydraulic system checks and adjustments
Section of this Croup (30) for procedures.
Torque to 37.8-43.2
SM 598, Apr ‘96
 Main Table of Contents

GROUP 32

GROUP 32

TILT CYLINDERS

Tilt Cylinder Specifications and Description ............... Section 1

Tilt Checks and Adjustments ......................................... Section 2

Tilt Cylinder Removal and Replacement .................... Section 3

Tilt Cylinder Overhaul ................................................... Section 4

IMPORTANT
Other hydraulic-related components and circuits are described and
illustrated in Group 25, “Steering Column and Gear,” Group 26 “Steer
Axle,” Group 29, “Hydraulic Sump, Filters, and Pump,” Group 30, Hydrau-
lic Control Valve/Lift Circuit,” and Group 34, “Uprights.” Refer to these
other groups for hydraulic components not covered in this group.

SM 598,Oct ‘94 Tilt Cylinders

 Main Table of Contents

Elmw Group 32, Tilt Cylinders

Section 1,

Tilt Cylinder Specifications and Description

Specifications Service Intervals

See Croup 30 for hydraulic system specifications. Tilt Cylinder Drift Test: Every 50-250 hours or each PM.
Tilt Cylinder Type: Double-acting Tilt Cylinder Check and Adjustment: Every 50-250 hours
or each PM.
Maximum Operating Pressure: 22,070 kPa (3,200 psi)
Tilt Cylinder Rod Seal Condition Check: Every 50-250
Tilt Ranges*: hours or each PM.
Tilt Cylinder Mounting Check and Tightening: Every 50-
Cushion -Tire Truck Uprights
250 hours or each PM.
Std (through 2667 mm (105 in) MFH) 6OB-10°F
Tilt Cylinder Rod-End Check and Tightening: Every 50-
Std (above 2667 mm (105 in) MFH) 8”B-8°F 250 hours or each PM.
TSU (through 4775 mm (188 in) MFH) 5”B-6”F Tilt Cylinder Rod-End Lubrication: Every 50-250 hours or
TSU (48006096 mm (189-240 in) MFH) 5”B-3”F each PM.

TSU (above 6096 mm (240 in) MFH) 30B-0°F with

Pneumatic -Tire Truck Uprights
Std (through 2667 mm (105 in) MFH)
Std (above 2667 mm (105 in) MFH)
TSU (through 4775 mm (188 in) MFH)
tilt limit over Description
ride to 3°F
The tilt cylinders provide backward and forward tilt of the
uptight. The forward and back tilt angles are governed by
the cylinder stroke and by use of spacers. The tilt cylinders
8”B-8°F
are pin-mounted to the truck frame and upright using yokes,
lO”B-6°F clevises, and pins. Pins are held in place by a lock plate and
5OB-6°F fastener to prevent the pins from working their way out.

TSU (48006096 mm (189-240 in) MFH) 5”B-3°F The tilt cylinders are serviced by removing them from the
truck and disassembling them for complete overhaul, in-
TSU (above 6096 mm (240 in) MFH) 3”B-0°F with cluding installation of new seals and or other cylinder
tilt limit over components.
ride to 3°F
The tilt lock valve is integrated into the tilt section of the
* Abbreviations: Std = Standard, high-visibility upright; TSU = Triple- main hydraulic control valve. The tilt lock valve prevents
stage upright hfFH = maximum fork height; B = back tilt; F = forward
tilt. See tmck data plate for upright h4FH. the upright from tilting forward when the truck is not
running. The tilt lock valve is not serviceable and must be
replaced as a valve section if defective.
FastenerTorques
Rod-End Yoke Bolts: 166-193 Nom (122-142 ft-lb)
Rod-End Pm Lock Plate Fasteners: 8-10 Nom
(10.8-13.5 f&lb).
Base Mount Pin Lock Plate Fasteners: 8-10 N*m
(10.8-13.5 ft-lb).

SM 598, Apr ‘96 Tilt Cylinder Specifications and Description l 32-l-l

 Main Table of Contents

ClRRK Group 32, Tilt Cylinders

Section 2.

Tilt Cylinder Checks and Adjustments

Tilt Cylinder Drift Test .................................................................................................................
1
Drift Causes and Remedies .............................................................................................................. 2

Tilt Cylinder Racking Check ........................................................................................................ 2

Forward Adjustment ........................................................................................................................ 2
Backward Adjustment.. .................................................................................................................... 3

Tilt Flow Control Adjustments ....................................................................................................

3

!n CAUTION
SAFE PARKING. Before working on truck:
1. Park truck on a hard, level, and solid sur-
face, such as a concrete floor with no gaps
or breaks.
2. Put upright iu vertical position and fully
lower the forks or attachment.
3. Put all controls in neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the
wheels.

Tilt Cylinder Drift Check 4. Measure and write down the distance between the
cylinder-spacer face and the rod-end yoke.
To check tilt cylinder drift, a rated capacity load is placed
on the forks, lifted up and held to determine if the tilt
cylinder rods moves (drifts) in a specified length of time. Measure rod
distance here
It is recommended that a test load, made up of a full-
capacity load equally distributed on a 1220 x 1220 mm (48
x 48 in) pallet, be used. The material used to make up the
test load must be stacked to provide load stability and must
not extend beyond the pallet. It must be secured on the
pallet. Refer to the truck data plate for capacity rating.
Adjust fork width as wide as possible to distribute the
load. Refer to truck nameplate for capacity rating.

A ! CAUTION
r
I
Test load must be stacked stably, not ex-
tend beyond the pallet, and be secured on
the pallet.

Drive the forks into the load pallet until the test load and
pallet rest against the load backrest. Apply the parking NOTE
brake and chock the wheels. An alternate procedure is to measure the
change in the inclined angle of the upright,
Raise the capacity load 305 mm (12 in) off the ground
using a protractor and level, or inclinom-
and tilt the upright fully back. Shut off the truck.
eter.

SM 598,Oct ‘94 Tilt Cylinder Checks and Adjustments l 32-2-l

 Main Table of Contents

Group 32, Tilt Cylinders CUiRK

5. Wait five minutes and remeasure and write down the
distance between the same two points.
6. The decrease in the measure must not exceed the
following measures:
Temuerature Drift
26.7O C (80” F) 0.6”, 4.0 mm, 0.157 in
37.8”C (100°F) 1. lo, 7.0 mm, 0.276 in
48.9”C (120°F) 1.5”, 10.0 mm, 0.394 in

Drift Causes and Remedies

Tilt cylinder drift indicates the following possible prob-
lems:
l Tilt cylinder hydraulic circuit hoses or fittings are
leaking. Check the circuit components and repair as
necessary.
l Cylinder piston seals are worn, damaged, or defective
allowing fluid past the piston and causing the rod to
drift. Consider rebuilding the cylinders if the other
remedies in this list are not successful. See Section 3
for cylinder removal and replacement and Section 4 for
cylinder repair, if necessary.
l The main hydraulic tilt valve is misadjusted, worn, or
defective. Fluid is leaking past the valve and causing
the tilt cylinders to drift. See Group 30 for hydraulic
valve troubleshooting.
Forward Adjustment
Slowly tilt uPright fully forward to the end of the tilt
cylinder stroke.
As the cylinders approach the end of the stroke, watch
both piston rods for equal movement and upright for
twisting. Note if upright “racks” (is twisted at the end
of its movement by unequal stroke of tilt cylinders).
NOTE
Correct the twisting effect by shortening
the cylinder that is the longest length. For-
ward twisting must be adjusted before back-
ward twisting. If forward adjustment is not
needed, continue with backward adjust-
ment.

To adjust, loosen rod-end yoke capscrew on the tilt

Tilt Cylinder Racking Check cylinder that extends the farthest, and turn piston rod
into rod-end yoke to shorten.
Upright racking occurs when tilt cylinder strokes are un-
equal. Cylinders should be checked regularly during opera-
i I /,A.
tion to determine if cylinder strokes are the same. To check
for racking:
l Make sure truck is parked on level surface with park-
ing brake applied and wheels chocked.
l Check condition of the tilt cylinder, rod-end yoke,
mounting pins, piston rod, rod wiper, cylinder gland,
etc., for excessive wear or damage. Make repairs be-
fore making twisting adjustment.
l Use a capacity load (see truck nameplate) centered on
the forks.
,
n ! CAUTION
Be sure to secure the load to the fork car-
riage to keep it from falling off when tilted
forward.
Raise the upright only to the height that
will allow the fork tips to clear the floor
Forward Adjustment: Pneumatic-tire truck rod-end yoke
when tilted fully forward.
orientation shown.

32-2-2 l Tilt Cylinder Checks and Adjustments SM 598,Oct ‘94

 Main Table of Contents

ClRRK Group 32, Tilt Cylinders

NOTE 4. Use rod shims to fill in the space between the rod-end
Use wrench flat on rod under spacer (if yoke and spacer. Screw rod back into yoke the same
installed). Move spacer for access. number of turns needed to remove.
4. Continue to turn rod into rod end until tilt cylinder
strokes are equal.
IMPORTANT
The rod must be threaded onto the rod-end
yoke a distance at least as great as the
dieter of the rod plus 6.5 mm (0.25 in).

Add 6.5
mm (25
in) to
diameter
of rod.
‘Thread rod into rod-
end yoke the rod
diameter plus 6.5 mm
(0.25in). Tighten capscrew of the rod-end yoke to 166-193 N*m
(122-142 f&lb), and repeat the racking test
5. Tighten capscrew of the rod-end yoke to 166 193 Nom
Repeat steps l-5 for fine corrections if any racking
(122-142 ft-lb), and repeat the racking test.
remains evident
6. Repeat steps l-5 for fme corrections if any racking
When no racking occurs, retighten yoke capscrew to
remains evident.
166193 N*m (122-142 ft-lb).
7. When no racking occurs, retighten capscrew of the
Check all tilt functions before returning the truck to
rod-end yoke to 166-193 Nom (122-142 f&lb).
service.
8. Check ah tilt functions before returning the truck to
service.

Backward Adjustment
Tilt Flow Control Adjustments
Perform forward check and adjustment first. Then:
Slowly tilt upright fully backwards while watching See checks and adjustments Section of Croup 30, “Hydrau-
piston rods. They should both bottom out at the same lic Control Valve/Lift Circuit,” for adjustment procedure.
time. If they don’t, adjust backward tilt using the
following steps.
Stop the upright when the first tilt cylinder bottoms out
against its rod spacer.
Go to the opposite cylinder and remove the capscrew
on the rod-end yoke and screw rod out of yoke. Count
the number of turns required to remove the rod from
the yoke.

SM 598, Apr ‘96 Tilt Cylinder Checks and Adjustments l 32-2-3

 Main Table of Contents

Group 32, Tilt Cylinders

ElmK

Section 3.

Tilt Cylinder Removal and Replacement

2
Tilt Cylinder Removal ...................................................................................................................

3
Parts Inspection ..............................................................................................................................

3
Tilt Cylinder Replacement ............................................................................................................

SM 598, Ott ‘94 Tilt Cylinder Removal and Replacement l 32-3-l

 Main Table of Contents

Group 32, Tilt Cylinders EllRIRK

A CAUTION
SAFE PARKING. Before working on truck:
1. Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
2. Put upright iu vertical position and fully
lower the forks or attachment.
3. Put all controls iu neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the
wheels.
Tilt Cylinder Removal
A WARNING
The upright assembly is heavy. Use only
hoists with enough capacity to lift the en-
tire assembly. Keep hands and feet away
from the assembly. Use prybars to move
the assembly into position for tilt cylinder
replacement.
3. Remove the floorboard.
NOTE
Put a drain pan under the truck at each tilt
cylinder position before removing the hy-
draulic lines.

1. Move tilt lever back and forth several times to relieve 4. Disconnect and cap hydraulic lines from the tilt cylin-
any pressure. ders (see illustration on facing page). Remove the hose
connections on both sides of the tee fittings ofthe right-
2. Use an adequate chain and hoist to support the upright
side cylinder. Keep all fittings and ports clean.
so that it cannot fall when tilt cylinder pins are re-

Rod-end yoke
position for
pneumatic-tire
truck

Base Pin

Tilt Cylinder Mounting Components

32-3-2 l Tilt Cylinder Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents

CmK Group 32, Tilt Cylinders

5. Support cylinder with a sling to prevent the cylinder Tilt Cylinder Replacement
from dropping when pins are removed.
Position tilt cylinder base yoke on frame mounting
6. Remove lock-plate from tilt cylinder rod-end yoke.
bracket.
Use a soft drift and hammer to tap rod-end pin out of
yoke. Insert base pin in cylinder base yoke and through frame
mounting bracket, making sure slot in pin is in line with
7. Pop the cover from tilt cylinder base access port on the
the lock-plate. Grease fitting must point toward center
step to the operator’s compartment.
of truck.
8. Remove the lock-plate from cylinder base yoke. Use a
IMPORTANT
soft drift and hammer to tap pin out of yoke.
Make sure the spherical bearing is aligned
9. Remove cylinder assembly. so that pin fits smoothly in yoke.

Install base pin lock-plate in slot and fasten to yoke

Parts Inspection
1. Clean all bearings, pins, and other components in an
approved cleaning fluid.
2. Inspect all parts for scratches, nicks, dents, and wear.
Check the cylinderrods to be sure they are smooth with
no scratches. Check all threaded parts for damage.
3. Replace all parts which show damage.
4. If parts are to be left exposed, coat all mating surfaces
of parts with a light layer of engine oil.
with fastener and washer. Tighten fastener to a torque
of 8-10 Nom (5.9-7.4 ft-lb).
Position rod-end yoke on upright mounting bracket
and insert rod-end pin, making sure lock-plate slot is in
correct position. Grease fitting must be toward center
of truck. Make sure the spherical bearing is aligned so
that pin fits smoothly in yoke.

Tilt Cylinder Hydraulic Fittings

SM 598,Oct ‘94 Tilt Cylinder Removal and Replacement l 32-3-3

 Main Table of Contents
Group 32, Tilt Cylinders
NOTE
If the rod-end yoke has been removed from
the rod or loosened for adjustment, rein-
stall the clamp bolts to a torque of 166-193
N-m (122-142 ft-lb). Nuts must be on inside
of upright rails
Orientation of the rod-end yoke is different
for the cushion-tire and pneumatic-tire
trucks. As the illustration shows, the bolt
hole of the rod-end yoke is down on the
pneumatic-tire truck but is up on the cush-
ion-tire truck.
32-3-4 l Tilt Cylinder Removal and Replacement
CUlRK
5. Install rod-end lock-plate in slot and fasten to yoke
with fastener and washer. Tighten fastener to a torque
of 8-10 Pm (5.9-7.4 ft-lb).
6. Install tilt cylinder hydraulic lines. Check Group 40for
hydraulic fitting tightening procedures. O-rings of
fittings should be lightly coated with clean hydraulic
fluid or compatible oil.
7. Remove hoist chain from upright.
8. See Section 2 for tilt cylinder adjustment procedures.
When adjustments are made, check all upright compo-
nents under load before returning the truck to service.
SM 598,Oct ‘94
 Main Table of Contents

EUIRK Group 32, Tilt Cylinders

Section 4.

Tilt Cylinder Overhaul

2
Preparation for Disassembly .........................................................................................................

Disassembly ....................................................................................................................................
2

Inspection ........................................................................................................................................
2

Reassembly .....................................................................................................................................
3

IMPORTANT
Before removing any component for overhaul, make sure the correct
repair parts, seals, and gasket sets are available.

r-c-
Cylinder Barrel 7 Hydraulic Ports

L-h
V--l

/ /-- Rod

-Wrench Flat
Piston

/ \ - Rod Wiper
O-Ring and --J
Piston Seal Gland Static
Seal Rod U-Cup
Seal

Typical Tilt Cylinder Cross section

SM 598,Oct ‘94 Tilt Cylinder Overhaul l 32-4-l

 Main Table of Contents

Group 32, Tilt Cylinders CMRK

Preparation For Disassembly
A WARNING
The use of compressed air to blow the pis-
IMPORTANT
Overhaul tilt cylinders only in a clean, dust- ton out of the barrel is not recommended.
free location, using clean tools and equip- High-pressure air can result in piston and
ment. Dirt or grit will damage the highly- rod being ejected at high velocity (explo-
machined surfaces and will result in leak- sively), causing severe injury to personnel
age or premature failure of components. and property damage.
Cleanliness of the hydraulic circuit is ex-
3. Remove and discard the piston seal and 0- ring from
tremely important to the proper operation
the piston.
and maintenance of the system. Be sure the
work area is clean.

Before disassembly, the exterior of the tilt cylinder

should be carefully cleaned to remove all dirt and
grease accumulation.
Be sure all hydraulic oil has been removed from the
cylinder. Stroking the piston rod will help force the oil
out.
Before starting disassembly, the tilt cylinder should be
carefully examined to determine if there is any evi-
dence of external damage.

Disassembly 4. Remove and discard the rod U-cup seal, static seal, and
piston rod wiper from the gland.
The tilt cylinder can be held by clamping the base end or
the barrel in a vise while disassembling.

IMPORTANT U-Cup Seal

Do not use excessive force when clamping
on the barrel.

1. Remove the retaining ring on the gland by unlatching

it from the hole in the side of the gland. Use a spanner Rod Wiper
wrench to rotate the gland and unwind the ring out of
the cylinder barrel.

Retaining Ring
2. Carefully pull the rod, piston assembly, and gland from
the cylinder barrel. Remove gland from rod.
Inspection
Carefully clean all parts in an approved solvent and
place on a clean surface.
Check the piston and rod for damage. Look for gouges,
scratches, corrosion, or evidence of unusual wear.
Minor surface damage may be repaired by use of fine
abrasion cloth or stoning. Deeper damage will require
replacement of piston rod assembly.
Be sure the threads on rod are undamaged.
Inspect the tilt cylinder barrel internal bore for wear,
scratches or other damage. Check the outside for
damage. Inspect all welds for cracks.

Tilt Cylinder Overhaul l 32-4-2 SM 598, Ott ‘94

 Main Table of Contents

CMRK Group 32, Tilt Cylinders

Deep gouges or pitted surfaces require replacement of
parts.
Check the gland, base end, and ports for cracks or
damage that could cause failure. Inspect the ports to be
sure they are free of contamination and that the threads
are clean and not damaged.
5. Put a light coating of hydraulic fluid on all parts. If
parts are to be left disassembled for a period of time,
e.g., overnight, they should be covered with a clean
cloth.
Reassembly
Be sure inside of cylinder and all parts are clean before
starting reassembly. Seals may be lubricated with hydraulic
oil to assist assembly into cylinder barrel.
1. Install piston rod wiper, rod U-cup, and static seal on
the gland. Make sure U-Cup and wiper are installed in
proper orientation as shown in the illustration.
3. Install gland on piston rod. Use gentle pressure and
careful movements to avoid damage to the U-cup seal
and rod wiper when these parts are moved over the
piston rod end.
NOTE
Reassemble cylinder carefully to prevent
damage to seal lips and O-rings.
4. Install piston into cylinder barrel. Be careful not to
damage the’piston seals when installing the piston into
end of cylinder.
5. Then, install gland into cylinder. Be careful not to
damage gland static seal. Make sure the gland is fully
seated in the cylinder barrel.
6. Install the gland retainer ring:
Retaining Ring
/-

U-Cup Seal

Rod Wiper Retaining Ring

Static Seal
a. Route the retainer ring through the slot in the
cylinder case.

2. Replace the piston O-ring and piston seal. b. Latch the retainerring to the hole in the side of the
gland.
c. Use a spanner wrench to rotate the gland and wind
the retainer in place.

7. Check the assembly by making sure the piston slides

freely in and out of the cylinder.

See Section 3 for replacement procedures; see Section 2 for

checks and adjustments before returning the truck to ser-
vice.

SM 598,Oct ‘94 Tilt Cylinder Overhaul l 32-4-3

 Main Table of Contents

GROUP 34

GROUP 34

UPRIGHTS

Upright Specifications and Description .... .... .... ... . .. . ... .. Section 1

Troubleshooting . .... .. ........... . .. ... . ....... . .. ... .. .. .. ..... .... . .. . ... .. Section 2

Upright Inspection ... .... ...... ... .. . . ... ..... .. . ... ... ....... . .... . .. .. .. .. Section 3

Carriage and Upright Roller Clearance Checks

and Shim Adjustments .. . .. .. .... .. . ... .. . .. .. ....... .. .. .. . ... ... Section 4

Cylinder Removal, Shimming,

Overhaul, and Replacement .. .... . .. .. ..... ... .. ... ... ... .. .. . Section 5

Upright Chain Inspection, Adjustment,

and Replacement ....... .. ... . .. .... .... .. .. .. .. . ....... ... .. . .. .. .... Section 6

Fork and Carriage Removal and Replacement .. . . ... . ... Section 7

Upright Removal and Replacement .. . .... ... .... .. ... .. . .. ... ... Section 8

IMPORTANT
Related service information is covered in Group 29,
“Hydraulic Sump, Filters, and Pump,” Group 30, “Hy-
draulic Control Valve/Lift Circuit,” and Group 32, “Tilt
Cylinders.”

SM 598, Ott ‘94 Uprights

 Main Table of Contents

clmu Group 34, Uprights

Section 1.
Upright Specifications and Description

General Specifications Upright

Upright Weight: Approximately 363 kg (800 lb) to ap- UDright Tvne Number Cvlinder Tvoe
proximately 1000 kg (2200 lb) without carriage Standard V1080 Piston-Type Lift Cylinder
Carriage Weight: Approximately 109 kg (240 lb) to 122 kg V1081 Piston-Type Lift Cylinder
(270 lb) with a41 inch carriage V1082 Ram-Type Lift Cylinder
V1083 Ram-Type Lift Cylinder
Fork Weight: Approximately 50-68 kg each (110-150 lb)

IMPORTANT TSU Ml080 Piston-Type Secondary Cylinder

Before hoisting, the weights of upright, car- Ml081 Piston-Type Secondary Cylinder
riage, forks and attachments being lifted Ml082 Ram-Type Secondary Cylinder
must be combined to determine what lift- Ml083 Ram-Type Secondary Cylinder
ing capacity is required of the hoisting
equipment. Drift:
Capacities and Lift Heights: Upright, carriage, and fork Upright should not drift (fall) 2.5 mm (1 in) in five minutes
capacity and upright lift heights are listed on the truck’s under a capacity load. If drift over 25 mm (1 in) in five
data plate. minutes is evident, cylinder should be checked for internal
Lubricants: leakage. See Section 3 for drift test procedures.
l All Purpose Grease (MS-g)
l Innerslide Lubricant (Clark P/N 886396)
Fastener and Fitting Torque Specifications
l Chain and Cable Lube (Clark P/N 886399) Tmnnion Mounting Bolts: 74.25 Nom (55 ft-lb)

Cylinder Types Load Back Rest: 168.75-189 Nom (125-140 ft-lb)

Chain Anchor Bolt Jam Nut: 100-200 Nom (74-148 ft-lb)
Standard uprights use two lift cylinders. Triple stage up-
rights use three cylinders, a primary (center-mounted) cyl- Carriage Side-Thrust Roller Bolts: 40-50 Nom (29.5-37 ft-
inder, and two secondary cylinders. All primary cylinders lb)
used on triple-stage uprights (TSUs) are piston cylinders.
Hose Fittings: See Group 40, “Hydraulic Fitting Tighten-
The lift and secondary cylinders used on standard uprights
ing Procedure.”
and TSUs can be piston or ram cylinders.
Rod End Bolts: 164-190 Nom (122-142 ft-lb)
The types of cylinders used on the truck are listed below.
Check the first five characters of the upright number stamped Tilt Cylinder Rod-End Pin Lock Plate: 19-21.5 Nom (121-
on the upright of the truck to determine the type of cylinder, 136 in-lb).
piston or ram, used on the upright.

IMPORTANT
Before removing any component for over-
haul, make sure the correct repair parts,
seals, and gasket sets are available.

SM 598,Oct ‘94 Upright Specifications and Description l 34-l-l

 Main Table of Contents
Group 34, Uprights
Service intervals
All upright components should be visually checked
every day during the Operator’s Daily Inspection.
A thorough visual inspection should be performed by
a trained service professional every 50-250 hours.
Lift chains should be inspected and lubricated every
50-250 hours or monthly.
Lift chain tension should be checked every 50-250
hours or monthly.
Upright and carriage roller checks should be per-
formed every 50-250 hours or monthly.
Roller patterns should be checked every 6 months or
after 1000 hours of service.
Racking and drift tests should be performed every 6
months or after 1000 hours of service.
The complete extended inspection should be performed
at least every year or 2000 hours of operation.
Description
The upright assembly includes the lift chains, lift cylinders,
carriage, forks, and mast or rail sets. Each of the compo-
nents can be serviced using the tests, checks, adjustments,
and removal and replacement procedures in the following
Sections.
The upright uses the hydraulic cylinders and chain sets to
lift the carriage and rail sets. On standard, two-stage up-
rights, the lift cylinders lift the carriage with chains and
directly lift the inner rail set. On triple-stage uprights, the
primary (free-lift) cylinder lifts the carriage by chains.
When the primary cylinder reaches its maximum exten-
sion, fluid is diverted to the secondary lift cylinders, which
lift the inner rails using a second set of chains and lit the
intermediate rails by direct lift.
Friction and play between the nesting rails is controlled by
roller sets mounted on the rails and carriage. When rails or
rollers become worn. the gap between the rollers and rails
becomes larger. creating more play in lifting and lowering
operations. The rail web to roller side clearances can be
reduced by shimming the rollers to close the gap between
the roller and rails. The gap between the rail flange and
roller bearing surface can be reduced by the use of over-
size rollers on a one-time basis.
34-1-2 l Upright Specifications and Description
EWRK
Forks use a hanger design for mounting on the carriage.
Auxiliary attachments may be added to the upright for
specialized handling operations. The hydraulic circuit is
modified with a hose adapter kit and an auxiliary section is
added to the main hydraulic valve to operate the attach-
ment.
The lift and secondary cylinders on standard uprights and
triple-stage uprights (TSUs) may be either piston- or ram-
type cylinders. The primary cylinder on TSUs is a piston-
type cylinder. See the chart under “Specifications” to
determine the type of cylinder used on the upright you are
servicing.
Piston-type cylinders contain a by-pass check valve in the
piston that allows air and fluid that have accumulated in the
rod end of the cylinder to return to the system. The check
valve can be removed and cleaned if indicated by trouble-
shooting_ A non-serviceable check-ball-type cushioning
function is built into ram and piston cylinders for smooth
staging during the lowering cycle. The primary cylinder on
TSUs incorporates cushioning on the lift cycle. A velocity
fuse in the hydraulic port of the lift cylinders (secondary
cylinders on TSUs) prevents the mast from falling rapidly
in case of sudden fluid pressure loss due to line breaks or
other malfunction of the hydraulic circuit.
As explained in more detail in Group 30, the main pump
sends fluid to the main hydraulic control valve, which
contains spools that route fluid to the lift cylinders and tilt
cylinders. The valve assembly also contains a counter-
balance valve that prevents upright tilt when the truck is not
operating.
Fluid flow rates for lift functions are factory set and not
adjustable. Flow rates for tilt and auxiliary functions are
controlled by adjustments on the main hydraulic valve. A
non-adjustable “load-lowering” flow valve mounted on the
upright limits upright lowering speed.
Groups 29 and 30 contain general hydraulic information
including upright hydraulic functions. Other hydraulic
checks for the upright appear in “Troubleshooting,” Sec-
tion 2.
SM 598,Oct ‘94
 Main Table of Contents

CUIRK Group 34, Uprights

/-- Upper Roller

Lift Cylinder

L - Chain Sheave

Outer Rail Set

Chain Anchor
1

Lift Chain

Load-Lowering I
Flow Valve
Lower Roller -

Inner Rail Set

Typical Standard (Two-Stage) Upright Assembly

SM 598,Oct ‘94 Upright Specifications and Description l 34-l-3

 Main Table of Contents
Group 34, Uprights CmK

Upper Roller - r- Hose

Sheave Chain
I Sheave
,-- Chain Anchor
Outer
Rail --I

Secondary
Cylinder _

/--- Upper Roller

Chain Sheave 7

Lowering
Flow Valve
Lower Roller

Intermediate
Rail Set
Lower Roller

/
Inner Rail Set 1 Carriage

Typical Triple-Stage Upright Assembly

34-l-4 ’ Upright Specifications and Description SM 598,Oct ‘94

 Main Table of Contents

Group 34, Uprights

EmK
Internal Thrust

Upright

Outer-Rail Tie Bar i IL/’

Intermediate-Rail -I Inner-Rail Tie Bar

1

Tie Bar

Typical Triple Stage Upright - Overhead View

Fork Hanger Bar

Adjustment Shims

External Thrust Roller

(on TSUs only)

Carriages and Roller Sets

SM 598,Oct ‘94 Upright Specifications and Description l 34-l-5

 Main Table of Contents

Group 34, Uprights CUlRK

Two-Hose A&ptation for the

Triple-Stage Upright

Two-Hose Adaptation for the

Standard Upright

34-l-6 l Upright Specifications and Description SM 598, Apr ‘96

 Main Table of Contents
emI6
Section 2.
Troubleshooting
The visual inspection and the operational checks presented
in Section 3 should be used to determine problems with the
upright. Possible problems, causes, and remedies are listed
below.
Other troubleshooting information about the hydraulic cir-
cuit and components appears in the troubleshooting Sec-
tions of Groups 29 and 30. Use these other troubleshooting
Sections for more detailed problem isolation with Upright
hydraulic functions.
A
WARNING
The procedures for troubleshooting up-
rights, carriages, and forks involve move-
ment of the components. Failure to follow
these warnings can result in serious injury.
Make sure overhead clearances are ad-
equate before raising the upright to full lift
height.
Do not walk or stand under raised forks.
Block carriage and upright whenever mak-
ing checks with the upright elevated.
Keep clear of load and carriage when mak-
ing any check or adjustment.
Keep your arms and fingers away from
moving parts of the upright.
Do not reach through open areas of the
upright.
Upright noise
Bent or broken components; inspect upright thoroughly
and repair or replace components as required.
Damaged upright roller; check condition of rollers
and replace defective rollers.
Roller scuffing rails; clean and lubricate rails.
Roller (carriage or upright) shimming needs adjust-
ment; check and adjust as required.
SM 598, Ott ‘94
Group 34, Uprights
. Fit between roller edge and rail flange excessively
loose in rails; replace with oversized, “Select-Fit”
rollers. See “Upright Roller Clearance Check and Shim
Adjustment.”
. Dry lift chain; lubricate chain.
. Dry hose sheave or rollers; check condition of all
sheaves and rollers and lubricate as necessary.
. Damaged chain sheaves; check condition of chain
sheaves and repair or replace.
. Excessive fork hanger or carriage fork bar wear; in-
spect and replace as necessary.
. Seals dry; lubricate rod.
. Seals dry - all primary cylinders; remove gland and
add 100 ml (3.4 oz) of hydraulic oil to rod side of
piston, see “Cylinder Removal, Shimming, Overhaul,
and Replacement.”
No lift, tilt, or auxiliary function
. Hydraulic fluid level low; check level and fill.
. Broken hoses or fittings; check and repair.
. Damaged or blocked sump strainer; check and clean.
. Hydraulic pump defective; see Group 29 for pump
troubleshooting.
. Defective main hydraulic control valve; see Group 30
for valve troubleshooting.
. Defective upright load-lowering flow valve; disas-
semble valve, check and clean or replace.
No lift function but tilt operates
. Broken hoses or fittings; check and repair.
. Cylinder is damaged; inspect and repair.
. Main hydraulic control valve, lift section defective;
see Group 30 for valve troubleshooting and service
information.
. Upright load-lowering flow valve damaged; disas-
semble valve, check and clean or replace.
Troubleshooting l 34-2-l
 Main Table of Contents
Group 34, Uprights
Load cannot be lifted to maximum height
Hydraulic fluid level low, check level and fill.
Debris in upright; check and clean.
Hydraulic hose fittings loose or damaged; check and
torque correctly (see Group 40 for specifications) or
replace.
Check cylinder for external leakage; replace cylinder
if cracked.
Cylinder shimming is incorrect; check and adjust shim-
ming.
Internal leakage on lift or secondary piston cylinders;
remove rod and piston and clean check valves; also
clean and inspect/replace piston seals. See Section 5.
. Cylinder check valve on lift or secondary piston cyl-
inders not functioning properly; remove rod and pis-
ton and clean check valves; also clean and inspectf
replace piston seals. See Section 5.
Hydraulic pump defective; see Group 29 for pump
troubleshooting information.
Upright rails binding:
a. Perform a visual inspection and check for worn, or
distorted parts, broken or cracked rails or tie-bars,
correct chain and hosing placement and operation
b. Check rollers for contamination and proper opera-
tion, perform roller clearance check and adjust-
ment
Lift speed sluggish
. Hydraulic fluid level low; check level and fill.
. Broken hoses or fittings; check and repair.
. Pump inlet line restricted;
remove from pump and
clean.
. Damaged or binding upright roller; check condition
of roller and replace if necessary.
. Internal leakage on piston-type lift and secondary
cylinders (with load): perform cylinder checks listed
under “Load cannot be lifted to maximum height.”
Hydraulic pump defective; see Group 29 for pump
troubleshooting information.
Defective main lift valve; see Group 30 for valve
troubleshooting and service information.
Defective velocity fuse; remove fuse from cylinder
hydraulic port, clean and recheck for proper opera-
tion.
Defective priority valve; see Group 30 for valve
troubleshooting information.
Defective upright load-lowering flow valve; remove
valve clean, inspect, and replace if necessary.
34-2-2 l Troubleshooting
EMRK
Lowering speed sluggish
Damaged or binding upright roller; check condition
of roller and replace if necessary.
Damaged or kinked hydraulic hose or tube; check
condition of hose and tube, repair or replace as neces-
sary.
Defective upright load-lowering flow valve; check,
clean and replace valve if necessary.
Defective velocity fuse; remove fuse from cylinder
hydraulic port, clean and recheck for proper opera-
tion.
Load bounces excessively when lowering
Air in hydraulic system, TSU ram-type cylinders; set
capacity load on upright and lift from fully collapsed
to full lift height for lo-15 cycles.
Defective upright load-lowering flow valve; check,
clean and replace valve if necessary.
Defective main lift valve; see Group 30 for valve
troubleshooting and service information.
Defective velocity fuse; remove fuse from cylinder
hydraulic port, clean and recheck for proper opera-
tion.
Upright mis-staging (TSU lifting)
Debris in upright roller area of carriage; check and
clean.
Interference between carriage and inner rail or cylin-
der; check staging alignment and adjust or repair as
necessary.
Bent or broken carriage or inner rail; replace part - do
not try to repair by welding.
Damaged or binding carriage roller; check condition
of roller and replace if necessary.
Carriage roller shimming or thrust roller out of adjust-
ment; perform roller checks on carriage and make
adjustments as necessary.
Damaged or kinked primary cylinder hose; check con-
dition of hose, repair or replace as necessary.
Primary cylinder chain or chain sheave binding or
damaged; inspect and repair.
Internal leakage in primary lift cylinder; perform cyl-
inder checks listed under “Load cannot be lifted to
maximum height.”
Damaged primary lift cylinder causing binding in the
cylinder; inspect and repair or replace cylinder.
SM 598, Ott ‘94
 Main Table of Contents

Group 34, Uprights

Emu
l Defective velocity fuse; remove fuse from cylinder
hydraulic port, clean and recheck for proper opera-
tion.
Upright mis-staging (TSU lowering)
External leakage on primary cylinder
l Gland loose; check and tighten primary cylinder gland
to 13.5 Nom (100 ft-lb) and glands on lift (secondary)
cylinders to 100 wrn (73 ft-lb).

. Debris in upright roller area or tie bar area; check and l Cracked cylinder tube; replace tube.
clean. l Rod seal damage; replace seals and check for:
. Bent or broken carriage or inner rail; replace part - do - Damaged rod seal groove in gland; check for
not try to repair by welding. damage to groove and replace seal or gland if
necessary
. Damaged or binding roller on upright; check condi-
- Scored cylinder wall; repair or replace cylinder
tion of roller and replace if necessary.
tube if necessary
. Carriage and upright roller shimming or thrust roller
- Leaking check valve; clean and replace if neces-
out of adjustment; perform roller checks on upright
and/or carriage and make adjustments as necessary. sary
. Damaged or kinked lift cylinder hose; check condi- - Leaking O-ring seal on check valve; replace check
valve.
tion of hose, repair or replace as necessary.
. Lift cylinder chain or chain sheave binding or dam- l Gland static seals (O-rings and back-up ring) dam-
aged; replace back-up ring.
aged; inspect and repair.
. Bent cylinder rod; inspect l Gland static seals sealing surface damaged; check
and replace rod and/or
groove and bore and repair or replace as necessary.
cylinder as necessary.
. Internal leakage in piston-type cylinders; perform cyl- External leakage on lift (Standard) and
inder checks listed under “Load cannot be lifted to secondary cylinder (TSUs)
maximum height.”
. Damaged lift cylinder causing binding in the cylinder; Gland loose; check and tighten gland on cylinders to
inspect and repair or replace cylinder. 100 N*m (73 ft-lb).
. Defective velocity fuse; remove fuse from cylinder Cracked cylinder tube; inspect and replace tube.
hydraulic port, clean and recheck for proper opera- Seal damage in piston-type cylinders; replace piston
tion. seals and rod seals.

Upright mis-staging (Standard upright Rod seal damage, ram-type cylinders; replace rod
seals.
lowering)
Damaged seal groove, piston-type cylinders; check
Damaged or binding roller on upright; check condi- for scratches, nicks, or burrs and repair or replace rod
tion of roller and replace if necessary. and piston.
Top carriage roller retaining cap screw loose; check Scored cylinder wall, TSU piston-type cylinders; re-
and replace cap screw. place tube and all seals.
Lift cylinder chain or chain sheave binding or dam- Scored or damaged rod; replace rod and all seals.
aged; inspect and repair. Damaged gland back-up seal; inspect and replace seal.
Debris in upright roller area or tie bar area; check and Gland static seals sealing surface damaged; check
clean. grooves and bore.
Bent or broken carriage or inner rail; replace part - do
Oil leak at top of lift cylinder
not try to repair by welding.
Carriage and upright roller shimming or thrust roller l Scored cylinder wall; see Section 5.
out of adjustment; perform roller checks on upright
l Worn or damaged gland rod-seal; see procedures for
and/or carriage and make adjustments as necessary. piston-type cylinders under “Cylinder leaking inter-
Defective velocity fuse; remove fuse from cylinder nally.”
hydraulic port, clean and recheck for proper opera-
tion.

SM 598, Ott ‘94 Troubleshooting l 34-2-3

 Main Table of Contents

Group 34, Uprights CMRK

Unsatisfactory lift or tilt cylinder drift test results . Cylinder hydraulic fittings loose or worn; check fit-
ting O-rings, tighten fittings according to Group 40,
l Cylinder leaking internally; remove cylinder gland “Hydraulic Fitting Tightening Procedure.”
and check: . Check valve worn or damaged; remove rod and pis-
a. Primary cylinder should have only 3.4 ounces ton, clean check valve and replace if necessary.
(100 ml) on rod side of the piston
. Control valve spool linkage malfunctioning, damaged,
b. Piston- and ram-type lift and secondary cylinders or worn; see Group 30, Section 5 for linkage adjust-
should be dry on rod side of piston. ment and/or replacement.
If fluid is leaking past piston: . Counterbalance function in main hydraulic control
a. On piston-type cylinders, remove rod and piston, valve malfunctioning, damaged, or worn; inspect and
clean check valves and clean and inspect/replace clean or replace if necessary.
piston seals
b. On ram-type cylinders, inspect/replace rod and
piston.
See Section 5.

34-2-4 l Troubleshooting SM 598,Oct ‘94

 Main Table of Contents

CUlRK Group 34, Uprights

Section 3.

Upright Inspection

Basic Visual Inspection .................................................................................................................. 2

Extended Inspection ....................................................................................................................... 3

Forks .._............................................................................................................................................
. 3
Lift Chains ....................................................................................................................................... 4
Carriage and Upright Weldments .................................................................................................... 5
Carriage and Upright Rollers ........................................................................................................... 6
Cylinders .......................................................................................................................................... 7
Hydraulic Plumbing ......................................................................................................................... 9
Upright Drift .................................................................................................................................... 9
Trunnion Bearings ......................................................................................................................... 10

CAUTION A
SAFE PARKING. Before working on truck:
Park truck on a hard, level, and solid surface, such as a
concrete floor with no gaps or breaks.
Put upright in vertical position and fuiiy lower the forks or
attachment.
Put aii controls in neutral. Turn key switch OFF and re-
move key.
Apply the parking brake and block the wheels.

Upright -

I//

Forks

SM 598,Oct ‘94 Upright Inspection l 34-3-l

 Main Table of Contents
Group 34, Uprights
Basic Visual Inspection
Use the following steps to conduct an initial visual inspec-
tion of the upright. This is the same type of inspection
operators should be conducting on a daily basis.
If you note problems with any component during the basic
visual inspection, continue with “Extended Inspection” for
checks and service.
A WARNING
The procedures for checking, maintaining,
and adjusting uprights, carriages, and forks
involve movement of the components. Fail-
ure to follow these warnings can result in
serious injury. Always use extreme cau-
tion.
Do not walk or stand under raised forks.
Keep clear of load and carriage when mak-
ing any check or adjustment.
Keep your arms and fingers away from
moving parts of the upright.
Do not reach through open areas of the
upright.
General
Check to make sure all fasteners are secure.
Check to make sure the upright lifts and lowers
smoothly with and without a capacity load.
Check for visible damage to components.
Forks
Check function and security of the fork latch.
Inspect the forks for cracks, especially the hanger and
heel areas.
Check for wear in the fork heel. If heel wear is evi-
dent, perform the extended inspection.
Inspect the fork hanger and carriage fork bar for ex-
cessive wear.
Inspect for bent forks.
Load Backrest
l Inspect load backrest for damage such as cracks or
bending.
l Check for tight mounting fasteners.
34-3-2 l Upright Inspection
Elmw
Lift Chains
Inspect the chains for:
Proper lubrication. The links should have a coat of oil
on all surfaces. Lubrication oil should penetrate com-
pletely into chain joints.
Good condition of the chain links and pins. No rust,
corrosion, stiffness, or cracking should be evident.
Pins should not be turned or protruding.
Excessive side wear or edge wear on the chain plates.
Correct, equal tension on chain sets.
Secure anchor bolt, adjustment nut, and jam nut mount-
ing.
Correct alignment of the chain anchors to the chain
and chain sheaves. Adjust turned chain anchors.
Loose, broken, or damaged anchor bolt pins and cot-
ter pins. Replace defective pins and cotter pins.
Rollers
Inspect the upright and carriage rollers for:
Broken or loose rollers.
Loose, broken, or misadjusted thrust roller on the
carriage.
Obvious signs of failed bearing seals.
NOTE
Some grease will purge from the bearings
in the first 100-200 hours of operation.
Excessive looseness in carriage or upright roller shim-
ming.
Upright and Carriage Weldments
Inspect the upright and carriage for:
l Debris or foreign objects on the components.
l Bent, cracked, or broken components.
l Undesirable wear on or contact between components.
l Irregular roller patterns and signs of excessive wear
or scraping on the rails.
Hydraulic System
Inspect the upright hydraulic system components for:
l Damage or wear on all hoses and hydraulic tubes.
l Leaks on hoses, fittings, or valves.
l Leakage on the cylinders.
l Excessive drift in lift or tilt operations.
SM 598, Ott ‘94
 Main Table of Contents

Group 34, Uprights

clmu
Extended Inspection
The extended inspection should be performed whenever
(0.6 in)
the basic visual inspection indicates upright problems, as
specified for PMs, or at least every 2000 hours.

Forks
Forks have a limited service life because of wear and
fatigue. Forks should be tested every SO-250 hours using a -Carpenter Square
visual inspection, a fork thickness check, a fork bending
check, and a fork gap check. If replacement is necessary,
always replace the pair to ensure fork integrity.
Fork Alignment
Park the truck on a flat, even surface, tilt upright to
vertical position, and set forks 25-50 mm (l-2 in)
above the ground. Fork Bending Check

Compare fork arms to be sure they are straight, on the Set a carpenter’s square oti the block against the fork
same plane (level), and the same length. shank

Measure the distance from the fork tips to the ground.
The height difference between the forks tips should be
no more than 3% of the fork length. For example, a
1066 mm (42 in) fork should not vary more than 30.5
mm (1.2 in) up or down from its mate. See “B” in
following figure.
Fork
Hanger
Check the fork 508 mm (20 in) above the blade to make
sure it is not bent more than 14.5 mm (0.6 in) at the
maximum.
If blades are bent over the 14.5 mm (0.6 in) allowance
they should be replaced as a set.
See Section 7, “Fork and Carriage Removal and Replace-
ment,” for procedures to remove and replace the forks.
Fork Fatigue
Fatigue cracks normally start in the heel area or on the
underside of the top hanger. If cracks are found, the fork
should be replaced. Dye penetrants or magnaflux can be
used for a more accurate inspection.

Fork Wear and Heel Wear

Fork Arm Height
4. If the fork tips are not aligned within the specified 3%
difference, the cause of the problem must be deter-
mined and corrected before returning the truck to
service. If replacement is necessary, always replace
the forks in a set.
Fork Bending
Overloading, glancing blows against solid objects, or pick-
ing up loads unevenly can bend or twist a fork. Use the
following procedure to check for fork bending.
1. Placea50x1OOx610mm(2x4x24in)woodblock
flat on the fork. Make sure the block is not resting on
the heel radius.
Industrial Truck Association (ITA) standards require that a
fork be removed from service when the blade or heel thick-
ness is reduced by 10% over its original thickness. If the
heel is 10% smaller than the arm, the load capacity could be
reduced by 20%. A 5,000-pound (2272 kg) capacity fork
with 10% wear can only safely handle 4,000 pounds (18 18
kg).
Use of fork wear calipers are recommended (Clark part
number 1803641) to gauge fork wear as follows:
1. Use the outside jaws of the caliper to measure fork
thickness in the shank area of the fork.

SM 598,Oct ‘94 Upright Inspection l 34-3-3

 Main Table of Contents

Group 34, Uprights ClClRK

Step 1,
measure with
outside jaws
of caliper.
Step 2,
measure with
inside jaws of
caliper.
NOTE
A small amount of lubricant can be applied
NOTE
to the fork latch. Do not over lubricate and
Hold the caliper square and use light pres-
allow lubricant to run down on carriage
sure to squeeze the outer jaw tips against
fork bar.
the fork shank. Take care not to acciden-
tally alter the reading of the calipers. 2. Check fork stops for widening of notches or rounding
of top edge. Replace the carriage if fork stops are
2. Check the fork blade area to the inside jaws of the
excessively worn.
caliper.
3. If the inside jaws fit over the fork in the blade area,
Lift Chains
wear exceeds allowable 10% wear and a new set of
forks should be installed. The following checks should be performed every 50-250
hours to ensure correct chain performance See Section 6 for
Fork Hanger Wear and Carriage Fork Bar Wear more complete chain inspection and maintenance proce-
dures.
Inspect the fork hangers and carriage fork bar. Excessive
wear can cause the fork to disengage the fork bars or reduce
Chain Wear (Stretch) - All Lift Chains
fork hanger life.
Lift chain stretch due to wear in the joints can be measured
n 7 Fork
using a measuring tape or Clark’s chain check ruler.
Hanger

L--- Car-
riage
Fork
Bar
l If fork hangers are excessively worn, replace the forks
as a set. Chain Check Ruler - Clark Part Number 59-960-9908
l If carriage fork bar is excessively worn, replace the
carriage. When any section of the chain has worn and increased its
IMPORTANT original length by 3% or more, the chain must be replaced.
Welding is not recommended for repairing When checking chain wear, always measure a segment of
forks or carriage. Replace the worn parts the chain that rolls over a sheave.
with new parts.

Fork Latch and Carriage Fork Stops

1. Check fork latches for proper operation. Latches should
operate smoothly. The spring should be in good condi-
tion and securely lock the fork into position. Replace
the fork latch if it does not operate properly.

34-3-4 l Upright Inspection SM 598,Oct ‘94

 Main Table of Contents
GlmK
IMPORTANT
Never replace a single chain in a set. Al-
ways replace the two chains in a set for
consistent lift operation. Always replace an-
chor pins when replacing chains.
For example, measure a 305 mm (12 in) segment of the
chain that does not roll over a sheave and count the
number of links in the segment.
Find an area of the chain that normally runs over the
sheave. This can usually be identified by wear on the
plate edges that roll over the sheave.
If the same number of links measures over 315 mm
(12.36 in) the chain must be replaced.
If using a chain check ruler, see instructions on the ruler.
Chain replacement procedures appear in Section 6.
Chain Length
IMPORTANT
Perform a chain length check and adjust-
ment every SO-250 hours. Checks and ad-
justments should also be performed to ad-
just for chain stretch and tire wear.
Chain length must be adjusted if:
The fork-to-ground clearance is less than 5 mm (.20 in)
or more than 25 mm (1.0 in) when the upright is
vertical.
The center of the bottom carriage roller comes within
20 mm (0.80 in) of the bottom edge of the inner rail.
The carriage safety stop hits the inner rail stop at full
lift height.
On TSUs, the difference between the bottom of the
inner rail and the outer rail is greater than 10 mm (0.40
in).
See Section 6 for chain length adjustment procedures.
Chain Tension
IMPORTANT
Center any auxiliary attachments before
beginning tension check
1. Raise the upright enough to put tension on the chains
to be checked.
2. Push the chains forward and pull them backward; the
amount of tension should be equal on both sides.
A WARNING
Do not reach through the upright to push
chains for tension check.
SM 598,Oct ‘94
Group 34, Uprights
If one chains moves more than the other;
a. Lower the forks to ease tension on the chains.
b. Adjust chain adjustment nuts for equal tension on
both chains. See Section 6 for chain adjustment
procedures
Repeat the tension test and make adjustments until the
tension is equal on both chains when the carriage and
upright are raised.
Carriage and Upright Weldments
The carriage and upright should be checked for fatigue
cracks and bent components every 2000 hours or every
year..Fatigue cracks start in areas of stress after a high
number of load cycles. Stress concentrations typically exist
in welded joints, in the area around a welded joint, or in the
comers of parts. Dye penetrant, magnaflux, or other crack
detection methods can be used to find or trace cracks. If
cracks are found in any structural weldment, the compo-
nent should be replaced before returning the truck to ser-
vice.
Bent components indicate excessive loading or high
impacts to the weldments. Bent components are usu-
ally structurally damaged and should be replaced.
Inspect roller contact patterns on the rail sections.
Roller contact patterns should be smooth and regular.
- In some applications, it may take up to 500 hours
of operation to develop a roller contact pattern on
the flange of the rail.
- In applications where heavy loads are common, a
rail lubricant may be required to allow proper
wear-in on the roller.
Check rails and carriage for wear due to undesirable
contact between components. Such contact can be an
indication of broken rollers, loose components, for-
eign objects or debris on the upright, or a broken
weldment.
- If contact or rubbing exists, the condition must be
corrected immediately.
- Rail and carriage weldments with damage should
be replaced.
Tie bar areas should be free of foreign objects and
debris. The roller area of the rail should be cleaned
every 500- 1000 hours in a normal application.
- In applications where excessive amounts of con-
taminants settle in the rail channels, cleaning may
be required on 50-250 hour intervals.
- If excessive contamination exists, therollers should
be exposed and the bearing seal areas cleaned
thoroughly.
See Section 4 for carriage roller and upright roller
removal and installation.
Upright Inspection l 34-3-5
 Main Table of Contents

Group 34, Uprights CIRRK

Carriage and Upright Rollers Carriage and Upright Main Load Rollers
Inspect the carriage and upright main load rollers for bro-
Carriage Thrust Rollers ken, loose, or rough bearings. Defective rollers should be
The carriage uses two types of thrust rollers. replaced.
Shoulder 7
l The internal thrust roller is found on both standard
Bearing
and TSUs. The carriage internal thrust rollers are
Outer -
located on the lift bracket and run on the inside web of
Race
the inner rail. The internal thrust roller is intended to
carry a portion of the carriage lateral load.
- The second type of carriage thrust roller is an external
thrust roller. The external thrust roller runs along the
outside flange of the inner rail to control lateral load
on the carriage. External thrust rollers are found on Indications of broken or damaged rollers include:
TSUs only. Part of all of roller bearing missing
Bearing outer race loose
Scraping noise from the upright
Internal’
Thrust Scraping of carriage fork bar on inner rail (carriage
Roller rollers)

External, Upright rail sections scraping together (upright roll-

Thrust Roller ers)
(TSlJs only) Upright mis-staging
Excessive looseness of the rail section or carriage
demonstrated by the following load test.
NOTE
Some grease will purge from the bearings
in the first 100-200 hours of operation. This
is not necessarily a sign of a failed roller
Both types of thrust rollers should be checked for smooth
bearing seal.
rotation, seal integrity, radial bearing tightness, and a tight
cap screw. A roller should turn smoothly without sticking
and be grit free. Replace the roller if any defect is found. Load Test

External thrust roller cap screws have a locking patch to
prevent the cap screw from backing out. Repeated removal
will deteriorate the ability of the patch to hold the cap
screw. If the cap screw is backing out without holding, a
new cap screw is recommended. The cap screw can also be
A load test helps you to determine the amount of clearance
between the moving upright parts. The upright requires
some lateral movement between the interlocking rails and
the carriage. But, too much or too little clearance can be the
cause of binding and uneven operation.

cleaned and set using thread locking compound Loctite 271
(Clark Part 1802302). The internal thrust rollers use a jam
nut to ensure that the bearing remains secure.
NOTE
Some grease will purge from the bearings
in the first 100-200 hours of operation. This
is not necessarily a sign of a failed roller
bearing seal.
A
WARNING
An upright or carriage can move unexpect-
edly during service procedures causing se-
vere injury:
Do not walk or stand under raised forks.
Keep clear of load and carriage when mak-
ing any check or adjustment.

The external thrust rollers on a TSU are not adjustable. The Keep your arms and fingers away from
internal thrust roller adjusts using a locking cam on the moving parts of the upright.
mounting cap screw. See Section 4 for roller replacement Do not reach through open areas of the
and internal thrust roller adjustment procedures. upright.
Failure to follow these warnings can result
in serious injury.

34-3-6 l Upright Inspection SM 598, Ott ‘94

 Main Table of Contents
CUIIW
1. Place a capacity load on the forks and secure it to the
carriage.
n ! CAUTION
Test load must be stacked stably, not ex-
tend beyond the pallet, and be secured on
the pallet. Operate the truck only from
within the operator’s compartment.
2. Tilt the upright back slightly and raise the upright to its
maximum extension several times. Note the smooth-
ness of operation, the carriage play, and play between
the rails.
3. Move the load 102 mm (4 in) off center on the forks and
resecure it to the carriage.
4. Raise the upright to its maximum extension and lower
the load to the floor several times.
5. Repeat the step, moving the load 102 mm (4 in) off
center to the other side.
6. Raise the upright to its maximum extension and lower
the load to the floor several times.
Carefully observe the smoothness of operation, particularly
in carriage play, and play between the rails. If any unusual
movement, staging, or noise occurs during the test, correct
the problem before returning the truck to service. Continue
with the following roller shimming checks if too much play
is evident in the carriage and rails in the load test. The
troubleshooting guide may also help to identify specific
problems with upright operation.
Roller Side-Clearance
The carriage and upright rollers are shimmed between the
inner race and the roller shaft shoulder to maintain minimal
clearance between the side of the roller and the web of the
adjacent rail. Shim adjustments help accommodate manu-
facturing tolerances and wear in the upright rail sections.
Side Clearance
Roller Shaft
and Shoulder
Signs of loose shimming
‘_
include:
1. Excessive lateral (side-to-side)
Rail Web
movement in the up-
right rail sections
SM 598,Oct ‘94
Group 34, Uprights
2. Excessive lateral shift in the upright at, or near, full
maximum fork height (MPH)
3. Irregular roller patterns on the rail.
Signs of over shimming include:
1. Mis-staging or hanging up of the upright
2. Excessive wear in the rail web
3. Premature bearing failure.
Perform the following roll pattern check and the load test if
the need for roller shimming is suspected. See Section 4
for detailed clearance measurement procedures.
Roll Patterns
Impressions made by rollers on upright rails are called roll
patterns. Roll patterns can provide indication of the need
for upright or carriage adjustment.
A WARNING
Keep clear of load and carriage when mak-
ing any checks or adjustments.
Elevate the carriage about 4 feet (1.3 m).
Apply a light, thin layer of grease to the roller contact
area.
Lower the forks and pick up a capacity load. Raise and
lower the upright several times.
Back out from the load and raise the carriage.
Compare the impressions of the rollers on each side of the
upright rails. The impressions should look the same on both
sides. Look for signs of metal scoring or gouging which can
indicate excessive pressure caused by damaged or
misadjusted rollers.
Carriage rollers, including side-thrust rollers, and all up-
right rollers can be checked by examining roll patterns. If
irregular impressions result from the checks, perform the
“Lift Cylinder Shimming Check” and the “Load Test” to
further diagnose problems.
See Section 4 for procedures to measure clearances and
adjust carriage or upright rollers.
Cylinders
Use the Drift Test, presented under “Hydraulic Checks”
below, for additional diagnosis of cylinder condition. See
Section 5 for cylinder repair.
External Leakage (All Cylinders)
To check for external leakage on the primary cylinder:
1. Clean the top of the gland and rod to remove any
buildup of debris.
Upright Inspection l 34-3-7
 Main Table of Contents
Group 34, Uprights
2. Check rod surface for defects or unusual wear.
Nicks, burrs, or other sharp defects can cause
l length of the primary stroke and lower forks com-
damage to the seal and will lead to leaks. The rod
should be repaired or replaced.
l For piston-type cylinders, small blunt defects in
the top and midsection of the rod can be tolerated
in this cylinder design. The high pressure sealing
is over the last several inches of stroke. This type
of defect is acceptable if leakage is not evident.
l For ram-type cylinders, defect tolerances are nar-
rower than for sealed-piston cylinders. Damage to
these rods requires replacement.
3. Check for external leakage from the cylinder barrel,
gland O-rings and backup ring, and the rod seal.
Rod Wiper
Rod (U-Cup) Seal
Gland
Lock Ring -a
O-Ring -a
Back-Up Ring
O-Ring
-q5
l The gland O-rings and backup ring are near-zero
leakage seals. If, after cleaning the gland and tube,
oil accumulates to form a run, the O-rings and
backup ring should be replaced (see Section 5).
l External leakage from the barrel requires replace-
ment of the barrel.
NOTE
The seals are installed with lubricant and a
trace amount will be in the gland/tube in-
terface area.
4. After cleaning the top of the gland and the barrel, cycle
the upright 5- 10 times. If a ring of oil forms to run 3 mm
(0.125 in) down the rod, the cylinder must be over-
hauled or replaced.
Internal Leakage on Primary Cylinder
To check for internal leakage on the primary cylinder:
1. Lift the upright to maximum height then lower forks
completely.
34-3-8 l Upright Inspection
GUIRU
Cycle the upright 5-10 times through the first 2/3
pletely.
Slowly lift the carriage 305-610 mm (1-2 ft) into the
secondary lift stage then lift to full extension.
If the carriage does not lift to full height, the problem
is likely an internal leak and the cylinder should be
overhauled.
If the carriage does lift to full height, but you still
suspect an internal leak, repeat the procedure with a
40-70% capacity load.
NOTE
The primary cylinder normally has ap-
proximately 100 ml (3.4 oz) of hydraulic
fluid on the rod side of the piston as a pre-
charge.
Use the Drift Test, presented under “Hydraulic Checks”
below, for additional diagnosis of cylinder condition. See
Section 5 for cylinder repair.
internal Leakage on Piston-Type Lift and Secondary
Cylinders
To check for internal leakage in Standard lift and TSU
secondary cylinders:
Lift the upright to MFH then lower forks completely.
Cycle the upright 5-10 times through the first 2/3
length of the lift cylinder stroke and lower forks
completely.
Lift the upright to full MFH.
Watch for the lift cylinder to increase lift speed. If you see
an increase in lift speed, one or both of the lift cylinders
have an internal leak and requires overhaul.
If the upright does not increase lifting speed, but you still
suspect an internal leak, repeat the procedure with a capac-
ity load. If the upright does not extend to full MFH, the
problem is likely an internal leak and the cylinder should be
overhauled.
Lift Cylinder Shimming
The lift cylinders on both standard uprights and TSUs
bottom out at the end of the stroke to limit upright exten-
sion. The upright has dual lift cylinders and the cylinders’
extension length must be equal. If not, “racking,” or side-
to-side shifting, results. Rod extension length is made equal
by using shims under the rod end of the cylinder. To
determine if shimming of the cylinders is required to pre-
vent racking, perform the following operational check:
SM 598,Oct ‘94
 Main Table of Contents

Group 34, Uprights

ClmK
A! CAUTION
Make sure truck is parked on level surface
with parking brake applied and wheels
chocked; make sure overhead clearance is
adequate to extend upright to its full height.
Do not walk or stand under raised forks.
Keep clear of load and carriage when mak-
ing any check or adjustment.
Keep your arms and fingers away from
moving parts of the upright.

1. Center the forks or attachments on the upright. Do not reach through open areas of the
upright.
2. Check for equal chain tension.
Failure to follow these warnings can result
3. Raise the upright from the retracted position to full lift in serious injury.
height. Note the point when the lift cylinders reach the
end of their stroke. Raise the empty upright and carriage to its full exten-
l If the upright shifts right or left noticeably, shim- sion and lower to a point halfway down from full
ming is required. extension.
l Repeat the check three times before adding shims. Shut off the truck. Apply the parking brake and chock
NOTE the wheels.
Offset or unbalanced loads and off-center With a pencil or chalk, make a mark across the rails on
attachments can cause the upright to shift one side of the upright.
even with proper lift cylinder shimming.

See Section 5 for lift cylinder shimming procedure. Rack-

ing adjustments for tilt cylinders appear in Group 32, Sec-
tion 2, “Tilt Cylinder Checks and Adjustments.”

Hydraulic Plumbing
Use the Lift Cylinder Shimming Check, the Load Test, and
the following Drift Test to check the performance of the
hydraulic system.
1. Check all fittings for leakage. Disassemble fittings and
inspect the seals. Replace seals as required. See Group
40 for hydraulic fitting tightening procedures.
2. Check all hoses and tubes for wear and damage.
Ii
rails- here.
‘1:I
a. Hoses or tubes with scrapes or kinks should be
replaced.
b. Hoses with outer cover wear exposing the rein-
forcement braiding should be replaced. A WARNING
Keep clear of load and carriage when mak-
Upright Drift ing any checks or adjustments. Do not use
the upright to climb; use an approved plat-
Drift tests check cylinder, main valve, and hydraulic circuit form.
integrity under load pressures. A load is held elevated for
an extended period to determine how much the upright Wait five minutes and recheck the mark. Measure and
“drifts” (moves) over a specified time period. A tilt cylin- write down the distance the marks on the inner and
der drift test appears in Group 32, Section 2, “Tilt Cylinder intermediate rails have drifted from the mark on the
Checks and Adjustments.” outer rail.

A WARNING
If upright rails drift 25 mm (1 in) or more in the five
minutes, read and follow the procedures presented in
An upright or carriage can move unexpect- “Drift Causes and Remedies.”
edly during service procedures causing se-
vere injury:

SM 598, Ott ‘94 Upright Inspection l 34-3-9

 Main Table of Contents

Group 34, Uprights CUlRK

6. If no drift does not exceed 25 mm (1 in) in five minutes,
retest the upright with a 50% load. Adjust fork width as
wide as possible to lift the half-load equally distributed
on a 1220 x 1220 mm (48 x 48 in). Refer to truck
nameplate for capacity rating.
Consider rebuilding the cylinders if the first two remedies
in this list are not successful. See Section 5 for removal,
overhaul, and replacement procedures for primary and sec-
ondary cylinders.

n ! CAUTION
Test load must be stacked stably, not ex-
Trunnion Bearings
To check the trunnion mounting:
tend beyond the pallet, and be secured on Check for missing, broken, bent, or loose trunnion cap
the pallet. fasteners. Replace any damaged parts.
Lift the upright 305-6 10 mm (l-2 ft) and tilt the upright
Drift Causes and Remedies fully forward.
If drift of 25 mm (1 in) or more is evident under a half-load, Check for trunnion bearing or cap wear by inserting a
consider the following causes and remedies: feeler gauge between the trunnion cap and the axle-
The main hydraulic valve is misadjusted, worn, or mounting bearing surface.
defective. Fluid is leaking past the valve and causing
the upright cylinders to drift. See Group 30 for hydrau-
lic valve troubleshooting and service.
Upright hydraulic circuit hoses or fittings are leaking.
Check the circuit components and repair as necessary.
Cylinder piston seals are worn, damaged, or defective
allowing fluid past the piston causing drift.
Primary cylinder or piston-type lift or secondary cyl-
inders have a check valve that allows oil to flow back
to the rod side of the cylinder. This check valve may be
clogged or defective. Inspect the check valve for
proper sealing and operation.

Trunnion
Cap

l The gap should not exceed 0.75 mm (0.03 in).

l If the gap exceeds 0.75 mm (0.03 in) the bearing
or cap may need replacement.

See Section 8, “Upright Removal and Replacement,” for

procedures to remove and replace the trunnion bearing.

34-3-10 l Upright Inspection SM 598,Oct ‘94

 Main Table of Contents

GIRRK Group 34, Uprights

Section 4.

Carriage and Upright Roller Clearance Checks

and Shim Adjustments

Roller Side Clearance Checks ....................................................................................................... 3

General Roller Side Clearance Checking Procedure ....................................................................... 3
Directions for Checking Specific Rollers ........................................................................................ 4
Carriage Rollers ........................................................................................................................ 4
Upright Rollers ......................................................................................................................... 5

Internal Thrust Roller Adjustment .............................................................................................. 5

Oversize Rollers ............................................................................................................................. 6

Lift Roller Shimming ..................................................................................................................... 6

Carriage Roller Shimming .............................................................................................................. .6
Upright Roller Shimming ................................................................................................................ 7
Upright Disassembly ................................................................................................................ 7
Roller Removal, Shimming, and Replacement.. ....................................................................... 8
Upright Reassembly.. ................................................................................................................ 9
Overshimming.. .............................................................................................................................. 10

IMPORTANT
Before removing any component for overhaul,
make sure the correct repair parts and/or kits
A
WARNING
Use an approved safety platform to reach
are available. the upper areas of the upright. Never use

A
the upright as a ladder.
WARNING
An upright or carriage can move unexpect-
edly:
Introduction
l Do not walk or stand under raised forks Standard upright assemblies have two lift roller sets
mounted on the rails, three lift roller sets mounted on the
l Keep clear of load and carriage when
carriage, and one internal thrust roller set mounted on the
making any check or adjustment
carriage.
l Keep your arms and fingers away from
moving parts of the upright. The triple-stage upright assemblies have four lift roller
sets mounted on the rails, three lift roller sets mounted on
l Block the carriage or upright when
the carriage, and two thrust roller sets (“internal” and
working with the components in a raised
“external”) mounted on the carriage. (see the “Roller Side
position.
Clearance Chart” on next page.)
l Do not reach through open areas of the
Each carriage and upright lift roller is nested within its
upright.
adjacent rail set. The front “face” of the lift roller handles
l Never attempt to move or align the rails front-to-back friction and play between the nesting seg-
by hand. Use a prybar. ments of the upright assembly, the side “face” of the roller
Failure to follow these warnings can result radius handles side-to-side friction and play. The rollers
in serious injury. are canted (tilted) to allow the side face to bear properly
on the web.

SM 598,Oct ‘94 Carriage and Upright Roller Clearance Checks and Shim Adjustments l 34-4-l
 Main Table of Contents

Group 34, Uprights CUlRK

Rail flange wear can cause excess play between the lift
rollers and the rail flange. The only way to correct this is to
install oversize rollers-only one size of which is avail-
able. If oversize rollers were fitted previously, the only
remedy for excessive front-to-back play is to replace the Lift
rail set. (carriage middle rollers are always standard-size Roller - Gap
rollers; see “Oversize Rollers” later in this Section for
details on roller replacement.) Side Face
The gap between the roller “side” and the web of adjacent of Roller
rail set affects the side-to-side motion of the upright- Rail Web
which should be as small as possible without causing the
sliding segments to bind. The same is true of the internal Shoulder / Rail
thrust rollers. Flange
You check the performance effect of the lift roller side clear- _ ..
ante and internal thrust roller clearance by means of the load Adjacent
Nesting
Rail

Roller Side Clearance Churt

Roller Set #1 Carriage

Roller Set #2
E
1
Roller Set #3

Inner Rail Set

Roller Set #4

1
Roller Set #!5

Intermediate Rail Set

l-
CrSU only)
Roller Set #/6-

Roller Set #7-

- Outer Rail Set

. .
Web Area Gau at B at MaximumSpan of Rail Set
Roller Set # J&nine Gau Target? Allowedb Targeta Allowedb
(mm) (in) (mm) (in) (mm1 (in) (mm) On)
#l Front, Inner milt 0.5-1.5 0.02-0.06 0.05-1.25 0.02-0.05 a d
2.25 o-0.09
#2 Front, Inner rail o-o.75 o-0.03 o-1.5e o-0.06 d d 2.25 o-0.09
#3 Back, Inner rail o-o.75 o-0.03 o-0.04 d d 2.25 o-0.09
O-1.0
#4 Back, Inner rail o-o.75 o-0.03 O-1.0 o-0.04 d d 2.25 o-0.09
#5 Back, Intennd rail o-O.75 o-0.03 O-1.0 o-0.04 d d 2.25 o-0.09
#6 Back, Intermd rail o-O.75 o-0.03 O-1.0 o-0.04 d d 2.25 o-0.09
#7 Back, Outer rail o-o.75 o-0.03 O-1.0 o-0.04 d d 2.25 o-0.09
a. Target is the desired gap after reshimming the roller set.
b. Allowed is the acceptable gap when checking roller set.
c. Internal side thmst rollers should extend 0.25-0.50 mm (0.01-0.02 in) beyond #l I
d. Ideal is same as final measured gap at minimum width point of rail set
e. Measured at top of inner rail.
L J

34-4-2 l Carriage and Upright Roller ClearanceChecksand Shim Adjustments SM 590,Oct ‘94
 Main Table of Contents

CWRK Group 34, Uprights

test described in Section 3. To evaluate with certainty that the 2. Position the carriage or rails so that the roller set you
clearance is excessive, you perform the checks given below. want to check is at the mark for the narrowest span on
the adjacent nesting rail set.
To correct excessive lift roller side clearance, you add shims
as described later iu this Section. To correct internal thrust
roller clearance, you adjust thrust roller position as described
later in this Section.

Roller Side Clearance Checks Narrowest

Span
The same basic procedure is used for checking all the lift
rollers. That general procedure is given in the subsection
directly below. Special instructions for specific rollers follow
that subsection. Follow those directions (m the subsection Widest
called “Directions for Checking Specific Rollers”) and you Span
will be directed to general and specific information you need.

General Roller Side Clearance Checking

Procedure Example of Aligning Roller Set with Widest and
Narrowest Spans Marked on Adjacent Rail Set.
For each roller set, you need to measure the gap between the Rail sets are shown separatedfor clarity.
outside face of a roller and its adjacent nesting rail. In general,
the lift roller side clearance check procedure is as follows:
3. Clamp the rails together opposite the roller you intend
1. Withthespannertool,findandmarkthenarrowestand to check Use wooden shim blocks to protect the rails.
widest spans in each rail set at the roller-contact areas Place clamp as close to roller as possible. Torque clamp
in the rail webs: to 25 Nom (20 ft-lb).
l Inner Rail Set-Mark narrowest and widest spans
for both the front and back web areas.
l Outer and Intermediate Rail Sets-Mark narrow-
est and widest spans for the back web area only.

4. Measure the gap with a feeler gauge. Make sure roller

is tight against its shoulder. Write down the result.

Web Areas on Typical Rail Set M&sure

here.

5. Repeats steps 2 through 4 for the widest span marked on

the rail set.

Spanner Tool. Clark part #I80109

SM 598,Oct ‘94 Carriage and Upright Roller Clearance Checks and Shim Adjustments l 34-4-3
 Main Table of Contents

Group 34, Uprights ClmK

6. If the clearance at the widest rail set span is more than
2.25 mm (0.09 in), the roller set needs shimming.
If the clearance at the nC2rruWeStrail set span is more
than l.Omm (O.O4in),therollersetshouldbeshimmed;
however, it is OK for the middle carriage roller gap to
be up to 1.5 mm (0.06 in).
7. Repeat entire procedure for each roller set, following
the instructions in “Directions for Checking Specific
Rollers” below.
Top Carriage and Internal Thrust Rollers
Rollers
The internal thrust rollers are nearly perpendicular to the
top carriage lift rollers and contact the same flange area as
the carriage rollers. The top carriage lift rollers and the
internal thrust rollers should be checked together.

Directions for Checking Specific Rollers

Use these directions to supplement the general procedures 1. Move the top carriage lift roller to the narrowest span
given above. on the inner rails set.
2. Clamp rail to one side as in general procedures. Check
Carriage Rollers
clearance of lift roller on clamped side. Locate the
clamp between the thrust roller and the bottom roller of
BottomCarriage
Rollers
the carriage
Follow the general procedure above.
Measure gap here
MiddleCarriage
Rollers
The middle rollers are difficult to access and require the
following special procedures.
1. Raise the carriage until the middle rollers are at the top
of the inner rails.
2. Measure roller side clearance at the top of the inner
rails. Note measurement here:

If gap is less than 1.5 mm (0.06 in), shimming is not

required.
The internal thrust roller should contact the web and
If gap is more than 1.5 mm (0.06 in), check clearance
cause the lift roller to stand off from the web by .Ol to
at narrowest span by comparison with the top of the
1 mm (0.001-0.03 in). If the gap is outside this range,
rail set as follows:
the internal thrust roller must be adjusted as explained
a. With spanner tool, measure span of inner rail set later in this Section under “Internal Thrust Roller
at top of the front web area. Note measurement Adjustment”
here:
3. Check clearance on lift roller opposite clamped side as
b. With spanner tool, measure span of inner rail set
inthegeneral procedures. If clearance is greater than
at narrowest span of front web area. Note mea-
1.25 mm (0.05 in), the roller set should be shimmed.
surement here:
c. Subtract measurement in step b from measure- 4. Move clamp to opposite side and check clearance on
ment in step a, Write result here: clamped side as in step 2 directly above. Gap should be
0.01-1.0 mm (0.001-0.03 in).
b-a=
If the calculated gap is less than or equal to the gap 5. Move the top carriage lift roller to the widest span on
the inner rail set and check clearance as in general
measured in step 2, the roller set does not require
shimming. Otherwise, the roller set should be procedures.
shimmed.

34-4-4 l Carriage and Upright Roller Clearance Checks and Shim Adjustments SM 598,Oct ‘94
 Main Table of Contents

ElmK Group 34, Uprights

Upright Rollers Internal Thrust Roller Adjustment

1. Remove the carriage as described in Section 7 of this The internal thrust rollers should be adjusted to extend O-
Group. 0.75 mm (0.03 in) into the top carriage roller side clear-
ance. Carriage roller side clearance should be within
2. Fully extend the upright making sure carriage hoses
tolerances before you adjust the thrust rollers.
and chains are secured out of the way to prevent
damage. NOTE
A WARNING Carriage must be replaced on upright be-
fore adjusting internal thrust rollers. See
An upright or carriage can move unexpect-
edly: Section 8 for carriage replacement proce-
dures.
Do not walk or stand under raised forks
Keep clear of load and carriage when 1. Lift the carriage to the top of the inner rail.
making any check or adjustment 2. Loosen the jam nut on the back of the thrust roller cap
Keep your arms and fingers away from screw and then loosen the cap screw. Rotate the
moving parts of the upright. bearing to pivot toward the carriage and away from the
rail.
Do not reach through open areas of the
upright.
Never attempt to move or align the rails
by hand. Use a prybar.
Use an approved safety platform to reach
the upper areas of the upright. Never
use the upright as a ladder.
Failure to follow these warnings can result
in serious injury.

3. Follow the “General Roller Side Clearance Checking 3. Lower the carriage to a convenient height to do the
Procedure” given earlier in this Section. adjustment.
The clamping procedure is as illustrated below. 4. Clamp the carriage between the top and middle car-
riage roller.
l Use a shim block under the clamp on the outside
of the channel rail.
l Torque on the clamp should not exceed 25 N*m
(20 ft-lb).

5. Insert a 0.5 mm (0.02 in) temporary shim between the

top carriage roller and the rail web on the side opposite
the clamp. If a0.5 mm (0.02 in) shim will not fit, insert
a 0.25 mm (0.01 in) shim.

SM 598, Ott ‘94 Carriage and Upright Roller Clearance Checks and Shim Adjustments l 34-4-S
 Main Table of Contents
Group 34, Uprights
6. Move the clamp to the shimmed side and clamp the
rollers against the shim and the rail web by positioning
the clamp between the top and middle carriage rollers.
7. Cam the thrust roller on the shimmed side against the
rail clockwise and tighten the cap screws fmly.
NOTE
Make sure the roller does not rotate with
the cap screw when tightening.
8. Insert a 0.5 mm (0.02 in) shim in the opposite roller. If
a 0.5 mm (0.02 in) shim will not fit, insert a 0.25 mm
(0.01 in) shim.
9. Loosen the clamp and remove the shim.
10. Reposition the clamp on the opposite side and draw the
roller against the shim and rail web.
11. Cam the thrust roller on this shimmed side toward the
rail clockwise and tighten the cap screws firmly.
NOTE
Make sure the roller does not rotate with
the cap screw when tightening.
12. Loosen the clamp and remove the shim.
13. Use a crow’s foot to torque the cap screws 70-80 Nom
(5 1.5-59.2 ft-lb).
NOTE
If a crow’s foot is not available, the car-
riage can be raised to the top of the inner
rail and a socket used to tighten to the
correct torque.
14. Position the carriage to access the jam nut on the back
side of the cap screw and torque to 70-80 Nom (5 1.5-
59.2 f&lb).
Oversize Rollers
f-7
At the time of roller shimming, you may
want to replace the lift rollers with oversize
rollers to counter rail flange wear as detected
by inspection and the load test. Because there
is only one size of oversize rollers, you can
install them only if they were not installed
previously.
indented Radius -/
34-4-6 l Carriage and Upright Roller Clearance Checks and Shim Adjustments
CUIRK
Identify oversize rollers as follows: If a roller is oversize, it
has an indented radius in the outer edge of its mounting
side, as shown below.
Lift RollerShimming
You need to shim lift rollers if the roller side clearance
checks indicated that clearance was excessive at either the
narrowest or widest span of the roller set’s adjacent rail
set.
Your objective in shimming is to add only enough shims
to bring the clearances at both the widest and narrowest
spans into tolerances. In practice, you achieve this by
shimming to obtain the smallest possible clearance at the
narrowest span of the rail set.
Carriage Roller Shimming
Using the measurement you recorded in previously in the
“Roller Side Clearance Checks,” determine the number of
shims required to reduce the carriage roller clearance at the
narrowest span on the inner rail to O-O.75 mm (O-0.03 in):
1. Remove the carriage as described in Section 8, “Fork
and Carriage Removal and Replacement.”
2. Remove the rollers (note the number of shims already
on the roller shafts, if any).
Clean and inspect roller bearings, shims, and
l
shafts.
l Replace any defective parts.
3. Add shims to the top and bottom rollers as determined
in the previous steps.
l Install shims with the same number on each side.
l When an odd number of shims is required, always
place the odd shim on the same side on all roller
sets.
SM 598, Ott ‘94
 Main Table of Contents

clmu Group 34, Uprights

4. Use a straight bar to determine the number of shims to
add to the middle roller shaft as shown in the following
illustration. This shimming may be asymmetric, mean-
ing the numbers of shims do not have to match those of
the top and bottom rollers.
-n /;-
5. Using a hoist and lifting strap of adequate capacities,
connect the lifting strap to the inner rail on standard
uprights or intermediate rails on triple-stage uprights.
Lift hoist to remove slack from the strap.

-0.25 to +0.25
mm (-0.01 to
+O.Olin) gap

6. Disconnect the flow control valve manifold from the

upright bracket.

5. Reinstall all bearings; torque top roller fasteners to 40-

45 Nom (30-33 in-lb).
Carriage internal thrust rollers must be adjusted after the
carriage is shimmed. Adjust as described previously.

Upright Roller Shimming

Use the following procedures to remove, shim, and replace
rollers. Use the preceding checks to determine the number
of shims required to reduce the roller clearances to 0.75
mm (0.03 in) or less. r
A WARNING
Use an approved safety platform. Never
7. Disconnect the cylinder guide bolts.

use the upright as a ladder.

A CAUTION
The carriage should be removed for shim-
ming or when any service is performed on
the upright. See Section 8, for removal and
replacement procedures.

Upright Roller Removal

1. After the carriage has been removed, lower the upright
rails until both of the secondary (final) lift cylinders are
completely collapsed.
2. Jack the truck and block under the frame so that the
bottom of the upright is approximately 254 mm (10 in)
off the floor. See “Lifting, Jacking, and Blocking” in
Group SA for safe procedures.
3. Set the parking brake and block the steer wheels.
4. Tilt the upright to as near vertical as possible.

SM 598, Ott ‘94 Carriage and Upright Roller Clearance Checks and Shim Adjustments l 34-4-7
 Main Table of Contents
Group 34, Uprights
8. Secure the cylinder to prevent its falling and discon-
nect the cylinder rod retaining bolts.
;i
NOTE
For 4-hose adapters, you must disconnect
the hose sheave and bracket. This is not
necessary for 2-hose adapters.
9. Move the sheave with the hoses and any other con-
nected components out of the way.
10. Disconnect the rail cylinders by raising the rails to free
the cylinderrod ends from the tie bar. Tilt the cylinders
inward and secure out of the way of the tie bars.
11. Lower the assembly completely to expose the rollers.
The lower roller set of the inner rail and upper roller set of
the outer rail on standard and triple-stage uprights are now
exposed for shim adjustment.
34-4-8 l Carriage and Upright Roller Clearance Checks and Shim Adjustments
CmK
Roller Removal, Shimming, and Replacement
To add shims to, or replace the rollers:
1. Use a puller to remove the rollers from the posts. Or,
gently pry the rollers off the posts. Pry at different
points aroundthe bearing to work it off. Do not damage
the bearing seals on the backside of the roller.
2. Inspect all roller components when removed:
a. Clean and inspect the rollers, shims, and roller
shafts.
b. Bearings should be in good condition and allow
the roller to spin smoothly with a true rotation.
c. Clean rail sections and add lubricant if necessary.
d. Replace any worn or damaged component.
3. If the clearance check indicated an even number of
shims needed, split the number evenly between the
rollers on either side of the upright.
4. If the clearance check indicated an odd number of
shims needed, keep the odd number to the same side on
all rails of the upright. If three shims are needed, for
example, add one to the rollers on the left side. Add the
other two on the rollers on the right side.
5. Reposition the rollers onto the roller shaft and use a
plastic or hard-rubber mallet to gently tap the roller.
Seat the roller evenly by continuing to tap gently until
it is fully seated and snug against the added shims.
SM 598,Oct ‘94
 Main Table of Contents

clam Group 34, Uprights

Upright Reassembly 3. Reconnect the cylinder guide bolts. Do not tighten

until inner and/or intermediate rails are in the fully
The following steps detail the procedures for reassembling
lowered position. Torque guide bolts nuts to 20-2.5
the upright.
N*m (14.8-18.5 ft-lb).

AWARNING
The upright can move unexpectedly:
l Keep your arms and fingers away from
moving parts of the upright.
l Do not reach through open areas of the
upright.
l Never attempt to move or align the rails
by hand. Use a prybar.
Failure to follow these warnings can result
in serious injury.

1. Connect the lifting strap to the inner rail on standard

uprights or intermediate rails on triple-stage uprights
4. Reconnect the cylinder rod retaining bolts. Torque rod
and raise the rails just high enough to clear the lift
retaining bolts to 20-25 Nom (14.8-18.5 ft-lb).
cylinders. Use a prybar to guide the rails and allow the
rollers to reenter the rail channel.

6. Replace the 4-hose sheave and bracket assembly onto

the upright. Torque nuts to 20-25 N*m (14.8-18.5 ft-
lb).
7. Reconnect the load lowering flow valve to the upright
bracket. Torque nuts to 20-25 Nm (14.8-18.5 ft-lb).
2. Reposition the rail cylinders and slowly and carefully
lower the rails to seat the rod end into the mounting.

SM 598,Oct ‘94 Carriage and Upright Roller Clearance Checks and Shim Adjustments l 34-4-9
 Main Table of Contents

Group 34, Uprights CIRRU

8. Jack up the truck only enough to remove the blocking
and slowly lower the truck so that its full weight is on
the floor.
9. Replace the carriage and forks.
10. Test the upright lift and tilt functions; make sure all
upright components work correctly and smoothly.
Check for overshimming as described in the next
subsection. Repeat the load test to make sure the
upright works correctly under load. When you are sure
all components are operating correctly, perform the
chain adjustment checks in Section 3 before returning
the truck to service.
Overshimming
Use these steps to check for overshimming:
1. With the forks removed, lift the upright to maximum
fork height.
2. Slowly lower the upright.
l The carriage should not bind or hang up at any
point along the rails.
l If the carriage binds or hangs up, and the rails are
not clogged with grease or debris, the carriage
requires reshimming. See “Troubleshooting” for
other mis-staging problems

34-4-l 0 l Carriage and Upright Roller Clearance Checks and Shim Adjustments SM 598,Oct ‘94
 Main Table of Contents

ClRRK Group 34, Uprights

Section 5.
Cylinder Removal, Shimming, Overhaul, and Replacement
1
Cylinder Types ...............................................................................................................................

1
Lift Cylinder Shimming Procedure ..............................................................................................

Primary Cylinder Removal and Replacement (TSU Only) .......................................................

2

Lift and Secondary Cylinder Removal and Replacement ..........................................................

3

Cylinder Overhaul ......................................................................................................................... 4

Cylinder Disassembly ...................................................................................................................... 4
Parts Inspection and Service ........................................................................................................... .5
Cylinder Reassembly ...................................................................................................................... .5

CylinderTypes
Standard uprights use two lift cylinders. Triple stage up-
n ! CAUTION
To remove, or partially remove, the cylin-
rights use three cylinders, a primary (center-mounted) cyl- ders from the upright for shimming or over-
inder, and two secondary cylinders. All primary cylinders haul, start with the truck in a safe position:
used on triple-stage uprights (TSUs) are piston cylinders. l Ignition off
The lift and secondary cylinders used on standard uprights l Parking brake applied
and TSUs are either piston or ram cylinders. l Directional lever in neutral
The types of cylinders used on the truck are listed below. l Forks lowered completely
Check the first five characters of the upright number stamped l Wheels blocked.
on the upright of the truck to determine the type of cylinder,
piston or ram, used on the upright.
Lift CylinderShimming Procedure
IMPORTANT
To shim the lift cylinders to correct unequal cylinder stroke:
Before removing any component for over-
haul, make sure the correct repair parts, 1. Fully lower upright until both lift cylinders are col-
seals, and gasket sets are available. lapsed.
2. Attach a hoisting strap to the tie bar of the inner rail or
Upright Upright
intermediate rail tie bar of TSUs.
m Number Cylinder Tvne

Standard VI080 Piston-Type Lift Cylinder

V1081 Piston-Type Lift Cylinder
V1082 Ram-Type Lift Cylinder
V1083 Ram-Type Lift Cylinder

TSU Ml080 Piston-Type Secondary Cylinder

Ml081 Piston-Type Secondary Cylinder
Ml082 Ram-Type Secondary Cylinder
Ml083 Ram-Type Secondary Cylinder

SM 598,Oct ‘94 Cylinder Removal, Shimming, Overhaul, and Replacement l 34-5-l

 Main Table of Contents

Group 34, Uprights

To load

n
! CAUTION
Make sure hoisting equipment is of ad-
lowering
flow valve.
equate capacity and in good working or-
der.

3. Remove the cylinder rod retaining bolt.

Shim
3. Remove and discard cotter pins from chain anchor bolt
pins on the cylinder.
4. Remove the pins, draw the chain through the sheave,
and drape the chain over the carriage.

4. Slowly lift the inner (or intermediate) rails off the top
of the cylinder to expose the cylinder rod top.

n ! CAUTION
Block rail in up position.

5. Insert shim(s) over rod end of cylinder with the shorter

stroke to compensate for unequal stroke length.
6. Slowly lower the inner or intermediate rail back onto
the rod ends.

A WARNING
Do not try to maneuver the cylinder
rails with your hands. Use a prybar.
or
5. Remove the snap ring holding the chain sheave (and
hose bracket, if equipped) on the rod end and move
assembly off top of rod.

7. Replace cylinder rod retaining bolt to secure rod end

into inner or intermediate rail mounting hole. Torque
the cylinder rod retaining bolts to 20-25 N*m (14.8-
18.5 ft-lb).
8. Repeat the racking test and adjustment until no racking
is evident during upright lift extension.
9. Check all upright functions before returning the truck
to service.

Snap
Primary Cylinder Removal and Ring
Replacement (TSU Only)
Remove the primary cylinder for replacement only. Cylin-
der can be overhauled without removing it from the up-
right. See “Cylinder Overhaul” for procedures.
1. Make sure the cylinder is completely collapsed and
pressure is released.
2. Disconnect and cap the hydraulic line at the base of the
cylinder.

34-5-2 l Cylinder Removal, Shimming, Overhaul, and Replacement SM 598,Oct ‘94

 Main Table of Contents

ClRRK Group 34, Uprights

6. Disconnect cylinder mounting collar bolts and lift 4. Disconnect and cap the hydraulic line from the base of
cylinder off mounting base. each cylinder. Remove the mounting bolts from the
manifold block.
Remove
mounting
l- Line to
main
bolts from hydraulic
manifold. valve.

l- Disconnect
and cap
lines here.

5. Lower the carriage

Use these steps in reverse to replace the cylinder. Check
6. Using a hoist and lifting strap of adequate capacities,
Group 40 for hydraulic fitting tightening procedures. If
connect the lifting strap to the inner rail on standard
complete cylinder was removed, torque hydraulic line
uprights and inner and intermediate rails on triple-
bracket to 40-45 N*m (30-33 ft-lb); torque cylinder mount-
stage uprights.
ing collar bolt nuts to 70-80 Nom (52-59 ft-lb).

Lift and Secondary Cylinder Removal

and Replacement
Only piston-type lift and secondary cylinders must be re-
moved from the upright for overhaul. Ram-type cylinders
do not need to be removed for overhaul; the cylinder gland
and rod can be removed for overhaul while leaving the
cylinder tube mounted on the truck. Use these procedures if
any piston- or ram-type lift or secondary cylinder must be
completely replaced.
1. Make sure the cylinders are completely collapsed and
pressure is released.
2. Tilt the upright to as near vertical as possible.
7. Disconnect the cylinder guide bolts.
3. Using a hoist and lifting strap of adequate capacities,
lift the carriage to access the hydraulic lines at the base
of the cylinders.

n ! CAUTION
Make sure hoisting equipment is of ad-
equate capacity and in good working or-
der.

SM 598, Ott ‘94 Cylinder Removal, Shimming, Overhaul, and Replacement l 34-5-3
 Main Table of Contents

Group 34, Uprights CUIIRK

8. Disconnect the cylinder rod retaining bolts. not necessary to remove these cylinders from the
upright for overhaul. Instead, free the rod end of the
cylinder as explained in “Cylinder Removal.”
1. Clean the rod-end and gland thoroughly to prevent
contamination from falling into the cylinder during
disassembly.
2. With a blunt punch or chisel, bend the lock ring out of
the locking grooves of the gland.
3. Use a spanner wrench to remove the gland. Reuse the
lock ring if undamaged.
4. Carefully lift the rod out of the cylinder and place in a
9. Remove the cylinders by raising the inner rail (and clean area.
intermediate rail on the triple stage upright) to free the 5. Inspect the tube and tube end for damage and cover the
cylinder rod ends from the tie bar. cylinder tube end to prevent contamination.
10. Remove any shims and note number and location. 6. Remove all rings and seals from the piston and the
11. Lift the cylinders off the base mount. gland.
Rod Wiper-
Use these steps in reverse to replace the cylinders. Torque
the cylinder rod retaining bolts to 20-25 wrn (14.8-18.5 ft- Rod (U-Cup)
lb). Torque the cylinder guide bolt nuts to 30-35 Nom Seal Rod
(22.2-25.6 ft-lb). Check Group 40 for hydraulic fitting Gland Piston
tightening procedures.
Lock Ring Back-Up Ring
Cylinder Overhaul O-Ring 3 Cylinder Seal

Use these steps to overhaul the primary and lift and second- Back-Up Ring e
Wear Ring
ary (TSU) cylinders. O-Ring
Check Valve
NOTE
F -O-Ring
During overhaul, set rod or cylinder on a Spacer
work bench with adequate support for safe Washer
7$
and convenient disassembly. Two sets of
Snap Ring
4x4 in (100x100 mm) ‘V-notched blocks Rod
are helpful; one set for the cylinder barrel *
and one set for the piston rod. The blocks
prevent nicks and scratches from harming 7. For piston-type cylinders:
the piston or rod.
a. Remove the check valve from the piston for inspec-
tion and cleaning by removing the snap ring from the
Cylinder Disassembly piston bore.
l To overhaul the primary cylinder, it is not necessary
to remove the cylinder from the upright. Instead, free
the rod end of the cylinder as explained in “Cylinder
Removal.”
l To overhaul piston-type cylinders, you should re-
Check Valve. Arrow shows direction ofjl’ow
move the cylinders from the upright as explained in
“Cylinder Removal.” The cylinders have seals on the b. Use a blunt hook to pop the check valve out.
piston, and the rods must be removed for seal replace- IMPORTANT
ment. Use extreme care that you do not make
l The ram-type lift cylinders are sealed on the rod only. nicks and burrs on the interior surface area
The only serviceable seals are inside the gland. It is of the cap or cylinder or the piston.

34-5-4 l Cylinder Removal, Shimming, Overhaul, and Replacement SM 598,Oct ‘94

 Main Table of Contents

CIRRK Group 34, Uprights

Parts Inspection and Service 3. Replace the piston seals:

a. Primary cylinder pistons require a piston seal and
1. Clean all parts completely in a suitable solvent. Dry all
wearring. Install the piston seal from the top of the
parts with a soft clean cloth.
rod. Use a ring compressor to compress the piston
2. Inspect cylinder barrel and bore for cracks, pining, seal. This prevents damage to the seal during
scoring, or other irregularities that may require re- reassembly.
placement of the barrel.
Wear Ring -, rPiston Seal
3. Inspect the piston and rod for nicks, scratches, scoring,
or other defects that may demand new parts.
4. Check all gland and piston seal grooves for nicks,
burrs, and scratches that can damage seals during
reinstallation.
5. Inspect and clean the check valves.
b. Piston-type lift and secondary cylinder require a
6. Inspect all seals, including the check valve O-ring. cylinder seal, a back-up ring, and a wear ring on
the piston. Install the cylinder seal from the top of
NOTE
the rod.
Minute imperfections inside the cylinder
Cylinder Seal and
barrel or on the piston or rod may be im-
Spacer7 Back-Up Ring ,- Wear Ring
proved for acceptable use by careful hon- 7
ing. However, removal of material that pro-
duces a notch, groove, or out-of-roundness
may cause excessive leakage during opera-
tion and a shortened lie.
c. Ram-type, lift (secondary) cylinder pistons re-
7. Use new parts as necessary. Always use the Packing quire no seals.
Kit listed in the parts manual. New kits include all the
4. For protection against corrosion, lubricate spacers
seals, wiper rings, wear rings and O-rings necessary
(where used) with petroleum-based hydraulic fluid.
for the particular cylinder
Slide the spacer onto the rod.
5. Insert the piston and rod into the cylinder. Be careful
Cylinder Reassembly not to scratch or damage the cylinder gland nut threads.
Take care when installing these parts to make sure that no 6. For primary cylinders, add 3.4 oz (1OOml) of hydraulic
parts are damaged. oil into the cylinder on the rod side of the piston.
1. Coat all packing, seals and rings in clean, hydraulic oil 7. Install the lock ring onto the gland. Lubricate cylinder
(Clarkpartnumber 1800236qt., 1802155 gal.) priorto threads and screw gland onto cylinder. Be careful not
reassembly. Coat the inside of the gland nut bore with to damage gland seal. Make sure the gland is fully
hydraulic oil. seated on the cylinder barrel. Deform the lock ring into
2. Replace the U-cup seal (groove toward bottom of slots in the tube and the gland.
cylinder), rod wiper, and O-ring and back-up seals on 8. Check the assembly by making sure the piston slides
the gland. freely in and out of the cylinder.
O-Ring and O-Ring -, r Lock Ring 9. Tighten the gland nut:
Back-Up Seal 7

L3 A--F&%.ww;mp-
T-s, L...
j-y-j ‘2:; I%.
l On primary cylinders, tighten the gland nut to 135
Wm (100 ft-lb).
11 l On lift and secondary cylinders, tighten the gland
Rod U-Cup Seal nut to 100 N*m (75 ft-lb).
NOTE This competes the cylinder repair procedure. Replace the
O-rings should be carefully installed to cylinders as described in “Cylinder Removal and Replace-
eliminate cuts or twisting. ment.” Complete the chain length adjustment in Section 3
for correct carriage and rail position. When all adjustments
are completed, return the truck to service.

SM 598,Oct ‘94 Cylinder Removal, Shimming, Overhaul, and Replacement l 34-5-5

 Main Table of Contents

Group 34, Uprights CICIRU

Rod Wiper -42

U-Cup Seal

Gland

O-Ring-

.Back-Up Ring
e O-Ring
Back-Up Ring
Lock Ring
I
I
O-Ring
I
‘Lock Ring
gg - Spacer

Spacer

?l5- Spacer
O-Ring

Barrel
- Rod

Barrel -
- Rod

-Piston
- Piston
Back-Up Ring
.Back-Up Ring
Cylinder Seal
.Cylinder Seal
Wear Ring
. Wear Ring
-Check Valve -Check Valve
O-Ring &-- O-Ring
Washer
I.
‘.
Snap-Ring

Typical Piston-Type Standard Upright Lifi and TSU Triple-Stage Upright Primary Cylinder
Secondary Cylinder

34-6-6 ’ Cylinder Removal, Shimming, Overhaul, and Replacement SM 696,Oct ‘94

 Main Table of Contents

C1RRK Group 34, Uprights

Rod Wiper
-%zb
U-Cup Seal

Gland

O-Ring a

p.
’ ‘.
cs Back-Up Ring
I s O-Ring
I
,
I Q- Lock Ring

4EB Spacer

Barrel - - - Rod

c
@Q’
4
-
I
I
1
3- Ram
Piston

I
I

Standard and Triple-Stage Uprights Ram Cylinder

SM 598,Oct ‘94 Cylinder Removal, Shimming, Overhaul, and Replacement l 34-5-7

 Main Table of Contents

emI Group 34, Uprights

Section 6.
Upright Chain Inspection, Adjustment, and Replacement
Periodic Inspections .......................................................................................................................
3

Chain Length Adjustments ...........................................................................................................

4
Standard Upright Chain Length Adjustment ................................................................................... 5
Triple-Stage Upright (TSU) Chain Length Adjustments ................................................................. 5

Chain Lubrication ..........................................................................................................................

7

Chain Removal and Replacement ..........................................................................................7......

General Guidelines ........................................................................................................................... 7
Lift Chains (Standard and TSUs) ..................................................................................................... 7
Primary Cylinder/Carriage Chains (TSUs). ..................................................................................... 8

Other Chain Service Notes ......................................~...._...._...~...................................................

8

Chain Configuration - Standard Uprights

SM 598,Oct ‘94 Upright Chain Inspection, Adjustment, and Replacement l 34-6-l

 Main Table of Contents

Group 34, Uprights CIRRK

I
‘I

/
\
,

Chain Configurations - Triple Stage Uprights

34-6-Z l Upright Chain Inspection, Adjustment, and Replacement SM 598,Oct ‘94

 Main Table of Contents

CMRK Group 34, Uprights

Periodic Inspections in correct alignment. Chain with rotated/displaced heads or

abnormal pin protrusion should be replaced immediately.
Each SO-250 hours of operation (more frequently in severe Do not attempt to repair the chain by welding or driving the
or extreme environments), chains should be inspected and pin(s) back into the chain. Once the press fit integrity
lubricated. Inspection should focus on the following: between outside plates and pins has been altered, it cannot
be restored. Any wear pattern on the pin heads or the sides
Elongation of the link plates indicates misalignment in the system.
This condition damages the chain and increases frictional
When a length of 12.00 inches (305 mm) of new chain has
loading, and should be corrected.
elongated to a length of 12.360 inches (315 mm), it should
be discarded and replaced. It is important to measure the
chain in the section that moves over the sheaves because it
receives the most frequent articulation. Measuring the chain
near its clevis terminals could give an erroneous reading as
it would not have flexed as frequently, if indeed at all, as
nearer the middle of the assembly.

Turned pins and abnormal pin protrusion.

Cracked Plates
The chains should periodically be inspected very carefully,
Chains should be replaced when wear exceeds 3% or
front and back as well as side to side, for any evidence of
when I2 inches (305 mm) of chain is stretched 3/8 inch (IO
cracked plates. If any one crack is discovered, the chain(s)
mm).
should be replaced. It is important, however, to determine
the causes of the crack before installing new chain so the
Edge Wear
condition does not repeat itself.
Check the chain for wear on the link plate edges caused by l Fatigue Cracking - Fatigue cracks are a result of
running back and forth over the sheave. The maximum repeated cyclic loading beyond the chain’s endurance
reduction of material should not exceed 5%. This can be limit. The magnitude of the load and frequency of its
compared to a normal link plate height by measuring a occurrence are factors which determine when fatigue
portion of chain that does not run over the sheave. Distorted failure will occur. The loading can be continuous or
or battered plates on leaf chain can cause tight joints and intermittent (impulse load).
prevent flexing.

Fatigue cracks generally run from the pin hole toward the
I5X of H edge of the link plate approximately 90”from the line of
pull.
Worn contours and worn sulfates on the outside links or Fatigue cracks almost always start at the link plate pin
pin heads should not exceed 5% of new link height. hole (point of highest stress) and are perpendicular to
the chain pitch line. They are often microscopic in their
Turning or Protruding Pins early stage. Unlike a pure tensile failure, there is no
noticeable yielding (stretch) of the material.
Highly loaded chain operating with inadequate lubrication
can generate abnormal frictional forces between pin and
link plates. In extreme instances, the torque could surpass
the press fit force between the pins and the outside plates,
resulting in pin rotation. When chain is allowed to operate
in this condition, a pin, or series of pins, can begin to twist
out of a chain resulting in failure. The pin head rivets
should be examined to determine if the TEE” flats are still

SM 598,Oct ‘94 Upright Chain Inspection, Adjustment, and Replacement l 34-6-3

 Main Table of Contents
Group 34, Uprights CUIRK
l Stress-Corrosion Cracking - The outside link plates, Tight Joints
which are heavily press fitted to the pins, are particu-
All joints in leaf chain should flex freely. Tight joints resist
larly susceptible to stress corrosion cracking. Like
flexure and increase internal friction, thus increasing chain
fatigue cracks, these initiate at the point of highest
tension required to lift a given load. Increased tension
stress (pin hole) but tend to extend in an arc-like path
accelerates wear and fatigue problems.
between the holes in the pin plate.

If lubrication does not loosen a tightjoint, the chain may

Arc-like cracks in plates are a sign of stress corrosion.
have corrosion and rust problems or bent pins and must
More than one crack can often appear on a link plate. be replaced.
In addition to rusting, this condition can be caused by
See Section 3 for detailed chain stretch, length, and ten-
exposure to an acidic or caustic medium or atmo-
sions checks.
sphere.
Stress corrosion is an environmentally assisted failure.
Two conditions must be present: a corrosive agent and Chain Length Adjustments
static stress. In the chain, static stress is present at the
pin hole due to the press fit pin. No cyclic motion is
required, and the plates can crack during idle periods.
A WARNING
An upright or carriage can move unexpect-
The reactions of many chemical agents (such as battery edly:
acid fumes) with hardened steel can liberate hydrogen
Do not walk or stand under raised forks
which attacks and weakens the steel grain structure.
Keep clear of load and carriage when
For this same reason, never attempt to electroplate a
making any check or adjustment
leaf chain or its components. The plating process
liberates hydrogen, and hydrogen embrittlement cracks Keep your arms and fingers away from
will appear. These are similar in appearance to stress moving parts of the upright.
corrosion cracks. Block the carriage or upright when
If a plated chain is required, consult Clark. Plated working with the components in a raised
chains are assembledfrom modified, individually plated position.
components which may reduce the chain rating. Do not reach through open areas of the
l Corrosion Fatigue - Corrosion fatigue cracks are very upright.
similar (in many cases identical) to normal fatigue Never attempt to move or align the rails
cracks in appearance. They generally begin at the pin by hand. Use a prybar.
hole and move perpendicular (90”) to the chain pitch Failure to follow these warnings can result
line. in serious injury.
Corrosion fatigue is not the same as stress corrosion.
Corrosion fatigue is the combined action of an aggres-
sive environment and a cyclic stress (not a static stress
alone, as in stress corrosion).

Ultimate Strength Failure

Thistype of failure is caused by overloads far in excess of
the design load.

Broken plate caused by overload.

34-6-4 l Upright Chain Inspection, Adjustment, and Replacement SM 598,Oct ‘94
 Main Table of Contents

Group 34, Uprights

Standard Upright Chain Length Adjustment
To adjust chain length on the standard
following illustration and procedures:
b. Tilt upright fully back and completely lower.
c. Raise carriage about 1 m (3.2 ft) and measure the
upright use the
distance from where the center of the bottom
carriage roller stopped to the bottom edge of the
inner rail. Distance should not be less than 20 mm
(0.80 in) or chain length adjustment is required.
3. Carriage stop-to-upright:
a. Lift upright to its full height and check for clear-
ance on the carriage safety stop.
b. If the carriage stop hits the upright stop, adjust the
chain anchor adjustment nuts out until there is at
least 3 mm (0.12 in) clearance between the stops.

IMPORTANT
The carriage stop must not be allowed to
To
carriage. contact the upright stop under any circum-
Adjust chain length here.
stance during normal operations.
1. Fork-to-ground clearance: If all three chain length requirements listed above cannot be
a. Set the upright to vertical position. met, the tire diameter may be out of the design range
b. Break the jam nuts loose on the chain anchors. allowance. Also, excessive tire wear will decrease carriage
stop clearance.
Oversized tires will reduce the bottom carriage roller en-
gagement on the inner rail when the carriage is in the
lowered position. The fork-to-ground clearance can deviate
from the lo-20 mm (0.40-0.80 in) allowance by a small
amount if necessary to maintain the safe 20 mm (0.80 in)
clearance of the bottom carriage roller to the lower edge of
the inner rail.

Adjustment
Nut
Jam Nut
c. Turn the chain adjustment nuts until clearance
between forks and ground is IO-20 mm (0.40-0.80
in).
IMPORTANT
For all chain anchor adjustments:
l Threaded chain anchors must be left free to
pivot in mounting hole.
l Anchor cotter pin heads must be to the inside of
the upright.
l Torque jam nuts to adjustment nuts to 100-200
N*m (74-148 f&lb).
l Make sure chain anchors are secured so that no
twist is evident in the chains.
2. Carriage roller position:
a. Raise carriage about 1 m (3.2 ft) and smear a bead
of grease on the bottom 75 mm (3 in) inner rail in
the area of the roller pattern.
Triple-Stage Upright (TSU) Chain Length
Adjustments
Triple-stage uprights use two chain sets; one set for car-
riage lift and one set for rail lift. Adjustment anchors for
the lift cylinder stage are located at the back of the outer
rail. Adjustment anchors for the primary lift stage are be-
hind the primary cylinder. Carriage chain anchors are not
intended for adjustment.
For TSU inner rail lift chains, chain length must be adjusted
if the difference between the bottom of the inner rail and
the outer rail is greater than 10 mm (0.40 in).
For the TSU primary cylinder lift chain, the chain length
must be adjusted if:
l The fork-to-ground clearance is less than 5 mm (0.20
in) or more than 25 mm (1.0 in) when the upright is
vertical.
l The center of the bottom carriage roller comes within
20 mm (.80 in) of the bottom edge of the inner rail.
l The carriage safety stop hits the inner rail stop at full
lift height.

SM 598,Oct ‘94 Upright Chain inspection, Adjustment, and Replacement l 34-6-5

 Main Table of Contents

Group 34, Uprights ClRRK

To adjust the cylinder lift chains on a TSU use the follow-
ing illustration and procedures:
Adjust chain length
here. To inner rail. -J
1. Set the upright in the vertical position.
2. Break the jam nuts loose on the chain anchors.
3. Adjust the chain anchor adjustment nuts until the
bottom of the inner rail is within 2.5 mm (0.10 in) of
the bottom of the outer rail.
To adjust the primary cylinder lift chain on a TSU use the
following illustration and procedures:
IMPORTANT
For all chain anchor adjustments:
l Threaded chain anchors must be left free to
pivot in mounting hole.
l Anchor cotter pin heads must be to the inside of
the upright.
l Torque jam nuts to adjustment nuts to 100-200
N-m (74-148 f&lb).
l Make sure chain anchors are secured so that no
twist is evident in the chains.
2. Carriage roller position:
a. Raise carriage about 1 m (3.2 ft) and smear a bead
of grease on the bottom 75 mm (3 in) of the inner
rail in the area of the roller pattern.
b. Tilt upright fully back and completely lower.
c. Raise carriage again about 1 m (3.2 ft) and mea-
sure the distance from where the center of the
bottom carriage roller stopped to the bottom edge
of the inner rail. Distance should not be less than
20 mm (0.80 in) or chain length adjustment is
required.
3. Carriage stop-to-upright:
a. Lift upright to its full height and check for clear-
ance on the carriage safety stop.
b. If the carriage stop hits the upright stop, adjust the
chain anchor adjustment nuts out until there is at
least 3 mm (0.12 in) clearance between the stops.

IMPORTANT
The carriage stop must not be allowed to
contact the upright stop under any circum-
stance during normal operations.

If all three chain length requirements listed above cannot be

met, the tire diameter may be out of the design range
allowance. Also, excessive tire wear will decrease carriage
stop clearance.
Adjust chain length here. Oversized tires will reduce the bottom carriage roller en-
I gagement on the inner rail when the carriage is in the
0 carriage
lowered position. The fork-to-ground clearance can deviate
from the lo-20 mm (0.40-0.80 in) allowance by a small
1. Fork-to-ground clearance:
amount if necessary to maintain the safe 20 mm (0.80 in)
a. Set the upright to vertical position.
clearance of the bottom carriage roller to the lower edge of
b. Break the jam nuts loose on the chain anchors. the inner rail.
c. Turn the chain adjustment nuts until clearance
between forks and ground is IO-20 mm (0.40-0.80
in).

34-6-6 l Upright Chain Inspection, Adjustment, and Replacement SM 598,Oct ‘94

 Main Table of Contents
CUIRK
Chain Lubrication
Like all bearing surfaces, the precision-manufactured, hard-
ened-steel, joint-wearing surfaces of leaf chain require a
film of oil between all mating parts to prevent accelerated
wear.
Maintaining a lubricant film on all chain surfaces will:
Minimize joint wear.
Improve corrosion resistance.
Reduce the possibility of pin turning.
Minimize tight joints.
Promote smooth, quiet chain action.
Lower chain tension by reducing internal friction in the
chain system.
Laboratory wear tests show #40 oil to have greater ability
to prevent wear than #lO oil. Generally, the heaviest (high-
est viscosity) oil that will penetrate the joint is best.
Whatever method is used, the oil must penetrate the chain
joint to prevent wear. Applying oil to external surfaces will
prevent rust, but oil must flow into the live bearing surfaces
for maximum wear life.
To prepare the chain for oiling, the leaf chain plates should
be brushed with a stiff brush or wire brush to clear the
space between the plates so that oil may penetrate the live
bearing area.
Oil may be applied with a narrow paint brush or directly
poured on. Chain should be well flooded to be sure the oil
penetrates the joint.
In locations difficult to reach, it may be necessary to use a
good quality oil under pressure such as an aerosol can or
pump pressure spray.
Chain Removal and Replacement
A WARNING
The procedures for removing and replac-
ing chain sets involve hoisting and blocking
components.
l Do not walk or stand under raised forks.
l Keep your arms and fingers away from moving
parts of the upright.
l Do not reach through open areas of the up-
right.
Failure to follow these warnings can result
in serious injury. See “Lifting, Jacking, and
Blocking” for safe blocking procedures.
SM 598,Oct ‘94 Upright Chain Inspection,
Group 34, Uprights
General Guidelines
Chain Movement - Make sure that the chain operating
path is clear and that the chain articulates freely through
its full range of operation.
Lubrication - Assure that the chain is well lubricated
with the heaviest oil that will penetrate the void be-
tween the link plate apertures and the pins.
Paint - Make sure the chain does not get painted over
at any time.
Protection - Where necessary, as a protection from
atmosphere or sliding wear, the chain may be covered
with a layer of grease. It should be noted, however, that
the grease will have to be removed at a later date for
chain inspection and relubrication.
Chain Mountings - Double check to be sure all chain
fastening devices are secured and all adjustments have
been made to assure uniform loading of multiple chain
applications. Check chain anchors and pins for wear,
breakage, and misalignment. Damaged anchors and
pins should be replaced.
Sheaves-Sheaves with badly worn flanges andoutside
diameter should be replaced. This wear may be due to
chain misalignment or frozen bearings.
Lift Chains (Standard and TSUs)
To remove and replace the lift cylinder and/or carriage
chain set on standard and triple-stage uprights (TSU):
Attach a hoist strap on the carriage of the standard
upright or inner rail of the TSU.
Lift the carriage or inner rail slightly to create slack in
thechains.Blockthecaniageorinnerrailupforsafety.
Remove the chain anchor pins on the outer rail and pull
the chains off of the sheaves on the inner or intermedi-
ate rails.
Adjustment, and Replacement l 34-6-7
 Main Table of Contents
Group 34, Uprights
4. Remove the chain anchor pins from the carriage on the
standard upright or the inner rail on the TSU. On the
TSU, the inner rails must be lowered to the floor to
access the chain anchor pins.
Lift Chain Removalfrom Carriage (standard upright)
Lower rail to floor.
Triple-Stage Upright Lift Chain Removalfrom inner Rail
NOTE
If a hose adapter assembly is used, the chain
sheaves must be loosened and removed to
prevent the hoses from stretching when the
inner rails of the TSU are lowered to access
the chain anchor pins.
5. Use the steps in reverse order to replace the lift chain
set.
Primary Cylinder/Carriage Chains (TSUs)
1. Tilt the upright forward, lower it, and completely
collapse the primary cylinder to create slack in the
chains. The carriage may also be lifted and blocked in
position and the primary cylinder completely col-
lapsed to create slack in the chains.
2. Remove the chain anchor pins from the back of the
primary cylinder. Pull the chains through the chain
sheave and lay over the carriage load backrest.
34-6-8 l Upright Chain Inspection, Adjustment,
3. Remove the chain anchor pins from the back of the
carriage.
4. Use these steps in reverse to replace the primary
cylinder/carriage chain.
Perform the chain length adjustment and chain tension
check before returning the truck to service.
Other Chain Service Notes
Use lengths of factory assembled chain. Do not build
lengths from individual components.
Do not attempt to rework damaged chains by replacing
only the components obviously faulty. The entire
chain may be compromised and should be discarded.
Never electroplate assembled leaf chain or its compo-
nents. Plating will result in failure from hydrogen
embrittlement. Plated chains are assembled from modi-
fied, individually plated components.
Welding should not be performed on any chain or
component. Welding spatter should never be allowed
to come in contact with chain or components.
Leaf chains are manufactured exclusively from heat
treated steels and therefore must not be annealed. If
heating a chain with a cutting torch is absolutely
necessary for removal, the chain should not be reused.
and Replacement SM 598,Oct ‘94
 Main Table of Contents

CIRRK Group 34, Uprights

Section 7.

Fork and Carriage Removal and Replacement

A CAUTION 3. Lift tip of each fork and put a 100 x 100 mm (4 x 4 in)
SAFE PARKING. Before working on truck: block under the fork arm near the heel.
1. Park truck on a hard, level, and solid
surface, such as a concrete floor with no
n ! CAUTION
gaps or breaks. Forks weigh 45-68 kg (100-150 Ibs) each.
2. Put upright in vertical position and fuBy Take care when lifting.
lower the forks or attachment.
3. Put all controls in neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the
wheels.

Fork Removal
NOTE
Forks do not need to be removed to remove
the carriage.

1. Release the fork latches.

Blocking the Fork

4. Push down on tips of the forks to disengage the fork
hooks from the carriage fork bar.
5. Lift fork heel and remove block.

Latch Operation n ! CAUTION

2. Move each fork to the notch on the bottom of the lower Forks are not stable sitting free in upright
carriage cross bar. position. Use care when working around
the forks.

6. Back the truck away from the forks.

Fork Replacement
1. Carefully drive truck up close to forks.

n ! CAUTION
Forks are not stable sitting free in upright
position. Use care when working around
the forks.

2. Drag forks into position close to carriage and to line up

with the notche on the lower carriage cross bar.
3. Lift fork heel and place block under arm near the heel.

SM 598,Oct ‘94 Fork and Carriage Removal and Replacement l 34-7-l

 Main Table of Contents

Group 34, Uprights CIRRK

4. Lift tips of forks to engage the fork hooks on the upper You may need a helper to hold the control
carriage fork bar. handle in the lowering position while you
pull on the carriage chains to fully collapse
5. Remove blocks from under fork.
the primary cylinder (on TSUs). When pull-
6. Check fork latches when repositioning forks to upper ing on the chains to lower the primary cyl-
carriage fork notches. inder (on TSUs), the ignition must be off.

Once the carriage is fully lowered, clamp the front of

Carriage Removal one fork to the pallet to prevent the carriage from
The carriage should be removed for shimming or when any falling over backwards when removed.
service procedure is performed on the upright.

A WARNING
The procedures for checking, maintaining,
and adjusting uprights, carriages, and forks
involve movement of the components.
l Do not walk or stand under raised forks.
l Keep clear of load and carriage when making
any check or adjustment.
l Keep your arms and fmgers away from moving
parts of the upright.
l Do not reach through open areas of the up-
right.
l Always use a prybar to move the upright or
carriage.

Failure to follow these warnings can result

in serious injury. For carriage auxiliary components, the hose sheave
1. Set upright tilt to 0 degrees (vertical). Raise the car- bracket must be unbolted from the primary cylinder
riage about 12 in (305 mm). chain sheave bracket. Move the hose bracket off the
chain bracket.
2. Place a heavy pallet under the forks. Turn the key off.
3. Lower the carriage onto the pallet and keep lowering Remove
(until the primary cylinder is all the way down on hose
TSUs). Before proceeding with the next step read the sheave
following warning. using
these

A WARNING
nuts.

You may need to pull on the hoses/cables Chain -

and chains while lowering the primary cyl- Sheave
inder to get it all the way down. This is
done to create slack in hoses/cables and
chains and to displace as much oil as pos-
sible, which will reduce oil loss when dis-
connecting hydraulic lines for auxiliary
components.

34-7-2 l Fork and Carriage Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents

ElfIRK Group 34, Uprights

6. Disconnect the carriage chains at the base of the

carriage. Pull chains back off primary cylinder sheave.

10. Remove steer wheel blocks. Release the parking brake

7. For carriage auxiliary components, disconnect hoses and slowly back the truck away from the carriage.
(2- or 4-hose assemblies) from carriage. Remove the 11. Lower the upright rails until both of the secondary
bolts and strap fixture also. cylinders are completely collapsed.
Remove
strap
here. Carriage Replacement
To replace the carriage:
Remove
hose 1. First check to be sure the carriage is securely clamped
fittings to the pallet.
here.
2. Move the truck up to the carriage assembly with the
inner rail centered on the carriage.
3. Raise the upright until the inner rail is high enough to
clear the upper carriage rollers.
4. Tilt the upright until it is at the same angle as the
carriage assembly.
5. Now slowly move the truck forwarduntil the inner rail
is centered over the carriage rollers.

l Cap all lines to prevent leaks.

l Label all lines and fittings for correct reassembly.
8. Elevate the primary cyimder to its maximum height.
Be sure all hoses and loose parts are secured out of the
way to prevent damage.
9. Continue elevating the upright until the inner rail clears
the carriage.

SM 598,Oct ‘94 Fork and Carriage Removal and Replacement l 34-7-3

 Main Table of Contents

Group 34, Uprights CIRRK

A WARNING
10. If the carriage is equipped with a carriage auxiliary
component, reconnect the hose sheave bracket to the
Never attempt to move or alii
the car- top of the primary cylinder chain sheave bracket.
riage or bearings by hand. Use a pry bar.

6. Lower the upright until the inner rail clears all of the Replace
hose
carriage rollers.
sheave
NOTE using
If the rail or bearings bind, raise the up- these
right, back away from the carriage and nuts.
check to be sure the carriage rollers are
installed properly.

7. When the inner rail has cleared the carriage rollers,

continue to lower the upright until the lift cylinders are
lowered completely.
8. Reset the truck in a safe position:
l Ignition off
11. Reconnect the hoses and mounting strap to the carriage
l Parking brake applied
auxiliary component if the carriage is so equipped.
l Directional lever iu neutral
l Forks completely lowered
l Block steer wheels.
9. Reinstall the carriage lift chains to the base of the
carriage.

l Lubricate all O-rings with a light coating of sys-

tem hydraulic fluid or a compatible oil.
l Use two wrenches to tighten hose fittings to pre-
l Set anchor bolts so that no twist develops in the vent hoses from twisting.
chains. l See Group 40 for hydraulic fitting tightening
. Anchor pin heads must be pointing to the inside of procedures.
the upright. 12. Adjust carriage height according to Section 6 and
l Use new cotter pins. chain tension according to Section 3.
IMPORTANT 13. Remove the “C” clamp from the pallet and check the
operation of the carriage and the upright. Carefully
Always use new anchor pins when replac-
check for oil leaks. Make sure the carriage and upright
ing chain sets.
worksmoothly andcorrectlybeforereturningthetruck
to service.

34-7-4 l Fork and Carriage Removaland Replacement SM 598,Oct ‘94

 Main Table of Contents

CIRRK Group 34, Uprights

Section 8.

Upright Removal and Replacement

This Section describes how to remove the entire upright A CAUTION
assembly from the truck. The carriage and forks must be SAFE PARKING. Before working on
removed from the upright assembly before the upright is truck:
removed. (For uprights with an auxiliary component, a Park truck on a hard, level, and solid
side-shifter for example, the two hydraulic hoses powering surface, such as a concrete floor with no
the auxiliary component must be removed before the car- gaps or breaks.
riage is removed.) See Section 7, “Fork and Carriage Re- Put upright in vertical position and fully
moval and Replacement,” for procedures to remove the lower the forks or attachment.
carriage and fork assembly from the upright. Put all controls in neutral. Turn key switch
OFF and remove key.
Apply the parking brake and block the
wheels.

Load-Lowering Flow Valve and

Two-Hose Hardware Mounting
Bracket

r Tilt Cylinder Mount

SM 598,Oct ‘94 Upright Removal and Replacement l 34-8-l

 Main Table of Contents

Group 34, Uprights EUIRK

2. Disconnect and cap hydraulic line at the load-lowering

Upright Removal
flow valve. Secure the hose out of the way of the
The following procedures are for uprights with carriage upright.
and forks, or auxiliary components removed. See Section 7,
“Fork and Carriage Removal and Replacement,” for in-
7 Discon-
structions on removing the forks and carriage. nect and
cap line
A WARNING from main
hydraulic
The upright assembly is heavy. Use only
hoists with enough capacity to lift the en- control
0 valve.
tire assembly. Keep clear of the assembly
as it is being hoisted and set down. Keep
hands and feet away from the assembly.
Use prybars to move the assembly into po-

1r
sition for reattachment.

1. Attach a hoist and strap of adequate capacity to the

.i I
upright as shown below. Tension the hoist so that the
upright cannot fall when upright mounting pins and tilt NOTE
cylinder pins are removed. For two-hose adapter assemblies, the hy-
draulic lines to the upright must also be
disconnected and capped.

- Disconnect

34-8-2 l Upright Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents

Group 34, Uprights

CUIRK
3. Remove tilt cylinder rod-end lock plates and rod-end Upright Replacement
pins from upright.
1. Use an overhead chain hoist of adequate capacity and
an approved lift chain to lift upright into position

Cushion-tire

Pneumatic-tire
trucks with bolt

A WARNING
Use prybars to move the assembly into po-
4. Remove trunnion ring bolts and lift upright off frame. sition for reattachment.
See illustration on page 1.
2. Secure mounting bearing to inner, load-bearing half of
5. Slowly set upright down on the floor, 100 x 100 mm (4
the trunnion mounting using double-sided tape. Install
x 4 in) blocking, or sturdy pallets set end-to-end.
trunnion ring mounting bolts and use Loctite 271
(Clark part number 1802302). Torque to 55 ft-lb (74.25
Nom).

SM 598,Oct ‘94 Upright Removal and Replacement l 34-8-3

 Main Table of Contents

Group 34, Uprights CUIRK

3. Install rod end pins, lock plates, and fasteners. Tighten NOTE
lock plate fasteners to a torque of 121-136 in-lb (19.3- Reconnect two-hose adapter assembly hy-
21.5 Nom). draulic lines to the upright-mounted
bracket.

Cushion-tire

Pneumatic-tire
trucks with bolt

5. Remove the lift chain between the upright and hoist.

6. Completely check all upright and hydraulic compo-
nents under load before returning the truck to service.
4. Attach hydraulic lines to the upright flow control
7. See Section 8, “Fork and Carriage Removal and Re-
valve:
placement,” for steps to replace the carriage and fork
assembly.
Reconnect
hydraulic
line here.

l Lubricate all O-rings with a light coating of sys-

tem hydraulic fluid or a compatible oil.
l Use two wrenches to tighten hose fittings to pre-
vent twisting lines.
l See Group 40 for hydraulic fitting tightening
procedures.

34-8-4 ’ Upright Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents

GROUP 38

GROUP 38

COUNTERWEIGHT AND CHASSIS

Counterweight Specifications and Description . ... .. .. ... . Section 1

Counterweight Removal and Replacement . .. ... .. ..... .. .. . Section 2

Overhead Guard/Operator’s Cell Removal

and Replacement .... .. ........... .. .. ......... ... ..... .... .... ... ... . Section 3

Floorboard, Radiator Cover, and Seat Deck

Removal and Replacement .... .. . ... .. ..... .. ..... ... ..... .. .. . Section 4

Operator’s Seat Removal and Replacement .. .. ... ..... .. ... Section 5

SM 598, Ott ‘94 Counterweight and Chassis

 Main Table of Contents

ClflRK Group 38, Counterweight and Chassis

Section 1.

Counterweight Specifications and Description

Specifications Description
Counterweight weights: The counterweight is a solid, cast-iron piece mounted to the
back of the lift truck to counter-balance the loads placed on
Cushion Frame Pneumatic Frame
the upright at the front of the truck. The weight must be
1180 Kg (2600 lbs) 1090 Kg (2400 Ibs) great enough to counteract forward tipping when lifting or
stopping with a capacity load. The weight of the counter-
1590 Kg (3500 Ibs) 1450 Kg (3200 Ibs)
weight is determined by the lifting capacity of the truck.
1950 Kg (4300 Ibs) 1700 Kg (3900 ibs)
The counterweight is cast with mounting niches molded in.
The niches fit the truck frame mounting and allow the
Fastener Torques counterweight to “hang” on the truck frame bracket. Large,
Counterweight Mounting Bolt: 340-380 N*m (250-280 ft- hard steel bolts hold the counterweight to the frame and
prevent the counterweight from being dismounted acciden-
lb)
tally.
LPG Tank Support Assembly Bracket Nut: 170-190 N*m
(125-140 ft-lb)
A WARNING
The counterweight is extremely heavy. Do
General Maintenance not remove the counterweight unless you
The counterweight must be maintained in good condition have training and are familiar with the
and securely attached to the lift truck. Because of its heavy correct procedures. Counterweights can fall
weight and bulky mass, the counterweight must be care- if not handled correctly and can cause se-
fully supported and handled. When removed from the truck, vere injury or death. Keep your hands, feet,
store at floor level in a stable position to be sure it will not and body clear of the counterweight at all
fall or tip, causing damage or injury. times.
Hoisting equipment must be capable of han-
dling the weight of the counterweight when
removing or replacing. Make sure your
hoist is of adequate capacity to handle the
weight.

SM 598,Oct ‘94 Counterweight and Chassis Specifications and Description l 38-l-l

 Main Table of Contents

Group 38,
ClmK
Section 2.
Counterweight Removal and Replacement

A CAUTION LPG Tank Removal

SAFE PARKING. Before working on Remove the LPG tank from the counterweight if servicing
truck: a LPG-fuel truck. The tank must be removed to install the
1. Park truck on a hard, level, and solid lifting eyebolts on the counterweight. Remove the two
surface, such as a concrete floor with no bolts mounting the tank support assembly bracket to the
gaps or breaks. counterweight.
2. Put upright in vertical position and fully
lower the forks or attachment.
3. Put all controls in neutral. Turn key switch Counterweight Removal
OFF and remove key.
1. Install eye bolts into the counterweight. Eyebolts must
4. Apply the parking brake and block the
be able to lift 1090- 1950 kg (2600-4300 lb) depending
wheels.
on truck model (see illustration next page).

Observe
A WARNING
proper, safe lifting practices when
Using an overhead hoist with sufficient lifting capac-
ity, chain the eyebolts to the hoist; slowly hoist chains
until slack is removed.
lifting counterweight onto or off truck.
Remove the tow bar and the counterweight anchor
Counterweight should only be lifted by ap-
propriately-sized eye bolts installed through bolt(s).
both top lifting holes. Slowly lift the counterweight from the truck frame.
Use only overhead lifting equipment hav-
ing a safe lifting capacity in excess of that
of the counterweight.

LPG Tank

Tank support
Assembly Bracket

Torque to 170-
190 Nom
(1250140 ft-lb).

SM 598, Ott ‘94 Counterweight Removal and Replacement l 38-2-l

 Main Table of Contents

Group 38, Counterweight and Chassis

EIRRK

Stand clear
A WARNING
of the counterweight as it is
3. Make sure that the bolt holes in the countenveight
properly with the mating holes in the frame.
align

being hoisted, moved, or mounted.
5. Slowly lower the counterweight onto a sturdy pallet.
Set the counterweight on its flat side if possible. If set
on its curved side, use chocks to prevent the counter-
weight from shifting or rolling.
Counterweight Replacement
1. Bring counterweight vertically near the rear of the
truck and positioned so that it is within 25-50 mm (l-
2 in) of the frame.
2. Move the counterweight forward and lower it, making
sure that the support hooks on the frame engage with
the counterweight.
4. Inspect the counterweight mounting bolts to make sure
they are in good condition before re-installing. Use
only Clark replacement parts. Torque the mounting
bolts to 340-380 N-m (250-280 ft-lb).
5. Remove the hoist and eyebolts.
IMPORTANT
Never allow a truck to be put into service
without the counterweight mounting bolt(s)
in place. Check the bolt(s) and torque regu-
larly.
LPG Tank Replacement
Remount the LPG tank support assembly bracket. Torque
the bracket mounting bolt nuts to 170- 190 Nom (125- 140

A WARNING
During mounting, always use prybars for
ft-lb).

location adjustments. Do not place any part

of your body between the counterweight
and truck.

Eyebolts

Anchor
/T Bolts

A Towbar and
Pin

Counterweight Installation. A standard cushion-tire truck counterweight andframe is shown. Removal and replacement
of pneumatic-tire models is the same.

38-2-2 l Counterweight Removal and Replacement SM 598,Oct ‘94

 Main Table of Contents

CUlRU Group 38, Counterweight and Chassis

Section 3.

Overhead Guard/Operator’s Cell

Removal and Replacement

A
CAUTION Operator’s Cell Removal and
SAFE PARKING. Before working on truck: Replacement
Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks. Removal
Put upright in vertical position and fully 1. Tilt the steering column fully forward.
lower the forks or attachment.
2. Raise the seat deck.
Put all controls in neutral. Turn key switch
OFF and remove key. 3. Lift out the operator’s compartment floor plate.
Apply the parking brake and block the 4. Remove the operator’s seat deck; see Section 4.
wheels.
5. Disconnect and label all wiring for cell-mounted lights
or other electrical devices.
6. Disconnect air induction tube from cell leg.
Overhead Guard Removal and
Replacement
l Loosen and remove the six hex capscrews securing the
overhead guard to the cell.

7. Loosen and remove the four mounting nuts securing

the bolts and cell to the truck chassis as shown in the
illustration on page 2.
8. Use an overhead hoist to lift the cell from the truck
chassis.

l Replace overhead guard and torque hex capscrews to

70-75 Wm (52-55 ft-lb).

SM 598,Oct ‘94 OHG/Operator’s Cell Removal and Replacement l 38-3-l

 Main Table of Contents

Group 38, Counterweight and Chassis CUIRK

Replacement
1. Set cell into place on the truck chassis using an over-
head hoist.
2. Replace the four mounting bolts and nuts. Torque the
nuts to 70-80 Nom (52-59 f&lb).
NOTE
If the cell is a new replacement or has been
repaired, install new cushion mounts
3. Reconnect the air induction tubing to the cell leg.
4. Reconnect all wiring for cell-mounted lights or other
electrical devices according to the labels made during
removal.
5. Replace the operators seat deck; see Section 4.
6. Replace the operator’s compartment floor plate and
readjust, if necessary, using the procedures in Section
4.

Remove this nut

only to remove
cell.

38-3-2 l OHG/Operator’s Cell Removal and Replacement SM 598, Ott ‘94

 Main Table of Contents

6lmK Group 38, Counterweight and Chassis

Section 4.

Floorboard, Cowls, Radiator Cover, and Seat Deck

Removal and Replacement

Floorboard Removal and Replacement .......................................................................................

2

2
Cowl Removal and Replacement ..................................................................................................

Radiator Cover Removal and Replacement ................................................................................

3

Operator’s Seat Deck Removal and Replacement ......................................................................

3

SM 598,Oct ‘94 Floorboard, Cowls, Radiator Cover, and Seat Deck Remove and Replace l 38-4-l
 Main Table of Contents

Group 38, Counterweight and Chassis ElmK

3. Assemble the screws and pins to the floor plate as

A CAUTION shown in the following illustration.
SAFE PARKING. Before working on truck:
1. Park truck on a hard, level, and solid
surface, such as a concrete floor with no
gaps or breaks.
2. Put upright in vertical position and fully
lower the forks or attachment.
3. Put all controls in neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the
wheels.

Floor Plate Removal and Replacement

1. Tilt the steering column fully forward.
2. Raise the seat deck.
3. Lift out the operator’s compartment
ber mat lifts out with floor plate.
4. Snug the retention screws to the pins but allow move-
floor plate. Rub-
ment of the parts in the floor plate slot.
5. Orient and place pins into mating holes in cell sides.
Allow the floor plate to rest on the cell sides.
6. Adjust floor plate to center by moving the pins in the
slots.
NOTE
Make sure the accelerator pedal has a full
stroke and does not bind.

7. Once centered, torque the retention screws into the

pins to 8-10 Wm (5.9-7.3 ft-lb).
8. Lower and latch seat deck.

Cowl Removal and Replacement

1. Remove the right, center, and left cowl covers as
shown in the following illustration.

4. To replace the floorplate, position the floor plate so

that the retention pins mate with holes in the operator’s
cell side plates.

Floor Plate Adjustment

1. Remove the pins from the floor plate retention screws.
2. Apply Loctite thread locking compound 27 1 to threads
of the screws.

2. To replace the cowl covers top lip of the right and left
cowl covers must be inserted under the dash prior to
fastening covers into position.

38-4-2 l Floorboard, Cowls, Radiator Cover, and Seat Deck Remove and Replace SM 598,Oct ‘94
 Main Table of Contents

CIRRK Group 38, Counterweight and Chassis

Radiator Cover Removal and 5. Remove the wire circle cotter and washers from the
seat deck prop plate.
Replacement I

Remove and replace the radiator cover as in the following

illustration.
Seat
Deck
Prop
Plate

shers \ \!
Cotter k..

6. Unbolt the seat deck bracket from the hinge bracket

from left and right sides.

/i/ CAUTION
Support the s&&deck in position when re-
Operator’s Seat Deck Removal and moving bracket nuts to prevent falling and
possible injury.
Replacement

Removal
Tilt the steering column fully forward.
Raise the seat deck.
Lift out the operator’s compartment floor plate.

n ! CAUTION Hinge
Seat deck is not supported when gas springs Bracket
and prop plate are removed. Support the
seat deck in position when disconnecting to
prevent falling and possible injury.
7. Remove the seat deck.
Unclip the upper gas spring connections. Insert a
narrow, flat-head screwdriver into the clip and pry
gently. Clip separates allowing gas spring to be pulled Replacement
off post.
To replace the operator’s seat deck:
Post IOB 1. Set the seat deck in place.

A8
n ! CAUTION
Clip Support the seat deck in position when re-
placing to prevent falling and possible in-
Pry clip
ii jury-
fl gently.

!A

SM 598,Oct ‘94 Floorboard, Cowls, Radiator Cover, and Seat Deck Remove and Replace l 38-4-3
 Main Table of Contents
Group 38, Counterweight and Chassis
ClRRK
2. Line up the seat deck bracket and the hinge bracket and 5. Check the alignment of the seat deck to make sure it
replace the lockwashers and nuts. Hand tighten nuts. latches correctly.
l Adjust seat deck to center on overhead guard cell
frame.
l Check for an even gap along the bottom edge.
l Torque the lock nuts to 40-45 N*m (30-33 ft-lb).
Do not overtorque.
6. Check hood release latch to make sure it is catching on
Hinge seat-deck-mounted striker. Loosen and adjust deck
Bracket striker as necessary.

3. Reset the seat deck prop plate and replace the wire
circle cotter.

Deck
Striker

Hood Release
\

4. Replace the two gas springs by clipping back onto seat 7. Lift and lower the seat deck several times to make sure
deck posts. the latch is catching and that the seat deck is balanced
before returning the truck to service.

38-4-4 l Floorboard, Cowls, Radiator Cover, and Seat Deck Remove and Replace SM 598,Oct ‘94
 Main Table of Contents

EmIt Group 38, Counterweight and Chassis

Section 5.
Operator’s Seat
Removal and Replacement

A CAUTION Seat Removal

SAFE PARKING. Before working on truck:
1. Park truck on a hard, level,-and solid
surface, such as a concrete floor with no
gaps or breaks.
2. Put upright in vertical position and fully
lower the forks or attachment.
3. Put all controls in neutral. Turn key switch
OFF and remove key.
4. Apply the parking brake and block the
wheels.
1. Tilt steering column fully forward and raise the seat
deck.
2. Remove the four nuts (with washers) securing the seat
rails to the seat deck.
n ! CAUTION
Make sure to support seat on deck so it
does not fail when bolts are removed. Seat
may be damaged or injury can result.

Remove nuts and

washers here.

SM 598,Oct ‘94 Operator’s Seat Removal and Replacement l 38-5-l

 Main Table of Contents

Group 38, Counterweight and Chassis ElRRK

Seat Replacement 3. Check seat for correct, smooth adjustment when slid-
ing forward or back. Make sure the seat locks in place
1. Set and hold the seat in position on the raised seat deck.
on the rails when adjusted for different positions.
2. Replace the four bolts securing the seat rails to the seat
deck and torque to 23-25 Wm (17- 18.5 ft-lb).

38-5-2 l Operator’s Seat Removal and Replacement , SM 598,Oct ‘94

 Main Table of Contents

GROUP 40

GROUP 40

SPECIFICATIONS

Nameplates and Decals ................................................... Section 1

General Specifications .................................................... Section 2

Hydraulic Fitting Tightening Procedures ..................... Section 4

Specifications
SM 598, Apr ‘96
 Main Table of Contents

Emu Group 40, Specifications

Section 1.
Nameplates and Decals

Nameplates and Decals .............................................................. .................................................... 1

Nameplate, Decal Locations .......................................................................................................... 4

Nameplates and Decals

This Section shows the nameplate (data and capacity plate) (4) Truck weight-The approximate weight of the truck
and decals required to be on all operating Clark industrial without a load on the forks. This weight plus the weight
trucks. The nameplate lists the data on the truck - type and of the load must be considered when operating on
serial number - and the capacities of the truck. Decals elevators, elevated floors, etc. to be sure they are safe.
depict or explain the hazards the operator must avoid when
operating the truck. The nameplate and decals are placed in (5) Capacity rating, load center, and lifting height data-
Shows the maximum load capacity of this truck with
specific locations on the truck and are intended to warn
relation to load centers and fork heights (see diagram
others working around the truck of its hazards as well.
on plate). Personal injury and damage to the truck can
These nameplates and decals MUST BE IN PLACE on all
occur if these capacities are exceeded. Do not exceed
trucks.
the maximum capacity specified.
If any decals or the nameplate are missing from the truck,
check with your local Clark dealer for replacements.
n ! CAUTION
IMPORTANT When attachments are added or if the truck
Do not allow a lift truck with damaged or is modiied, the capacity of the truck may
missing decals or data plates to be placed be affected. Contact your authorized Clark
in service. Replace them immediately. They dealer for a new nameplate showing the
contain important information as described revised capacity.
on the following pages. The location of all
decals is also shown on the following pages.

Truck Data and Capacity Plate

The truck data and capacity plate provides essential infor-
mation about the truck. This information is important for
both operators and service personnel. Operators can see
what the truck’s capacities and load ratings are. Service
personnel must identify the truck model, type, and serial
number when ordering parts. Refer to example data plate
illustration for callout numbers.

(1) Truck model number or registered name.

(2) Truck serial number-An identification number as-
signed to this particular truck and should be used when
requesting information or ordering service parts for
this truck from your authorized Clark dealer. The serial
number is also stamped on the frame.
Truck Data and Capacity Plate
(3) Attachment description (if any installed)-The user
must see that the truck is marked to identify the
attachment(s), including the weight of the truck/at-
tachment combination and truck capacity with the
attachment.

SM 598,Oct ‘94 Nameplates and Decals l 40-l-l

 Main Table of Contents

Group 40, Specifications ClaRK

Operator Safety Warning Plate General Safety Decal

The Operator Safety Warning Plate describes basic, safe The General Safety Decal
operating procedures that should be used when operating depicts important points
the truck. about truck operation and
warns operators about truck Read the
manual
safety hazards. The General
Safety Decal is meant as a
reminder for operators and
Buckle up!
is placed where operators
can review the points daily
as they conduct a visual in-
BEFORE OPERATING lift truck, operator must:
spection and prepare the
l be trained and authorized
l read and understand operator’s truck for work.
manual
l not operate a faulty lift truck Watch Ou
l not repair lift truck unless trained and authorized For Other
l have the overhead guard and load backrest People
extension in place

DURING OPERATION, lift truck operator must:

l wear a seat belt
l keep entire body inside truck cab Most lifl tNC!
l never carry passengers or lift people Y INJURIES
are to other
l keep truck away from people and obstructions peoplenear
l travel with lift mechanism as low as possible the Iii tNCk.
and tilted back
Prevent
TO PARK lift truck, operator must: Overturns!
l completely lower forks or attachments
l shift into neutral

*turn off key

l set oarkina brake
AVOID :
l slippery,
sloping,
or uneven
surfaces
IMPORTANT l loads over
capacity or
Safety and warning decals are placed in nameplate
unstable 01
conspicuous locations on the truck to re-
l
high loads
mind operators of essential procedures or - low tire
pressure
to prevent them from making an error that
’ poorly
could damage the truck or possibly cause maintained
lift tNCk
personal injury. Safety and warning decals
1 fast or
should be replaced immediately if missing sharp turns
or defaced (damaged or illegible).
In Case of
Tip-Over:

40-l-2 l Nameplates and Decals SM 598,Oct ‘94

 Main Table of Contents
CUIRK
Seat Belt/Tip-Over Warning Decal
This decal is located on the seat deck, to the left of the
operator. It’s purpose is to remind the operator that staying
in the seat provides the best chance of avoiding injury in the
event of a truck-tipping mishap.
Lift trucks can be tipped over if operated improperly. Expe-
rience with lift truck accidents has shown that the driver
cannot react quickly enough to jump clear of the truck and
overhead guard as the truck tips. To protect operators from
severe injury or death in the event of a tip-over, make sure
this decal is in place to remind them to always use their
seatbelts .
Hand Safety Warning Decal
This safety decal is placed on the upright to warn of the
danger of injury from movement between rails, chains,
sheaves, fork carriage, and other parts of the upright assem-
bly. Operators and others should never climb on or reach
into the upright. Personal injury will result if any part of
someone’s body is put between moving parts of the up-
right.
SM 598,Oct ‘94
Group 40, Specifications
Keep Away from Forks Decal
This safety decal is placed on the upright to warn of the
danger of injury from forks when they are in the raised
position. Operators and others should never ride on or stand
under forks or attachments. The forks can fall and cause
injury or death.
Fan Warning Decal
The fan warning decal reminds operators and service per-
sonnel not to touch or work around a spinning radiator
cooling fan. The decal is placed on the radiator fan shroud.
IMPORTANT
The Engine Coolant Fan, on all internal
combustion engines, can cause extensive
injury and bodily harm. Keep hands, arms
and clothing away from a spinning fan.
Also, don’t stand in line with a spinning
fan.
Nameplates and Decals l 40-l-3
 Main Table of Contents

Group 40, Specifications ClRRK

Nameplate, Decal Locations The Hand Safety Warning Decal is located on the outer rail
upper tie bar.
The following illustrations show decal locations for the
nameplate and safety decal required on all Clark industrial
lift trucks.
The Data Plate is located on the dash panel to the right of
the hydraulic control levers.

The Keep Away from Forks decal is placed on both sides of

the upright on the outer rail just above the tilt cylinder yoke
mount.

The Operator’s Safety and Warning Plate is located on the

dash panel to the left of the instrument pod.

The Fan Warning decal is placed on the cooling fan shroud

as shown.
The General Safety Decal is located on the operator’s cell
leg as shown.

40-l-4 l Nameplates and Decals SM 598,Oct ‘94

 Main Table of Contents

CIRRK Group 40, Specifications

Section 2.

General Specifications

Weights and Performance Specifications ........................................................................................................................... 2

Capacities ............................................................................................................................................................................... 2
Truck Weights and Axle Weights .......................................................................................................................................... 2
Maximum Gradeability .......................................................................................................................................................... 2
Parking Brake Test ................................................................................................................................................................. 2
Drawbar Pull.. ......................................................................................................................................................................... 3
Travel Speeds ......................................................................................................................................................................... 3
Turning Radius ....................................................................................................................................................................... 3
Drift, Lift and Tilt Cylinders .................................................................................................................................................. 3
Lift and Lowering Speeds, Upright ........................................................................................................................................ 4

Critical Fastener Torque Specifications .............................................................................................................................

4

Group Specifications ......................................................................... 5

.:. ................................................................................
Group 00(G), 4064 Gas/LPG/CNG Engine Specifications ................................................................................................... 5
Group 00(D), S4S Diesel Engine Specifications .................................................................................................................... 5
Group 01, Cooling System Specifications ............................................................................................................................. 5
Group 02(G), Gas-Carb Fuel System Specifications ............................................................................................................. 6
Group 02(LP), LPG Fuel System Specifications ................................................................................................................... 6
Group 03, Air Induction and Exhaust Systems Specifications .............................................................................................. 6
Group 06(S), Standard Transaxle Specifications ................................................................................................................... 6
Group 06(H), Hydrostatic Transmission Specifications ........................................................................................................ 7
Group 12, Ignition System Specifications (4664 Standard Electronic Ignition) ................................................................... 7
Group 13, Instrument Pod Specifications.. ............................................................................................................................. 7
Group 14, Electrical System Specifications ........................................................................................................................... 7
Group 22, Wheels and Tires Specifications ........................................................................................................................... 8
Group 23(S), Brake/Inching System Specifications (Standard Transaxle) ............................................................................ 8
Group 25, Steering Column and Gear Specifications ............................................................................................................ 8
Group 26, Steer Axle Specifications ...................................................................................................................................... 8
Group 29, Hydraulic Sump, Filters, and Pump Specifications .............................................................................................. 9
Group 30, Hydraulic Valve/Lift Circuit Specifications ......................................................................................................... 9
Group 32, Tit Cylinders Specifications ................................................................................................................................. 9
Group 34, Upright Specifications ......................................................................................................................................... 10
Group 38, Counterweight and Chassis Specifications ......................................................................................................... 10

SM 598, Feb’98 General Specifications l 40-2-l

 Main Table of Contents

Group 40, Specifications

Weights and Performance Specifications

Capacities
For standard transaxle trucks and hydrostatic transmission trucks.

At 500 mm (24 in)

Models Load Center

CGC/CGP/CDP 20 2000 kg 4000 lbs

CGCICGPICDP 25 2500 kg 5000 lbs

CGC/CGP/CDP 30 3000 kg 6000 lbs

Note: Rated capacity applies when using uprights with maximum fork height up to and including 3861 mm (152 in).

Truck Weights and Axle Weights

Approximate weights for standard transaxle trucks with cutoff height upright.

Loaded Vehicle Emutv Vehicle Loaded Drive Emutv Drive Emotv Steer
Weight) Weipht Axle Weight Axle Weisht Axle Weieht
&g&g* (ksr/lbsl* (keAbs)* (ks/lbs)** (kellbs)*

CGC 20 5254111560 343917566 4562/10035 144413176 199414396

CGC 25 6091/13405 3823/8410 5235/l 1540 133912947 248315474
CGC 30 6960/15313 422719302 594903090 1273/2800 2954 I6512

CGP 20 5270/l 1595 345517600 4679/10295 167213680 1783/3930

CGP 25 6109/13441 3841/8450 5358111788 1600/3520 224114940
CGP 30 6924115232 420219245 6076113370 156613445 2636 /5812

CDP 20 537001815 355517820 4718/10381 171113765 1844 I4066

CDP 25 6209113662 394118670 5397/l 1875 1638/3603 230215075
CDP 30 7024115450 430219465 6115/13455 1604/3530 269715945

*Subtract approximately 2% for hydrostatic transmission trucks.

**Subtract approximately 5% for hydrostatic transmission trucks.

Note: Refer to the truck data plate for exact service and axle weights.

Maximum Gradeability
At stall in forward with standard upright on surface of 0.9 friction coefficient.

without load with canacitv load

CGC 20 25.5% 42.6%

CGP 20 29.6% 32.8%
CDP 20 29.5% 39.4%

CGC 25 21.0% 35.8%

CGP 2.5 25.3% 27.9%
CDP 25 25.3% 33.5%

CGC 30 17.1% 30.6%

CGP 30 22.5% 24.4%
CDP 30 21.6% 29.4%

Parking Brake Test

For standard transaxle trucks and hydrostatic transmission trucks.

The brake must be capable of holding the truck with a full rated-capacity load on a 15 % grade.

40-2-2 l General Specifications SM 598, Feb’98

 Main Table of Contents

CUlRK Group 40, Specifications

Drawbar Pull
With standard upright and standard trausaxle.

with load without load

CGC 20 20170 N (4536 lbs) 11220 N (2523 lbs)

CGP 20 17120 N (3850 lbs) 13205 N (2970 lbs)
CDP 20 20360 N (4580 lbs) 13500 N (3036 lbs)

CGC 25 20140 N (4523 lbs) 10501 N (2362 Ibs)

CGP 25 17290 N (3890 lbs) 12715 N (2860 lbs)
CDP 25 20560 N (4625 lbs) 13025 N (2930 lbs)

CGC 30 19940 N (4425 lbs) 10080 N (2267 lbs)

CGP 30 17470 N (3930 lbs) 12515 N (2815 lbs)
CDP 30 20770 N (4672 lbs) 12850 N (2890 lbs)

Travel Speeds
Maximum speeds with standard upright and standard transaxle.

without load with load

CGC 20 16.5 kph (10.3 mph) 16.6 kph (10.4 mph)

CGP 20 20.2 kph (12.6 mph) 19.7 kph (12.3 mph)
CDP 20 20.5 kph (12.8 mph) 20.5 kph (12.6 mph)

CGC 25 16.5 kph (10.3 mph) 16.5 kph (10.3 mph)

CGP 25 20.2 kph (12.6 mph) 19.5 kph (12.2 mph)
CDP 25 20.5 kph (12.8 mph) 20.0 kph (12.5 mph)

CGC 30 16.3 kph (10.2 mph) 16.3 kph (10.2 mph)

CGP 30 20.2 kph (12.6 mph) 19.4 kph (12.1 mph)
CDP 30 20.5 kph (12.8 mph) 19.8 kph (12.4 mph)

Turning Radius (outside)

For standard transaxle trucks and hydrostatic transmission trucks.

mm m

CGC 20 1950 76.8

CGP 20 2200 86.6
CDP 20 2200 86.6

CGC 25 2013 79.3

CGP 25 2266 89.2
CDP 25 2266 89.2

CGC 30 2069 81.5

CGP 30 2336 92.0
CDP 30 2336 92.0

Drift, Lift and Tilt Cylinders

For standard transaxle trucks and hydrostatic transmission trucks.

Lift Cylinder Downdrift: Should not exceed 25 mm (1 in) in a S-minute period.

Tilt Cylinder Drift: Should not exceed 25 mm (1 in) in a lo-minute period.

Determined by marking and measuring carriage descent and upright forward tilt from
raised, non-tilted position with hydraulic fluid at operating temperature; and a capacity
load held evenly distributed on lift forks. (If a pallet is used, load should not extend
beyond pallet; load should be stacked to provide maximum stability.) Fork completely
engaging load and adjusted as wide as possible to provide even distribution of weight.

SM 598, Feb’98 General Specifications l 40-2-3

 Main Table of Contents

Group 40, Specifications ClMK

Lift Speeds, Upright
For the standard two-stage upright, with standard transaxle or hydrostatic transmission.

Note: Hydraulic fluid should be at operating temperature when testing these specifications.

Lift Speed Lowering Speed

CGP 20 Loaded 0.54 m/s (106 fpm) 0.43 m/s (85 fpm)
Empty 0.56 m/s (110 fpm) 0.48 m/s (95 fpm)

CGP 25 Loaded 0.53 m/s (104 fpm) 0.44 m/s (87 fpm)
Empty 0.56 m/s (110 fpm) 0.48 m/s (95 fpm)

CGP 30 Loaded 0.52 m/s (102 fpm) 0.45 m/s (89 fpm)
Empty 0.56 m/s (110 fpm) 0.48 m/s (95 fpm)

CDP 20 Loaded 0.55 m/s (108 fpm) 0.43 m/s (85 fpm)
Empty 0.56 m/s (110 fpm) 0.48 m/s (95 fpm)

CDP 25 Loaded 0.54 m/s (106 fpm) 0.44 m/s (87 fpm)
Empty 0.56 m/s (110 fpm) 0.48 m/s (95 fpm)

CDP 30 Loaded 0.53 m/s (104 fpm) 0.45 m/s (89 fpm)
Empty 0.56 m/s (110 fpm) 0.48 m/s (95 fpm)

Critical Fastener Torque Specifications

For standard transaxle trucks and hydrostatic transmission trucks.

Tightening Toraue. Drv

m ft-lb

Engine Mounting Bolts

4664 (GaslLPGICNG) 170-190 125-140
S4S (Diesel) 170-190 125-140

Transaxle to Engine Bolts 40-45 30-33

Torque Converter to Drive Plate Bolts 20-25 14.8-18.5

TransaxlelDrive Axle-to-Frame Mounting Bolts: 542-596 4cQ-440

Hydrostatic pump-to-Frame Mounting Bolt: 40-45 30-33

Drive Wheel Lug Nuts 640-720 470-530

Steer Axle Mounting Bolts 170-190 125-140

Steer Wheel Lug Nuts 221-251 163.7-186.6

Steering Handwheel Retaining Nut 35-40 25.5-29.5

Tilt Cylinder Yoke Clamp Bolts 166-193 122-142

Tilt Cylinder Pin Retainer Bolts

Front S-10 5.9-7.4
Rear S-10 5.9-7.4

Counterweight Mounting Bolts (Bottom) 340-380 250-280

Overhead Guard Mounting Bolts 70-75 52-55

Upright Trunnion Mounting Bolts 74.25 55

40-2-4 l General Specifications SM 598, Feb’98

 Main Table of Contents

Group 40, Specifications

elIaRK
Group Specifications
Group 00(G), 4G64 Gas/LPG/CNG Engine
Specifications

General Specifications Overhaul Specifications

Engine Type: Mitsubishi 4664 in-line, overhead valve, single overhead Overhaul specifications are listed in the engine overhaul Section of this
camshaft Group.

Number of Cylinders: 4
Fuel System Specifications
Combustion Chamber: Semi-spherical
See Group 02 for fuel system specifications.
Total Displacement: 2350 cu cm(143.4 cu in)

Cylinder Bore: 86.5 mm (3.41 in) Group OO(GM), 3.OL GM LPG Engine
Piston Stroke: 100.0 mm (3.94 in) Specifications
Compression Ratio: 8.5 General Specifications
Cylinder Compression: 1880 kPa (163.5 psi) at 300 rpm Engine Type: General Motors Powertrain 3.OL in-line, overhead valve.
Number Of Cylinders: 4
Valve timing:
Combustion Chamber: Semi-spherical
Camshaft Identification (D)
Total Displacement: 3.OL
Intake valve Open 12’ BTDC
Close 40” ABDC Cylinder Bore: 101.6 mm (4.00 in)
Exhaust valve Open 54” BBDC Piston Stroke: 9 1.44 mm (3.60 in)
Close 6” ATDC Compression Ratio: 9.25:1
Cam Shaft: Gear Driven
Lubrication System: Pressure feed, full-flow filtration
Lubrication System: Pressure feed, full-flow filtration
Oil Pump Type: Involute gear type Oil Pump Type: Involute gear type
Engine Oil: 15W40, API, CC, CD/SG, SF engine oil
Engine Oil: 15W40, API, CC, CD/SG, SF engine oil
Sump Capacity: 4.7 L (5.0 qt)
Sump Capacity: 4.5 L (4.8 qt) Cooling System: Water-cooled circulation
Water Pump Type: Centrifugal impeller type
Cooling System: Water-cooled circulation
Valves: Self Adjusting
Water Pump Type: Centrifugal impeller type Firing Order: 1 - 3 - 4 - 2

Tune-Up Specifications Tune-Up Specifications

Spark Plug Type: Tune-up specifications are listed in the engine tune-up Section of this
Gas Engine: NGK BP4ES, Champion NY16 Group.
LPG Engine: NGK BPSES, Champion NY12 Spark Plug Type:
LPG Engine: AC44TS or ACR44TS
Spark Plug Gap: 0.7-0.8 mm (0.028-0.031 in)
Spark Plug Gap: 0.7-0.8 mm (0.028-0.031 in)
Spark Plug Tightening Torque: 25 Nrn (18.4 in-lb)
Spark Plug Tightening Torque: 25 Nom (18.4 in-lb)
Ignitor Air Gap: 0.8 mm (.031 in)
Ignitor Air Gap: 0.8 mm (.031 in)
Ignition Timing: Gasoline 4” BTDC @ 650 rpm; LPG 9” BTDC @ 650
Ignition Timing: LPG 13” to 14” BTDC @ 780 rpm
rpm
Advance: 17” @SO0 & Total of 24” 2600 RPM
Centrifugal Advance: Beginning: 0” at 1000 rpm (engine). End: lo” at
5000 rpm (engine) GM HE1 Ignition and Coil
Engine Speed (rpm):
Vacuum Advance: Beginning: 0” at 80 mmHg (3.14 inHg.) End: 11.5” at Idle: 780 to 800
280 mmHg (11 .O inHg.) Maximum No-Load Governed: 2550-2650 RPM
Engine Speed (rpm): Converter Stall-LPG: Approx. 2400 RPM

Idle: 650-700 rpm Engine Vacuum kPa (psi):

Idle: 406-457 mmHg (16-18 inHg)
Converter Stall: Gasoline Fuel System: 1850-1950
Maximum No-Load Governed: 330-381 mmHg (13-15 inHg)
LPG Fuel System: 1790-l 890
Converter Stall: 38-64 mmHg (1.5-2.5 inHg)
Maximum No-Load Governed RPM: 2500-2650 (gas and LPG) Conv. Stall: 2400 RPM
Engine Vacuum at No-Load Governed Speed: 330-381 mmHg (13-15 Hyd By-Bass: 1950 RPM
inHg) Emissions .6 - .9 CO @ Converter Stall
.4 - .6 CO @ Idle
Idle Vacuum: 406-483 mmHg (16-18 inHg)

SM 598, Feb’98 General Specifications l 40-2-5

 Main Table of Contents

Group 40, Specifications CIARU

Group 00(D), S4S Diesel Engine Fuel Pump Type: Electric.

Specifications Octane Recommended: 87-93.

Governor Speed Settings:

For general specifications, see Mitsubishi manual copied into Group
00(D). No Load: 2600 rpm

Engine Speed @pm): Idle: 650 rpm (w/o accessories).

Idle: 650-700
Maximum No-Load Governed Speed: 2550-2650
Converter Stal Speed: 2150-2250 Group 02(LP), LPG Fuel System
Specifications
Group 01, Cooling System Specifications
LPG Tank
Radiator Type: Crossflow radiator with coolant recovery system.
Capacity: 9.1,15.2,19.7 kg (20.33.5, or 43.5 lb).
System Pressure (Radiator cap): 89-103 kPa (13-15 psi).
Working Pressure: 138-1654 kPa (20-240 psi).
Thermostat:
Safety Relief Valve: Opens when pressure exceeds 1896 kPa (275 psi).
Gas/LPG/CNG: open (cracking) at 82’C + 1.5’ (180’F * 2.7’);
fully open 95°C (203’F) Shut-off Valve: Manual with maximum withdrawal valve.
Diesel: open (cracking) at 76.5”C + 1.5” (17O’F + 2.7’); fully Maximum Withdrawal Valve: Closes when flow rate exceeds 5.7 Lpm
open 90°C (194’F).
(1.5 gpm).
Coolant Mixture: 50% water and 50% low-silicate, ethylene glycol, Fuel Gauge Type: Float level.
permanent-type antifreeze with rust and corrosion inhibitors.
-Low Fuel Light: Instrument pod light comes on at 138 kPa (20 psi).
Cooling System Coolant Capacity:
Cushion-tire truck with 3-row radiator capacity is 6.3 L (6.6 qt )
Carburetor
Pneumatic-tire truck with 3-row radiator capacity is 7.5 L (7.9 qt)
Type: Diaphragm-operated air-gas valve design with self-contained air-
Diesel truck with 4-row radiator capacity is 10 L (10.5 qt).
fuel metering device
Fan Type: Pusher type
Idle Air-Fuel mixture: 0.30-0.70% CO (carbon monoxide) @ 650 rpm.
Fan Drive Belt: V-type belt
Power Mixture: 0.6 to 1.5 % CO at stall.
Water Pump Type: Centrifugal-type
Idle Speed: 650 rpm.
Hose Clamp Sizes:
Gas/LPG - 47 mm (1.8 in) @ radiator end; 44 mm (1.7 in) @ Vaporizer-Regulator
engine (water pump or thermostat) end
Primary Chamber Pressure: tank pressure to 10.3 kPa (1.5 psi).
Diesel - 51mm (2 in).
Secondary Chamber Pressure: 10.3 kPa (1.5 psi) to a negative pressure to
vapor outlet pressure.

Vapor Outlet Pressure: -38.1 mm (-1.5 in) water column.

Group 02(G), Gas-Carb Fuel System
Specifications
Lock-Off Valve
Carburetor Type: Downdraft, 2-barrel (using 1 barrel).
Type: Solenoid-operated valve actuated by external vacuum switch.
Choke Control: Electrically-heated bi-metallic coil.
Filter Element: Replace every 2000 hours.
Fuel Cut-Off Solenoid Valve Resistance: 9OQ @ 20°C (66°F).

Throttle Bore Diameter: 32 mm. Fuel

Outer Venturi Diameter: 24 mm. HD-5 Propane.
Inner Venturi Diameter: 9- 12 mm.

Main Jet: 120 mm.

Main Air Jet Diameter:
Pilot Jet Diameter: 0.55.
Pilot Air Jet Diameter:
Enrichment Jet Type: #85.
Group 03, Air Induction and Exhaust Systems
0.9.
Specifications
Air Cleaner Type: Canister style with replaceable paper element and air-
1.6. restriction indicator.

Enrichment Spring: 65 mmHg.

Fast Idle Opening Angle: 18.5.

40-2-6 l General Specifications SM 598, Feb’98

 Main Table of Contents

emu Group 40, Specifications

Group 06(S), Standard Transaxle Group 12, Ignition System Specifications

Specifications (4G64 Standard Electronic ignition)
Ignition Type: Non-contact, electronic.
General Specifications Firing Order: l-3-4-2.
Model: Clark TA-30 Transaxle. Rotation (viewed from cap): Clockwise.
No. Ratios: l-speed, forward and reverse. Ignition Timing:
Transaxle Ratio Forward: 19.86. Gasoline Engine: 4” BTDC @ 650 rpm
LPG Engine: 9” BTDC @ 650 rpm.
Transaxle Ratio Reverse: 16.17.
Centrifugal Advance: Beginning: 0” at 1000 rpm (engine). End: 6.5” at 2600
Ring & Pinion Gear Type: Spiral Bevel. rpm (engine).
Ring Gear Backlash: 0.20-0.28 mm (0.008-0.011 in). VacuumAdvance: Beginning: 0” at 80 mmHg (3.14 inHg.) End: 11.5” at 280
Differential Type: 2-pinion. mmHg(ll.OinHg).

Differential bearing preload: 0.075 mm (0.003 in) deflection of each Ignitor Air gap: 0.8 mm (.031 in).
carrier ear. Primary Coil Resistance: 1.08-1.32Q between terminals (+) and (-).
Service Brake Size: 300 x 500 mm (11.81-19.68 in). Secondary Coil Resistance: 22.1-29.9 kQ between terminals (-) and center.
Torque Converter Size: 310 mm (12.20 in). Ignition Coil Resistor Resistance: 1.22-1.49 Q.
Torque Converter Stall Ratio: 3.2. Spark Plug Type:
Hydraulic Pump Drive Ratio: 1.028 x engine rpm. Gas Engine: NGK BP4ES, Champion NY16

Dry Weight: 390 kg (858 lb). LPG Engine: NGK BPSES, Champion NY12.

Oil Capacity 18.5 L (19.5 qt). Spark Plug Gap: 0.7-0.8 mm (0.028-0.031 in).

Transaxle Fluid: Clark # 2776236. Spark Plug Tightening Torque: 25 N-m (18.4 in-lb).

Plug Wire Resistance: 8,000 ohms per foot.

Pressure Specifications*
Charge Pump Flow: 10 gpm (37.8 L/min) @ 1800 rpm.
Group 13, Instrument Pod Specifications
Regulator Valve Pressure: 190-245 psi @ 1800 rpm.
Indicator lights: LEDs integral with circuit board.
Clutch Pressure (Forward/Reverse): 1240 kPa (180 psi) @idle rpm.
Buzzer:Integral with circuit board.
Cooler Return Pressure: 50-125 psi (345-862 kPa) @ 1800 rpm.
Fuel gauge: Analog.
*Notes
1. All rpm’s noted are engine speed. Engine Coolant Temperature Gauge: Analog.
2. All clutch pressures are at engine idle speed with clutch engaged.
Hour Meter: Analog, with running indicator. Integral to circuit board.
3. Oil at operating temperature (82-93 “C) 180-200 “F
Pinout Locations: See Group 14, “Electrical System,” for schematic.

Group 06(H), Hydrostatic Transmission

Specifications Group 14, Electrical System Specifications
Hydrostatic Pump:
Voltage and Ground
Type: Axial piston, variable displacement.
Maximum Displacement: 75 cm%ev (4.57 i&rev). System Voltage: 12 volt.

Maximum Pressure: 480 bar (7,000 psi). System Ground: Negative.

Rated Pressure: 420 bar (6,000 psi).
Drive Ratio: 1: 1. Alternator
Hydrostatic Drive Axle: Type: 12 volt.
Type: Two integral radial piston hydraulic motors with hydraulic
shoe brakes.
Motor Displacement: 2 x 56.5 cm%ev (2 x 34.5 in3/rev).
Maximum Pressure: 450 bar (6,500 psi).
Rated Pressure: 420 bar (6,000 psi).
Drive Ratio: 1: 1.
Service Brake Size: 300 x 500 mm (11.81-19.68 in).

SM 598, Feb’98 General Specifications l 40-2-7

 Main Table of Contents

Group 40, Specifications ClRRK

Battery Steer Tires:

CGPKDP 20/25 862 kPa (125 psi)

Gas/LPG/CNG Engine:
Type: 12 volt CGPKDP 30 862 kPa (125 psi).

Cold Crank Current: 420 amps at 0” F (-18” C)

Reserve Capacity: 80 minutes at 80’ F (27” C). Cushion Truck Wheel and Tires

Diesel Engine: Drive Tires Steer Tires

Type: 12 volt CGC 20-25 21X7X15 16 x 5 x 10.5

Cold Crank Current: 625 amps at 0” F (-18” C) CGC 30 21 x8x 15 16 x 6 x 10.5
Reserve Capacity: 160 minutes at 80” F (27” C).

Starter Group 23(S), Brake/Inching System

Gas/LPG/CNG Engine:
Specifications (Standard Transaxle)
Type: Positive engagement, planetary gear reduction, offset.
Voltage: 12 volts Service Brake
Output: 1.2 kW. Type: Drum and shoe. Power boost provided by main hydraulic pump.
Self-adjusting.
Diesel Engine:
Fluid: Fluid provided by main hydraulic pump.
Type: Positive engagement, offset gear reduction.
Voltage: 12 volts Brake System Relief Pressure: 897 kPa (1300 psi).

Output: 2.2 kW. Shoe-to-Drum Gap: 0.45-0.60 mm (.017-.024 in).

Shoe Lining Thickness: 1.0 mm ( 0.039 in) min.

System Protection
Fuse: 5A Direction Control.
Fuse: 15A Ignition, Horn, and Options.
Fuse: 15A Headlights.
Fuse: 15A Brake Lights.
Group 22, Wheels and Tires Specifications
Steer Tire Types: Pneumatic
urethane.
Drive Tire Types: Pneumatic
urethane.
Dmm Thickness: 20.6 mm (0.787 inch) min.
Maximum Rebore Diameter: 303 mm (11.92 in).
Pedal Freeplay: None.
Star Wheel Adjustment Gap: 0.5-0.6 mm (0.020-0.023 in).
Parking Brake
Type: Ratchet linked to service brake shoe at each wheel.
Holding Test: Rated load on 15% grade.
rubber/Cushion rubber, non-marking, and
Inching (also see transaxle specs)
rubber/Cushion rubber, non-marking, and
Type: Inching pedal mechanically linked to brake pedal and to inching
spool on transaxle.

Pneumatic Truck Wheel and Tires Pedal Freeplay: None.

Overlap Adjustment: 3.5-5.5 mm (0.13-0.22 in).

Tire Sizes and Ratings
Drive Tires:
CGP/CDP 20/25 Single: 7.00 x 12, 14-ply rating
Dual: 7.00 x 12, 14-ply rating
CGPICDP 30 Single: 28 x 9 x 15, 14-ply rating
Dual: 7.00 x 12, 14-ply rating.

Steer Tires:

CGPICDP 20125 6.00 x 9, lo-ply rating

CGPKDP 30 6.50 x 10, lo-ply rating.

Tire Pressures
Drive Tires:

CGPICDP 20125 Single: 862 kPa (125 psi)

Dual: 862 kPa (125 psi)

CGP/CDP 30 Single: 862 kPa (125 psi)

Dual: 862 kPa (125 psi).

40-2-8 l General Specifications SM 598, Feb’98

 Main Table of Contents

Group 40, Specifications

CIRRK
Group 25, Steering Column and Gear Group 30, Hydraulic Valve/Lift Circuit
Specifications Specifications
Steering System Type: Hydrostatic power steering with load sensing, Hated Flow:
dynamic signal neutral circuit. Lift spool (spool #l): 76 L/min (20 gpm)
Steering System Relief Pressure Setting: 8270-8960 kPa (1200-1300 Tilt spool (spool #2): 38 L/min (10 gpm)
psi) Auxiliary spool (spool #3): 38 L/mm (10 gpm).
Nominal Flow Rating: 23 L/min (6 gal/mm)
Integral Pressure Compensated Flow Control Settings:
Inlet Pressure Rating: 12400 kPa (1800 psi) Tilt spool (spool #2): 24 L/mm (6 gpm)
Return Pressure Rating: 1000 kPa(l50 psi) maximum Auxiliary spool (spool #3): 15 L/min (4 gpm).

Maximum Pressure Drop at Rated Flow:

Inlet to outlet: 689 kPa (100 psi)
Group 26, Steer Axle Specifications
Lift spool (spool #l):
- Inlet to cylinder port: 689 kPa (100 psi)
Cushion-Tire Truck - Cylinder port to outlet: 550 kPa (80 psi)

Steering System Relief Pressure Setting: 8970 kPa (1300 psi). Tilt spool (spool #!2):
- Inlet to cylinder port: 689 kPa (100 psi)
Steer Cylinder Type: Double-acting, piston-type. - Cylinder port to outlet: 550 kPa (80 psi)
Turning Arc: 83” max. inside turning angle; 60” max. outside turning Auxiliary spools (spools #3 and #+4):
angle. - Inlet to cylinder port: 345 kPa (50 psi)
- Cylinder port to outlet: 207 kPa (30 psi).

Pneumatic-Tire Truck Auxiliary Component Flow Control Adjustments:

Steering System Relief Pressure Setting: 8970 kPa (1300 psi) Flow Setting Clockwise Turns
L/mingpmJ of Adiustment Screw
Steer Cylinder Type: Double-acting, piston-type 6 1.5 4.00
Turning Arc: 75” max. inside turning angle; 54” max. outside turning 9 2.5 5.25
angle 15 4.0 6.00
21 5.5 6.75
The number of handwheel turns required for lock-to-lock turning 26 7.0 7.50
differs between the cushion- and pneumatic-style axles 38 10.0 9.50

Group 29, Hydraulic Sump, Filters, and

Pump Specifications
Hydraulic Pump Type: Transmission-driven, gear-type with integral
load sensing priority flow valve and pressure relief valve; pump is
connected to, and works in conjunction with, the transmission charg-
ing pump.

Sump Type and Capacity: Tank is built into truck frame with capacity
of 40.16 L (9.5 gallons) for cushion-tire trucks and 52.85 L (12.5
gallons) for pneumatic-tire trucks.

Hydraulic Fluid Type: Clark Hydraulic Fluid specification MS-68.

Hydraulic Fluid Filters: In-tank return line filter and suction line
screen, both mounted in sump.

In-Tank Return Filter Type: Disposable, glass micro-fiber element.

Suction Screen: 100 mesh stainless steel screen.

Dirty Filter Element Indicator Pressure Switch Setting: 138&20 kPa

(2M3 psi).

SM 598, Feb’98 General Specifications l 40-2-9

 Main Table of Contents

Group 40, Specifications ClRRK

Group 32, Tilt Cylinders Specifications Group 38, Counterweight and Chassis
Tilt cylinder type: double-acting with shims Specifications
Maximum operating pressure: 22,070 kPa (3,200 psi; 220 bar) Counterweight weights:

Tilt Flow Control Adjustments (factory setting is 15 L/min (4 gal/min): Cushion Frame Pneumatic Frame

CW Turns of 1180 Kg (2600 lbs) 1090 Kg (2400 lbs)

Tilt Sueed Adiustment
1590 Kg (3500 lbs) 1450 Kg (3200 lbs)
Uariaht Useaee “/set Lom (smm) m
5715 mm (225 in) MFH & above 3 9 (2.5) 0.50 1950 Kg (4300 lbs) 1700 Kg (3900 lbs)
Below 5715 mm (225 in) MFH 5 15 (4) 0.75
European Upright Option 8 26 (7) 1.25

Tilt Ranges
(Abbreviations - Std = Standard, high-visibility upright; TSU = Triple-
stage upright; MFH = maximum fork height; B = back tilt; F = forward
tilt)

Cushion Uprights
Std (through 2667 mm (105 in) MFH) 6”B-10°F

Std (above 2667 mm (105 in) MFH) 8”B-8°F

TSU (through 4775 mm (188 in) MFH) 5”B-6°F

TSU (4800-6096 mm (189-240 in) MFH) 5”B-3°F

TSU (above 6096 mm (240 in) MFH) 3”B-O”F with

tilt limit over-
ride to 3°F

Pneumatic Uprights
Std (through 2667 mm (105 in) MFH) SOB-8°F

Std (above 2667 mm (105 in) MFH) 10”B-6°F

TSU (through 4775 mm (188 in) MFH) 5”B-@F

TSU (4800-6096 mm (189-240 in) MFH) 5”B-3°F

TSU (above 6096 mm (240 in) MFH) YB-O”F with

tilt limit over-
ride to 3°F

Group 34, Upright Specifications

Upright Weight: approximately 482 kg (1060 lb) to approximately 682
kg (1500 lb)

Carriage Weight: approximately 111 kg (245 lb)

Fork Weight: approximately 50-68 kg each (1 lo-150 lb)

IMPORTANT
Before hoisting, the weights of upright, carriage, and
forks must be combined to determine what lifting
capacity is required of the hoisting equipment.

Capacities and Lift Heights: Upright, carriage, and fork capacity and
upright lift heights are listed on the truck’s data plate.

Lubricants:
All Purpose Grease (Clark spefication MS-9)
Innerslide Lubricant (Clark part #886396)
Chain and Cable Lube (Clark part #886399)

40-2-10 l General Specifications SM 598, Feb’98

 Main Table of Contents

ClRRK Group 40, Specifications

Section 4.

Hydraulic Fitting Tightening Procedure

1. Tighten fitting finger tight until it stops turning, while 2. Using finger tips only. lightly snug fitting with a
moving the fitting lightly side to side to prevent wrench until it bottoms out on the seat or port. Do not
cocking or thread damage. overtighten.

SM 598,013 ‘94 Hydraulic Fitting Tightening Procedure l 40-4-l