Clark GPX 35, 40, 50E Service Manual SM-606

Description

• Model List:
  • GPX 35
  • GPX 40
  • GPX 50E

• 1. SERVICE MANUAL
• 2. CONTENTS
• 3. INTRODUCTION
• 3.0.1. Safety Signs and Messages
• 3.0.2. User Safe Maintenance Practices
• 3.1. Planned Maintenance
• 3.1.1. PM Report Form
• 3.1.2. Visual Inspection
• 3.1.2.1. Wheels and Tires
• 3.1.2.2. Brake and Inching Pedal Freeplay
• 3.1.3. Functional Tests
• 3.1.3.1. Key/Start Switch
• 3.1.3.2. Battery Light
• 3.1.3.3. Fuel Light
• 3.1.3.4. Engine Oil Pressure Light
• 3.1.3.5. Coolant Temperature Light
• 3.1.3.6. Brake Malfunction Light
• 3.1.3.7. Air Filter Restriction Light
• 3.1.3.8. Transmission Temperature Light
• 3.1.3.9. Hydraulic Filter Restriction Light
• 3.1.3.10. Parking Brake Light
• 3.1.3.11. Hour Meter
• 3.1.3.12. Accelerator, Service Brake, Parking Brake, and Inching
• 3.1.3.13. Lift Mechanisms and Controls
• 3.1.3.14. Auxiliary Controls
• 3.1.3.15. Steering System
• 3.1.3.16. Shift Control and Brakes
• 3.1.4. Under the Hood
• 3.1.4.1. Belts and Hoses
• 3.1.4.2. Engine Air Cleaner
• 3.1.4.3. Battery
• 3.1.4.4. Engine Cooling System
• 3.1.4.5. Engine Oil
• 3.1.4.6. Engine Oil and Filter Change
• 3.1.4.7. Hydraulic Sump Tank
• 3.1.4.8. Hydraulic Fluid and Filter Change
• 3.1.4.9. Sump Tank Breather
• 3.1.4.10. Transmission Fluid Check
• 3.1.5. Truck Chassis Inspection and Lubrication
• 3.1.6. Air Cleaning
• 3.1.7. Upright and Tilt Cylinder Lubrication
• 3.1.8. Critical Fastner Torque Checks
• 3.1.9. Lift Chain Maintenance
• 3.1.9.1. Lift Chain Adjustment Check
• 3.1.9.2. Lift Chain Inspection and Measurement
• 3.1.9.3. Lift Chain Lubrication
• 3.1.9.4. Lift Chain Replacement
• 4. ENGINES
• 4.1. Engine Removal and Replacement
• 4.1.1. Engine Removal
• 4.1.2. Engine Replacement
• 4.2. Vortec V6 GM Engine Repair Procedures
• 4.2.1. General Description
• 4.2.2. General Information
• 4.2.3. Disassembly of the Engine
• 4.2.4. Cleaning, Inspection, and Repair
• 4.2.5. Assembly of the Engine
• 4.3. Delco Distributor
• 5. COOLING SYSTEM
• 5.1. Troubleshooting
• 5.2. Cooling System Testing and Maintenance
• 5.2.1. Engine Coolant Check
• 5.2.2. Cooling System Inspection
• 5.2.3. Cooling System Pressure Tests
• 5.2.3.1. Testing the Radiator Cap
• 5.2.3.2. Testing Radiator and Cooling System
• 5.2.3.3. Testing the Thermostat
• 5.2.4. Flushing the Cooling System
• 5.2.5. Cooling System Drain and Refill
• 5.3. Fan Belt Replacement
• 5.4. Radiator Removal
• 6. FUEL SYSTEM
• 6.1. Fuel Pump Pressure Test (Gas Only)
• 6.2. The IMPCO LPG Fuel System
• 6.3. Carburetor Overhaul
• 6.4. Velocity Governor Overhaul
• 6.5. Removal of IMPCO Vaporizing System
• 7. TRANSMISSION
• 7.1. Transmission Checks
• 7.1.1. Tools Required
• 7.1.2. General Checks
• 7.1.3. Stall RPM Checks
• 7.1.4. Pressure Checks
• 7.1.4.1. Inching Pressure
• 7.1.4.2. Clutch Pack Pressures
• 7.1.4.3. Converter Pressure
• 7.1.4.4. Neutral Start Switch
• 7.1.5. Transmission Cooling System Checks
• 7.1.6. Fluid Aeration Checks
• 7.1.7. Fluid Leakage Checks
• 7.2. Transmission Drain and Refill
• 7.3. Transmission Removal
• 7.4. Transmission Overhaul
• 8. ELECTRICAL SYSTEM
• 8.1. Wiring Color Codes
• 8.2. Wiring Diagrams
• 8.3. Electrical Checks
• 8.3.1. Battery Load Test
• 8.3.2. Positive Post Volt Drop Test
• 8.3.3. Negative Post Volt Drop Test
• 8.3.4. Positive Cable Volt Drop Test
• 8.3.5. Negative Cable Volt Drop Test
• 8.3.6. Starter Ground Test
• 8.3.7. Solenoid Disc Contact Volt Drop Test
• 8.3.8. Solenoid Circuit Volt Drop Test
• 9. DRIVE AXLE
• 9.1. Axle End Lubrication
• 9.2. Axle End Removal
• 9.3. Axle Ends Overhaul
• 9.4. Differential Overhaul
• 10. WHEELS AND TIRES
• 10.1. Lifting, Jacking, and Blocking
• 10.1.1. Lifting and Blocking
• 10.1.2. Jacking and Blocking
• 10.2. Wheels and Tires Mounting
• 10.2.1. Safe Handling of Split Rim Wheels
• 10.2.2. Filling Tires with Air
• 11. BRAKING/INCHING SYSTEM
• 11.1. Braking/Inching System Description and Troubleshooting
• 11.1.1. Braking/Inching Description
• 11.1.1.1. Braking
• 11.1.1.2. Inching
• 11.1.2. Service Brake Troubleshooting
• 11.1.3. Inching System Troubleshooting
• 11.2. System Brake and Inching Bleeding
• 11.2.1. Manual Bleeding Procedure
• 11.2.2. Power Bleeding Procedure
• 11.3. Brake and Inching Pedal Adjustment
• 11.4. Master Cylinder Overhaul
• 11.5. Power Booster Assembly Overhaul
• 11.6. Caliper and Disk Inspection and Overhaul
• 11.6.1. Inspection
• 11.6.2. Axle End Removal
• 11.6.3. Piston Replacement
• 11.6.4. Caliper Replacement
• 11.6.5. Disk Lining Renewal
• 11.6.6. Reassembly and Bleeding
• 11.7. Parking Brake
• 12. STEERING COLUMN AND GEAR
• 12.1. Troubleshooting
• 12.2. Steering Column and Gear Removal
• 12.3. CharLynn Steering Control Unit (Steering Gear)
• 12.3.1. Trouble Shooting Information
• 12.3.2. Repair Information
• 12.3.3. Parts Information
• 13. STEER AXLE
• 13.1. Steer Axle Removal and Replacement
• 13.2. Steer Axle Overhaul
• 13.3. Steering System Adjustment
• 13.4. Steer Cylinder Removal and Replacement
• 13.5. Steer Axle Wheel Bearings
• 13.6. Steer Cylinder Overhaul
• 14. HYDRAULIC SUMP, FILTERS, AND PUMP
• 14.1. Hydraulic Sump and Filters
• 14.2. Hydraulic Pump (Vane Type) Troubleshooting and Overhaul
• 15. HYDRAULIC VALVE/LIFT CIRCUIT
• 15.1. Hydraulic System Pressure Check
• 15.2. Hydraulic Valve Troubleshooting and Overhaul
• 15.3. Hydraulic Valves
• 15.3.1. Priority Valve and Flow Divider Assembly
• 15.3.1.1. Priority Valve
• 15.3.1.2. Flow Divider
• 15.3.2. Main Hydraulic Valve (Control Valve)
• 15.3.3. Control Valve Linkage
• 15.4. Hydraulic Schematic
• 16. TILT CYLINDERS
• 16.1. Tilt Cylinder Removal and Replacement
• 16.2. Tilt Cylinder Overhaul
• 16.3. Tilt Lock Valve
• 17. UPRIGHTS
• 17.1. Troubleshooting and Visual Inspection
• 17.2. Operational Checks
• 17.2.1. Lift Chain Checks
• 17.2.2. Fork Checks
• 17.2.3. Upright Checks
• 17.2.3.1. Roller Patterns
• 17.2.3.2. Upright Racking
• 17.2.3.3. Load Test
• 17.2.4. Hydraulic Cylinder Checks
• 17.2.4.1. Cylinder Seal Checks
• 17.2.4.2. Drift Test
• 17.3. Carriage Check and Adjustment
• 17.3.1. Carriage Roller Check
• 17.3.2. Carriage Removal and Reinstallation
• 17.3.2.1. Carriage Removal
• 17.3.2.2. Shimming the Carriage Rollers
• 17.3.2.3. Carriage Reinstallation
• 17.4. Upright Check and Adjustment
• 17.4.1. Roller Clearance Checks
• 17.4.2. Roller Bearing Replacement Procedures
• 17.4.3. Upright Reassembly
• 17.5. Cylinder Repair
• 17.6. Lift Chain Maintenance
• 17.6.1. Lift Chain Inspection
• 17.6.2. Lift Chain Lubrication
• 17.6.3. Lift Chain Replacement
• 17.6.4. Check List
• 17.7. Upright Removal and Replacement
• 18. COUNTERWEIGHTS
• 18.1. Counterweight Removal
• 19. SPECIFICATIONS
• 19.1. Nameplate and Decals
• 19.2. GPX 30/50E General Specifications
• 19.2.1. Capacities
• 19.2.2. Service Weights
• 19.2.3. Axle Weights
• 19.2.4. Maximum Gradeability
• 19.2.5. Parking Brake Test
• 19.2.6. Drawbar Pull
• 19.2.7. Travel Speeds
• 19.2.8. Turning Radius
• 19.2.9. Wheels Tires
• 19.2.10. Drift Lift and Tilt
• 19.2.11. Lift Speeds, Upright
• 19.2.12. Lowering Speeds, Upright
• 19.2.13. Drive Axle
• 19.2.14. Service Brakes
• 19.2.15. Parking Brake
• 19.2.16. Cooling System
• 19.2.17. Electrical
• 19.2.18. Gasoline/LPG Engine Specifications
• 19.2.19. Engine Fuel Specifications
• 19.2.20. Engine TuneUp (Gas/LPG)
• 19.2.21. Hydraulic System
• 19.2.22. Critical Fastener Torque Specifications
• 19.2.23. Transmission
• 19.3. PM Inspection and Drivers Daily Inspection Forms
• 19.4. Lubricants and Shop Supplies
• 19.4.1. Lubricants
• 19.4.2. Sealants
• 19.4.3. Gasket Materials
• 19.4.4. Threadlocks and Threadsealers
• 19.4.5. Adhesives
• 19.4.6. Cleaners
• 19.4.7. Miscellaneous Shop Supplies
• 19.5. Lubrication Intervals