Clark GPX, DPX 30, 35, 40, 40S, 50, 55 Service Manual SM-593

Description

• Model List:
  • GPX 30
  • GPX 35
  • GPX 40
  • GPX 40S
  • GPX 50
  • GPX 55
  • DPX 30
  • DPX 35
  • DPX 40
  • DPX 40S
  • DPX 50
  • DPX 55

• 1. CONTENTS
• 2. INTRODUCTION
• 2.0.1. SAFETY SIGNS AND MESSAGES
• 2.0.2. USER SAFE MAINTENANCE
• 2.1. PLANNED MAINTENANCE
• 2.1.1. PM REPORT FORM
• 2.1.2. VISUAL INSPECTION
• 2.1.3. FUNCTIONAL TESTS
• 2.1.4. UNDER THE HOOD
• 2.1.5. TRUCK CHASSIS INSPECTION AND LUBRICATION
• 2.1.6. AIR CLEANING
• 2.1.7. UPRIGHT AND TILT CYLINDER LUBRICATION
• 2.1.8. CRITICAL FASTENER TORQUE CHECKS
• 2.1.9. LIFT CHAIN MAINTENANCE
• 3. ENGINES
• 3.1. ENGINE REMOVAL AND REPLACEMENT
• 3.1.1. ENGINE REMOVAL
• 3.1.2. ENGINE REPLACEMENT
• 3.2. PERKINS WORKSHOP MANUAL GAS/LPG ENGINES
• 3.2.1. FOREWORD
• 3.2.2. CONTENTS
• 3.2.3. ENGINE VIEWS A
• 3.2.4. GENERAL INFORMATION B
• 3.2.5. PERIODICAL ATTENTIONS C
• 3.2.6. FAULT FINDING D
• 3.2.7. CYLINDER HEAD E
• 3.2.8. PISTONS AND CONNECTING RODS F
• 3.2.9. CYLINDER BLOCK AND LINERS G
• 3.2.10. CRANKSHAFT, MAIN BEARINGS AND BALANCER UNIT H
• 3.2.11. TIMING CASE AND DRIVE J
• 3.2.12. TIMING K
• 3.2.13. LUBRICATION SYSTEM L
• 3.2.14. COOLING SYSTEM M
• 3.2.15. FUEL SYSTEM N
• 3.2.16. FLYWHEEL AND FLYWHEEL HOUSING P
• 3.2.17. GOVERNOR AND DISTRIBUTOR DRIVE Q
• 3.2.18. DISTRIBUTOR R
• 3.2.19. ELECTRICAL SYSTEM (ALTERNATOR DYNAMO STARTER MOTOR) S
• 3.2.20. LUBRICATING OIL DATA APPENDIX
• 3.2.21. EXAMPLES OF SERVICE FACILITIES APPENDIX
• 3.3. PERKINS WORKSHOP MANUAL DIESEL ENGINES
• 3.3.1. GENERAL INFORMATION
• 3.3.2. SPECIFICATIONS
• 3.3.3. CYLINDER HEAD ASSEMBLY
• 3.3.4. PISTON AND CONNECTING ROD ASSEMBLIES
• 3.3.5. CRANKSHAFT ASSEMBLY
• 3.3.6. TIMING CASE AND DRIVE ASSEMBLY
• 3.3.7. CYLINDER BLOCK ASSEMBLY
• 3.3.8. ENGINES FITTED WITH CAV FUEL INJECTION PUMPS
• 3.3.9. LUBRICATION SYSTEM
• 3.3.10. FUEL SYSTEM ENGINES FITTED WITH A ROTARY FUEL INJECTION PUMP
• 3.3.11. COOLING SYSTEM
• 3.3.12. FLYWHEEL AND FLYWHEEL HOUSING
• 3.3.13. ELECTRICAL EQUIPMENT
• 3.3.14. AUXILIARY EQUIPMENT POWER STEERING PUMP
• 3.3.15. LIST OF SPECIAL TOOLS
• 4. COOLING SYSTEM
• 4.1. TOUBLESHOOTING
• 4.2. COOLING SYSTEM TESTING AND MAINTENANCE
• 4.2.1. ENGINE COOLANT CHECK
• 4.2.2. COOLING SYSTEM INSPECTION
• 4.2.3. COOLING SYSTEM PRESSURE TESTS
• 4.2.4. FLUSHING THE COOLING SYSTEM
• 4.2.5. COOLING SYSTEM DRAIN AND REFILL
• 4.3. FAN BELT REPLACEMENT
• 4.4. RADIATOR REMOVAL
• 5. FUEL SYSTEM
• 5.1. FUEL PUMP PRESSURE TEST (GAS ONLY)
• 5.2. THE IMPCO LPG FUEL SYSTEM
• 5.3. CARBURETOR OVERHAUL
• 5.4. VELOCITY GOVERNOR OVERHAUL
• 5.5. REMOVAL OF IMPCO VAPORIZING SYSTEM
• 6. TRANSMISSION
• 6.1. TRANSMISSION CHECKS
• 6.1.1. TOOLS REQUIRED
• 6.1.2. GENERAL CHECKS
• 6.1.3. STALL RPM CHECKS
• 6.1.4. PRESSURE CHECKS
• 6.1.5. TRANSMISSION COOLING SYSTEM CHECKS
• 6.1.6. FLUID AERATION CHECKS
• 6.1.7. FLUID LEAKAGE CHECKS
• 6.2. TRANSMISSION DRAIN AND REFILL
• 6.3. TRANSMISSION REMOVAL
• 6.4. TRANSMISSION OVERHAUL
• 7. ELECTRICAL SYSTEM
• 7.1. WIRING COLOR CODES
• 7.2. WIRING DIAGRAMS
• 7.3. ELECTRICAL CHECKS
• 7.3.1. BATTERY LOAD TEXT
• 7.3.2. POSITIVE POST VOLT DROP TEST
• 7.3.3. NEGATIVE POST VOLT DROP TEST
• 7.3.4. POSTIVE CABLE VOLT DROP TEST
• 7.3.5. NEGATIVE CABLE VOLT DROP TEST
• 7.3.6. STARTER GROUND TEST
• 7.3.7. SOLENOID DISC CONTACT VOLT DROP TEST
• 7.3.8. SOLENOID CIRCUIT VOLT DROP TEST
• 8. DRIVE AXLE
• 8.1. AXLE END LUBRICATION
• 8.2. AXLE END REMOVAL
• 8.3. AXLE ENDS OVERHAUL
• 8.4. DIFFERENTIAL OVERHAUL
• 9. WHEELS AND TIRES
• 9.1. LIFTING, JACKING, AND BLOCKING
• 9.1.1. LIFTING AND BLOCKING
• 9.1.2. JACKING AND BLOCKING
• 9.2. WHEELS AND TIRES MOUNTING
• 9.2.1. SAFE HANDLING OF SPLIT RIM WHEELS
• 9.2.2. FILLING TIRES WITH AIR
• 10. BRAKING/INCHING SYSTEM
• 10.1. BRAKING/INCHING SYSTEM DESCRIPTION AND TROUBLESHOOTING
• 10.1.1. BRAKING/INCHING DESCRIPTION
• 10.1.2. SERVICE BRAKE TROUBLESHOOTING
• 10.1.3. INCHING SYSTEM TROUBLESHOOTING
• 10.2. BRAKE AND INCHING SYSTEM BLEEDING
• 10.2.1. BRAKE/INCHING BLEEDING PRECAUTIONS
• 10.2.2. GENERAL PROCEDURES
• 10.2.3. BLEED POINTS
• 10.3. BRAKE AND INCHING PEDAL ADJUSTMENT
• 10.4. MASTER CYLINDER OVERHAUL
• 10.5. POWER BOOSTER ASSEMBLY OVERHAUL
• 10.6. CALIPER AND DISK INSPECTION AND OVERHAUL
• 10.6.1. INSPECTION
• 10.6.2. AXLE END REMOVAL
• 10.6.3. PISTON REPLACEMENT
• 10.6.4. CALIPER REPLACEMENT
• 10.6.5. DISK LINING RENEWAL
• 10.6.6. REASSEMBLY AND BLEEDING
• 10.7. PARKING BRAKE
• 11. STEERING COLUMN AND GEAR
• 11.1. TROUBLESHOOTING
• 11.2. STEERING COLUMN AND GEAR REMOVAL
• 11.3. CHARLYNN STEERING CONTROL UNIT (STEERING GEAR)
• 11.3.1. TROUBLESHOOTING INFORMATION
• 11.3.2. REPAIR INFORMATION
• 11.3.3. PARTS INFORMATION
• 12. STEER AXLE
• 12.1. STEER AXLE SPECIFICATIONS AND DESCRIPTION
• 12.2. STEER AXLE LUBRICATION AND ADJUSTMENT
• 12.2.1. BEARINGS CHECK
• 12.2.2. LUBRICATION
• 12.2.3. WHEEL BEARING ADJUSTMENT
• 12.3. STEER AXLE REMOVAL AND REPLACEMENT
• 12.4. STEER AXLE OVERHAUL
• 12.4.1. PREPARATION FOR STEER AXLE DISASSEMBLY AND OVERHAUL
• 12.4.2. STEER KNUCKLE DISASSEMBLY
• 12.4.3. PARTS INSPECTION
• 12.4.4. GREASING PROCEDURE
• 12.4.5. STEER KNUCKLE REASSEMBLY
• 12.4.6. STEER CYLINDER REMOVAL
• 12.5. STEER CYLINDER REMOVAL AND REPLACEMENT
• 12.6. STEER CYLINDER OVERHAUL
• 12.6.1. PREPARATION FOR STEER CYLINDER DISASSEMBLY AND OVERHAUL
• 12.6.2. STEER CYLINDER DISASSEMBLY
• 12.6.3. PARTS INSPECTION
• 12.6.4. STEER CYLINDER REASSEMBLY
• 12.6.5. OPERATIONAL PRESSURE TEST
• 13. HYDRAULIC SUMP, FILTERS, AND PUMP
• 13.1. HYDRAULIC SUMP AND FILTERS
• 13.2. HYDRAULIC PUMP (VANE TYPE) TROUBLESHOOTING AND OVERHAUL
• 14. HYDRAULIC VALVE/ LIFT CIRCUIT
• 14.1. HYDRAULIC SYSTEM PRESSURE CHECK
• 14.2. HYDRAULIC VALVE TROUBLESHOOTING AND OVERHAUL
• 14.3. HYDRAULIC VALVES
• 14.3.1. PRIORITY VALVE AND FLOW DIVIDER ASSEMBLY
• 14.3.2. MAIN HYDRAULIC VALVE
• 14.3.3. CONTROL VALVE LINKAGE
• 14.4. HYRAULIC SCHEMATIC
• 15. TILT CYLINDERS
• 15.1. TILT CYLINDER REMOVAL AND REPLACEMENT
• 15.2. TILT CYLINDER OVERHAUL
• 15.3. TILT LOCK VALVE
• 16. UPRIGHTS
• 16.1. TROUBLESHOOTING AND VISUAL INSPECTION
• 16.2. OPERATIONAL CHECKS
• 16.2.1. LIFT CHAIN CHECKS
• 16.2.2. FORK CHECKS
• 16.2.3. UPRIGHT CHECKS
• 16.2.4. HYDRAULIC CYLINDER CHECKS
• 16.3. CARRIAGE CHECK AND ADJUSTMENT
• 16.3.1. CARRIAGE ROLLER CHECK
• 16.3.2. CARRIAGE REMOVAL AND REINSTALLATION
• 16.4. UPRIGHT CHECK AND ADJUSTMENT
• 16.4.1. ROLLER CLEARANCE CHECKS
• 16.4.2. ROLLER BEARING REPLACEMENT PROCEDURES
• 16.4.3. UPRIGHT REASSEMBLY
• 16.5. CYLINDER REPAIR
• 16.6. LIFT CHAIN MAINTENANCE
• 16.6.1. LIFT CHAIN INSPECTION
• 16.6.2. LIFT CHAIN LUBRICATION
• 16.6.3. LIFT CHAIN REPLACEMENT
• 16.6.4. CHECK LIST
• 16.7. UPRIGHT REMOVAL AND REPLACEMENT
• 17. COUNTERWEIGHTS
• 17.1. COUNTERWEIGHT REMOVAL AND INSTALLATION
• 18. SPECIFICATIONS
• 18.1. NAMEPLATE AND DECALS
• 18.2. GPX 30/50 GENERAL SPECIFICATIONS
• 18.2.1. CAPACITIES
• 18.2.2. SERVICE WEIGHTS
• 18.2.3. AXLE WEIGHTS
• 18.2.4. MAXIMUM GRADEABILITY
• 18.2.5. PARKING BRAKE TEST
• 18.2.6. DRAWBAR PULL
• 18.2.7. TRAVEL SPEEDS
• 18.2.8. TURNING RADIUS
• 18.2.9. WHEELS TIRES
• 18.2.10. DRIFT LIFT AND TILT
• 18.2.11. LIFT SPEEDS, UPRIGHT
• 18.2.12. LOWERING SPEEDS, UPRIGHT
• 18.2.13. DRIVE AXLE
• 18.2.14. SERVICE BRAKES
• 18.2.15. PARKING BRAKE
• 18.2.16. COOLING SYSTEM
• 18.2.17. ELECTRICAL
• 18.2.18. GASOLINE/LPG ENGINE SPECIFICATIONS
• 18.2.19. DIESEL ENGINE SPECIFICATIONS
• 18.2.20. ENGINE FUEL SPECIFICATIONS
• 18.2.21. ENGINE TUNEUP (GAS/LPG)
• 18.2.22. ENGINE TUNEUP (DIESEL)
• 18.2.23. HYDRAULIC SYSTEM
• 18.2.24. TRANSMISSION
• 18.2.25. CRITICAL FASTENER TORQUE SPECIFICATIONS
• 18.3. PM INSPECTION AND DRIVERS DAILY INSPECTION FORMS
• 18.4. LUBRICANTS AND SHOP SUPPLIES
• 18.4.1. LUBRICANTS
• 18.4.2. SEALANTS
• 18.4.3. GASKET MATERIALS
• 18.4.4. THREADLOCKS AND THREADSEALERS
• 18.4.5. ADHESIVES
• 18.4.6. CLEANERS
• 18.4.7. MISCELLANEOUS SHOP SUPPLIES3
• 18.5. LUBRICATION INTERVALS