PMA-346 C300 40/50INDUSTRIAL TRUCK DIVISION CLARK MARKETING TRAINING DEPT. OWNER SAFE MAINTENANCE PRACTICES Powered industrial trucks may become B. Use blocks or other positive hazardous if adequate maintenance is truck positioning devices. not done. ‘Therefore, maintenance facilities, personnel and procedure: Put blocks under the load aust be provided. engaging means, innernast (s), or chassis before working Maintenance and inspection of all under then. powered industrial trucks should be Gone in agreenent with the reconnenda- Before working on engine fuel tion in this manual and the following system of gasoline powered trucks practices. with gravity feed fuel systems, make sure fuel shutoff valve is A scheduled prevent ive maintenance, closed. lubrication, and inspection systen must be followed. Before working on engine fuel system of LP gas powered trucks, Only qualified and authorized close LP gas cylinder valve and personnel should be permitted to tun engine until there is no more maintain, repair, adjust, and fuel in the system and engine inspect industrial trucks. stops running. 3. Before Leaving The Truck: Operation to check performance of the truck or attachnents must be A. Stop Truck. done in a clear, authorized, safe area. B. Fully lower the load engaging means. 5. Before Starting To Operate The Truck: C. Put directional controls in A. Be in operating position. neutral. B, Push clutch (or brake pedal D. Apply the parking brake. on autonat ic transaission and electric trucks). E. Stop the engine or turn off power. C. Put the directional controls in neutral. F. Lock the control or ignition circuit. D. Start engine or turn on power. G. Put blocks at the wheels if E. Before operat ing truck, check truck is on a ramp, or being functioning of lift and tilt worked on. systens, directional and speed controls, steering, warning Before Working On Truck: devices, brakes, and any attachment. (If used) A: Raise wheels free of floor or disconnect power source. F. Release parking brake. = continued = vozga ah mesertp eto) Do ater daneINDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPT. OWNER SAFE MAINTENANCE PRACTICES (CONT.) 6. Avoid fire hazards and have fire protection equipment available. Do not use an open flame to check level, or for leakage, of fuel, electrolyte or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. 7. Provide ventilation to the work area, vent exhaust fumes, and keep shop clean and floor dry. 8. Handle LP gas cylinders with care. Do not drop, dent, or damage in 13. 1. ALL hydraulic systens must be regularly inspected and maintained in conformance with good practice Tilt cylinders, valves, and other Like parts must be checked to make sure that “drift" has not devel~ oped to the extent that it would create a hazard. Capacity, operation and maintenance instructions plates, tags, or decals must be maintained in legible condition. any way. 15. Batteries, motors, controllers, limit switches, protective devices 9. Brakes, steering mechanisms, con- electrical conductors and connec~ trol mechanisms, warning devices, tions must be inspected and lights, governors, lift overload maintained in conformance with good devices, guards and safety devices practice. Special attention must must be inspected regularly and be paid to the condition of elec~ maintained in a safe operating trical insulation. condit ion. 16, Industrial trucks must be kept in 10. All parts of lift and tilt mechan- a clean condition to minimize fire isms and frame menbers must be hazards and help in the detection carefully and regularly inspected of loose or defect ive parts. and maintained in a safe operating condit fon. 17. Modifications and additions which affect capacity and safe truck 11. Special trucks or devices designed operation must not be done by and approved for hazardous area the customer or user without operation must receive special manufacturers prior written ap- attention to make sure that maint~ proval. Capacity, operation and enance keeps the original, maintenance instruction plates, approved safe operating features. ‘tags or decals must be changed accordingly. 12. Fuel systems must be checked for Leaks and condition of parts. 18. Care must be taken to make sure Extra special consideration must that all replacement parts are be given in the case of a leak in interchangeable with the original the fuel system. Action must be parts and of a quality equal to taken to prevent the use of the that provided in the original truck until the leak has been equipment . corrected. Copynahicd Mar 1023-GuenREW SBR 83er(BACK)INDUSTRIAL TRUCK DIVISION MARKETING TRAINING DEPT, SAFETY MESSAGES PLEASE READ AND UNDERSTAND THE SAFETY MESSAGES SHOWN BELOW BEFORE YOU D0 ANY MORK ON A LIFT TRUCK FWA Nate NAMEPLATES & DECALS DO _NOT OPERATE A LIFT TRUCK WITH DAMAGED OR LOST DECALS AND NAMEPLATES. REPLACE THEM IMMEDIATELY. THEY CONTAIN IMPORTANT INFORMATION. PERSONAL INJURY WEAR EYE GLASSES, SAFETY SHOES AND CORRECT FITTING CLOTHING WHEN WORKING ON LIFT TRUCKS. INJURY CAN RESULT IF YOU DO NOT WEAR ROTECT IO! WARNING FALLING FORKS DO NOT WALK OR STAND UNDER RAISED FORKS. THE FORKS CAN FALL AND CAUSE INJURY OR DEATH. inmunis SU SREB BA FWA NaIN Ne LIFT TRUCK MAINTENANCE 00 NOT WORK ON THIS TRUCK UNLESS YOU ARE TRAINED AND AUTHORIZED AND KNOW THE CORRECT MAINTENANCE PROCE- DURES. 7A) AIR PRESSURE WEAR EYE PROTECTION & PROTEC- TIVE CLOTHING WHEN CLEANING OR DRYING WITH AIR PRESSURE. REDUCE PRESSURE TO [207 kPa] 30 PSI. DEBRIS REMOVED WITH AIR PRESSURE CAN CAUSE INJURY. HYDRAULIC FLUID PRESSURE| 00 NOT USE YOUR HANDS TO CHECK FOR HYDRAULIC LEAKAGE. FLUID UNDER PRESSURE CAN PENETRATE YOUR SKIN AND CAUSE SERIOUS INJURY.INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK yet Pr Ld hg 300 0-50 (UPA) Codes PHEBME, MAR 75INDUSTRIAL TRUCK DIVISION PRtTT% Go CLARK Pathe STONER SERVICES CAGINECKING DEPARTMENT, BATTLE CHEER FOREWORD PLANNED MAINTENANCE SECTION ‘The Planned Maintenance Procedures located in the front of this book provide a basic step by step guide which should be followed In servicing the vehicle. Adjustaent Procedures, specifications and other data including lubrication guides, are found in the rear of this Book ‘ond are listed uncer GROUP and Section Numbers. Refer to the Index or the Product Identification Card. About Planned Maintenance Planned Maintenance is» progran in which Inspections, minor adjustments, lubrication, of! changes and replacenent of Filters are performed fon a scheduled and systenatic basis. A solid PH program should incorporate a method of record keeping which enables you to better determine PH Schedules and enables you to track the maintenance costs per machine. An effective FM program should incorporate two basic phases: 1. An inspection performed by the driver or maintenance man at the beginning of each shift. This is a quick visual check for obvious damage and leaks... check of engine of! and water levels, lights, instruments and warning devices. 2. THE PLANNED MAINTENANCE ROUTINE 15 BASED OW 50 To 250 OPERATING HOURS ... WITH THE INTERVAL BEING DETERMINED BY OPERAT} CONDITIONS. Records wil! tell you how often FH should be done. If an operation is clean and not punishing, 9 PH interval can be extended. If an Operation ‘Is extrenely dirty and punishing, the PH interval may have to be reduced. Thus the PH interval can be tailored to answer the needs of your operation. If the FM Is religiously followed, needs for repair, major adjustment and component Feplacenent will be discovered sutonatical ly and Such work will be done only as needed. For Instance, brake checks which are part of the PA will uncover the need for adjustments and/or repairs which may be required periodically. Who can say? The point Is that this will be done only when needed and that's true for all systems and components. Thus, in this progran we are able to eliminate 500, "1000 and 2000 hour Inspections and the things normal ly covered in these inspections will be done only ven the FM uncovers the need for repairs. The objectives of FM are: To reduce costly unscheduled downt ine. Reduce maintenance costs. 3. Increase vehicle productivity. ‘Above all, to increase personal safety of drivers and other personnel. Inspection Forms To insure thet the daily Inspection and FH are properly performed, we recomend the use of the inspection forms in GROUP 40, Such forns not only provide a guide for the inspections ané Procedures, but serve as a record in tracking Inaintenance requirenents for each vehicle. Moreover, they will assist you in determining hen to schedule a vehicle for mejor repairs hich can be done without the disruptive effect Of unscheduled downtine, Inspection Forms may be purchased fron your local CLARK Dealer. SPECIAL MOTICE TO ALL USERS OF THIS MANUAL, IF... in the process of using this menual for PH procedures, adjustments, reference: you find that this manual can be Improved in any way, put your Ideas in writing end send then tor CUSTOMER SERVICES ENGINEERING CLARK EQUIPHENT COMPANY BATTLE CREEK, MICHIGAN (49016) We cantt pronise that your idea will be used, but it will be seriously considered If you do submit any such Ideas, please understand that Clark Equipment Conpany can use it without obligation. Pose 2 , Code: PH-270, REV JUN 77 Inner CLARK dak ony ‘Dnt el or date1, Planned Maintenance Procedures Pages Alternator Maintenance GROUP 12, 3. Axle End Lubrication aig GROUP 20, Section 1 4, Brake Adjustment (Parking) ........ 21 GROUP 23, Section 4 5. Brake Adjustment (Service) ........ 22 GROUP 23, Section 3 6. Brake Bleeding . te 23 GRUUP 23, Section 1 7. Brake Pedal Adjustment .. ‘i 24 GROUP 23, Section 2 8. Carriage Roller Adjustment ......+. 25 GROUP 34, Section 1 9. Cooling System Maintenance 5 26 GROUP 01, Section 2 10. Counterweight Removal . 4 2 GROUP 38, i 10. Driver Restraint System Checks .... 28. GROUP 39, Section 1 11. Hydratork Pres. Checks. Ee 2. GROUP 06, Section 1 12. Hydraulic Sump Drain .. ee 30 GROUP 29, Section 1 13. Hydraulic System Pressure Check ... 31 GROUP 30, Section 1 14. Jacking Procedure " 32 GROUP 40, Section 5 15. Lift Chain Adjustment ... ‘ 33. GROUP 34, Section 3 14, Lubrication Charts . 34. GRO! 17. Lubrication Key Conynahe Materia Inne fr CLARK dele cay Code: PM-346, REV MAY 84 |. Name Plates/Machine Stampings . . Neutral Start Switch .. . Inspection Forms . Specifications .. . Starter Maintenance . Steering Adjustment ... . Steering Pressure Check . Steer Wheel Bearings . Tit Cylinder Adjustment’... . Transmission Drain . Transmission Fluid Aeration Check . Transmission Pressure Check . |. Transmission 011 Cooler ... . Upright Roller Adjustment ... PM GROUP 40, Section GROUP 13, Section GR GROUP’ 40, GROUP ii; GROUP 26, GROUP 26, GROUP 26, Section GROUP 34, Section GROI GROUP 06, Section GROUP 06, Section’ i GROUP 06, Section 3 Tune-Up .. ane GROUP 00, Section 1 GROUP 34, Section 2 Upright & Tilt Cylinder Drift Tests GROUP 34, Section 4 GROUP 22, Section Wheels & Tires . Page 3PIETTy INDUSTRIAL TRUCK DIVISION [ETT ERUIEMENT, SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK (lel our PM A special coding systen on the PH check sheet ‘allows the PH man to efficiently report truck Condition, with @ minizun number of words. As ‘the PH Is’ perforned, a check Is made on the check sheet indicating truck condition + 2 potential problem, or needs urgent rep Whenever a systen or component Is faulty oF un- Sofe, it must be noted on the PM check sheet, ‘and reported to the designated authority et the Conclusion of the PM. ing What should a What should @ PH include? The best answer Is to g0 through @ PM based on the knowledge and Perlence of PM men, service managers, eng ‘and custoner services engineering personne! P.M. include? P.M, OBJECTIVES? To reduce costly unscheduled downtime, reduce maintenance costs, Increase ‘above all s.. to yy of drivers and other personne rthwhile ends can be met only through sensible, consistent measures which Include .+. 1, Complete inspection to uncover minor or potential trouble before It becones major. 2. Alr cleaning and lubricating the machine to reduce dirt danage and excessive wear. 3. Making adjustrents to assure proper and safe Functioning of systens and components. ocr 6 Coder PH ~ ® copaghtttinea nnaPIrTyg INDUSTRIAL TRUCK DIVISION Pe CUSTOMER SERVICES ENGINEERING DEPARTMENT, BATTLE CREEK PERFORMING A PM: First check the oil level and add oil if it is below the add mark. Check the transmission fluid level with engine idling. The transmission must be in neutral and the fluid hot. Check the hydraulic sump ofl level with the carriage fully lowered. If necessary, add fluid to bring the level up to the full mark on the dipstick. Check the water level. Fig. 14796 Code: PM-346, REV OCT 81 PLS.L. Corchad Marl Intended or CLARK dak ony ‘Dnt el or dateINDUSTRIAL TRUCK DIVISION [ATF EQUIPMENT cast NG DEPARTMENT, BATTLE CHEEK services Check the Fuel level. Check the brake pedal Firmess by pressing down on the pedal with your foot .., hold for at least 10 seconds. Pedal must be solid, must not be spongy or drift under Foot pressure. Brake pedal sponginess Indicates air In the systen. Imediately report to designated authority if either of the conditions exist. Next ... set the parking brake, start the engine, shift into gear and slowly rev up the engine to make sure the brake holds, If It does not, it should be adjusted or repaired before placing machine into service. Fig. 9781 Check the seat mounting security end the seot edjuster for proper forward and back operation. Fig. 14776 Page 6 sceelaci seen Code: PHH346, MAR 75 Intended for CLARK dks onyMtrig INDUSTRIAL TRUCK DIVISION a) aud CUSTOMER SERVICES ENGINEERING OEFARTOMERT BATTLE CREEK Check the neutral start switch by trying to start the engine in forward and reve: engine should not start with the transmission in gear. If it does, mark this under critical on your P.M. REPORT sheet. Check the safety relief valve for damage. Open the LPG fuel valve. Using a soapy solu- tion, check all fittings and connections for leaks and tighten or repair all that are found. Check instruments, horn, head and tail lights, indicator lights and warning lights. Fig. 13722 Code: PM-346, REV OCT 81 P.S.L. : Page 7 Intended or CLARK dak ony ‘Dnt el or datePITT1y INDUSTRIAL TRUCK DIVISION PRET? cy com st tn a, ca Make sure the hour meter starts. 7-= > NOTE Also, make sure the hour meter starts with the hydraulic system, This should be done Tater In the PM, since a tine delay Is required between hour neter checks with the drive motor and hydraulic systen. With the engine running, listen for unusual engine noise. low check the hydraulic control levers for security and Freedom of movement. Check the upright for racking In full forward 8i1t ses Fig, 13718 Page & Code: PH-346, MAR 75 Copyrighted Mater Intended for CLARK deters nlyINDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK yo EQUIPMENT ses and full backward tilt, Racking Is caused by uneven adjustment of t11t cylinder rods and will result In excessive Stress on all related conponents. Now ... check for upright free play and racking by tiTting the dpright fore and aft with the forks fully raised. If there 1s excessive free play between rails ané channels, 2 ae Upright adjustment Is required, If there Is racking, adjustnent of cylinder rod yokes Is required. : Now «+. check the power steering, To ¢o this, drive slowly Forward and cramp the hand whee! full right and left ... to reduce tire winé-up and to neutralize the power steering booster valve. Steer wheels should respond immediately with ‘each turn of the steering wheel. Cramp the hand wheel very hard to left and right ... with fengine idling and truck not moving. The engine should not Tug down. If It does, power steering adjustnent Is indicated. Fig. 12158 Codes PHASE, MAR 75 Page 9 Anveded fo CLARK deers olyPity INDUSTRIAL TRUCK DIVISION [RET Pai la TONER SERVICES ENGIMERINGaEPARTMENT, MATTE CREEK Ps Then... check drive tire inside turning dianeters which ‘should ‘be about equal in forward left and right tu Wnile driving, listen for unusual drive train nol Fig. 11458 Moke 2 visual check of the truck. Look for signs of obvious Veaks. Then, Inspect the sheet metal and battery cover. Any danage occurring on the truck since the lest P.M, shovid be notee fon the P.M, check sheet, Fig. 16708 Check mounting and condition of the driver's overheed guard. Fage 10 Code: PH-346, ge 1 omen PH-346, MAR 75 evened for CLARK deers oly ‘Do nots or daraPIPTTy INDUSTRIAL TRUCK DIVISION ri SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Check the condition of the load back rest. Check for excessive leakage st the Tift cylinder. Check for nileks and scoring. Check for denaged chains. Fig. 14815 Check chain adjustment by making sure the chains are under ‘equal tension. Fig, 12146 Code: PHH3K6, HAR 75 Conve Marit Page 11 Isl or CLARK dsstpi INDUSTRIAL TRUCK DIVISION [yt ba UT Tg usroue services enGMEHINGaEPARTHENT, HATE REER ERUIEMENT, The corriage choin retainers ond cotter pins must be In place and not danaged, Check fork latches to make sure they work properly. rd Uprights: Deck Nunbers beginning with an UF, Check the Fabreeke (Stop) Pads for damage, and check to make sure the pads contact the rail tle bar at the sane tine when lowering inner slide. Reference: Fig, 10910, With innerslide fully lowered, both stop blocks must contact rail tle bar. Full Free Lift Uprights: Deck Winders beginning with an Ui! Check the Fabreeke (Stop) Pads for denege, ond see if there {is some clearance between botton of pad/s and tie bar. Pads must not contact tie bar. Reference: Fig, 10911, Check to make sure Inner rails are not lower than outer rails, Fig. 10911 Page 12 ‘esas ea Eade: PHA346, MAR 75, Inner CLARK dak ony ‘Dnt el or datePITT INDUSTRIAL TRUCK DIVISION Li tll SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Check the forks to make sure they are not bent or broken. Check wear patterns In the rails, A wear pattern like this indicates that chain adjustment is about right. But ... weer pattern like this seans thet the cheins are too 1g and must be adjusted to correct length. See GROUP 34, Section 3. Se Gi sinnies aeata Von We = Codes PH-3K6, MAR 75 . Poge 13 Tor CLARK dese nlyPIETY INDUSTRIAL TRUCK DIVISION PRETT? Bl liald ‘SERVICES ENGINEERING DEPARTMENT, BATTLE CREEK eth Working on the sane side, check for play at the upper end of e the upright. 1 1 ft. Fig. 15735 Wow move to the other side of the machine and perform sini lar checks at the lover end of the upright +. Fig. 15736 ‘and at the upper end, These four checks should be Fepeated with the upright raised halfway and also with the upright fully extended. (Use an approved platform, raised by another lift truck, to perform these checks in the fully ratsed position.) Refer to GROUP 34, Section 2 for adjustnent procedures . Check to see that the cylinder hold-down bolts are not missing and are tightened securely et the base of the lift cylinder, Page 14 Fader OMTM6, HAR 76 Copymghed Mater Inne fr CLARK desl ‘Dont sel or darneerary INDUSTRIAL TRUCK DIVISION el Sas SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Now make a drift test. Drift should not exceed one inch per fi ninute. If It does, cylinder or control valve repair is indicated Perform a tilt drift test. Drift should not exceed 1/2 to 3/4 of an Inch In a five minute period. Check the drive axle mounting bolts with e torque wrench for proper torque. If any + torque each bolt, then Fetorque, according to specifications. Check and tighten securely, the steering column clanp and Usboles Code: PH-346, MAR 75 2 = Page 15 Inde er CUA Ses onyINDUSTRIAL TRUCK ‘cusTowEn Senvices ENGIMEERIMG OEP ARTWEN Check the filler screen to be sure It Is In place and not damages, Trucks equipped with the type shown s+ check Orring seal to be sure Te Is not damaged (must be located between cop sereen and the Filler neck) WARMING NEVER WELO IN THE VICINITY OF THE FUEL TANK Check tires for excessive wear and cuts. Pry out of tire treads any objects which could damage the tires. Also check wheel lug nuts for tightness and make sure none are missing, Torque the counterweight bolt to specifications. 1 pipe to make sure exhaust is not blowing into Page 16 Coppi Materia YiuTER ScAEEN Fig. 6627 Fig. 12917 Fig. 11455 Fig. 16711 Code: PH-3K6, NOV 79 REV Intend fr CLARK dealer cay ‘Dome dineNow ... remove the side hoods ... ses remove the floorboard and... ses expose the engine conpartnent by lifting the seat and Swinging the battery out. Then ... using @ two-foot extension on the air hose, blow ‘through the radiator fran the counterweight side and ... WARNING DO NOT USE AIR PRESSURE OVER 30 PSI. Code: PH-346, NOV 79 REV Copyrighted Mtl Incerdedor CLARK desley ‘Dot lr dts Poe 17Piryyy INDUSTRIAL TRUCK DIVISION PRETT GO cusronen services ex snTwEnT, BATTLE CHEEK TE sss blow through the radiator from the engine side. Blow off the engine ++ se the transnission and axle adapter and ... ++ the upright, Including chains and rollers. If the upright hes 9 compound cylinder, sir clean the tops of the outer cylinders. Fig. 13729 Page 18 reemiainae Codes PABMG, MAR 75 Inde or CLARK deo syliq INDUSTRIAL TRUCK DIVISION Peat SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Now check the brake pedel for free play and the pedal pad for excessive we Check the by-pass port operation by pushing sharply on the brake pedals Fluid In the eylinder should bubble,” Indicat ing fan open by-pass port, which prevents pressure build up in the hydraulic system. Clean off cap before renoving. Check the fluid level In the master cylinder and Fi11 to within 1/4" of the top If necessary. ne Fig. 14777 Check the neutral starting switch after the floorboard is removed, At that tine, make sure the wires are spread 2s Shown. "If the engine still starts in gear, the switch must be adjusted or replaced. Code: PHH346, MAR 75 Conynahe Materia Page 19 Inne fr CLARK dele cayINDUSTRIAL TRUCK DIVISION [RET Pid [CUSTOMER SERVICES ENGINEERING HEPARTWENT, BATTLE CHECK Inspect the complete hydraulic control linkage for mounting security ond freedon of operation, Check the torque on all the steering gear mounting nuts. Check the power steering gear valve for leaks. Check the mounting security of the tilt cylinder yokes and rnake sure the yoke locking keys are in place. Fig. 14803 Page 20 Conynahe Materia Code: PHH346, MAR 75 Intend fr CLARK dele cay ‘Dome dinePIPTT INDUSTRIAL TRUCK DIVISION Zu SIE SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Make sure thet the tilt cylinders are securely fastened to their brackets. Check the tilt cylinder rods for pitting, scratches and scoring. Check the torque of the yoke nuts. Now inspect the air cleaner hose and its connections, making sure they are tight. Fig. 16715 Code: PHH346, MAR 75 Copii Materia Paget Inne fr CLARK dele cayGTTY INDUSTRIAL TRUCK DIVISION PITT Print [CUSTOMER SERVICES ENGINEERING OCPARTWENT, BATTLE CREEK ba dial Remove the air cleaner housing and elenent. Check the elenent with » light bulb. Wipe off the air cleaner base, being careful not to wipe dirt Into the Intake opening Inspect both ends of the new elenent and clean if necessary. Install It and the housing with the sir Intake pofntin: toward the air scoop, Page 22 Comping Masih ‘Dae al ordre Zaz Fig, 12184 Code: PH-346, MAR 75FIFTY INDUSTRIAL TRUCK DIVISION Za tolled es SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Check the alternator mounting bolts to make sure they are secure and sex adjust the drive belts for proper tension. If tension is iow, belts will slip ... If high, bearing and seal danage can cccir In generator and water punp. Check the fen blades for loo the fan is properly installed. Check the radiator coolant and F111 to the proper level. Fig. 14796 Code: PHH346, HAR 75 Page 23TTY INDUSTRIAL TRUCK DIVISION FAP tl LS ast ‘SERVICES ENGINEERING DEPARTWENT, BATTLE CREEK bla ld If the radiator requires mich water and the engine has been overheating «++ ressure test the radiator cap, replacing it if ary. Pressure test the cooling system, elininating any leaks which are found. Check the specific gravity of the battery and recharge if necessary. Pace 24 Code: PHH3H6, HAR 75 Conyriphed Moe PEUARK desler ty dariatry INDUSTRIAL TRUCK DIVISION iy Eee SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Check the tightness of battery cable connections and... s+ check the battery ground wire for condition and security OF connection. Check the battery for danage and electrolite. WARNING NEVER ALLOW FLAME OR SPARKS NEAR THE BATTERY FILLER HOLES BECAUSE EXPLOSIVE GAS HAY BE PRESENT. Now, disconnect the high tension coll wire and install a ground wire in the coil .., clipping one end of the wire to ‘an engine bolt, Then, WIPE OFF THE COIL to prevent its top from burning. Fig. 12129 Code: PH-3K6, HAR 75 ‘atime Page 25 Ine fr CLARK desler onlyINDUSTRIAL TRUCK DIVISION PTET EQUIPMENT HSTOMER SERVICES ENKOVERINGDCPARTMENT BATTLE CREEK Then connect 9 volt meter to the battery. Now, floorboard the accelerator to obtain higher compression and crank the starter for three to five seconds, During cranking, voltage should exceed 9.6 volts. If it is low, there is trouble in the battery, cables or starter. Immediately after cranking, no-losé voltege should be ot least {2 volts. low, renove the ground wire and connect the coll wire, Then ss. +. start end accelerate the engine. Charging system output Should excued 12-1/2 volts. These simple, quick tests show whether charging and cranking systens are okay or in need of repair. fenove the volt meter and s+. ++ check the battery to make sure cells are Filled and check for cracks. If terminals are corroded, clean and protect then with battery fever. Fig. 13786 Page 26 Code: PH-3M6, MAR 75INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Check the engine mount for tightness and condition. Then remove the to cap, rotor, Wipe the cap or cap and check for vistble danege ‘Spark plug wires and boots, ‘out to prevent arcing. Also, make sure you grease the distributor drive shaft through Its grease fitting. Check can condition, If it is rough, distributor replacenent nay be necessary. if the can Is In good condition, lubricate it'with special cam lubricant. Code: PHe3H6, MAR 75 Page 27Check the points for burning Replace if nec- essary. Set the dwell at 25-34° for Delco distributors and 66-72° for Prestolite distrib- utors. Check all wiring for damage and looseness. Check the wire from the oil pressure switch to the solenoid to make sure it is not loose. Check the wires connected to the ofl pressure switch for security. Pai Conia Mara ge 28 Inunded or CLARK deo o PM Fig. 14595 Fig. AQS21 Code: PM-346, REV JUL 83 P.S.L.Trtq INDUSTRIAL TRUCK DIVISION oT Tg [CUSTOMER SERVICES CABINEERNG OEFARTWMERT BATTLE CREEK Start the engine and using the spark indicator shown, check the coil and spark plug wires to make gure the coil is producing adequate volt- age to all plugs. At the same time, check all ‘the spark plug wire connections for tightness. Check the ofl level and the condition of the ofl. Add of1 to the full mark if the ofl does not need changing. If the oil does need changing, jack up the machine and put blocks under the frame. Fig. 21569 Code: PM-346, REV OCT 81 PeSebe Os ugus Page 29 Irn fr CLARK desler oly ‘Do nots daraerary Tq INDUSTRIAL TRUCK DIVISION [FETT Got Customen sevice exsinccnine 0 rue ee ee s+ Slip a shallow pan (of sufficient capacity) under the truck, remove the crankcase drain plug and allow the crankcase to drain. While the of drains, clean and... ses lubricate all grease fittings. When you lubricate steer wheels vee ses check for loose wheel bearings by trying to rock the wheels. Looseness can also indicate wear or alsadjustnent in the steering linkage. Fig. 12173 Page 30 ‘esas ea Code: PHH34N6, HAR 75 Inner CLARK dak onyarya INDUSTRIAL TRUCK DIVISION bth Tg SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Lubricate the roller guides with chassis grease. Fig. 14716 Check Vinkages, lubricating all connections. In dirty, abrasive operations, use a dry type lubricent. Now, remove the engine of! filter and replace with » new cartridge. Install the drain plug and renove the drain pan. FIN1 the engine crank Filler cap locking es pd check the condition of the oi! seal, Replace the cap if It, or Fig. 13734 Code: PHH346, MAR 75 Page 31PATTY] INDUSTRIAL TRUCK DIVISION [PTT etn as CUSTOMER SUAVICES ENGINEERING OEPARTWENT, BATTLE CREEK Next, check the engine of] level which must be at the full fmark. These checks are made at this time because of] has hed @ chance to circulate and Fill up the entire system. Wow, check for leaks at the engine of! filter and crankcase plug while the engine Is running. Fig. 16720 Now check transmission fluid level with engine idling and transmission in neutral, Also check condition of the flutd. check for leaks around the transmission filter. Fig. 16721 Pace 32 ‘coananataian Codes Pre3N6, MAR 75 Arce or CLARK dsr oly Do staat rarINDUSTRIAL TRUCK DIVISION CUSTOMER SeaVices ENGINEERING DEPARTMENT, BATTLE CREEK po ou Lay Check the hydraulic sump filler cap and clean it. Replace it if damaged. Check the hydraulic ‘sunp oil level with the carriage fully lowered. I£ necessary, add fluid to the full mark on the dipstick. Change the hydraulic systen filter once a year or every 2000 operating hours (whichever cones first). Cheek the power steering rod for security of — mounting and for grooves and scratches. Make sure the choke and linkage operate correctly. Fig. A0495 Code: PM-346, REV OCT 81 PS Oa Page 33 evened for CLARK deers oly ‘Do nots or daraPIPTT4 INDUSTRIAL TRUCK DIVISION fAtry Sy cmon ss tn sn a Install 2 timing light and ... ++ check engine tining. DELCO DISTRIBUTOR #1112673 built before 1 DEC 74 (Code 4H0): Time 2 deg. ATDC © 450 ENGINE RPM. DELCO DISTRIBUTOR #1112673 built on or after TEC 74 (Code 4H0): Time TOC @ 450 ENGINE RPM. Then install the side covers, take the hour meter reading .. = fI11 cut and plece the lube report inside the hood. Wipe # the truck and clean up the ares. Page 34 Code: par346, OCT 76 REV Ine fr CLARK desler onlyMerry INDUSTRIAL TRUCK DIVISION Lipioldin Dts SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK a GROUP 00 SECTION 1 ENGINE TROUBLESHOOTING wader owragis, agree Section 1, Page 1yet EQUIPMENT TROUBLE SHOOTING A preventive maintenance systen includii Inspection, lubrication and adjustnent recomended in our Maintenance Section will prevent the greater portion of gasoline engine Eroubles.. due to two things; ignition trouble or failure In the fuel systen, Operators handling the sane engine every day, s00n develop a sense of Impending trouble when abnormal operation occurs. Immediate attention to these danger signals can prevent najor failures, insure dependable operation and increase the life of the engine. A good rule to follow in locating trouble is to never make more than one adjustnent at a tine, Then locate the trouble by a process of elimination. Renenber the couse is usually SIMPLE, rather thon mysterious and complicated. Following are listed sone of the nornal complaints encountered in routine operation of all gasoline engines and the probable causes. A. STARTING MOTOR - WILL NOT CRANK ENGINE: 1. Weak or dead battery. 21 Poor ground connection. 3. Faulty starting switch or relay. G2 oefective starting motor. 5. Internal engine seizure.” Turn engine manually to determine couse, 5. ENGINE CRANKS = BUT DOES NOT START: Disconnect one spark plug wire, turn Ignition on with starter cranking engine fond free end of wire 1/8 inch fron cylinder head. Note spark. 1. No Spark - if meter shows no discharge, it indicates an open prinary circuit due to Foints not closing. Open primary wires: ion switch. Faulty coll, 2, Weak Spark ~ may be caused by: 8, Loose ignition wiring connections. bl Burned or pitted distributor points. <1 Wet spark plug wires. 4. Defective condense €. Cracked distributor ‘cap. Weak ignition coil, Sectfom 1, Page 2 INDUSTRIAL TRUCK DIVISION PRET CHSTOMER SeHVICES ENGINEERING DEPARTAENT, BATILE CREEK a Good Spark at Each Flug = indicates that ignition syaten iz OK and trouble may due to: 18, No gas in carburetor, which may be due (1) No gas in tank. (2) Clogged Filter or lines (3) Foulty fue! pump. (B) Leaky fuel Vine from tank. (5) Plugged vent in fuel tank necks by Gas in carburetor, which may be Flooded due to: (1) Too much choking (2) Wrong flost level. (3) Choke not operating correctly. (4) Water in gas. Flugs ere wet. ENGINE RUNS WITH CONTINUOUS MISFIRING DUE 10: Uneven compression. Wet or deteriorated high tension wires. Cracked distributor cap. Faulty sperk plug = if spark plug porcelain Is white when renoved, use COLOER plug, If Vight brown OK, If black or of ly use HOTTER plug. [ENGINE RUNS UNEVENLY At Idling Speed = which may be due to: 2. Too wide spark plug gaps. 5. roar carburetor idle adjustnent. €. Wrong float level. 4. Corburetor or intoke menifold air leaks. fe. Leaky cylinder head gasket. At High Speed ~ which may be due to: 2. Wide breaker points, b. Weak distributor breaker arm spring. €. Weak valve springs. 6. Spark plug of wrong type or incorrect ep. 0 snows, ENGINE RUNS IMPROPERLY : Bock-Firing into Manifold - indicates too rich a fue! sixture; Into carburetor indicates too lean a nixture, may be due tor Code: PHACBHS, REV MAY 78 Copyrighted Mate Imwended for CLARK deers nly "Do nat sl or ibeyt ad a. Lat jon timing. b. Clogged air cleaner. INDUSTRIAL TRUCK DIVISION €. Fuel line restrictions. 1 4. Clogged carburetor jets. 2 fe. Sticking valves. 3: #1 Weak or broken valve springs. a 5: 6 Excessive Ping (Detonation) ~ results in z daneyed pistons and bearings and is coused by preignition or using inferior grade of sas 1 Engine Idles Too Fast = indicates improper in throttle adjustment or weak throttle return 2 springs. 2 i Engine Dies When Idling = which indicates e Incorrect speed or mixture adjustnent; & clogged idling circuit In carburetor or om lwrong choke adjustrent, or air leaks in & intake nani fol Engine "'Stunbles!! on Acceleration = which ae may be due to defective accelerator pump or sir in fuel lines. Defective Spark Plugs. F, LACK OF POWER = which may be due t 1. Poor compression. 1. 2) Wrong tining. 2 31 Throttle control not opening fully. 3 4. Alp leak in fuel systen, i 5. Restriction In alr clearer, should have vacuum less than 10-inches of water 6, Exhaust line obstructed, should have back kK. pressure of not more than 20-inches of water. 1 7. Poo fuel. 4 8. Piston rings sticking or worn. 3 a 5: «POOR COMPRESS 10N: & Check with compression gauge, if irregular, 7 seal the piston with a teaspoonful of engine ofl through the spark plug hole, and take 2 8. Second reading; If pressure does not 3. increase, this will Indicate that poor 1. seating of valves is the trouble, Pressure between the four cylinders should not vary nore than 10%, Poor compression may be due L tot 1. Valve holding open. No tappet clearance. 2, Leaky cylinder head gasket. 31 Broken or weak valve springs. 4. gurned or sticking valves. 5. Badly worn, broken or stuck piston rings 6! Wrong valve tining. ode: PHAR3U5, OCT 7h és , Inner CLARK dak ony ‘Dnt el or date GROUP [00] SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK OVERHEATING Lack of water in radiator. Fen Belts slipping. Thersostat sticking or inoperative. Radiator ciogged or leaky. Late Ignition tining. Back pressure in exhoust line. Overloading of engine. Low O1L PRESSURE: Low of! level. OF! pressure gouge or line faulty. Oil too light, diluted. Suction screen plusged. Dirt in rellef valve oF broken spring. Worn bearings . Worn or donaged of! pump gear Worn cam bushings. HIGH O1L PRESSURE: pressure should not exceed recomended pressures except when engine Is starting up fold. Abnormally high oi] pressure is not desirable because It increases of] ‘consumption, Possible causes of high of] pressures are: Engine ol too heavy. Stuck relief valve. Obstruction In distributing Vee Faulty oll pressure gauge. HIGH O1L CONSUMPTION: O11 Teaks. Too high oi} level. Incorrect grade of oi! used. Clogged crankcase breather. Oil pressure too high, stuck relief velve. Piston rings not run-in, due to too smooth cylinder bore finish or glazed condition. Worn, broken or stuck piston rings and clogged ofl control rings. Worn pistons and sleeves. Worn bearings. Worn valve guides. ENGINE KNOCKS AND OTHER NOISES: Operating Knocks = which may be due tor Preignition, most common cause is due to wrong type plugs which are too hot. Carbon, noticeable when engine is accelerated while hot. Clean head and pistons. Section 1, Page 3aud CLARK €. Timing. Early timing causes knocks similar to carbon, but may tend to kick back when starting. Fuel. Detonation knock caused by poor ga. + Overloads, particularly at lower operating’ speeds. Mechanical Knocks ~ result from wear, abuse or improper edjustments, which may be due tot ‘8, Cranksheft ond Main Bearings: (1) Morn oF Burned-out Hein Beerings = & heavy, dull knock when accelerating Under load. Locate by shorting out plugs on both sides of the bed bearing. (2) Crankshaft End Play ~ excessive end play is indicated by an intermittent knock whien will cone and go when the load Ts released and engaged. b, Connecting Rod Bearings: (1) Morn or Surned-out Beorings= the worst condition, 2 light pound or metallic knock, 1s noted at idling end to about 2/3 maximum speed. Bad beerings can determined by shorting out plugs. €, Pistons and Piston (1) Loose Piston Pins - noise doubles when the correct plug is shorted out, most noticeable at idling speed. (2) Piston Loose In Cylinder = » Js noted by metallic knocking at low Speed under load; but disappears at high istoneStaptt INDUSTRIAL TRUCK DIVISION [YET SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK EQUIPMENT (4) Tappet Noise = excessive clearances cause noise when cold vhich diminishes at normal operating temperature. fF. Camshaft - noise due to loose bearings ‘or end play, usuelly occurs et half ‘engine speed. Vibration Originating at Engine = the most common sources of vibration originating in of on the engine, as distinguished from Causes created outside the engine are as Fol lows: Misfiring. Misalignoent of engine. Bent of off-center coupling. Engine loose on bed and type of rnountings @. Out-of-baiance condition of flywheel ‘and clutch asseably.. PREPARATION OF ENGINE FOR SEASONAL STORAGE caution BEFORE STARTING THE PROCESSING, ENGINE HUST BE COOLED DOWN TO THE SURROUNDING TEMPERATURE, SINCE OIL WILL ADHERE MUCH BETTER TO COLD METAL SURFACES. Drain of! Fron plug. pan end replace drain ‘00 snows speed, sls0 most noticeable wen 2. Refill of! pen with anti-rust of! thot Starting cold. Test by shorting out ests Specification MIL-L21260-30 to one~ plugs. half Tes normal capacity. 4, Broken Piston Ring or Pin - sherp 3. Start up engine and run at above 600 RPH clicking noise that won't short out. for two minutes to complete of! distribution on al] surfaces. 00 NOT RUN ©. Valves: LONGER THAN TWO MINUTES. (1) Burned Valves and Seats - engine misses, 4. Stop engine, fenove all spark plugs. especially at low speeds, or acceleration under load. 5. Pour one ounce of anti-rust engine ofl into each spark plug hole, (2) Weak or Broken Valve Springs ~ aissing ‘at low or high speeds when under load, 6. Ignition cut-off. Crank engine with starter For at least 9 dozen revolutions to (3) Sticking Valves - loss of power end distribute this of! over the cylinder walls popping sound when bad. ‘and valve mechanism. (Spark plugs renoved.) Section 1, Page 4 cosa Codes PHARSHS, OCT 74 Ieee for CLARK dele ‘Do nots or daraCLARK ad 74 Drain of} from pan and reassenble plug. 8, Drain cooling systen and close drain cocks. 9. Drain all gasoline fron tank, Ines and carburetor bowl. 10, Replace all spark plugs. 11, Seal sir cleaner inlet, exhaust outlet, crankcase breather tube with weather masking tone. 12, Check ofl filler cap, gas tank and radiator cap to nake certain they are securely in place. SHORT TERM STORAGE The following instructions should be fol lowed every 30 days on outside storage and every six smonths on Inside storage. INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK GROUP 100] If the shut down period Is to be over 30 days duration, the following instructions should be adhered tor 1, Stop engine, renove spark plugs. x fone ounce clean engine of! in each plug hole. With ionition off ané plugs out, crank ‘engine with starter at least 2 dozen revolutions to distribute this of] over the cylinder walls ané valve mechanism. 4, Replace all spark plugs. 5. Renove drain plug fron carburetor bow! and drain gasoline. Replace drain plugs. caution GASOLINE EVAPORATES. IF LEFT IN CARBURETOR FOR LONG PERIODS. THIS EVAPORATION OF GASOLINE WILL LEAVE & GUM ANO VARNISH COATING OVER JETS AND MOVING PARTS; WHEN ENGINE 1S STARTED UP AGAIN, YOU MAY HAVE FLOODING ‘OR POOR OPERATION FROM CARBURETOR. Code: PMAR345, OCT 7h Copyrighted Matera Section 1, Page 5 Inner CLARK dak onyINDUSTRIAL TRUCK DIVISION PItTT% Tod ye PEs SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK NORMAL ENGINE OPERATION: [At smooth idling speed, @ late model engine at sea level will show 2 steady reading between 14 and 22, Opening the throttle and closing It quickly should cause a drop of 4 to 6 inches, followed by @ steady rise to the original reading. At these approximate altitudes, readings should be: Sea level eee eee eee ee tO 22 PN feat faa nes ces 92 13 to 21, 2,000 feet 22 l 12 to 20 Kes wes coe pel ee teases ces te OR Ge fel Gis Ou" sited IGNITION TIMING: At Idling speed, @ steady pointer 2 or 3 Inches lower than normal shows late timing, as marked on the vacuun gauge dial. A steady reading higher than normal indicates that timing is too early, To adjust, set Idling speed below where autonat ic re (400 to 700 RPA) and loosen jeket locking screw, Advance the spark slowly until the highest gauge reading occurs, then retard the spark until the gauge reacing falls off about one inch. Hold the distributor in that position and tighten the distributor bracket locking screw. LEAKAGE FROM EXHAUST TO INTAKE MANIFOUE With the engine warm, but not running, tura the engine with the starter. A normal engine will show a reading of about 5, If the battery carries @ charge that will give the starter full speed, Less than 5 Indicates a leak (as marked on the dial). Since this condition would make any other test Feadings Incorrect, the leak should be corrected before attempting any other tests. (In making this test, be sure to disconnect any autonatic starting devices or automatic electric chokes ... and turn the carburetor throttle screw back to completely close the carburetor throttle.) VALVE LeaKage: Test at idling speed. Cech tine a valve closes but does not seat properly, the vacuum gouge pointer will drop an inch or nore. In this illustration, the black pointer shows the Steady reading and the white pointer shows the drops that oceur as each leaky valve fails to perform its function. The valve or valves cousing the trouble can be located by conpression gauge tests. Fig. 15655 Section 1, Page 6 Code: PMAR34S, OCT 74 1, Peg cosa 345, OCT 7 Inne for CLARK deses oy ‘Do nots or dara ‘00 snowsery INDUSTRIAL TRUCK DIVISION [Ey ERSIEMERY) SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 10.9) CYLINDER HEAD GASKET LEAKAGE: With the engine Idling, the vacuum gauge pointer will drop sherply, every time the leak occurs, from the steady reading Shown by the black pointer to a reading of 10 to 12 or less, as Indicated by the white pointer in this iustration. If the leak is between two cylinders, the drop will be much greater. The location of the leak can be determined by Gompression gauge tests .., almost identical low readings Will be Zound in edjacent cylinders if the leak is between them. INTAKE SYSTEM LEAKAGE: With the engine idling, this leakage will cause the vacuum gauge pointer to fluctuate between readings 3 to 8 Inches Tower then normal. In this Illustration, the black pointer shows normal steady reading while the white pointers. Indicate Fluctuations below normal, Such reeding shows leekege through intake manifold gaskets, windshield wiper or tubing, manifold-to-carburetor gaskets, vacuum starting switch, ‘Yecuun brakes, vacuum transmission control, or vacuum clutch, (If the pointer renains et about 5 to 6, the throttle valve nay have failed to close, or the riser tube may be burned.) VALVE TIMING: With the engine idling, a bad condition of lete timing will cause the vacuum gauge pointer to fluctuate between 5 and 10. However, valves tined only slightly lete will probably give norma) ind. the condition will be detected only by the engine overheating or laboring. TON RINGS Tnis test can be eccurate only If the engine has given nornal readings on all other tests. Oil in the crankcase must be (good . poor or diluted off will cause Incorrect readings . Beginning with the engine at idling speed, quickly open the throttle all the way. Hold 1t open until ‘the engine ‘about 2,000 RPM, Then close the throttle quickly . Fings are in good condition, the pointer will jump five or tmore inches higher than the normal idling position end then return quickly to normal, Less than @ fiverinch increase shows a loss in compression ... and a further check should be made with a compression gouge. Fig. 15659 Code: PHAGSMS, OCT 74 Section 1, Page 7 Conynahe Materia Inne fr CLARK dele cayINDUSTRIAL TRUCK DIVISION FRET EQUIPMENT os EQUIPMENT SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK GENERAL IGNITION TROUBLES With the engine idling, continued vi above or below normal reading shows defective spark plugs, improper spark plug gapping, burned or Improperly unsynchronized Gistributor contact points, high ter leaks, defective distributor cap, or weak Ignition coll... @ careful check of each is necessary. In this illustration, the black pointer indicates steady, normal perfornence and the white pointers show locations of vibrating pointer actions, EXWAUST BACK PRESSUR Starting with the engine at idle, open the throttle slowly until the engine reaches approxinately 2,000 RPM, then close the throttle quickly, The vacuum seuge pointer will probably jump above the normal reading. If it returns quickly and ‘smoothly to normal, no back pressure exists. However, if the pointer returns to normal very slowly or in uneven Jerks, fan exhaust back pressure Is probably present in the exhaust pipe, heat control valve, heat control valve shaft, or muffler, The black pointer in this illustration shows normal reading end the white polnter Indicates a hesitation of the pointer near its top reading, before returning to normal. STICKING VALVES: With the engine idling, irregular drops below normal will ‘occur when a valve sticks, The drop is apt to be more pronounced with a valve sticking then if it were leaking Through improper seating. A leaking valve also is apt to perform regularly, while a sticking valve will show pointer ection only when the valve sticks ... so a sticking valve characterized by irregular pointer action. (A little dit of penetrating of! may serve to clear up a sticking valve at Teast terporarily, while it will nave no appreciable effect one leaking valve.) In this illustration, the black pointer shows normal, steady reading, while white pointers show the range of fluctuations that can be expected, WEAK OR BROKEN VALVE si Starting with Idling speed, steadily increase engine speed to approximately 2,000 RPA. If the pointer jumps rapidly between 10 and 21 inches, as shown by the white pointers In the Illustration, and the fluctuations becone faster as the engine speed is increased, it is an indication of weak valve springs. If the valve springs are broken, the pointer wil! fluctuate rapidly each tine the troublesore valve attempts to close, giving an irregular action. Section 1, Page 8 Copyrighted Matera Code: OMAR BUS, OCT 7 Inner CLARK dak ony ‘Dnt el or date 00 nousMiri INDUSTRIAL TRUCK DIVISION ey [o0] EQUIPMENT SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK CARBURETOR _AD,JUSTHE All other units in an engine must be functioning properly before 9 carburetor can be adjusted properly. The black pointer in this illustration shows the noraai, steady reading Between 14 and 22 at idling speed produced by'an engine in good operating condition. If, Instead of renaining steady, the pointer hes e slow floating motion .., above or below normal .. the carburetor should be adjusted. Fig. 15664 h the engine idling, turn the idling edjustnent screw on the carburetor to richer or leaner mixtures until the vacuum gauge pointer reaches the highest possible steady rating. (On carburetors equipped with both high end low speed adjustaents, make high speed adjustment first. With spark ‘Bdvenced and engine speed equal to about 20 of 25 m.pshes adjust the high speed screw for the highest steady vacuum gouge reading ... then make the idling edjustnent.) If parts Of the carburetor are Worn, or If jets are stopped up or of Improper size, satisfactory carburetor adjustments will be possible only after the carburetor hes been repeired. Pmac3HS, OCT 7h a Section 1, Page 9 Ine fr CLARK desler onlyNOTES 1146-Z REV DEC 83 PMINDUSTRIAL TRUCK DIVISION [00] SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK GROUP 00 ENGINE TUNE-UP SECTION 2 Code: PHAC3N6, MAR 75 Section 2, Page 1PIT Ty INDUSTRIAL TRUCK DIVISION [FETT EQUIPMENT ics i lind So eri EQUIPMENT ANTRODUCTION TO LPG ENGINE TUNE-UP: 1. First, let's examine just how a basic LPG fuel systen functions. All Clark systems are liquid withdrawal systens, In these, liquid fuel flows Fron the tank to a vaporizer surrounded by coolant from the cooling system, Here the fuel is vaporized and then it Flows through primary and secondary pressure regulators to the carburetor. 2, Acomplete liquid withdrawal system consists of these main components Filter, bulkhead Fitting, pressure switch, solenoid, vaporizer-primary regulator, final regulator-carburetor. Now s+ let's examine in detal 3. ss. the system used In the series C+500 lift trucks whlch Incorporates... Section 2, Page 2 orn) rs TT Dad Reson Fig. 1st. Fig, 14456 Code: PHAR3H6, MAR 75 00 snowsPT INDUSTRIAL TRUCK DIVISION [ERG Ts O} SERVICE ENGINE ING DEPARTMENT, BATTLE CREEK 4 2 filter, bulkhead fitting, relief Vaive, solenoid, Zenith vaporizer-prinary regulator, and the Zenith PC=1 final Fegulator-carburetor. The engine of! pressure switch .., not shown here... 1S Wired to the solenoid, Now s+. letis 5 how this system works starting with . ‘the tank which carries the liquid fuel and which Ts designed to withstand e test pressure of 500 PS! .., though actual Operating pressures range fron 25 to 250 6, The tank hes s fuel gage, relief valve, shut-off valve and an alr vent valve which ‘cracked to bleed the tank of air when it's cleaned or Initially filled. Code: PMA-BMG, HAR 75 section 2, Page 3ye bt) 7+ The fuel goge assembly Is» magnetic, float = which provides accurate fuel level 8. The pre-set relief valve controls maximum tank’ pressure. tank pressure to rise above 275 P51, this valve opens to relieve the pressure, 5+ If the relief valve and spring assenbly does not function properly replaced ance Te earect be « Section 2, Page 4 INDUSTRIAL TRUCK DIVISION FRET NER SERVICES ENGINE EQUIPMENT PARTMENT, BATTLE CREEK If atmospheric heat causes Fig. 1462 Code: PASH, MAR 75 00 snowsINDUSTRIAL TRUCK DIVISION [eran ys “ Le SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 10. The service valve has seals around the stem and seat and ... M1... threaded Into the base of the service Vaive Is the 10 percent maximum withdroval valve which Is a constant flow valve, If fuel flow exceeds norma! engine denands by 10 percent, this valve closes. Any sudden surge ... such as that caused by hose breakage or sudden opening of the service valve... closes the 10 percent valve ond shuts off fuel flow. 12, Several types of quick-disconnect fittings e used on tank hoses. This is the Rego Screw type which, wen ‘connected, allows fuel to Flow to the systen.. when disconnected, It autonatically seals off ‘any flow through the hoses. NoTe This Fitting Is used on production trucks. Section 2, Page 5 Code: PHAT3H6, MAR 75 Pecaeniianaa Irena for CLARK detity INDUSTRIAL TRUCK DIVISION PIETT Se EQUIPMENT esowcn Snes evgncnng acranraer, ear cnet 13, The other quick-disconnect Is the Wiggins snap fItting which also allows fuel flow when connected ... but which, when disconected, provides automatic sealing of both hoses. NOTE This Fitting Is widely used in field instal lations. 14, High pressure LPG hose ... used between the tank and the solenoid... consists of an inner rubber tube, » cloth-webbed binder to prevent expansion, and an outer rubber Covering whlch Is". 15, s+. porous to prevent blistering If fuel Seeps through the hose. Only this type of UL-approved, non-netal Iie LPG hose can be used... never standard hydraulic hose uibich can short because of its netel webbing and cause fire, NOTE High pressure hose does not hove reusable fittings. Low pressure hose with reusable fittings may be used between the final and primary regulators but it must meet UL standards. Section 2, Page 6 Code: PHAN346, MAR 75 Copyrighted Mart Irended for CLARK, dele only 00 snowsrIrTTy INDUSTRIAL TRUCK DIVISION EQUIPMENT SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 16, The high pressure hose runs from the tank to the bulkhead fitting and then to the solenoid. Just ahead of the fitting there 16 ik 17. ss. a petal fuel filter, If it is plugged it'mist be cleaned. NOTE Never operate an LPG truck without Tes fuel filters Fig. 14470 18. In the bulkhead fitting there Is @ safety ‘elief valve which prevents excessive hose pressures. ¥ Amine THIS VALVE, INSTALLED OUTSIDE THE ENGINE COMPARTHENT, HUST ALWAYS POINT ‘AWAY FROM THE OPERATOR. Fig. 1447 Code: PHAR3N6, MAR 75 Cope Matra Amended for CLARK deers nlyZI MENT 19. Liquid fuel Flows from the ti bulkhead fitting to the sole prevents any flow into the vi the engine is being cranked or is running. The solenoid is actuated 20. ... by the oll pressure switch which In turn Is actuated by engine of! pressur When the engine is started fuel can NOTE Pressure switch contects close at about 1-1/2 PSI. 21, se. Flow into the vaporizer where the wid fuel becones a dry gas. The gas Flows Into the primary regulator which reduces tank pressure to 8 to 12 PSI. This Is a Zenith vaporizer-regulator. With this units. Section 2, Page 8 CUSTOMER SERVICES ENGINEERING OE PARTWENT, rity INDUSTRIAL TRUCK DIVISION [tT oa UTD Tg arn exten Fig, 14473 Fig. way Code: PMARBH6, MAR 75 00 nowCLARK BS rs SERVICE ENGINEERING 2. 2. 2s. fuel flows Into the vaporizer colls Where it Is heated by coolant and vaporized Into dry gas. The flow of the gas to the Final regulator is controlled by the movenent of the primary regulator diaphragn which opens and closes the fuel valve to maintain » flow of fuel in response to engine denands .,. at a regulated pressure of 8 to 10 PSI. The fuel then flows to .. the final regulator-carburetor. This is the Zenith PC=1 unit. In this +. sss two dlaphragns, actuated by pressure Variations caused by air flow In the Carburetor, open and close the fuel valve which controls fuel flow Into the carburetor. When the diaphragns re Forced Jn by atmospheric pressure the fuel valve Is open, When the diaphragms are forced cut by fuel pressure, the fuel valve is Closed and flow to the carburetor is cut off. RUCK DIVISION [eters DEPARTMENT, BATTLE CREEK Fig, 1h76 Fig. 18477 Section 2, Page 9Pets EQUIPMENT 25. Now that we have covered the basic operation of the system. One of the most comon causes of chronic LPG system trouble is .. 26... fuel. it t may be dirt} having trouble .. he Is using HO- 27. s+. whether he tanks and his. section 2, Page 10 INDUSTRIAL TRUCK DIVISION OTs beranven, sare ence ET custo seavices een ore einen) © mens Jie Peed pee nay Fig. 14479 periodicelly has his bulk biiieg gl i Oe an Pai] — Fig. 1460 Code: PHAN346, MAR 75 apie Ma 00 enousMtiya INDUSTRIAL TRUCK DIVISION Perr Premera 0] SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 28, +. truck tanks cleaned. Sell him on the importance of doing these things to keep his trucks running satisfactorily. 29. In one fleet operation, virtual ly all LPG problens were licked when HO=5 propane was Used, and bulk tanks and truck tanks were cleaned periodic fs a matter of good practice Fig. 14482 30, «2+ when you run into LPS engine problens, Sivays perform the following checks before Starting your trouble shooting ... to nake sure the Cause of trouble is in the LPG system. Code: PHH346, MAR 75 Section 2, Page 11 Coprighted Mart Inner CLARK, delet ‘Deal ordretly INDUSTRIAL TRUCK DIVISION Ss [cHSTOMER SERVICES CAGINEERINE DEPARTAMET, BATTLE CREEK ENGINE Tune-Up: Before performing » tune-up on any engine, first find out If ‘engine ‘condition for tune-up. If it needs «8 tune-up would probably be a waste of But first check the of] level and odd of! if necessary. Check the fuel level. Check the water level. Now start the engine and check al Instruments and warning Tights. Fig. 14829 OTs EQUIPMENT Section 2, Page 12 Code: PMAR3N6, MAR 75 Copyhte Motel Innded for CLARK deers ny (00 enousIf you smell fuel Ks at the various connections ... brushing 2 soapy solution on joints. IF bubbles appear, If the leak is at the quick disconnect coupling, replace seals in the coupling. If a leak appears at a hose fitting « pot eliminate the | ‘there is 2 leak at a pipe thread fitting, renove Always apply thread sealant one threed below the fend of the fitting to keep sealant fron entering the LPG systen, To check the condition of the rings and valves, take @ compression check of each cylinder. Loosen a Sperk plug «+. ‘and blow dirt out of the spark plug well to keep any Sccumlated foreign matter from falling into the cylinder. Renove the sperk plug. Code: PHAR3M6, MAR 75 INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK take the precaution of checking for nate tho leaks. NOTE ‘tighten it. If this coes k, replace the hose. If ply @ thin coat of pipe thread GROUP 100] ‘threads and instell the Fitting. Copyrighted Matra Inne for CLARK desis oy ‘Donte or drinae Section 2, Page 13PITT INDUSTRIAL TRUCK DIVISION [FETT pat T Tg pT Td lg CHSTOMER SERVICES XGNEERING DEPARTMENT. While you have the plugs cut and if you feel sure that Complete engine tune-up can be done now, then check the plugs fas you do the compression check on each cylinder. If they ‘are badly fouled or burned, clean or replace th If the plugs are in good condition, check th reset if necessary to .025 of an inch. gaps and When you replace then ... torque to 35 Ib. ft, and connect the spark plug wires. To check the compression on any one cylinder, First attach » compression gauge to an eapty spark plug opening. Section 2, Page 14 sarne eneex Inne for CLARK desis oy Fig. 3278 Fig. 14580 Code: PMARBH6, MAR 75 00 snowsPIETY] INDUSTRIAL TRUCK DIVISION [Ea Tou SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Then == disconnect the high tension coll wire from the distributor cap and ground It, Then floorboard the accelerator pedal and crank the engine, ‘The pressure reading should be sbout 140 P.S.1, Remove the ‘gauge and adaptor and Install the new or cleaned spark plug s+ torquing it to 35 Ib, ft. Repeat this ... one cylinder at's time ... for each of the other cylinders. If pressure varlation across the cylinders Is sore than 15 P.S.1, ++ Ke EER ae) ses squirt of! into any cylinder with @ low reading and check the conpression again. If the conpression cones up to equal the other cylinders ... it Indicates faulty rings. If it does not rise ... it indicates © sticking or burnt valve. NoTe A sticking valve Is Indicated by an Irregular clattering noise and power loss. A burnt valve Ie indicated by a constant miss of one cylinder . Another good way to determine the internal condition of an engine is thru the use of 9 vacuun gouge. To perforn a vacuum check; first Install a vacuum gauge 9s shown, Fig. 14584 Code: PHAT3HG, HAR 75 opemenapin Section 2, Page 15 Inne fr CLARK dele cayPITT INDUSTRIAL TRUCK DIVISION [FETT EQUIPMENT [CHSTOMER SEHVICES ENGINEERING BEPARTMERT, HATTLE CREE EQUIPMENT NORNAL ENGINE OPERATION: At smooth idling speed, a late model engine at sea level, will show @ steady reading between 14 and 22. Opening the Throttle end closing it quickly should cause a drop oF 4 to 6 Inches, followed by # steady rise to the original resding. At these epproxinate altitudes, readings should be: Sea level vee eee tO 1,000 fer 22222222513 to 21 2}000 fest sss tt se T2012 te 20 3,000 feet 22 tile Dll inte i Wooo feet 222222222 toto 8 FOO fest ys ce nes oe 1 9t017 VALVE Leakage: Test ot idling speed. Each tine a valve closes but does not seat properly, the vacuum gauge pointer will érop an inch or nore. In this illustration, the black pointer shows the Steady reading and the white pointer shows the drops that occur es each leaky valve fails to perform its function. ‘The velve or valves causing the trouble can be located by compression gauge tests, be accurate only If the engine has given normal Fepdings on all other tests, Oil in the crankcase must be good ... poor or dilutes off will cause incorrect readings. Beginning with the engine at idling speed, quickly open the throttle al! the way, Hold it open until the engine reaches about 2,000 r.psn. Then close the throttle quickly «.. if the rings are in good condition, the pointer wil! jump five for more inches higher than the normal’ idling position and ‘then return quickly to normal. Less than » fiverinch fe shows a loss in compression ... and @ further check bbe made with a compression gauge - STICKING vatves With the engine idling, irregular érops below normal will Occur when a valve sticks, The drop is apt to be nore pronounced with @ valve sticking than if it were leaking through Improper seating. A leaking valve also is apt to perform regularly, while a sticking valve will show pointer action only when the valve sticks ... so a sticking valve is characterized by irregular pointer action. (A little bit of penetrating of] may serve to clear up 2 sticking valve at Teast temporarily, while it will hove no appreciable effect on a leaking valve.) In this Illustration, the black pointer shows normal, steady reading, while white pointers show the ange of fluctuetions that cen be expected, Sect jon 2, Page 16 Conynahe Materia Inne fr CLARK dele cay Fig, 14588 Code: PMARBH6, MAR 75 00 snowsINDUSTRIAL TRUCK DIVISION [egy SERVICE ENGINEERING 109} DEPARTMENT, RATTLE CREEK yo EQUIPMENT PET. ADJUSTMENT: If the conpression or vacuum test Indicates a valve problen, check and if necessary, set tappet clearanc First, start and run engine unti) normal operating temperature 18 reached. Shut off the engine and remove the Intake manifold (with carburetor), exhaust manifold and valve cover. Renove the distributor cap and crank the engine until the rotor points to the #1 cylinder position with breaker points ‘Open, “In thls position, the #1 platon Is at the top of les, ‘compression stroke with both Ilfters on the base circle of the can and both valves can be adjusted. Adjust the valve clearance to 0,012 Inch on the (0,020 inch on the exhaust, The exhaust (E) and Intake (I) valve arrangenent on the four cylinder engine I ElEE-IeI-e, The other valves may be adjusted by setting the engine with the distributor rotor pointing to the rest of the cylinder sitions In the sequence of the Firing order which Is: 1e3le2, Reinstall the valve cover, exhaust manifold, int (with corburetor) end all linkages, lines, ete, fe manifold Now, remove the air cleaner housing and ... « check the air cleaner elenent, If it Is clogged, it will Cause power loss. Code: PMARIUG, HAR 75 Section 2, Page 17 Conyriphed Moe Intro CLARK desler ty ‘Dome al or dareEQUIPMENT MITTTY INDUSTRIAL TRUCK DIVISION PRET iit tte [CUSTOMER SCHVICES ENGINEERING DEPARTMENT, BATTLE CREEK Always wipe the air cleaner housing base before installing ‘an air cleaner elenent to prevent dirt from going into the air cleaner hose, Check the battery for danage and electrolite. Check the tightness of battery cable connections and ... make sure the negative ground wire is securely connected. Section 2, Page 18 = ynghted Materia Inia er CUARK ons nly Fig. 14592 Fig. 14804 Code: PMA-3N6, HAR 75 (00 snowINDUSTRIAL TRUCK DIVISION [Regi SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Wow, blow out the radiator ... using a two-foot extension fon the air hose. Blow first, through the radiator from the counterweight side and ... ++ then From the engine side. Next... check to make sure the fan Is installed properly and that its blades are not loose or danaged. Then «++ Fig. 14795 theck and, if necessary, adjust drive belts for proper Eension which’ Is 50 to 80 pounds for used belts ... 80 to 120 pounds for new belts. If tension is low, beits will slip vs. Ff It Is high, bearing and seal damage can occur in generator and water puro. W Fig. 14828 Code: PHASE, MAR 75 Section 2, Page 19 Conynahe Materia Inne fr CLARK dele caytty INDUSTRIAL TRUCK DIVISION Paty 14 es UIEee SERVICES (HEMEERIG oEPaRraenT, eaTTC CREEK Lalla all Pressure test the cooling tysten. Nore If the pressure test reveals leaks, eliminate then. Fig. 13483 Pressure test the radiator cop. NOTE trucks have 7 pound caps. Replace the cap If its pressure Is not correct Fig. 13162 2 Sy Check the exhaust pipe to make sure exhaust is not blowing Into the radiator, Then vs Fig. 16711 s+ check the thermostat ... and, If necessary, replace it. Fig. 14708 Section 2, Page 20 Code: PHAM346, MAR 75 00 nowtry 4 INDUSTRIAL TRUCK DIVISION [Regi rt SERVICE ENGINE joc} ERING DEPARTMENT, RATTLE CREEK Now, renove the distributor cap and check it for cracks, corrosion of ternine|s, and durnt center terminal. Remove the rotor. Remove the dust shield to expose ... ass the points and condenser. Check the condition of the points. Fig. 11139 Codes PMAR3K6, MAR 75 Section 2, Page 21 Anunded for CLARK deses vy ‘Donat sal or dotianeMtry4 INDUSTRIAL TRUCK DIVISION PRETTY? Pia custowen stavices ene PAMTMENT BATTLE CHEER If the points are in good cond should be .020 of an inch to correct ‘specification. fon, check their gap which nd, if necessary, set the gap If pitted, burned, or worn replace then and the condenser. If points and condenser require replacing ... remove then. Then... the distributor has no wick, lubricate the can flats. Fig. 19137 Section 2, Page 22 Code: PHAG3NG, MAR 75 ad Maer ARK dealers oly 00 snowsGli INDUSTRIAL TRUCK DIVISION Pata SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Use @ spectal cam lubricant. Now s+. NOTE ‘The Clark part number of this can lubricant is 1800636, : Install the new points and condenser ... securing then irmly. Set the gap between the points to ,020 of an Inch with the Ignition point cam follower on the high point of # can lobe. Be very careful not to get grease on point faces. Finally Install the dust shield, rotor and distributor cap ... fake sure all wires are firmly seated in the cap. Now Code: PHAR3WG, MAR 75 Copii Materia Section 2, Page 23 Inne fr CLARK dele caytlt INDUSTRIAL TRUCK DIVISION [FETT EQUIPMENT ‘CUSTOMER SERVICES ENGINEERING: SEATTLE CREEK bh eda i coll polarity, making certain the wire from the distributor Is’ connected to the negative coll terninel. If the wire Is connected to the positive coll terminal... short spark plug life will result, Start the engine and ... using the spark Indicator shown ... check the coil and spark plug wires to make sure the coll is producing adequate voltage to all plugs. At the sane tine, check all the spark plug wire connections for tightness. Now check cranking voltage. Disconnect the high tension coil wire fron the distributor cap, clip a jumper lead onto the coll wire and ground it on the engine block. Then ... Fig, 12129 Section 2, Page 24 eemiataae Code Ine fr CLARK desks only mae 3N6, MAR 75 00 snowsParTT] INDUSTRIAL TRUCK DIVISION [ERE A SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 100] sss hook up 0 voltmeter across the battery terminals. tow 1 floorboard the accelerator pedal to obtain higher Coapression and crank the engine for s few seconds. During ‘eronking, the voltage should exceed 9.6 volts. If It doesn't, ‘there fs trouble in the battery, cables, or starter. Innediately after crenking, no-load voltage should be at Teast 12 volts. Now... connect the coll wire to the distributor cap and start and accelerate the engine. NOTE If this voltage Is below 12 volts Tt indicat @ battery problen. Charging systen output should exceed 12-1/2 volts. These Wick tests show whether charging and creaking ‘or In need of repair. Remove the voltmeter ‘are made. Fig. 16861 Code: PHAKING, HAR 75 Section 2, Page 25 Copy Mas loaned fr CLARK desler ony ‘Domo sl ordrePTT] INDUSTRIAL TRUCK DIVISION FETT ba TT Tg CUSTOMER staves ENGINEERMG oePaNTMENT,sATTC CREEK ao SERVICE/SHUT-OFF VALVE SAFETY RELIEF VALVE BULKHEAD FITTING To paessine suirex PINK MIRE TERMINAL pe PRIMARY REGULATOR/ \\ varorizer Section 2, Page 26 Code: PHAR3HE, MAR 75 Inne fr CLARK desl ‘Dot sl or darce 00 nousTy? INDUSTRIAL TRUCK DIVISION [ERIE ChE SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK (9) ‘TROUBLE SHOOTING LPG FUEL sySTEM: The foregoing preliminary checks are made to determine sone basic causes of engine problens. Now we can trouble shoot the LPG fuel system os the source of trouble, We can then trouble shoot to correct specific LPG problems, Check to make sure the choke linkage fully opens ‘and closes the choke. Check the wire from the oll pressure switch to the solenoid to make sure It is not loose, If you smell fuel ... take the precaution of checking for leaks at the various connections s+ brushing @ soapy solution on joints. If subbles appear, eliminate the leaks. Note If the leak Is at the quick disconnect coupling, replace seals In the ‘coupling. If a leak appears at a hose fitting tighten it. If this does not eliminate the leak, replace the hose. If there is a leak at a pipe thread fitting, renove the Fitting, apply a thin coat of pipe thread Sealant to the threads and instal! the fitting. Alweys epply thread sealant one thread below the fend of the Fitting to keep sealant From entering the LPG systen. Fig. 14707 PhRe346, MAR 75 a . Section 2, Page 27 Intend fr CLARK dele cay ‘Dome dineMGT? INDUSTRIAL TRUCK DIVISION [PRET Ate CoSTOMER SERICESEMGIECRINGaEPAATWENT, sTLE CHEER CTE One of the most common LPG problems ts that the fengine won't start, To find the cau: +. first, make sure the service valve is open and oe +. that the hose coupling is tight. At the Sone time... Fig. 16866 Section 2, Page 28 Code: PHARSM6, HAR 75PIETY INDUSTRIAL TRUCK DIVISION eas ‘SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK s+ make sure the ten percent maximum withdrawal Valve Is not closed by shutting off the service valve and opening It slowly to prevent any fuel surge which would close the withdrawal valv Now ui AiIhTs Y ee +1 try starting the engine with the choke knob in'ond your foot off the accelerator. If it starts, then the problem was one of not getting fuel fron the tank. But If It doesn't stort and fuel is flowing Into the system then ... Fig. 16864 sss try starting the engine with the choke knob puilea out and with the... Fig. 16867 Code: PMAC3N6, MAR 75 Section 2, Page 29 opp Mater Inended For CLARK dele ny Dontsel or dariaeoa Ba PIETY INDUSTRIAL TRUCK DIVISION iat Te (HSTOMER SERVICES ENGINEERING OFPARTMENT, BATTLE CHECK srator pedal depressed. If the engine Storts, the problen is in the fine! regulator nich may be Incorrectly adjusted or have dirt in It which keeps the fuel valve from operating properly. If the engine does not start with the choke out +, hook up a jumper switch between the positive battery terminal and the solenoid, Now... +. close the switch and listen for solenoid Operation. If the solenold does not operate it must be replaced. If the solenoid operates, Tisten for the hiss of escaping fuel at the carburetor. If there is hissing, it Indicates that a fuel valve in one of the regulators not cutting off fuel flow. To check thi: Fig. 18510 Section 2, page 30 Code: PMA-3H6, MAR 75 (00 snowsmtriy INDUSTRIAL TRUCK DIVISION [yr pat SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK see shut off the tank service valve. Then ... WARNING MAKE SURE THE AREA IS FREE OF ANYTHING WHICH COULD CAUSE AN EXPLOSION: LIGHTED CIGARETTES, WELDING, PILOT LIGHTS, ELECTRIC GENERATORS, MOTORS, NYLON CLOTHING (PRODUCES SPARKS), ETC. sss loosen the bolt on the rear side of the primary regulator so that the regulator can be turned loctitse (a) far enough to allow a pressure Gauge to be Installed. Slowly renove the Fork’ plug {o)"in the. primary regulator co bleed the systen, Now Install a pressure gauge in the primary regulator port and Slowly open the tenk Service valve, Then, close the jumper switch. Fig. 16871 Consigts leven Tor CLARK dears ely "De ne sl or rine Code: PHAR34G, NAR 75 Section 2, Page 31Mtpy4 INDUSTRIAL TRUCK DIVISION CLARK EQUIPMENT Snes eneacnne ecrannacr, nT enEK Li If the pressure Is 20 PSI or more, the primary regulator is faulty. If the pressure is 8 to 12 PSI, the final reguiator is foulty. The Fegulator at fault mist be cleaned or rep After checking pressui shut the tank service valve, remove the gauge, install the test port plug, end slowly open the tenk service If, with the jumper switch closed, the solenoid works and no fuel is escaping at the carburetor + try starting the engine «.. with choke knob and accelerator pedal released. If it Starts then the problem is. Fig. 14516 Section 2, Page 32 Code: PMARIK6, MAF 75 righ Mot 00 anovety INDUSTRIAL TRUCK DIVISION [Rei Li laal LL SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK + caused by the of! pressure switch or by the Oi pump. To determine which Is at Fault vs ++ hook up a volt meter between the solenoid positive terminal and the negative battery terminal. Then crank the engine long enough to Tet of! pressure bulld up. You should get 9 reading of at least 9.6 volts. If there is no reading ... the pressure switch Is faulty, or the oll punp Is defective. To check this’... Fig. 14518 <-, remove the pressure switch and hook up @ Oto 30 PSI pressure gage in the pressure switch port. Then crank the engine long enough to give pressure a chance to bulld up. If youlve got at least five PSI, the pressure switch is at If you get no pressure, the pump Is at Fig. 14519 2 PNAS, MAR 75, Section 2, Page 33pos EQUIPMENT If the engine does not start when the Jumper switch Is closed, the solenoid Is open and there TS frost on hoses or connect ions, oF they are cold to the touch, check lines and conponents fat and ahead of the frosted ares to see whether they are clogged with dirt. customer stances ‘Another convon trouble Is that the engine starts but won't Idle. To trouble shoot this condition se check to make sure the idle stop pin is not aigsing. Then Section 2, Page 34 INDUSTRIAL TRUCK DIVISION yg EQUIPMENT 1 OEPARTENT, BATTLE CREEK Geese ag Fig. 14455 BN US [i 2g Code: PMAR34G, MAR 75 00 nousPITT INDUSTRIAL TRUCK DIVISION Pad he serefthe sure the Idle stop screw Us adjusted to’ obtain the correct idle speed of 500 to 550 Rew, sat the sone tine turning the screw in to get ture. If idle and vacuum are erratic ... check the throttle shaft. If It Is wor Feplace it. If the engine stil] wont idle Code: PMA3N, HAR 75 Meer Inde for CLARK dears ely ‘Dnt el or date Fig. 16874 Section 2, Page 35TTtq INDUSTRIAL TRUCK DIVISION [RETT% a sal cusvowen senvicesenGigeni tePanTaent, uTTL enEeK Coated i++ check the fine! regulator which may have danaged diaphragns or a damaged or gunned up fuel valve seat. Fig. 14526 To trouble shoot the engine vhen it is erratic of stops during acceleration or at full governed Speed... First ve ST pense eee eat ae | ss, check for frosting at the fuel filter ... with the engine running. If the fitting 1s cold to the touch or Is frosted ... clean or replace the fliter. Fig, 16875 Code: PMA-3U6, MAR 75 Section 2, Page 36 00 nowPIETY INDUSTRIAL TRUCK DIVISION BRM Gyr SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Install @ pressure gage in the prinary regulator a8 described defore and check the regulator Pressure at both Idle and maximun governed speed. her speed the pressure is 20 PSI or ‘or below 8 PSI’... the prinary Ts faulty and ‘mist be cleaned or If the pressure is 8 to 12 PSI... +. the final regulator Is faulty and must be Cleaned o repaired. Run the engine and check engine tenperature which should range between 170 to 200 degrees. NOTE If engine temperature Is low ... check the thermostat which, if faulty, can cause poor fuel veporizet ion, Code: PHA-346, MAR 75 Fig, 14530 Fig. 14531 Section 2, Page 37So Mtryy INDUSTRIAL TRUCK DIVISION Pet castouer services WENT, BATILE CREEK Install a tining Tight and... see adjust the Idle screw to 450 RPM, Loosen the distributor base lock nut. Then with the engine Idling «+ +. turn the distributer counterclockwise to advance the timing... or clockwise to retard it. Turn the distributor z fone way or the other... y hens Fig. 14607 Section 2, Page 38 ‘ , Code: PHAR3N6, MAR 75 Inner CLARK dak ony ‘Dnt el or date ‘00 snowsPITY INDUSTRIAL TRUCK DIVISION BED SUI Eae SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK sto set timing. DELCO DISTRIBUTOR #1112673 built before | DEC 74 (Code 4n0): Time 2 deg, ATOC © 450 ENGINE RPA, DELCO DISTRIBUTOR #1112673 built on or efter 1 DEC 74 (Code 4M0): Time @T.0.C. @ 450 ENGINE RPM, Now, slowly accelerate the engine to determine whether there is a steady sperk advance shown as the pointer moves to the Fight of the tining mark, If there is no advance or if erretic, the distributor edvance nechanisn must be repaired oF replaced, ADVANCE Tighten the distributor ‘and renove the tining light. Now r++ ses finally adjust the governor and accelerator linkage. Codes PHAR346, OCT 76 REV Section 2, Page 39 copped Maral Inne fr CLARK desl ‘Dot sl or darceyd Pat Ld cusToweR senvices exGMEERING 2¢PA INDUSTRIAL TRUCK DIVISION Pao EQUIPMENT nT, BATTLE exec Fig, 14612 GOVERNOR & ACCELERATOR ADJUSTHE 1, Disconnect governor spring (A). 7. Install governor spring (A) and adjust no Toad engine speed at 2500 APH. 2, Back out governor surge screw (8) in engine. 8. With accelerator pedal depressed to stop, 3. Adjust idle speed to 550 RPM. adjust accelerator stop bolt (6) 1-1/8" high so that clevis pin (F) moves away from 44. Install governor to carburetor linkage rod slip yoke (iH) .12 of an inch. Lock in place, (C) in full throttle position end adjust to approximately .06 the gap (0) between NoTe carburetor stop pin and throttle arm stop. Adjust idle air-fuel ratio screw 5. Move governor arm (E) to full idle position. between seated and 3/8 turn cut on low enission gas carburetors. 6, Adjust governor surge screw (8) inward untiT Readjust idle APM stop screw to ix just moves governor arn (€). Lock in obtain 550 RPH Final. place, Section 2, Page 40 naan Cone: PHARBHE, HAR 76 Inne fr CLARK dele cay 00 novoyo ou INDUSTRIAL TRUCK DIVISION (CUSTOMER SERYICES ENGINEERING OKPARTMENT, AATTLE CHECK GROUP [00] seni 300 40-50 7. Check for fouled spark plugs THE FOLLOWING ITEMS SHOULD BE CHECKED WHEN 8. Check for defective spark plug wires. ENGINE VIBRATION PROBLEMS ARE REPORTED: 9. Check distributor dwell - 25-34 degrees for Delco, or 66-72 degrees for Prestolite. 1. Torque Frane to axle mounting ring bolts, 710 to 785 Ib. fe. 10, Check ignition timing, Refer to Si bulletin Si-11-187-77 for applicable 2, Torque axle end to transnission bolts and specifications. nuts, 85 to 95 Ib. ft. 11, Check for leaks around inteke manifole and 3. Clearance between axle mounting ring and ‘at carburetor mounting gasker. bushings, .004 to .018. 12, Using vacuum gouge, adjust carburetor air 44, Stee! washer should be in place on top and fuel mixture screw to obtein the highest bottom of rubber motor mount. possible vacuum. Toraue motor support bolt, 115 to 130 13, Adjust engine idle to 550 RPM, tbe ft. 14, If vibration Is evident alll through the |. Be certain thet engine rubber mount has not seteriorated. range oF 600 RPM to governed speed, the Flywheel shoulé be checked for cut of belance condition. Section 2, Page 41 Seeds PHONE, HOV 79) Copii Materia Inne fr CLARK dele cayFittta INDUSTRIAL TRUCK DIVISION att Pema PM SERVICE ENGINEERI! ING DEPARTMENT, BATTLE CREEK lll WORK SAFELY DRIVE SAFELY BE CAREFUL ALWAYS GIVE MACHINE SERIAL NUMBER WHEN ORDERING PARTSGROUP CLARK ROK GROUP 00 SECTION 3 TROUBLESHOOTING IMPCO LPG SYSTEMS Code: PMA~346, OCT 81 a Section 3, Page 1 Insrdedor CLARK. desir oyGROUP 00 is Pay waren met ie 4 YRS wvonostaric oP RELIEF valve Lnquio as LocK-oFF vaLve| ‘a0 FiLTeR Fig. 19657 IMPCO LPG Fuel System (Typical Illustration) GENERAL DESCRIPTION: ‘This supplement describes the operation, maintenance and trouble shooting of the IMPCO LPG fuel system. The system is the same as the standard Clark liquid withdrawal type, except that it uses the IMPCO lock-off valve and filter, vaporizer-regulator, and carburetor. Fig. 19657 identifies the systen arrangement and its components. Section 3, Page 2 ‘opvehted Mate ‘The filter is in the fuel lock-off valve assembly. The system is vacuum operated and requires no choke or solenoid switch. ALL components are precision diecast to give long trouble free service with a minimum of maintenance. The carburetors meet state of California enission control standards. Recommended fuel is HD-5 propane. Code: PMA-346, OCT 81 evened for CLARK deers oly ‘Do nots or daraOPERATION (LPG TANK) 1. The fuel tank is a replaceable storage chamber for LP Gas. It is manufactured to ASME or ICC specifications in capacities of 20, 33-1/2 or 43-1/2 pounds of liquid fuel (9,07,15,20 or 19,7 Kg). Working pressure ranges between 25 and 240 PSI (172,4 and 1654,7 kPa) depending upon temperatures. One end of the tank is equipped with a shut-off valve, fuel gauge, safety relief valve and vent valve. The vent valve is opened manually only when filling or clean- ing the inside of the tank. 2, The safety relief valve opens autonatically when pressure in the tank rises above 275 PSI. It closes when the excess pressure is reduced. 3. The fuel gauge is a float Level type that indicates percentage of fuel remaining in the tank. 4. The shut-off valve is operated manually to control the flow of fuel from the tank. The valve opens counterclockwise, and closes clockwise. Threaded into its base is a maxinun withdrawal valve which closes automatically when a surge of fuel, such as that caused by a hose bursting, exceeds normal engine demand by 10%. At the end of each day's operation, close the shut-off valve no tighter than hand snug to avoid crushing the valve seat. “puss Copyrighted Matra Codes" PMA~346, OCT 81 eee ‘Dnt el or date Fig. 19659 Fig. 14505 Section 3, Page 3GROUP 00 5. A screw or cnap-type quick disconnect coupling is attached to the shut-off valve. It requires no tools to operate. When disconnected it automatically seals off any flow through the valve and the hose. For greatest safety, however, always close shut-off valve, run engine until it stops, and turn off ignition switch before disconnecting coupling. MAINTENANCE: 1, Clean surface of tank using a clean cloth and kerosene or equivalent petroleun solvent. Carefully check for frosted areas and gas odor which would indicate leakage. Open shut-off valve and again check for leakage at shut-off and quick disconnect valves. WARNING FEDERAL AND STATE REGULATIONS PROHIBIT WELDING OR SOLDERING AN LPG TANK — REPLACE IT. TANKS ARE EXPLOSIVE EVEN WHEN EMPTY. When changing tanks: a. Close shut-off valve and disconnect the quick disconnect coupling. Pull down on each of the two latches to release the tank. ® REINS NEVER SMOKE WHEN CHANGING TANKS. NEVER CHANGE TANKS WHEN THE ENGINE IS RUNNING. LPG FUEL IS HIGHLY FLAMMABLE. b. Place tank in guard and tighten quick disconnect coupling by hand. Keep shut-off valve closed until coupling is tight. Section 3, Page 4 Copyehted Mater Iron for CLARK dele Fig. 19672 WARNING DO NOT STORE FUEL TANKS NEAR HEAT OR OPEN FLAME. FUEL TANKS SHOULD BE FILLED ONLY BY QUALIFIED PERSONNEL IN ACCORDANCE WITH LOCAL ORDIN— ANCES. DO NOT REMOVE ANY COMPONENTS FROM TANK. Fig. 19674 Code: PMA-346, OCT 81GROUP CLARK tol c. Before tightening the clamps surrounding the tank, move the tank slightly and observe the level gauge. The gauge pointer should oscillate with the movement of fuel in the tank. A defective gauge can be suspected if the pointer fails to move. d. Carefully check for system leaks when the tank shut-off valve is first opened. Fig. 14707 LPG LINES 1, 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 formulated to carry liquid petroleum gas. It is rayon braid reinforced two tube construction with the outer tube perforated to prevent blistering if seepage occurs. All other hoses in the system are to Clark specification for vacuum or water usag Fig. 19675 WARNING NEVER SUBSTITUTE FOR UL APPROVED LPG HOSE. Fig. 19676 2, ALL lines in the LP Gas system should be inspected periodically (generally every 30 days). LOCATE MACHINE IN A WELL VENTILATED AREA. DO NOT An odorant is added to LP Gas to help SMOKE OR PERFORM THIS CHECK detect leaks. If at any tine this odor is NEAR OPEN FLAME OR OTHER detected, shut off the engine and fix the SOURCES OF IGNITION. DO leak. NOT DISCONNECT ANY LINES WHEN EXHAUST MANIFOLD IS EXCESSIVELY HOT. LP GAS IS HIGHLY FLAMMABLE. Code: PMA~346, OCT 81 tn Mae aan LARK dar aly Section 3, Page 5GROUP 00 3. 6. Section 3. Pase 6 Wipe hoses and fittings vith a clean cloth moistened with a UL approved cleaning solvent. Use soap and water or leak detector solution and check hoses, connections and assemblies vhile system pressure is not less than 90 PSI (620,6 kPa). When hose assemblies with reusable fittings are used, also test between the fitting ferrule and the hose. When necessary to replace fittings and hoses, or to reseal connections: a. Close shut-off valve on LPG tank, snug tight. b. Run engine until it stops and turn off ignition switch. Then open connection. Wore This burns fuel from Lines venting bleed-off to air. pre- Apply a UL approved thread sealant to all pipe threaded fittings (male threads only). A stick-type pipe joint compound only is reconmended. Copyighted Mater Fig. 19673 CAUTION DO NOT USE A LIQUID OR PLASTIC THREAD SEALER. IT MAY ENTER THE LPG LINES DURING ASSEMBLY. Code: PMA~346, OCT 81 Iesended For CLARK deers nly ‘Dont sel or dsbe7. Standard torque specifications do not apply to pipe threads. When installing: a. Hand tighten first. b. Then wrench tighten 1-1/2 to a maximum of 3 turns. 3. Pressurize the entire system, and recheck for leaks. 8. Fuel lines must have a minimum clearance of 2" (50,8 mm) from exhaust system parts, and be supported by clamps, straps or tape to minimize chafing or wear. HYDROSTATIC RELIEF VALVE A hydrostatic relief valve is used in the LPG systea to bleed off fuel line pressure in excess of 400 PSI (2758,0 kPa). It opens automatically and closes when the excess pressure is reduced. The valve is installed in the 3-way adaptor fitting outside the engine compartment, and must always point avay from the operator. Check for leaks and replace valve if it fails to seal properly. VACUUM AND WATER LINE! 1. The IMPCO LPG system depends on tight vacuun connections at the fittings. If hose ends are belled, split or loose, clip off damaged part and reconnect to the fitting. Code: PMA-346, OCT 81 (Typical) Fig. 19664 (fypical) Fig. 19661 Fig. 19677 Fig. 23167 Section 3, Page 72. Water 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. Push hoses solidly back into position. Do act use cement nor clamps on the push-on type fitting. FUEL LOCK-OFF VALVE AND FILTER OPERATION: The fuel lock-off valve is vacuum operated. When a slight vacuum is sensed, it opens and allows liquid fuel from the tank to flow through an internal fuel filter to the vaporizer- regulator. Any time the engine stops, whether the ignition key is on or off, the fuel is shut off automatically. Also, it filters any large particles of solid material, 5 microns and larger, out of the fuel before they reach the high pressure side of the vaporizer-regulator. MAINTENANCE: 1, The fuel filter element should be checked once a year and replaced if necessary. Foreign matter usually will be collected in filter only when installation is new. Often a new tank will have scale or rust particles in it which will be caught by the filter. 2. Check hose connections and filter cover (inlet side) for signs of leakage. Look for stains or frost caused by evaporation. Tighten cover screws as required. Discon— nect hoses and reseal threads if necessary. CauTION OVERLY TIGHT HOSE CONNECTIONS MAY CRACK THE CASTING. Fig. 19664 Section 3, Page 8 Code: PMA~346, OCT 81LETTER STICKER HAND VENT PART NUMBER SECONDARY COVER ATMOSPHERIC GROUP 00 LPG INLET 1/4 NPT WATER IN-OUT 3/8 NPT PRIMARY COVER. PRIMARY TEST PLUG 1/8 NPT Fig. A1589 Model J Vaporizer-Regulator STICKE! * LPG VAPOR OUTLET 1/2 NPT OPERATIO: The vaporizer-regulator is a combined two-stage regulator and vaporizer. It receives liquid fuel at tank pressure from the fuel lock-off valve and filter and reduces that pressure in two stages to siightly less than atmospheric. When the engine is cranking or running, a partial vacuum is created in the fuel line to the carburetor, which opens the regulator permitting fuel to flow to the carburetor. In the process of reducing the pressure from approximately 150 PSI in the tank to atmospheric pressure, the liquid propane expands to become a vapor, causing refrigeration. PMA~346, OCT 81 Copy Matera To compensate for this and to assist in vaporization, water from the engine cooling system circulates through the vaporizer and raises the tenperature of the fuel as it enters the vaporizer at 44 degrees F to +44 degrees F at full rated fuel flow. The regulator seals off fuel flow when the engine is stopped. IMPCO makes two sizes of vaporizer regulators, the Model J which is rated at 12 gallons/hr. and the Model EB with a rating of 32 gallons/hr. Both use mechanical primers for cold weather starts. Section 3, Page 9 Aounded for CLARK desers vly ‘Donat sal or dotaneGROUP gO CLARK MAINTENANC! 1. Check fuel, water and vapor connections for evidence of leakage, such as stains, frost, or gas odor. Tighten cover screws or reseal hose connections as required. 2, Remove fuel vapor hose and check for deterioration. Particularly check vapor outlet fittings for tighteness. CAUTION OVERLY TIGHT HOSE CONNECTIONS MAY CRACK THE CASTING. Fig. 23170 Renove and clean the vaporizer-regulator every 1000 hours or 6 months of operation s described in overhaul supplements: Model J - 08-373, GROUP 02, Section 6 & Fig. 19350 Section 3, Paze 10 as Code: PMA~346, OCT 81 Insane for CLARK deers ly Do not el odeFig. 03-203 Code: PMA-346, OCT 81 S. 2.103 Copyrighted Matera Inna for CLARK desl ‘Dnt el or date GROUP 00 02.100 CARBURETOR ASSEMBLY 02101 REPAIR KIT, CARBURETOR 02.103 SCREW, IDLE ADJUST 02.10% SPRING, IDLE ADJUST SCREW 02.114 SCREW, THROTTLE LEVER CLAMPING 02,116 GASKET, CARBURETOR MOUNTING 02.117 SPRING, THROTTLE STOP SCREW 02.118 SCREW, THROTTLE STOP 02,188 SCREW, THROTTLE PLATE 02.440 LEVER, THROTTLE 03.089 © SHAFT, THROTTLE 03.203 PLUG, ‘CARBURETOR ATR HORN 03.204 SCREW, CARB AIR HORN TO THROTTLE BODY 03.205 SPRING, CARBURETOR AIR VALVE 03.206 SPRING, CARBURETOR POWER JET VALVE 03.207 POPPET, CARBURETOR POWER JET VALVE 03.208 PLUG, CARBURETOR THROTTLE BODY 03.209 LEVER, CARBURETOR THROTTLE STOP 03.210 PLATE, CARBURETOR THROTTLE 03.211 BOLT, “CARBURETOR THROTTLE STOP’ LEVER 03.212 SEAL KIT, CARBURETOR THROTTLE SHAFT 24 *® BODY, THROTTLE 25 ** AIR HORN ASSEMBLY NOTE: Fig. No. 03-203 will assist you in identification of carburetor component parts and illustrate the relationship between these parts when dis-assembling or re-assembling the carburetor. This illustration is intended for use in locating and identifying parts during carburetor rebuild. Thoroughly clean the outside of the carburetor before dis-assembling. U kerosene or equivalent petroleum solvent to prevent damage to synthetic rubber seals used in these assenblies. ip Section 3, Page 11GROUP 00 OPERATIO: The carburetor is an air valve design that uses a relatively constant pressure drop to draw fuel into the carburetor fron cranking to full load. A pressure drop under the air valve is required to open valve during cranking. This vacuun is communicated to the vaporizer-regulator to draw out fuel and also actuates fuel lock-off valve. Engine will start best with throttle wide open, as on a governed engine, and ordinarily requires no priming for fast starts. Mixtures are controlled by a carefully contoured gas metering valve and carburetor adjustments. With engine stopped, fuel is sealed off within carburetor as well as in the vaporizer-regulator and fuel lock-off valve, giving a triple seal for safety. MAINTENANCE: Since the carburetor has the 1 Carburetor may be updraft or downdraft design depending on engine require~ ments. The carburetor has only two moving parts, an air-gas valve assembly and a throttle plate. Flow of air through carburetor is controlled by throttle valve (same as any other carburetor). Flow is measured by air-flow measuring valve in the bowl of carburetor. The greater the air flow, the higher air- flow measuring valve rises. The gi metering valve is connected directly to air valve so that it rises exactly the sane amount. Gas valve is shaped to admit correct anount of gas at any height to which air-flow measuring valve rises. et complicated function to perform, and has the fewest moving parts, it would be well to exhaust every other avenue of possible mechanical or electrical failure before tampering with carburetor adjustments, particularly if the system has been functioning normally in the past. Refer to the trouble shooting section. based on vacuum originating at the The proper operation of the LPG systen is carburetor, To assure fuli availability of vacuum at all component: a. Check vacuum hoses. Tighten clamps, clip off bad ends, or replace hoses as required. b. Tighten carburetor mounting flange bolts. c. Tighten throttle body and cover screws to the carburetor housing. 4. Check for loose intake manifold. Section 3, Page 12 Copyrighted Matra Fig. 23171 Code: PMA~346, OCT 81 Ine fr CLARK desler onlyEvery 1000 operating hours or 6 months of operation, remove the carburetor and clean the housing and air-gas valve assembly. Refer to overhaul supplement: CASO - 08-373, GROUP 02, Section 1 IMPCO carburetors are pre-set at the factory and should require no further adjustment. However, if they should require minor idle adjustments, use the following instructions: Before you make any air-fuel or idle adjust ments: dy Code: PMA~346, OCT 81 a. The air cleaner should be installed. b. ‘The engine and transmission should be at operating temperatures. cs Governor and idle speed must be set to specified RPM. Idle Air Fuel Adjustment: Turning the screw "IN" will make the fuel mixture richer and turning it "OUT" will make it lean. CAUTION ‘THE IDLE AIR FUEL RATIO SCREW IS SENSITIVE AND SHOULD BE CHANGED ONLY WITH THE USE OF A.C.0. EXHAUST ANALYZER. Set the idle air-fuel adjustment at .30 to +70 percent carbon monoxide. Alternate Method: Turn idle air-fuel mix- ture screw "OUT" until engine runs rough, then turn the idle air-fuel mixture screw “IN" approximately 1/4 to 1/2. Turn until engine begins to smooth out. GROUP 00 Fig. 23170 Section 3, Page 13GROUP 00 2. Power Adjustment (If applicable): This adjustment controls mixture a when gas metering valve is with- drawn from the jet. It is effec~ 2. tive only when the engine ap proaches full-load condition and can be set only with the engine 3 loaded, at or close to its rated RPM Limit. NOTE 4 Do not turn the power adjustment screw. It has been preset at the factory for maximum power at full load governed RPM. Further adjust- 5 ment is not required. ‘TROUBLE SHOOTING: Trouble shooting is a systematic approach to isolate the cause of a problem. Ninety-five percent of all engine problems will be found in the ignition system, air cleaner system, RCV system or the cooling system. To isolate the fuel system check the following: Check ignition coil, points, plugs, wires, ignition timing and dwell. Check radiator coolant level, hoses and thermostat. 3. Check for restricted air cleaner and muffler. Check governed RPM. 5. Check throttle travel. At full throttle opening there must be 1/32" clearance between throttle stop pin and stop screw. 6. Check PCV valve. Used only on Chrysler LH-318 engine. Section 3, Page 14 Copyehted Mater Before Working On Truck: Park in well ventilated area. Park away from or eliminate all sources of ignition. Position truck so LPG tank is out of path of forced air heaters and direct heat radiation. Have MULTI-PURPOSE ABC type fire extinguisher (preferably dry powder) available and in good working condition. Use gloves on high pressure frosted lines or components. Code: PMA-346, OCT 81 Inne for CLARK deses oy ‘Do nots or daraGROUP 00 Ir is is ib, es Fig. 19658 Checking IMPCO System an engine does not start, following 5. @ quick check to determine if problem in ignition or fuel system: Open shut-off valve on LPG tank. 6. Remove vacuum line (1) and suck on the vacuua hose. If you have an electrically operated filter lock, turn the ignition switch to the "ON" position. ty Push on primer button (2). Disconnect vapor line (3) and gas should escape PMA-346, OCT 81 opp Mater Inne for CLARK desler only Dontsel or dariae If gas does not escape from the Line, loosen fitting (4). If gas leaks from this fitting, the regulator is defective. If gas does not leak from fitting (4), loosen fitting (5). If gas leaks from fitting (5), the filter lock is defective. If gas does not leak from fitting (5), the tank is empty or the Liquid service valve is in the closed position. Section 3, Page 15GROUP ROK CLARK TROUBLE SHOOTING GUIDE ‘PROBLEM POSSIBLE CAUSE Engine Won't Start 1, Tank shut-off valve closed. 2. Low or no fuel in tank. 3. Vacuum line loose, pinched or plugged. 4. Lockeoff valve diaphragm leaking. Hard Starting 1. Loss of vacuum in systen. 2. Secondary valve in vaporizer sticking. Erratic Idle 1. Loss of vacuum in systen. 2. Primary valve in vaporizer-regulator defective. 3. Airgas valve diaphragm in carburetor stiff. Lack of Power 1, Tank shut-off valve not fully opea. 2. Withdrawal valve (10%) closed. 3. Tank low on fuel - pulling vapor only. 4. Lock-off valve filter plugged. 5. Low vacuum in systen. 6. Carburetor loose on manifold. 7. Vaporizer-regulator cover check valve restricted (Models JBC & JOC only). "Hunts" At Governed RPM 1. Secondary diaphragn in vaporizer-regulator stiff or leaking. 2, Secondary valve in vaporizer-regulator dirty and sticking. Frost, Ice or Moisture on 1, Lock-off valve filter plugged. Shut-Off or Lock-Off Valve 2. Withdrawal valve (102) closed. Frost, Ice or Moisture on 1, Vaporizer water hoses improperly connected, Vaporizer-Regulator bad hoses or air lock. 2. Primary valve seat in vaporizer-regulator not seating. Section 3, Page 16 Code: PMA~346, OCT 81 Copyehted Mater Inne for CLARK deses oy ‘Do nots or daratly INDUSTRIAL TRUCK DIVISION [RRM Ts lO 1} SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK GROUP 01 LUBRICATION CHARTS SECTION 1 Code: pMae345, OCT 74 Section 1, Page 1PITT] INDUSTRIAL TRUCK DIVISION EqUIPMENT SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK oy EQUIPMENT EVERY 50 To 250 OPERATING HOURS Wipe FITTINGS CLEAN GEFORE APPLYING GREASE PISTON HEAD GUIDE ROLLERS COLO STORAGE i STEERING LINKAGE. COLD STORAGE w TILT CYLINDER ENDS UPRIGHT MOUNTING RINGS PEDAL SHAFTS: w COLD STORAGE Section 1, Page 2 Codes PMARBHS, OCT 7H 40 anovaMery 'NDUSTRIAL TRUCK DIVISION be woe, ATE cate cast EVERY 50 TO 250 OPERATING HOURS CHECK LUBRICANT LEVEL OF AUTOMATIC ‘TRANSMISSION CHANGE ENGINE [F2 OIL FILTER SSS} CHECK FLUID LEVEL CAP VENT HOLE BY-PASS PORT OF BRAKE MASTER CYLINDER COLD STORAGE CHECK SUMP TANK FLUID LEVEL AND CONDITION OF FLUID ram DRAIN AND REFILL ENGINE CRANKCASE Code: PMA~345, REV OCT 81 P.S.L. Section 1, Page 3 Ince fr CLARK desir oyCLARK bah INDUSTRIAL TRUCK DIVISION HSTOMER SEAVICS ENGINEERING DEPARTMENT, arn cates [PERFORM AT THE [STATED INTERVA\ DRAIN AND REFILL HYDRATORK EVERY fy 1000 HOURS (GROUP 06, SECTION 4) REPACK WHEEL BEARINGS WHEN BRAKE SHOES ARE REPLACED (GROUP 26, SECTION 3) e- 0 CHANGE THE TRANSMISSION FILTER AFTER 50 HOURS AND 100 HOURS ON NEW TRUCKS. CHANGE EVERY 500 HOURS THEREAFTER. DRAIN AND REFILL HYDRAULIC SUMP EVERY 2000 HOURS OR ONCE A YEAR (GROUP 29, SECTION 1) rl COLD STORAGE CHANGE HYDRAULIC FILTER EVERY 2000 HOURS OR ONCE A YEAR Section 1, Page 4 Copy Matera Code: PMA~346, REV OCT 81 P.S.L. Aounded for CLARK desers vy ‘Donat sal or dota To anouaPIETY INDUSTRIAL TRUCK DIVISION BER a SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK jou) GROUP 01 COOLING SYSTEM HAINTENANCE SECTION 2 Code: PMAr270 Section 2, Page 1yo aud COOLING SYSTEM Pressure Cap: yo USE EXTRENE CARE IN REMOVING THE RADIATOR PRESSURE CAP. IN PRESSURE SYSTEMS... THE SUDDEN RELEASE OF PRESSURE CAN CAUSE A STEAM FLASH ANO THE FLASH, OR THE LOOSENED CAP CAN CAUSE SERIOUS PERSONAL INJURY, LOOSEN (CAP SLOWLY AND ALLOW STEAM To ESCAPE PLACE A RAG OVER THE CAP AND... THEN LOOSEN CAP, 1. Inspect pressure cap gasket and Filler neck to be sure they are providing 2 proper seal. If the rubber face of the valve is defective s+ anew cap should be instal led. 2. Inspect pressure cap for freedom of operation. Pressure caps employ either @ vacuum vaive held against its seat under Spring pressure, or a weighted vacuun valve hich hangs open until Forced closed by a Surge of vapor er coolant. check £0 be sure conponents are free to operate. NOTE If a new cap is required ... always Install e cap of the same type and pressure rating ... 7 pound cap. 3. Inspect for dented or clogged overflow pipe. To renove clogged material... run @ flexible wire through pipe until obstruction Is Fenoved.. When 9 pressure cap opens the sudden surge of vapor liquid mist pass thru the overflow pipe. If the pipe is dented or clogged, the Pressure developed by the obstruction may Cause damage to radiator or hoses. Inspect_and Clean Cooling Syst Check hose connections for coolent leaks as well as alr leakage. Air leakage allows oxygen Into the system which Is @ major factor In corrosion. NOTE Exhoust gas leakage between cylinder head and gasket also results In corrosion. Section 2, Page 2 INDUSTRIAL TRUCK DIVISION [RETT? SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Nao Maer EQUIPMENT Fig. 6458 VACUUM VALVE Pace To OPERATE RUBBER FACE WF DEFECTIVE ANEW INSTALLED. | PRESSURE veel OSE EXTRENE CAREIN | REMOVING PRESSURE CAP Fig. 6459 If exhaust gos discherges inte coolant the coolant and gas consine to 2 variety of ac! Inner CLARK dele cay 10 anovePITT Ta INDUSTRIAL TRUCK DIVISION PERg 101 | ey SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 9. 9740 IMPORTANT Meintaining the cooling system efficiency is Important, as engine tenperatures mst be Torque cylinder head stud nuts to brought up to and maintained within satisfactory specifications. Flush system with a range for efficient operation ... however, mst washing soda solution, then ... drain be kept fron overheating, in order to prevent systen, damage to valves, pistons and bearings. Continued overheating may cause internal damage vile continuously low operating tenperature iastes fuel, Increases engine wear and causes O11 sludge and corrosion of engine parts. 2, Boll other half of voluse and add washing soda until no sore will dissolve ‘overcooling may be caused by operating conditions such as excessive Idling, low speeds and light loads ... during cold weather. Over~ 3. Add hot soda solution to cooling system . #111 up. heating may be caused by faulty thermostat, clogged radiator or an improperly adjusted fan Lb, Operate engine normally for 24 hours. belt. 5. Drain ... flush ... refill with 50% clean water and 50% Ethylene Glycol. This solution is recommended for year round operation. Copyright ire Section 2, Page 3 Intended for CLARK dlrINDUSTRIAL TRUCK DIVISION (CUSTOMER SERVICES GROUP ‘THERMOSTAT REMOVAI 1 2, Remove the bolts which retain the water outlet and the thermostat housing to the cylinder head. NOTE Be sure to mark the bolts in such a manner, so that upon reassenbly, the sane bolts are placed back in the same holes they came from. Inspect and test thermostat. Fig. 3553 Typical Thermostat Testing ‘THERMOSTAT TEST: ‘The thermostat operation can be checked by the following method: i. Hang thermostat by its frame in a container of water so that it do not touch the bottom. Check specifications to see at vhat tenperature your thermostat is fully open. Heat the thermostat as shown to find out if it opens at the right temperature. If not, replace with a new thermostat. ‘THERMOSTAT REPLACEMENT: % Section 2, Page 4 Using gasket sealer on both sides, place thermostat on cylinder head. Place water outlet on the cylinder head over the thermostat. Install capscrews in their individual holes, finger tight. Gradually and alternately tighten capscrews to normal torque. Coppi Materia Intend fr CLARK dele cay ‘Dome dine Code: PMA-270, JUL 80 REV To anousINDUSTRIAL TRUCK DIVISION [Rei ol bill SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK yoy VISCOUS FAN (Trouble shooting) is Whenever a malfunction of the viscous fan is Stert engine and set throttle at about 2000 RPM minimum. This should be done In a warm Suspected, always make sure all other parts of eet the -coling systen are in good working order 3. It should be noted that the fen speed may be Firs. high upon initial engine start, but will Feduce in speed within a few minutes tine, ccHeck FoR: - “ 4, Within ten minutes there should be enough heat generated (180 degrees F. air temp at bicmetel coil) to couse the fan speed to Increase to specified linits. 1. Low coolant level. 2, Broken or loose fan belt. Defective radiator cap. 5. To make specific measurenents of cof! air tenpersture and fan speed, requires sone reliable equipnent. it is possible, with experience, to make » judgnent in this ares Without measuring equlpnent. Broken or les ing hoses. a+ Inaccurate tenperature sensing unit. 6, Radiator core fins blocked by debris. 6. If it te obvious that the viscous fan clutch did engage and Increase the fan speed to ‘Specified levels, then the clutch can be considered to be operating satisfactorily. 7. Stuck or broken thermostat. 8. Sludged radiator core. 7. If on the other hand, it is obvious that the viseous fon clutch did not engage and increase the fan speed to specified levels, the clutch can be considered defective due to low fan speed at operating temperature". 9. Worn water pump. 10. Transnission problens. If al] the above are checked out as not the 8. Finally, @ movenent of the fan blade in couse of overheating the engine, then follow See ibn ciuaice of fan blade these steps for checking the viscous fan. deflection, usually means a mechanics! Fal lure. The engine should be relatively cold (turned off for at least four hours). Code: PHA-273, REV JUL 77 iia ei Section 2, Page 5 Anunded for CLARK deers oly ‘Donat sal or dotianeMRT TY INDUSTRIAL TRUCK DIVISION [ETT ‘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. 1287-2 JUNE 80CLARK GROUP 06 SECTION HYDRATORK TRANSMISSION PRESSURE CHECKS (H-125, H-126, H-127) Code: PMA~345, REV APR 82 Section 1, Page 1 Copied Masri Intro CLARK desler ty ‘Dome al or darePIPTT] INDUSTRIAL TRUCK DIVISION taf Ltd bg SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Conpletely clean the truck and transmission before making pressure checks. This should include cleaning the conplete machine with stean. Hoking sure the radiator and Its tubes ‘are clean externaliy and internally. Fig. 13727 Check transmission fluid level. Run machine in forward and reverse for about one to three minutes total. Stop engine ‘and check fluid level, Fill if necessary to the "FULL! mark fon the transmission dip stick. Check the brake peda! free trovel and adjust according to GROUP 23, Section 2. Check engine for prescribed NO-LOAD 2350 RPH. Fig. 15642 Section 1, Page 2 a as Code: PHAe345, OCT 74 Inde ar CLARK dele oy Domtel or aurie 90 nowPrryya INDUSTRIAL TRUCK EQUIPMENT exsToMcR savices enenecRMs paar, Check the engine at 2200 RPM with rated load. ‘This may be done by holding the tilt lever in the back position. The engine must be cor rectly tuned before making the transmission pressure checks. Poor engine performance will give incorrect stall checks. Check for normal engine stall by putting truck against an imnovable object. With the truck in gear, accelerate to full throttle. The nor- nal engine stall RPM is 1350 to 1500. Low interim range engine stall (1000 to 1350 RPM) indicates a loss of engine power. Low engine stall (650 to 900 RPM) indicates that a converter stator is slipping. The con— verter must be replaced. Code: PMA-345, REV OCT 81 DIVISION [Revers 106} taTTUC CHEER Fig. 15643 Fig. 15644 Fig. 17096 Fig. 15645 Section 1, Page 3try INDUSTRIAL TRUCK DIVISION PyTry9 Pai ie SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK od FORWARD OUTLET PLUG QUTLET PLUG "COMBINATION FLUID LEVEL DIP STICK AND FILLER PIPE HOUSING OUTLET Sa (A) CONVERTER PRESSURE REGULATING VALVE CONVERTER PRESSURE_CHECK Section 1, Page 4 Fig. 6658 — Code: PHA-SNS, OCT 74 Intended for CLARK dks ony 90 snowCLARK eg Renove pipe plug and Install pressure gauge at the converter housing cutlet (A), (Fig. 6658), Check pressure with transmission In NEUTRAL and engine running et 1400 RPA. Pressure should be 125 to 135 P51, If pressure Is low, place shim stock (.001" to .002" thick by 11/2" wide) between the Inlet pressure hole (8) of the trensmission control cover and trensmission case, Check pressure again, Pressure should be 125 to 135 PSI. If pressure is still low, the transmission punp or pressure regulating valve may be defective. Report to designated ‘author ity. Check control cover of selectors at elther forward or reverse outlet plugs, (Fig. 6658). Securely block machine so It cannot move. Install pressure gauge a: either the forward or reverse outlet plugs. Start féngine and place directional control lever in either forward for reverse (depending upon which selector Is being checked). Run engine ot 1400 RPH. Pressure should be 125 to 135 PSI. (Fig. 17958) If pressure is low, Insert shim stock (.001" to .002 thick and. 1-1/2" wide) between elther the forward or reverse hole (whichever one was used) and the transmission case. Check pressure again. Pressure should be 125 to 135 PS! Pressure Is low, trouble Is in the control cover. if pressure Is 125'to 135 PSI, the trouble is inside of the transmission, Report to designated suthority. Conerter pressure should be checked with transnission In NEUTRAL and engine running at 1400 RPM. Pressure should be 65 to 75 PS: If pressure Is too high, the cowerter pressure regulator may be at fault; or If pressure is low, the pressure regulator nay be defective, there nay be internal leaks, bad seals, or 2 worn pump. Report to designated person in authority. Copyrighted Mart Insnded for CLARK, dsl ony ‘Dont sel or daibae INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK eee GROUP 10.6] Fig, 17058 race srin stock BeTveeN "F OLE a0” TRANGHISSION CASE Fig. 1705¢ Section 1, Page $NOTES 1146-2 REV DEC 83 PMGROUP CLARK ns GROUP 06 SECTION 2 TRANSMISSION FLUID AERATION CHECK Code: PMA~270, REV JAN 77 Section 2, Page 1 hed Mae Inna for CLARK dele enINDUSTRIAL TRUCK DIVISION (CUSTOMER SERVICES GROUP ‘TRANSMISSION FLUID AERATION CHECK A fluid level that is too high will cause the fluid to becone aerated. Aerated fluid will cause low control Pressure and the aerated fluid may be forced out the vent. Check the transmission fluid level. Low fluid level can affect the operation of the transmission and may indicate fluid leaks that could cause transmission damage. When converter drain plugs leak, remove drain plugs. Coat the threads with a sealing compound and install the plugs. Torque the drain plugs to specification. VHPORTANT THIS TRANSMISSION USES ONLY DEXRON OR DEXRON 11 AUTOMATIC TRANSMISS ON FLUID (ASTM 02882), TRANSMISSION FLUID LEAKAGE CHECK Leakage at the control cover, inlet and outlet ports often can be stopped by tightening the attaching bolts. If necessary, replace the gasket. Check the fluid lines and fittings between the transmission and the cooler in the radiator tank or on the trans- mission for looseness, wear, or damage. If leakage cannot be stopped by tightening a fitting, replace the defective parts. The cooler can be further checked for leaks by disconnecting the lines from the cooler fittings and applying 5 PSI air pressure to the fittings. If the cooler is leaking and will not hold this pressure, the radiator mst be replaced. The cooler cannot be replaced separately. Inspect the pipe plug on the left side of the transmission case at the front. If the plug shows leakage, torque the plug to specification. If tightening does not stop the leaks, replace the plug. Section 2, Page 2 pan Code: PMA~270, NOV 79 REV Inne for CLARK desis oy ‘Donte or drinae 90 énowsPIT INDUSTRIAL TRUCK DIVISION EQUIPMENT SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 106] GROUP 06 TRANSMISSION O1L COOLER SECTION 3 Code: PMAR345, OCT 74 Section 3, Page 1ftp14 INDUSTRIAL TRUCK DIVISION [FET Pat Tae ‘SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK CE Fig, 14610, Typical Transmission Cooling Lines TRANSHISS 10% O1L COOLER CHECK: The following procedure Is a process of Ae If 2 quarts are not collected in 5 seconds elimination to locate possible restrictions. at 1300 RPH, the sane procedure is followed at point #2'and #3. 1. Check all lines for kinks and line pinching conditions. If the flow Is stil] below 2 quarts in § Seconds at 1300 RPH, then the trouble wil! 2, Disconnect hydraulic Tine at point #1 and be faund in the transmission. place ine 3 gallon (or larger) container. 3, Start and accelerate engine to 1300 RPM, place in # 2 quart container for § seconds fand then renove, If the container fills in this time limit, at this RPM, then there are no restrictions In the of! cooling system. Section 3, Page 2 3, Page a Mae 345, OCT Th Ine fr CLARK desler only 90 snowsti INDUSTRIAL TRUCK DIVISION [ERR is 105) SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK GROUP 06 SECTION 4 TRANSMISSION DRAIN Code: PHAR 346, DEC 77 KEV Section 4, Page 1yoy ad INDUSTRIAL TRUCK DIVISION [FETT casTomen Senviceseneineenns ocpatrMenT SATE cxetx Ls lal YDRATORE TRANGUISSTON DRATNING 1, The transmission, convertor and axle adaptor have a common sump tank and should be drained when hot every 1000 hours. Remove both of the drain plugs to completely drain ‘the sump. IMPORTANT Do NOT USE FLUSHING OTL OR CaMPOUND TO FLUSH THE SYSTEX. 2, Remove and clean the transaission sump screen, Clean the old gasket material fron the ating surfaces. Use an approved cleas- ing eolvent to clean the screen. Dry sith compressed air. 3. Put number 3 Permatex on both sides of nev gaskets, Install the screen and sump cover to the bottom of the transeiesion. Tighten the capscrews to [27-34 W'n] 20-25 LBS. FT. TRANSHISSION CASE Sump coven Fig. 6885 ‘The fluid filter element is replaceable. The elesent should be changed vhenever the fluid is drained. To change the elenent just twist off. To replace vith a new one, twist on until snug and turn 1/4 turn nore. NOTE ‘The transaission filter should be changed after 50 hours and then again after 100 hours on any new machine. It should then be changed every 500 hours thereafter and after any tranentssion overhaul. Fig. 16877 Section 4, Page 2 Code: FAAW346, REV OCT 81 Copyright Mtr Inne for CLARK desler only its 90 anowomila INDUSTRIAL TRUCK DIVISION [Reni EQUIPMENT seavices excita oeranwcr, soc eee 4, Replace drain plugs and refill transmission thru the dipstick opening on the axle adapter with DEXRON OR DEXRON II. 5. Operate engine at fast Idle for approximately A minutes to distribute the lubricant through ‘out the systen, Check the new filter and erin plugs for leaks. 6. Shut down engine and check for fluid level Add fluid as required to bring the level to the full mark on the dipstick. Fig. 13735 Code: PMA-346, DEC 77 REV i Section 4, Page 3 Anveded fo CLARK deers olyNOTES 1146-Z REV DEC 83 PMPIPTTG INDUSTRIAL TRUCK DIVISION Ga LL SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK La GROUP Il STARTER MAINTENANCE SECTION 1 Code: PMAR3N6, MAR 75 Section 1, Page 1os Pa ‘STARTING MOTOR: 1. Remove end plate (or brush cover) fron sterter. Use a wire hook to lift a brush Spring and renove brush fron holder. Conpore brush size with that of a new brush. If Brush is worn beyond half the ori size, or If brushes are jammed, ci broken they must be replaced. caution NEVER ALLOW SPRING TO SNAP DOWN ON BRUSHES. INDUSTRIAL TRUCK DIVISION PFET? COSTOMER SERVICES CNGINECRING OEFARTMET, BATTLE CREEK PUSH ON A. LINE, PARALLEL WITH THE SIDES OF THE BRUSH Fig. 643 2, Check for brush spring tension. Refer to the following procedures for checking spring tension. wring Srush Soring Tension - Reaction Type rushes: Hook the scale under the Brush spring near the end and push or pull on a line parallel to the sides of the brush. To assist in telling the exact instant that the pressure is relieved, @ small strip of paper can be placed under the brush. Pull’ slightly on the paper and the paper WIT] Slip out at the correct instant for reading the spring scale. Section 1, Page 2 Aovended for EQUIPMENT Spring Tens Wook the spring Seale under the brush inet the Brush and push or pull fon a line parallel to the sides of the brush. Take the reading just as the brush leaves the commutator. Pulling slightly on a strip of paper which has been placed under the brush will indicate when the brush leaves the conutator snd the correct Instant for reading the spring 3. If conmitator Is glazed or dirty, clean with a strip of No. 00 sendpeper. Blow out all dirt and grit with compressed sir. caution DO NOT USE EMERY CLOTH TO CLEAN CommTATOR. PULLON ALINE PARALLEL WITH THE SIDES OF THE BRUSH. Fig. 6450 Condition Test: Use one of the two following methods to determine whether the starting motor should be renoved from the engine for Inspection, service or replacenent. . Code: PHARBNE, MAR 75 ELARK dsr oy 11 nowPry INDUSTRIAL TRUCK DIVISION [ERG iy EQUIPMENT SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK First Hothod: Gisconnecting the battery cable from the solenoid switch and holding the cable terminal Firmly against the starting notor terminal. Use a battery known to be fully charged and In good condition. To do this it will be necessary to renove solenoié switch. If the motor reacts correctly and the drive echanism engages and disengages each tine the starting motor is operated, the starting motor is in good condition. 3. If moter does not react properly, it must be renoved for Inspection or replacement. Second Method: Using 9 voltmeter and 2 ‘battery (fully charged) that is in good conditfon, comect positive lead of test voltmeter to positive terninel of battery ‘nd negative lead of voltmeter £0 negative (Grounded) terminal of battery. Record voltmeter reading. Now pull high-tension NOTE Wire from Ignition coli $0 engine will not Start when starter is engaged. Connect SLOW OUT ABRASIVE PARTICLES AFTER positive lead of test voltmeter to ground and negative lead wf test voltneter to SEATING BRUSHES. rch terwinal. Turn ignition switch to start ju ition and note voltmeter reading. Coapars: Lvis reading with the previously recora! reading. If the volt Grop Ts more than lh volts or If the second reading is below 8 volts, the starting motor Should be renoveil Iron the engine for further testing an repair or replacement. Code: PHA-3I6, MAR 75 Conynahe Materia Section 1, Fage 3 Intend fr CLARK dele cayNOTES PMMelly INDUSTRIAL TRUCK DIVISION [Reger mtn im SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK GROUP 12 ALTERNATOR MAINTENANCE SECTION 1 Codes PHAR270 Section 1, Page 1ytd Tad ALTERNATOR: IMPORTANT SINCE THE ALTERNATOR AND REGULATOR ARE DESIGNED FOR USE ON ONLY ONE POLARITY SYSTEM, THE FOLLOWING PRECAUTIONS MUST ‘BE OBSERVED WHEN WORKING OW THE CHARGING CIRCUIT, FAILURE TO OBSERVE ‘THESE PRECAUTIONS WILL RESULT IN SERIOUS DAMAGE TO THE ELECTRICAL EQUIPMENT. When installing 9 battery, elways make absolutely sure the ground polarity of the battery and the ground polarity of the elternater ere the some. When connecting @ booster battery, make certain to connect the negative battery Rerminals together and the positive battery terminals together. When connecting @ charger to the battery, connect the charger positive lead to the battery positive termina! and the charger negetive led to the bottery negetive Rerminal. 4. Never operate the alternator on open circuit. Hake absolutely certain all connections In the circuit ere secure. Do not short across or ground any of the terminals on the alternator or regulator. Do not attenpt to polarize the alternator. SPECT On 1. The termingls should be inspected for corrosion and loose connections. The wiring should be inspected for frayed insulation. 3. Check the mounting bolts for tightness. 4. Check the belt/s for correct alignment ++ proper tension and wear. Belt tension Should be Inspected and adjusted, if necessary, every 100 operating hours and adjusted. Section 1, Page 2 INDUSTRIAL TRUCK DIVISION PYty-7% SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 5. IM Phihed acl end for CLARK ddr ony EQUIPMENT After extended periods of operation, or at tlne of engine overhaul, the elternator may be renoved from the vehicle for a thorough Inspection end cleaning of all parts. The alternator requires no other service other than the previously mentioned Inspection. When it becomes necessary to perform tests ‘and internal inspection st the alternstor, See your nearest authorized Clark Equipment Dealer. Code: PHA-270 zt anovaratyt4 INDUSTRIAL TRUCK DIVISION 113] F a Riles SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK GROUP 13 NEUTRAL START SWITCH SECTION 1 Code: PHASE, OCT 74 Section 1, Page 1PIryTTq INDUSTRIAL TRUCK DIVISION [FETT LA Las SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK | i SHIMS (A/R)-THICKNESS 229362 (004 TO .006) 229363 (009 TO.011) 229364 (0145 TO 0175) U5. Se Ry “229365 (030 TO .040) — Ts 8 GAUGE es 010" g OO ps a 2 SOF oe ae “SS ye Y SF | VIEW FROM LEFT TOP REAR [TO ADJUST— USE .010” SHIM GAUGE AND MINIMUM NUMBER OF SHIMS UNDER THE SWITCH TO CLOSE WHEN TRANS-—| MISSION IS IN NEUTRAL. REMOVE GAUGE AND TORQUE SWITCH TO 25 FT-LBS. NOTE: SHIM GAUGE USED TO ALLOW FOR WEAR OF PARTS. Fig, 14611 NEUTRAL START swsTCH: The neutral start itch should be adjusted 3. If the engine doesn't start, repeat this so that the engine will not start except when check in all other gears. the transaission Is in the exact neutral position. 44. IF the engine shou! coming from any gear cosition bef ing exact neutral 1, Occupy the driver's seat, set the parking position, then the ne Ft switch brake, and put the transnission in gear fust be either replaced or agjusted. (with'cluten pede! depressed on standard transmissions). 5. Adjust by means of shins underneath the switeh until the engine will not start in 2, Turn and hold the ignition switch in the any gear position except exact neutral. start position while gently moving the shift ever towards neutrel position. Section 1, Page 2 Codes PHAR345, OCT 74 1 anovaCLARK GROUP 14 GROUP 14 SECTION 1 WIRING COLOR Cove Code: PHA+270, NOV 78 Section 1, Page 1INDUSTRIAL TRUCK DIVISION (CUSTOMER SERVICES GROUP WIRING COLOR CODE FOR INTERNAL COMBUSTION TRUCKS BLACK a) All ground wires. b) Anmeter battery terminal (-) to battery (starter solenoid serves as junction block). c) All lighting circuits (connects to battery thru ammeter) 4) Auxiliary valve circuit (connects to battery thru ignition switch). e) Voltage regulator battery terminal (Delco terminal No. 3) to battery (starter solenoid serves as junction block). f) L.P.G. solenoid to hour meter oil pressure switch. ne water temperature gauge to sender un! RED 2) Anmeter ignition terminal (+) to ignition switch and alternator battery terminals. b) Alternator No. I terminal to starter relay coil terminal and oil pressure switch. ¢) Cold start circuit (heater and switch to battery). ORANGE a) Starter motor circuit (starter terminal of ignition switch to neutral start switch to sterter solenoid coil terminal). YELLOW a) Hour meter of] pressure switch to Ignition switch ignition terminal b) Ignition coil positive terminal to hour meter oil pressure switch. a) Horn and switch to horn relay. DARK GREEN 2) Engine of} gauge or warning light to sender unit. b) MADLO" resistor (Delco) to hour meter of! pressure switch end voltage regulator terminal (Delco terminal No. 4). DARK BLUE a) Fuel gauge to sender unit. a) Voltage regulator field relay coil terminal (belco terminal No. 2) to ignition switch accessory terminal. Section 1, Page 2 Code: PMA-270, NOV 78 apy Mater Inne for CLARK desler only Dontsel or dariae ‘fn dnowsCLARK GROUP 14 WIRING COLOR CODE FOR INTERNAL COMBUSTION TRUCKS BLACK WITH YELLOW STRIPES Starter solenoid relay terminal to hour meter oil pressure switch. RED WITH WHITE STRIPES a) Accessory power (ignition switch accessory terminal to gauges). LIGHT GREEN WITH BLACK STRIPES a) Horn relay to battery (ammeter serves as junction block) DARK GREEN WITH WHITE STRIPES a) Alternator No. 2 terminal thru disconnect switch to starter solenoid battery terminal. LIGHT GREEN WITH WHITE STRIPES 9) Horn button connector to horn relay Code: PHA-270, NOV 78 ‘Corre Mart Section 1, Page 3 Intend fr CLARK dears ty ‘Do ntl odftir INDUSTRIAL TRUCK DIVISION PyETyT? pT Tg SEEVICE EMOINEERING DEPARTMENT, BATTLE caEEK EQUIPMENT WORK SAFELY DRIVE SAFELY BE CAREFUL ALWAYS GIVE MACHINE SERIAL NUMBER WHEN ORDERING PARTSCLARK GROUP 20 GROUP 20 SECTION 1 AXLE END LUBRICATION Code: PMA~273, REV MAY 76 Section 1, Page 1INDUSTRIAL TRUCK DIVISION (CUSTOMER SERVICES GROVP CLEAN AND REPACK AXLE ENDS: Each time brake shoes are replaced clean and repack axle ends, using lubricant outlined in lubrication section, 1, Tilt upright back. Place heavy blocks under each rail, Tilt upright forward until vertical to floor. This should allow drive wheels to clear floor. Deflate tires (machines so equipped) and remove wheels from hub assenbly, 2. Remove hub cap, cotter pin, washer, spindle nut and pull hub assembly from spindle. 3. Remove bearings, clean in Stoddard type cleaning solvent. Slosh bear- ings up and down in solvent. Remove and tap large side of bearing against block of wood to dislodge solidified particles of lubricant. Repeat operation until bearings are clean. Blow bearings dry with compressed air. Direct the air stream across bearings to avoid spinning. Slowly rotate by hand to facilitate drying, Dip bearings in gear of! and wrap in clean paper until they are to be reinstalled. 4, Clean ring gear, pinion drive shaft, hub assenbly, spindle and spindle support in Stoddard type cleaning solvent. 5. Inspect seal for cuts, scratches and nicks. It is necessary to replace if such @ condition is found. 6. Repack each axle end with specified lubricant. Each axle end holds approximately 1 pound of grease. Check axle end vent for obstruction, vent must be open. 7. Install bearings, seal, hub, washer, spindle nut, cotter pin and hub cap. Fig. 9775 Repack Axle End Tilt upright back and remove blocking. Section 1, Page 2 Conrehied Marit Code: PMA~273, REV MAY 76 Inne for CLARK dso oz anowsCLARK GROUP 22 SECTION PNEUMATIC TIRE & WHEEL MAINTENANCE Code: PMA-270, REV JUL 80 Copii Materia Section 1, Page 1 Intrdedfr CLARK delINDUSTRIAL TRUCK DIVISION (CUSTOMER SERVICES GROUP AN waguine FOR YOUR SAFETY AND THE SAFETY OF OTHERS! BEFORE YOU DO TIRE OR RIM MAINTENANCE: 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 THE SAFETY MESSAGES ARE IGNORED. "The Occupational Safety and Health Act (OSHA) specified re: procedures for servicing multi-piece rim wheels in 29 CFR Section 1910.177. It is the owners responsibility to comply with OSHA. In accordance with OSHA, the owner must provide a training progran to train and instruct all employees who service multi-piece rin 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 proper training. ‘The omer should obtain and maintain in the service area current copies of the United States Department of Transportation, National Highway Traffic Safety Administration publications entitled 'Safety Precautions for Mounting and Denounting Tube-Type Truck/Bus Tires’ and 'Multi-Piece Rin/Wheel Matching Chart' or other sinilar publications applicable to the types of multi-piece rim wheels being serviced. The following instructions supplement the OSHA requirement: In the event of any conflict or inconsistency between these instructions and the OSHA requirements, the OSHA requirenents shall be controlling." Section 1, Page 2 SyprawedMowrsl Code: PMA~270, REV JUL 80 ‘Dome dine zz anousMAINTENANCE FOR PNEUMATIC TIRES: REMOVE THE AIR FROM THE TIRES BEFORE YOU REMOVE THE WHEELS FROM THE TRUCK. Check the tire air pressure. Low tire pressure can decrease stability of the truck. (Refer to the truck PMA Manual GROUP 40 for the correct tire pressure specifications.) I IMPORTANT CHECK WHEELS AND TIRES FOR DAMAGE EVERY TIME YOU CHECK TIRE PRESSURE. MAKE REPAIRS WHEN NEEDED. DIRT CAN GET INTO CUTS AND CAUSE DAMAGE TO THE TIRE TREAD. REMOVE DEBRIS FROM ALL CUTS. CHECKING, MINOR REPAIR & CLEAN-UP: Check tires for cuts and breaks. Check for loose nuts or nuts not in position. Check the surface of the wheels for bent flanges. Check the nuts or bolts for damage. Check a11 parts for rust or corrosion. Mark the damaged areas with chalk so that the parts can be removed fron operation. Remove all parts that have damage and jastall new parts in the same position. Replace parts with the correct sizes and types. See your parts manual. 9. Include your truck serial number when ordering replacement parts. Sar - ee TIRES INSTALLED ON LOCK RING TYPE WHEELS: BEFORE YOU LOOSEN THE WHEEL MOUNTING BOLTS OR NUTS, REMOVE THE AIR FROM THE TIRE. FATLURE TO REMOVE THE AIR FROM THE TIRE CAN RESULT IN INJURY. Remove valve core from the valve stem. Code: PMA-270, REV FEB 84 ae Inner CLARK dak ony GROUP 22 Fig. A0821 Fig. 18631 Section 1, Page 3INDUSTRIAL TRUCK DIVISION (CUSTOMER SERVICES GROUP After you remove air from the tire, then loosen and remove the wheel bolts or nuts. Remove the wheel. Fig. 18630 Fig. 18314 CRACKS IN THE WHEEL ARE CAUSED 1, Deep rim tool marks. 2. Too much load on wheels. 3. Too much air pressure in the tires. Using the wrong size tires. Section 1, Page 4 Remove lock ring. Remove wheel wedge. Remove tire from wheel. Remove the rubber tube protector. Repair tire and/or tube. Check for cracks in the wheel. Code: PMA-270, Fig. 18304 REV JUL 80 zz anouoCRACKS IN THE LOCK RING ARE Check for CAUSED BY: cracks in the lock 1, Deep rim tool marks. ring. 2, Too much load on wheels. 3. Too much air pressure in the tires. 4, Using the wrong size tires. CRACKS ARE CAUSED 3: Check for cracks between 1, Loose wheel nuts. the stud holes 2. The wheel was not in the wheel. installed correctly. 3. The wrong size or type of parts were used. TOO MUCH TORQUE ON THE WHEEL FASTENERS. If the wheel mounting parts are too tight, the studs or bolts can break, causing cracks in the wheel between the stud holes. Check wedge ring for wear or damage. 100 MUCH CORROSION WILL CAUSE WEAR AND DAMAGE TO ‘THE WHEEL WEDGE RING. Code: PYAR270, REV JUL 80 utili GROUP Fig. 18305 Fig. 18306 TOO LITTLE TORQUE ON THE WHEEL FASTENERS. If the wheel mounting parts are too loose, damage to parts and tire wear will result. Fig. 18307 Section 1, Page 5INDUSTRIAL TRUCK DIVISION (CUSTOMER SERVICES GROUP Clean the wheels. Re move rust and dirt. Remove all rust and rubber. Fig. 18308 Clean wedge and lock rings. Make sure the seating surface and bead seat areas are clean. apply paint to the tire rim with a brush. Or, use an aerosol can of metal priner. The parts must be clean and dry before you apply the paint. Make sure to apply paint to the outside or tire side of the rim, This is important because air is on the metal surface of the tire side of the rim. Apply lubricant on the tire side of the rin base. Do not use a lubricant that has water or solvent which will cause damage to the rubber. CLARK DEALERS CAN SUPPLY THR CORRECT LUBRICANT WHICH CONTAINS A RUST INHIBITOR. Section 1, Page 6 Copy Mas Fig. 18309 Fig. 18310 Fig. 18311 Code: PMA+270, REV JUL 80 loaned fr CLARK desler ony ‘Domo sl ordre zz anousCLARK GROUP 22 Put the tube into the tire. Install washer 22.095 on tube over valve stem before flap is installed, if specified. Put the rubber tube protector (flap) over the tube. * on sree Sas ae Fig. 18629 Install the tire onto the wheel rim, against the bead seat area. Put the wheel wedge over the rim, Install the wheel wedge. Fig. 18316 Put the side ring over the rim and install the lock ring as shown. a0 Fig. 18627 Code: PMA-270, REV FEB 84 {opp Mater Section 1, Page 7 Inne for CLARK desley Dontsel or dartaeINDUSTRIAL TRUCK DIVISION (CUSTOMER SERVICES GROUP Connect air chuck and put [21 kPa] or 3 PSI of air into the tire. Turn wheel to the other side. Check to make sure lock ring Fig. 16142 is in correct Fig. 18318 location. Use a mallet and hit the ring to make sure the ring is fully installed. Disconnect the air chuck. Put the tire in an OSHA approved safety cage. Follow the procedures on the next two pages when you put air into your tires. If your air supply does not have enough pressure to fill the tire, you can use a nitrogen cylinder to get the correct tire pressure. Connect a nitrogen cylinder to the valve stem with the use of an air chuck. TIRE IS STILL IN SAFETY CAGE! Refer to pages 11 and 12 on "How to adjust the regulator on the nitrogen cylinder". AN wary MAKE SURE THE EQUIPMENT USED (NITROGEN CYLINDER, GAUGES, REGULATOR, HOSES) ARE ALL IN GOOD CONDITION. MAKE SURE ue THE EQUIPMENT IS U.L. APPROVED. Fig. 13985 USE THE CORRECT REGULATOR AND HOSE FOR THE. PRESSURES THAT A\ wans ARE NECESSARY. ET USE NITROGEN ONLY. DO NOT USE OXYGEN OR ANY OTHER GAS TO FILL YOUR TIRES. Section 1, Page 8 Cenyighed Matri Code: PMA-270, REV JUL 80 Inunded fr CLARK dele only @z anousGROUP 22 RELIEF VALVE SUPPLY VALVE CORE DEPRESSING ‘SOURCE COUPLING OF AIR SAFETY CAGE Pig. 9702 Typical Tire Filling Procedure Filling Tires With Air 3, All wheel and tire assemblies must be filled in a safety cage. ‘The air hose and components should be arranged as as shown in Fig. 9702, The hose must 4 have an adapter that can be connected to the valve stem. 1, Attach an air hose to valve stem, 2. Open the control valve which will let compressed air into the tire, Copyrighted Matera Intended fr CLARK desks ony ‘De ntl date Code: PMA-270, REY JUL 90 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 capacity. IMPORTANT PUT EQUAL AIR 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. Section 1, Page 9INDUSTRIAL TRUCK DIVISION (CUSTOMER SERVICES GROUP RELIEF VALVE Model 250V [6.35 mm] or 1/4-INCH NPT Humphrey Products P.O, Box 2008 Kilgore at Sprinkle Road Kalamazoo, Michigan AIR PRESSURE GAUGE MARSHALTOWN #23 {1,103 kPa] or 160 1b. (6.35 mm] or 1/4=INCH NPT [63.5 mm] DIAMETER or 2=1/2-INCH DIAMETER Kendall Industrial Supplies, Inc. 702 North 20th Street Battle Creek, Michigan -49016~ SHUT-OFF CONTROL IMPERIAL #77E [6.35 mm] or 1/4-INCH NPT SAFETY CAGE (OSHA APPROVED) Meyers Tire Supplies 6400 Epworth Blvd. Detroit, Michigan CLIP=ON AIR CHUCK NOTICE: YOU CAN ORDER PARTS FROM THE DEALERS LISTED ABOVE OR FROM ANY SUPPLIER. Section 1, Page 10 ncn te Meret ey -«COdes PMA~270, REV JUL 80 zz anousHOW TO ADJUST THE REGULATOR ON THE NITROGEN CYLENDE Be gure cylinder valve is closed. Turn the regulator valve counterclockwise until you can feel no resistance from the regulator. ‘This will adjust the regulator pressure to a low pressure near zero. Slowly turn the cylinder valve counterclock= wise to open position. The tank gauge will now show tank pressure. Fig. 18324 Turn the regulator valve clockwise until the regulator gauge reads the correct tire pressure. Fill the tire with nitrogen. Turn the tank valve clockwise and close the valve. Code: PMA-270, REV JUL 80 Suis nel or CUHK deo ny Dome or dba GROUP 22 | Fig. 18324 Fig. 18324 Section 1, Page LiINDUSTRIAL TRUCK DIVISION [MARKETING TRAINING DEPT Disconnect the air chuck from the valve stem, Fig. 16141 Turn the regulator valve counterclockwise to the off position. 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. GY caution USE A LONG HANDLED GAUGE SO THAT YOUR HAND DOES NOT GO INSIDE THE CAGE, OR IN FRONT OF ANY COMPONENT OF A MULTI-PIECE WHEEL. Section 1, Page 12 Imani er CLARK es oly Fig. 18324 Fig. 21523 Code: PMA-270, REV FEB 84 zz anowsPROCEDURES FOR ADDING AIR PRESSURE 70 MOUNTED SEMBLIES: ZN wansixe BEFORE YOU ADD AIR PRESSURE TO THE TIRE, MAKE SURE THE LOCK RING IS CORRECTLY POSITIONED IN THE RIM AND SIDE RING. ‘THE LOCK RING CAN SEPARATE FROM THE RIM WITH ENOUGH FORCE TO CAUSE INJURY OR DEATH. 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. If your air supply does not have enough pressure to fill the tire, you can use a nitrogen cylinder to get the correct pressure. Put a clip-on type air chuck on the nitrogen cylinder hose and attach it to the valve stem. Follow the procedures on pages 11 and 12 for adjustment of the nitrogen cylinder valves. ® S RNI USE NITROGEN ONLY TO FILL YOUR TIRES. DO NOT USE OXYGEN OR OTHER GAS. PMA~270, REV JUL 80 Coryraed Mati Intend for CLARK dears aly Fig. 18927 Section 1, Page 13INDUSTRIAL TRUCK DIVISION (CUSTOMER SERVICES GROLF SPLIT WHEEL ASSEMBLIES: Aware BEFORE REMOVING TIRES FROM SPLIT WHEEL ASSEMBLIES, REMOVE ALL AIR PRESSURE FROM THE TIRES. BEFORE YOU PUT AIR PRESSURE INTO TIRES WITH SPLIT WHEEL ASSEMBLIES, MAKE SURE THE SPLIT WHEEL ATTACHING BOLTS ARE INSTALLED AND TIGHTENED TO PROPER TORQUE VALUE. ALWAYS USE A SAFETY CAGE WHEN INFLATING TIRES. ug Outside (A) bolts hold split wheel together. Inside (B) bolts hold wheel assembly on the hub. (Fig. 13761) DIRECTIONAL TREAD TIRES. 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. Directional tread dual tires 1. Inside dual tire arrow to point in the direction of forward rotation, see Fig. 6422. Rotate wheel to bring arrow on tire above the wheel. Arrow must point toward front of truck, 2. Outside dual tire arrow to point in the direction of rearward rotation, see Fig. 6423. Rotate wheel to bring arrow on tire above the wheel. Arrow should point tovard rear of truck. Directional Tread Single Drive Tires: 1, Tire arrow to point in the direction of forward rotation, see Fig. 6422. Rotate wheel to bring arrow on tire above the wheel. Arrow must point toward front of truck, see Fig. 6422. Section 1, Page 14 Fig. 6422 PMA-270, REV JUL 80 zz anousINDUSTRIAL TRUCK DIVISION ‘CUSTOMER SERVICES GROUF LL 6 SAFETY Never attempt to weld on an inflated tire/rim assembly. Always remove all air from a single tire and from both tires of a dual assenbly prior to removing any rim components, or any wheel components, such as nuts and rim clamps. Make sure to remove the valve core and remove all air from the tire. Remove the valve cores from both tires of a dual assembly. Check the valve stem by inserting a piece of wire through the stem to make sure it is not plugged. Check rim components periodically for fatigue cracks. Replace all cracked, badly vorn, damaged and severely rusted components. Clean rims and repaint to stop detrimental effects of corrosion. Be very careful to clean all dirt and rust fron the lock ring gutter. This is important to secure the lock ring in its proper position. A filter on the air filling equipment to renove the moisture fron the air line prevents a lot of corrosion. The filter should be checked periodically to make sure it is working properly. Make sure correct parts are being sembled. Ask your distributor or the manufacturer if you have any doubts. Double cheek to make sure all the components are properly seated prior to filling tire with air. Cob bGQE REV 2 10. 12. 13. la JUL. Inne for CLARK desis 0 ‘Dont el or dtriae PROCEDURES Mixing parts of one manufacturer's rims with those of another is potentially dangerous. Alvays ask manufacturer for approval. Do not overload rims. Ask your rim manufacturer if special operating conditions are required. 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. Never run a vehicle on 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 ean result in damage to the rin. Do not be careless or take chances. If you are not sure about the proper mating 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. Do not use undersized rims. the right rims for the job. Use Do not seat rings by hitting with a hammer while the tire is filled. Do not hit a filled or partially filled tire/rim assembly with a hanmer. Do not let anyone mount or demount tires without proper training. 80INDUSTRIAL TRUCK DIVISION (CUSTOMER SERVICES GROUP 15. 16. a 18. 19. 20. 2. SAFETY Never sit on or stand in front of a tire and rim assenbly that is being filled with air. Use a clip-on chuck and make sure hose is lon, enough to permit the person filling the tire with air to stand to the side of the tire, not in front or in back of the tire assenbly. Do not, under any circumstances, attempt to rework, veld heat, or braze any rim components that are cracked, broken or damaged. Replace with new parts or parts that are not cracked, broken, or damaged, which are of the same size, type and make. Fill the tire with air in a safety cage. Regardless of how hard or firm the ground appears, put hardwood blocks under the jack. Block the tire and wheel on the other side of the vehicle, before you place the jack in position. Place blocks under the truck frane as near as possible to the jack to prevent the truck from falling, if the jack should fail. Remove the bead seat band slowly to Prevent it from dropping off and erushing your toes. Support the band on your thigh and roll it slowly to the ground. This will protect your back and toes. Bead breakers and rams apply pressure to bead flanges. Keep your fingers away from the bead flanges. Slant bead breaker about 10° to keep it firmly in place. If it slips off, it can fly with enough force to kill. PROCEDURES Always stand to one side when you apply hydraulic pressur 21. When using a cable or chain sling, stand avay ... it might break. 1146322, SCOR Ey ‘Do nots daemilly INDUSTRIAL TRUCK DIVISION 123] Gi Gall SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK GROUP 23 BRAKE BLEEDING SECTION 1 Code: PMAR34S, OCT 74 Section 1, Page 1PIETY INDUSTRIAL TRUCK DIVISION [FETT Ps ou SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Proper operation of the hydraulic brake system requires 0 Solld colum of fluid without air bubbles at all points in the pressure system. Under certein conditions it becones necessary to bleed fluid fron the system in order to expel air bubbles which have becone nixed with the fluid. The necessity of bleeding is indicated by 2 soft spongy pedal or ‘at any tine @ brake Tine Is renoved (or broken). THE upright back, Place solid heavy blocks under each Upright rail. TIit upright forvard unt!T vertical to the floor. This should ation the drive wheels to cleer the floor: Reneve erive wheels, vARNING DEFLATE TIRES BEFORE REMOVING WHEELS FROM MACHINES EQUIPPED WITH PNEUMATIC TIRES. Check the breke pedal free travel. Clean dirt fron eround the flller cap of the master cylinder reservoir. Brake Flu should be within 1/4 of an inch from the top. with filler ‘cap renoved from the master cylinder, depress and release brake pedal, A snail displacement of fluid should be noticed In the reservoir each tine the pedal Is actuated. If this happens, the brake pedal (upon being released) is returning ‘the master cylinder piston to its normal position to open 8 cylinder port. This port must be open. if 2 noticeable Aisplacenent of fluid is not observed in the reservoir, during depression of the brake pedal, improper pedal free travel is Indicated, and an adjustment Is required. Fig. 14821 To properly bleed the system it is recomended that @ pressure bleeder filled with about two quarts of S.A.E, 7OR-3 heavy duty brake fluid be connected to the master cyiinder reservoir. Pressure bleeder should then be pressurized to approximately 30 P51. Fig, 15651 Section 1, Page 2 Code: " age sina PHRR3US, OCT 74 Ine For CLARK desis oy ‘Dont el or dtriae © snowsPITTT] INDUSTRIAL TRUCK DIVISION Bott 123} Bei SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK GROUP 23 BRAKE BLEEDING SECTION 1 Code: PHAC345, OCT 7H Section 1, Page 1PIrTT4 INDUSTRIAL TRUCK DIVISION PyErTy Sob SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK pee ese BRAKE BLE es Proper operation of the hydraulic brake system requires a solid column of fluid without air bubbles at all points in the pressure system. Under certain conditions it becones necessary to bleed fluid fron the systen In order to expel ‘air bubbles which have becone mixed with the fluid, The necessity of bleeding Is indicated by 9 soft spongy pe at any tine @ brake Tine is removed (or broken). 1 or Fig. 15650 TiNt upright beck, Place solid heavy blocks under each 7 Upright Fall. Tile upright forsard until vertTen! fo the ficof, This should elton the drive oneels to clesr the | Floor Renove drive vowels MASMLAS Zz DEFLATE TIRES BEFORE REXOUING WHEELS FROM MACHINES +f ] aL AC ER TO Wi Check the brake pedal free travel. Cl the filler cop of the master cylinder reservoir. should be within 1/4 of an inch from the top. With filler cap renoved fron the master cylinder, depress and release brake pedal, A small displacenent of fluid should be noticed in the reservoir each tine the pedal Is actuated. If this hhappens, the brake pedal (upon being released) 1s returning the master cylinder piston to Its normal position to open # cylinder port. This sort must be open, If a noticeable Sisplacenent of fluid is not observed in the resei ‘during depression of the brake pedal, inprope travel is indicated, and an adjustment is required, To properly bleed the systen it is recomended that @ pressure bleeder filled with about two quarts of S.A,E. 7OR-3 heavy duty brake fluid be connected to the master cylinder reservoir. Pressure bleeder should then be pressurized to approxinately 30 PSI. Fig. 15651 Section 1, Page 2 : i 98 —_— Code: PMA-34S, OCT 74 Ande for CLARK dees oly ‘Do nots or dara € snowsyt Tad Loosen the brake line Fitting at point ‘enough to allow fluid and air to escay when escaping fluid is free of air bubbies. Loosen inching valve~check-ball stop bolt at point "B" (Fig. 6881) and depress brake pedal to the floorboard and hold in this position until connection is retightened. This operat ion Should be repeated until escaping fluid is free of air bubbles. Loosen line connection at highest position on Mp" Block (see point "C, Fig. 6881) and bleed In the same manner 2s described above. Install 9 bleeder hose on one of the whee! cylinder bleeder screws ond submerge the netteched end of the hose in e clean transparent Jar conteining several inches of brake fluid. NOTE During bleeding of the wheel cylinders, the jer should be elevated to a position higher than the bleeder screw, making Sure thet the end of the hose rensins Submerged in the fluid at all tines, Loosen bleeder screw and slowly push brake pedal 0 the floorboard and hold pedal in this position until bleeder screw is retightened. Repeat this operation until all alr bubbles disappear and clear fluid Is being punped into the jer. Code: PMAR3WS, OCT 7 INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, Copy Meter GROUP 123] BATTLE CREEK: Iw! (see next page) 1. Tighten Fitting Install bleeder hose on the remaining bleeder screw and proceed as above, After all bleeding has been completed, close the presture bleeder shutoff cock and loosen hose Connection at mastercylinder to allow pressure to escape. Replace master cylinder cap, Replace drive wheels. (Inflate tires if they ‘are of the pneunatic type). THIt upright back fond renove blocking from under each upright rail. If @ pressure blesder is unavailable, the systen may be bled manvally. It must be renenbered that the brake pede! should be depressed slowly and held to the floorboard until the line connections or bleeder screws are securely Elghtened, This prevents the possibility of ft being drawn Into the systen during th bleeding operation. Check master cylinder reservoir level periodically during manual bleeding and F111 to within 1/4 of an inch of ‘the top as required. Section 1, Page 3 Anne for CLARK dears oly etnaMolly INDUSTRIAL TRUCK DIVISION PRT Po ‘SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK EQUIPMENT (| t A i on rf \! roittonto wore Fein Revod Vatve ww Fig. 6861 Section 1, Page 4 — Code: PHA-BAS, OCT 74 Ande for CLARK dees oly ‘Do nots or dara € anovstpi INDUSTRIAL TRUCK DIVISION Gib SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 123) GROUP 23 BRAKE PEDAL ADJUSTMENT SECTION 2 Code: PhAR345, OCT 7% Section 2, Page 1Mery INDUSTRIAL TRUCK DIVISION ba SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK py EQUIPMENT Fig. 14613 BRAKE PEDAL FREE TRAVEL: Check the brake pedal Free travel (A) bys placing a ruler in front of the pecal, letting it rest on the floor plate. Push pedal down by nce fron the master cylinder This adjustment Is accomplished by loosening the Jock nut and turning the clevis (8) 95 shown above. WARNING CORRECT BRAKE ADJUSTMENT 1S IKPORTANT FOR SAFE OPERATING CONDITIONS , Section 2, Page 2 Copy Meter 1 ARK deers oly ‘Donat sal or dotine Code: PMARBUS, OCT 74 € snowsPItTT INDUSTRIAL TRUCK DIVISION [EQ Ale Et SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 23) GROUP 23 SERVICE BRAKE ADJUSTERS SECTION 3 Code: PMAe270 Section 3, Page 1Mepia INDUSTRIAL TRUCK DIVISION a SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK BRAKE ADAUSTERS: When the brake system Is operating properly, the can Ike ection of the reaction arm ellows self= adjustment for the total thickness of the inings, without any noticeable increase in brake pedal free travel, The self=adjustnent ture eliminates the need for manual sjustment of the brakes. When the brake linings becone worn beyond their designed limits there will be 9 noticeable ‘change In the brake pedal effort required to atop the machine or, brakes will becoe nolsy during application. If either of these conditions exist the axle ends should be Fenoved so an inspection of the brake linings can be made to deternine thelr further serviceabl lity, Report to designated person in ‘authority. Section 3, Page 2 SAN 7 Copied Mate Irena for CLARK desler ony CLARK To Code: PMAr270 €@ snovsPIPTT] INDUSTRIAL TRUCK DIVISION [gy Le tal SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 123) GROUP 23 PARKING BRAKE ADJUSTERS SECTION 4 Code: PASS, OCT 74 Section 4, Page 1PIPTTY INDUSTRIAL TRUCK DIVISION EQUIPMENT SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK The parking brake Is located Inside the transmission housing. The brake has two adjustments; a minor adjustment that Is the hand lever located next to the driver's seat and a major adjustment can be made at the brake assembly. IMPORTANT ‘The parking brake mist be capable of holding the truck (with @ fully rated capacity load) on a 15% grade. Test adjustment while occupying the driver's seat, HINOR PARKING BRAKE ADJUSTMENT To make a minor adjustnent, rotate knob on top of hand lever clockwise to increase tension and counterclockwise to decrease tension. Adjustment should be nade with hand lever in fully released position (forward). Fig. 10755 Test adjustnent by applying lever. Tension should be strong enough to monentarily stop the lever in its center position when pulling lever from full forward, to full back position, Section 4, Page 2 : Code: Inna fr CLARK desley CLARK EQUIPMENT PMAR345, OCT 7H €2 snowsPrTTa INDUSTRIAL TRUCK DIVISION [ERT 123] ad SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK w30¢10942) ‘APPROX | | reason 14614 WAJOR PARKING BRAKE AD JUSTHEN Jz ADJUST CLEVIS AND ROD (A) TO APPROKINATELY 4.3 BETWEEN CENTER LINE OF ‘CLEVIS AND CENTER LINE OF ROD AS SHOWN (8). 2, TURN HANDLE KNOB (G) COUNTERCLOCKWISE AS FAR AS POSSIBLE IN OFF POSITION (C). 3. PUT HANDLE IN ON POSITION (0). THEN CONNECT CABLE END TO BELLCRANK (E) ON SIDE OF TRANSMISSION, ADJUST CABLE HOUSING AT MOUNTING BRACKET (F) UNTIL BRAKE IS ENGAGED. 5. TURN HANOLE KNOB CLOCKWISE WITH MANDLE IN OFF POSITION TO INCREASE HOLDING POWER UNTIL BRAKE IN ON POSITION HOLDS TRUCK WITH RATED LOAD ‘ON MINIMUM GRADE OF 15%. Code: PMATBKS, OCT 7 Copy Matera Section &, Page 3 Intended fr CLARK dak onyNOTES PMPItTyy INDUSTRIAL TRUCK DIVISION [ERI EQUIPMENT SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 2) GROUP 26 STEERING PRESSURE CHECK SECTION 1 Codes PHAR3H5, OCT 74 Section 1, Page 1ys EQUIPMENT STEERING SYSTEM PRESSURE: The steering relief valve setting may be checked ith a Nico Qiedrigage (Clark Part No. 1800106) for, with a conventional pressure gauge having @ O-tor3000 PSI Seale ss. at the discharge (pressure) line of the steering pump. 1. Connect pressure line from gauge to test port at valve by installing @ Tee in the Vine. 2, Place blocking between axle and axle stop so that when the Wheels are turned the pressure relief valve will move off its seat when pressure builds up. 3. Apply parking brake ... start engine and run ‘at governed RPM, Rotate hand wheel all the Way In one direction and hold ... avoid holding the hand whee! (axle ageinst stop) longer then is necessary to check pressure Feading on gauge .... take reading release hend wheel and accelerator. ‘The pressure reading will indicate the setting of the relief valve, If reading Taken 1s not reasonably close to those listed below ... appropriate repairs should be made. Report to the desionated authority. spec. Ar Relief valve setting «. 250 P51. Section 1, Page 2 INDUSTRIAL TRUCK DIVISION [FETT SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Conynghe Materia EQUIPMENT POWER STEERING PRESSURE CHECK POINT Codes PMA-3US, OCT 7H Inunded fr CLARK dele only 9@ snowsad MITT INDUSTRIAL TRUCK DIVISION ws SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK GROUP 26 STEERING ADJUSTMENTS SECTION 2 Codes PHA-345, OCT 7H Section 2, Page 1PITT INDUSTRIAL TRUCK DIVISION PTET? Tau Prd SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK OUER STEERING SYSTEM ADJUSTHE NoTe In waking power steering adjustnents, cut to acconplish these basic (2) To torque all items which have a bearing on () re any steering linkage looseness caused by wear or misodjustment. (c) To set the axle stops to obtain the proper turning radius. ‘The Fol lowing procedures will achieve these objectives. They are laid out to enable you to do 2 thorough job, and at the sane tine, do It efficiently and fast... without jumping around for backtracking. Thus, It will say you to Follow the steps in the order given. It is also important to renenber that incorrect power Steering edjustnents can shorten the life of various steering syste components. Before sterting any adjustnent, strip the truck down to a point where you can get at the components. This Includes: Removing the side hoods; renoving the floor board; reneving the entire seat assenbly, With these operations out of the way, we can now Continue with the step-by-step procedure: 1. Check, and if necessary, adjust the tilt cylinder rods to elininate upright racking. Always make certaln the tilt cylinder yoke nuts ere torqued to 70 to 85 pound feet, Fig. 9841 Security Check 2, Torque the frane-to-axle edeptor bolts 650 to 700 pound feet. It may be necessary to renove the wheels to do this. WoTe Torque the center capscrew first; then, torque the top capscrew «+. then, torque the bottom capscrew. Recheck torque, again starting with the center capscrew. Section 2, Page 2 Code: PHA-SHS, OCT 7H Capit Mater Intended or CLARK del ony ‘Do ste ordre 9% snowsINDUSTRIAL TRUCK DIVISION Par 4 exo EQUIPMENT SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 125] Su ie one Ws Nas TC (k). ee valve mounting bolts (A) which should be torqued to 18 pound feet. Also, tighten the steering coluan U-bolt bracket nuts (8), 4h, Then se check the steering valve bracket bolts for proper torque. Heke certain they ‘are tightened (C) 80-90 pound feet and (0) 165-175 pound feet. All of the above torquing steps must be carried ‘out each tine you perform power steering adjustnents ... because each of the items torqued has @ definite bearing on the steering characteristics of the truck. With these torquing steps cut of the way ... we can now get ‘to work on checking out the steering system, 5. Inspect the shock mounts at the anchor end of the booster cylinder piston rod. If these mounts are danaged, replace then. 6, Now ... set the parking brake and raise the steer wheels off the floor ... making certain the truck Is securely blocked up with blocks under the frane ... and not under the counterweight . Drag Vink (6) should be screwed conpletely Into the steer cylinder (i). Then check the torque of the steer cylinder clamp bolt (E) ses which should be 30 to 40 pound feet, Torque the drag Vink ball socket screw (1) 20 pound feet and back off to the first cotier pin hole and secure with e cotter key. Now ... inspect the tie rod ends (J). If they are loose, replace them, If the tie rod stud Is lodse, tighten the stud nut. The tie rod stud rut should be torqued 40 pound feet and continue until cotter hole Is ‘exposed. 10, Now... Inspect the steer axle stop locknuts Ce) for tightness: If an axle stop is it 2 stop ... making Certain to maintain an 80 degree steer wheel ‘engularity. 11. Then ... place masking tape on right and left axie stop bolt heads. Now ... connect a tachometer and start the engine with the transmission in neutral, With the engine running at 500 RPM, turn the hand wheel full Fight and full left so that each steer wheel contacts Its axle stop, or until engine speed speed decreases. Code: PMA-3HS, OCT 74 Intended Copyrighted Matera RK desks ony Fig. 11458 Torque Steering Valve Mounting Bolts 12, Then ... shut off the engine and check the rnasking tape for an Imprint. Both tapes ‘should have an inprint, If one of the tapes has no Imprint’... then the rear drag Tink (6) must be adjusted so the tape will be inprinted when the wheel is fully turned. When the above adjustments have been made disconnect any gauges used and lubricate all axle and linkage points. Then lower the truck to the floor and install the seat assenbly, floorboard and side hoods. STEER Check drive tire inside turning disneters which should be about equal in forvard left and right turns. 13. Sprinkle flour o sone other powlered substance on @ smooth concrete floor. th, Drive the drive tire over this In forward with wheels turned full right end then on a different spot, full left. Section 2, Page 3PIGTy INDUSTRIAL TRUCK DIVISION [FETT ca te SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Cie Section 2, Page 4 henna Code: PMA-3HS, OCT 74 Anwnded for CLARK ders ny 9% snowsTT INDUSTRIAL TRUCK DIVISION [eye a SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 15. Measure the inside dlaneter of each circle from the inside edges of the tire tread. 16, This dimension should be 4.13", 17, Adjust appropriate stop bolt until proper diameter is reached, 18, Now torque all deive wheel lug nuts to the correct torque: 290 to 300 pound feet, 19. And torque all steer wheel lug nuts 115 to Fig. 9853 Code: PMARBYS, OCT 74 Copyhied Matera Section 2, Page 5 Intend for CLARK desks only ‘De ntl dateNOTES PMmel INDUSTRIAL TRUCK DIVISION EQUIPMENT USTOMER SERVICES ENGINEERING OEFARTMERT, BATTLE CREEK GROUP 26 SECTION 3 STEER WHEEL BEARINGS Code: PHA-381, MAR 76 Section 3, Page 1EQUIPMENT Paryyy INDUSTRIAL TRUCK DIVISION FETT ca Tle customer seavices enema CLEAN, REPACK AND ADJUST STEERING WHEEL BEARINGS Every time brake shoes are replaced, repack the wheel bearings. 1, Raise the rear of the machine far enough to clear the floor. WARNING AFTER RAISING MACHINE AND BEFORE MAKING ANY ADJUSTMENTS OR ADJUST- MENT CHECKS, PLACE ADEQUATE (HEAVY) BLOCKING (SUFFICIENT TO SUPPORT THE WEIGHT OF THE MACHINE) UNDER THE FRAME ... NOT UNDER THE COUNTERWEIGHT .., TO PREVENT ACCIDENTAL LOWERING OR FALLING OF THE VEHICLE, THUS PREVENTING PERSONAL INJURY TO MECHANIC OR BYSTANDERS. 2. Deflate the tires (machines so equipped) and renove wheels from hub assembly. Clean bearings in a Stoddard type cleaning solvent. After all solidified particles of lubricant are removed from the bearings, blow dry with compressed air, Direct air stream across the bearings to prevent spinning. Slowly rotate bearings by hand to facilitate drying. Inspect the bearings and races carefully to determine if they are in good condition and suitable for further service. Dry the hub with compressed air, Section 3, Page 2 ErARTWENT, BATTLE CREEK Fig. 9768 Steer Wheel Bearings Repack the bearings with the lubricant outlined In lubrication section. ADJUSTMENT CHECK is Copii Materia Inspect adjustment of bearings by gripping ton and bottom of tire, Chuck tire in and out to determine looseness or wobble. Now grip the front and rear side of tire, chuck tire in and out to determine looseness or wobble. NOTE Before making wheel bearing adjustment, be sure play (looseness or wobble) is in wheel bearings and not in king pins. If wheel bear~ ings need adjustment, clean and repack bearings before making adjustments. Code: PHA~381, MAR 76 Inunded fr CLARK dele only 92 dnows.Mery INDUSTRIAL TRUCK DIVISION [Revers Ea 126} HSTOMER ScAVICES ENGINEERING DEPARTMENT BATTLE CREEK 2. If looseness or wobble fs in the whee! bearings, remove hub cap and spindle cotter pin. Tighten nut with a 12" wrench and at the sane time rotate the wheel in one direction and then in the other until there is a slight bind to be sure all bearing surfaces are in contact. Then back off the nut 1/6 to 1/4 turn allowing the wheel to rotate freely. Secure nut at this position with a new cotter pin and replace hub cap. Code: PMA-381, MAR 76 Section 3, Page 3 Copyrighted Mater Ironded for CLARK dele olyMGETY INDUSTRIAL TRUCK DIVISION PTETTA bill Ls SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Gen WORK SAFELY DRIVE SAFELY BE CAREFUL ALWAYS GIVE MACHINE SERIAL NUMBER WHEN ORDERING PARTS Rev ocr 73 napPIryTyq INDUSTRIAL TRUCK DIVISION BeteMy Gi SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK i GROUP 29 SECTION 1 HYDRAULIC SUMP TANK DRAIN Code: PHAR3H6, REV JAN 77 Section 1, Page 1INDUSTRIAL TRUCK DIVISION (CUSTOMER SERVICES GROUP LIC SUMP TANK DRAIN: Drain and refill hydraulic sump tank every 2000 hours or once a year, in the following manner: 1, Lower upright and shut the engine off. 2. Place @ lerge container underneath sump tank which is located at right side of machine. 3. Remove sump tank drain plug, located at botton of tank and allow fluid to drain, CAUTION DO NOT START ENGINE WHILE SUMP TANK IS EMPTY AS DAMAGE TO THE HYDRAULIC PUMP WILL RESULT, 4, Disconnect hose and remove filter retainer bolts. 5. Pull filter assembly out of sump tank. 6. Remove any remaining gasket material from mounting flange. 74 Before installing @ new filter and gasket, be sure sump tank is absolutely clean. Flush sump tank with two quarts of clean hydraulic NOTE The filter attaching bolts should be tightened to 40 to 50 pound inches. If this torque is exceeded, distortion may occur, causing leakag 8, Install hose and tighten hose connections, 9. FII1 sump tank with MS 68 hydraulic fluid. CAUTION START ENGINE AND OPERATE HYDRAULIC CONTROL LEVERS SEVERAL TIMES, CHECK OIL FILTER FOR LEAKS, RECHECK OIL LEVEL, Section 1, Page 2 Copy Mate Ine For CLARK desis oy ‘Dont el or dtriae Fig. 5359 ee Fig. 14806 PMA-346, REV JAN 77 6z nousPIETY INDUSTRIAL TRUCK DIVISION J a LS SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK GROUP 30 HYDRAULIC SYSTEM PRESSURE CHECK SECTION 1 Codes PMARBNS, OCT 7H Section 1, Page 1try INDUSTRIAL TRUCK DIVISION fyRErTs Ore SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK ey Ye HYDRAULIC SYSTEM PRESSURE CHECK: The hydraulic relief valve setting may be checked with a hice Quadrigage (Clark Part No. 1800106) or, by installing a convent onal pressure gauge with 8 O-4,000 Psi scole ss. at fhe discharge. (pressure) ine of the pump or at the pressure port of the valve When using quadrigage or conventional pré gouge 1. Remove test plug at line fitting and connect gauge to this port. 2, Apply parking brake ... start engine and operate at governed RPM, Pull tilt lever backward and hold ... when pressure builds up and the relief vaive off-seats «+. Imediately take 2 reading. Release tilt lever and accelerator ... avoid holding the tilt lever back longer ‘than necessary to check pressure reading on the gauge, ‘The pressure reading will indicate the setting of the relief valve, If reading taken Is not reasonably close to t listed In Specifications, appropriate repairs should be made ... report to ated euthority. Pressure relief set at 2000 P51. Section 1, Page 2 seereaeaniiaaa Codes PHA BS, OCT 7 Ine For CLARK desis oy ‘Dont el or dtriae 0€ nowPITT] INDUSTRIAL TRUCK DIVISION [ERD EQUIPMENT 134) SERVICE ENGINEERING DEPARIMENT, BATTLE CREEK GROUP 34 SECTION 1 4 AND 6 ROLLER CARRIAGE CHECK AND ADJUSTMENT PROCEDURES Code: PrAL321, REV DEC 74 Section 1, Page 1rorya INDUSTRIAL TRUCK DIVISION PRET pT Td he SERVICE ENGINEERING DEPARTMENT, BATILE CREEK eT Tg A, CARRIAGE RENOVAL, Before nthe upright, set parking brake end block drive wheels. Fig, 9559. Blocking Machine and Carriage STEP 1, Raise carriage about 4 feet. Place 2 W' x ¥" oak bean 3 to 4 feet In length between Garriage and fost a5 shown. 90 NOT STAND DIRECTLY UWOER FORKS. Standing to" one "Sige, lower carriage onto bean as shown. WARNING BEFORE VORKING ON UPRIGHT, SET PARKING BRAKE AND BLOCK DRIVE WHEELS AS SHOWN Section 1, Page 2 Code: PHAR32I, REV DEC 7H Copyright Mi Anne for CLARK dears oly ‘Donat sal or dotine ne an0yePITT INDUSTRIAL TRUCK DIVISION PERIg PTs 13.4] SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Code: PrAR321, REV DEC 74 is : Intend for CLARK dears nly De hteyo EQUIPMENT INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK CLARK a ae STEP 6, Pull chains out of carriage enchor From Anchors Fig. 9562, Removing Chainsas mT INDUSTRIAL TRUCK DIVISION 134] ‘SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK STEP 7. Wire chains around chain sheaves 2¢ shown. wore Use the seme method on all cylinders Fig. 9563. Securing Chains (Typical) STEP 8. Guiding piston head with hands on chains raise piston to full up position. (i. Fig. 9564, Guiding Piston Head Code: PHAR321, REV DEC 7h Section 1, Page 5PiyyTq INDUSTRIAL TRUCK DIVISION [FETT oy SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Et STEP 9, Raise Inner rail so it just clears upper carriage rollers. Leave upright st full forward tilt, PALLET Fig. 9565. Inner Rail Clearing STEP 10, Renove blocks and rele: Back machine evay from carriage, Fig. 9566, Backing Machine Aney Fron Carriage Section 1, Page 6 ae Code: PHAG321, REV DEC 7h Arundel or CLARK deen nf an0¥9PIrTTa INDUSTRIAL TRUCK DIVISION [Ew Pa Te SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 2) CARRIAGE ROLLER ADJUSTMENT Fig. 9567. Spanning Inner Rail STEP 1. Span inner rail with inside spanning tool to find the smallest distance between the rails. Lock tool in position, Nore FOR SIX ROLLER CARRIAGE ONLY After finding the smallest distance between rails, place 2 shim between the spanning tool end the inner then lock spanning tool in posit Code: PAAL321, REV DEC 74 er Section 1, Page 7 Anne for CLARK dears olyPitti INDUSTRIAL TRUCK DIVISION aid ld ie SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK yo Pi tte CARRIAGE ROLLER SLIDING T BEVEL Fig, 9589. Setting T Bevel NoTe Check angle of carriage rollers. Roller pin bosses are welded at 2 degrees + 1/2 degree and If damaged, replace carriage roiler pin boss assenbly. To obtain this contact Central Parts. To check roller angle use 2 Sliding T Bevel and Protractor, Lay one side against roller sur= Foce and lock in place. _ SLIDING T BEVEL Fig 9590, Checking Roller Angle Determine degree of angle by placing Protractor on Sliding T Bevel. Section 1, Page 8 Code: PMA~321, REV DEC 74 omni ML Iman or CLARK desl on nf anowoPIrTTa INDUSTRIAL TRUCK DIVISION Pals SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 24) Fig. 9568. Setting Outsi¢e Spanning Too! STEP 2, Set outside spanning tool to match inside spanning tool. Lock tool in position. Fig. 9569. Spanning Upper Rollers (Four Roller Carriage) STEP 3. Span upper carriage rollers at their outer most conber point. Add or subtract... Code: PHAW321, REV DEC 74 Section 1, Page 9 Conyriphed Mara Intended for CLARK ele ty ‘meal or daineCLARK Eta INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK CLARK ba Td GrovP 34 Spanning Upper Rollers (Six Roller Carriage) Fis. 9570. Fig. 9571. Securing Outer Thrust Roller Code: PiAn321, REV DEC 74 Section 1, Page 10INDUSTRIAL TRUCK DIVISION [Regt (34) oh bi alll SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Fig. 9572. Centerin: STEP 4, Center cerriage rollers within out carriage roller surface and measuring the di Ter to the other to make messurenent equal. subtract shins fron one rol PALLET int the outer most cander of the... STEP 5, Square corrioge rollers by placing carpenter's squart Section 1, Page 1 Code: PHA321, REV DEC 74 Coppel Mant Irene fr CLARK desl ‘Dont sl or darncePITT INDUSTRIAL TRUCK DIVISION [ETT bail Td ae SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK EQUIPMENT Fig. 9574. Squering Cerriage Rollers (Six Roller Carriage) ++ upper and lower rollers. Hold square in place with ankle and hand as shown. STEP 6. Hold square and neasure the dis- tance between the top face (or lip) of the upper fork bar to the edge of the’ squere urerent at ‘add or renove shims on lover roller shaft until distance measured st each end is equal Fig. 9575. Measuring For Squareness Section 1, Page 12 —— Code: PHA=321, REV DEC 74 nf anowsPITT INDUSTRIAL TRUCK DIVISION [ers Tos 134] SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Fig. 9576. Spanning Lower Rollers (Four Roller Carriage) STEP 7, Spen lower rolle-s, Add or subtract shins to (the roller that has not been squared)... Fig. 9577. Spanning Lower Rollers (Six Roller Carriage) sss Peach the size of the outside epenning tool. Code: FuA-gai, “Ey D°E 7E Section !, Page 13PS Tt INDUSTRIAL TRUCK DIVISION PAptT" SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Li lett PALLET Section 1, Page 14 Fig, 9578. Checking Squareness (Four Roller Carriage) STEP 8. Check opposite side for squareness (by holding square In the save manner as before and checking... Code: PHAC321, REV DEC 74 ened Maer K dealers oly nf anorrvya INDUSTRIAL TRUCK DIVISION Em ei = SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK 25 (Six Roller Carriage) This side wil! Code: Pmie321, REV DEC 74 Section 1, Page 15EQUIPMENT PITY INDUSTRIAL TRUCK DIVISION [FETT ci dg SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK SIX ROLLER CARRIAGE ONLY Fig. 9580, Top Roller Clearance STEP 1. Place square on the vertical center line of the carriage rollers, a¢ shown sbove. There must be sone clearance between the square and the side surface of the top roller. This clearance should not ‘exceed 1/32" or one shim, USE ALLEN WRENCH STEP 2. If adjustment Is necessary, allen screw, lock washer and Flat washer to edd or renove shims on shaft. Tighten screw Securely after completing adjustnent. Fig. 9581, Renoving Top Roller Section 1, Code: PoAe321, REV DEC 7H ‘ne anovaPIPT 14 INDUSTRIAL TRUCK DIVISION GOL SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK Fig. 9582. Top Roller Clearance STEP 3. Check opposite upper roller in the sane manner; edjust if necessary. 2 CORRECT ? INCORRECT é use aver —] 9 } wenn SLioine SLIDING INNER THRUST, T BEVEL T BEVEL ROLLER IwweR THRUST? | ROLLER Fig. 9583. Checking Squareness (CORRECT) Fig. 9504. checking Squareness (INCORRECT) STEP 4, Check squareness of inner thrust rollers with Sliding T Gavel, Set Sliding T Bevel to 90 de~ grees using carpenter's square. STEP 5, Add or subtract shins for sdjustment (Use ellen wrench see Fig, 9584). Code: PhRe321, REV DEC 78 Copyrighted Mater Section 1, Page 17 Ande for CLARK dees oly ‘Do nots or darapo oud INDUSTRIAL TRUCK DIVISION SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK os EQUIPMENT PALLET Fig. 9574, Square STEP §, The inner thrust roller is to project 1/6 Vine of square. Use One thrust roller shim and eyeball dis Rance as show (Fig. 9573 and Fis. 9585). STEP 7. Repeat STEP 6, on opposite side. Section 1, Page 18 And Side Thrust Roller twweR THRUST ROLLER = 0 Ine For CLARK desis oy Fig. 9585. Resding Roller Projection Code: PMAL321, REV DEC 74 ‘ne anowoPIGT TY] INDUSTRIAL TRUCK DIVISION gers EQUIPMENT SERVICE ENGINEERING DEPARTMENT, SATTLE CREEK SEEEEEEEEEEEEEEE NOTE Refora installing carriage, check upright for proper shinning adjust nent. Ca CARRIAGE INSTALLATION STEP 1. drive:sachime up te cerriage nd goct= | tlon upeight to natch tlit of carriages | STEP 2. Reise inner rails to just clear upper . carriage rollers, 1s Corriase Rollers STEP 3, Continue to erive machine forward un- EIT Inner rats line uo with upper carriage rollers, then .... slowly lower inner rails to full doum position. caution CHECK TO BE SURE THE TOP CARRIAGE ROLLERS ARE GUIDING INTO INNER RAIL. \Wy | Fig 9591, Rollers Guiding Into Inner Rai! Code: PrAG}21, REV DEC 7h ai Section |, Page 19 Intended fr CLARK, desler ny ‘Dose al rdsmarry INDUSTRIAL TRUCK DIVISION [WETT% Jeet SERVICE ENGINEERING DEPARTMENT, BATTLE CREEK ey STEP 3(@). Rerove wires holding lift chains. (©). With a chain in each hand and soneone holding the lift cylinder lever down, pull the piston to full don position. Place chains be- hind carriage. STEP 4, Put chain anchors in carriage anchor brackets and install 3/8" x 2" bolts ia anchor pin holes. Section 1, Page 20

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